JFS Oil IOM
Contents
1. de ENS FIG 26 TDS and BLOWDOWN CONTROL CIRCUIT 47 JFS Series Oil 01 2008 Fulton CONTROL GT OR ORE H Li FIG 27 6J 30J BURNER CONTROL CIRCUIT Oil Boilers only JFS Series Oil 01 2008 48 1720801007 sjeg Aq 4 ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A 1091100 ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A peusyos 159 pales 5 UIEN ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A pepunos jno 490 jeuung ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A pepunos NO ino ISL Aq 1591 ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A dojs uejs J0 3u05 puz 1s QuBis Aq 19497 1972M SWE 4 ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A ON S9A Ajsoyoejsijes 159 umopmojq 1ojem 1641 1641 SU ui ejn2. Fulton Boiler Works Great Britain Ltd INSTALLATION OPERATION MAINTENANCE AND PARTS MANUAL JFS Series OIL FIRED STEAM BOILER This Manual must be available to the boiler operator at all times January 2008 Fulton Wi A IN CASE OF EMERGENCY This boiler has been designed and constructed to meet all of the essential requirements of the applicable European Directives and subject to proper maintenance should not give occasion to any hazardous conditions If such a condition should occur during commissioning or during subsequent operation of this product what so ever the cause then the fuel supply to the boiler should be isolated immediately until such time that the fault has been investigated by a competent person and rectified Z WARNING Steam Boilers are a potential hazard possibly fatal if not properly maintained Only Corgi registered personnel are allowed to work on the gas components of this boiler It is vitally important that the instructions givenin this manual are strictly adhered to Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the boiler Continual improvement in boiler design and fittings may result in some of the components used being different to those in this manual if in any doubt about individual components or their operation contact Fulton Service Department NOTE The Pre
3. 2 5 Note Note FLUE OUTLET The boiler is supplied with a stainless steel flue spigot that should be inserted into the flue outlet in the back of the boiler and secured with the three angle clips supplied loose in the trim box The height and type of flue will generally be subject to local planning regulations and approvals The following information is intended to provide assistance where the installation of a simple flue is required Where multi boiler flues or difficulties are experienced specialist advice should be obtained The flue diameter must be the same or larger than the flue flange provided with the boiler and the outlet should be at least 1 meter higher than the nearest ridge to avoid down draughts Where a chimney cowl is fitted care should be taken to ensure that the distance between the lowest point of the cowl and the top of the flue is 1 5X the diameter of the flue and that it is of the terminal cone type FIG 4 BOILER FLUE CONNECTION 1 If the flue layout is such that it may produce an excessive up draught a draught stabiliser may be required 2 Avoid fitting 90deg elbows whenever possible if unavoidable compensate by increasing the flue diameter 3 Ensure all flue pipes from the boiler to the main flue have a rising pitch WATER SUPPLY The quality of the water used in the boiler will affect the life and performance of the boiler Feed water contains solids and dissolved gases these may
4. Check voltage between pilot terminal and neutral and ignition terminal and neutral Check must be made before control locks out on safety If no power replace control Check oil nozzle s clean or replace as necessary Check to see if oil is being pumped to the boiler nozzle Repair or replace as necessary Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check air adjustment Air may be blowing flame away from the UV detector Open primary air until fire brushes the furnace wall Check for dirt on scanner clean as required Check for proper location of detector Adjust to proper setting Change to correct terminals Check oil level in supply tank ensure it is not below intake line Fill tank with oil Check for clogged nozzle Clean or replace Check oil filter and replace if necessary Check the voltage between oil valve neutral at terminal block to be sure oil valve is getting power Check for clogged strainer or filter Remove and clean Check for slipping or broken coupling Tighten or replace Check for seized pump shaft Replace Check all lines for possible air leak in intake line and tighten Check the intake line is not restricted replace Note One of the most common causes of flame failure is dirt sediment in the oil filter oil lines solenoid valves or no
5. Located on the control panel box and connected to the steam pressure gauge assembly by copper tubethe pressure regulator controls the on off cycle of the burner shutting the burner off when maximum pressure is reached and switching it on when the steam pressure falls Burner Programmer This is the main control in the panel box The programmer in conjunction with a sensing device supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lockout and the burner will shut down JFS Series Oil 01 2008 16 3 2 BOILER CONTROLS continued Fuel Pump Mounted on the burner scroll and driven by the burner motor the fuel pump delivers oil to the burner nozzles at the correct pressure to allow complete atomisation and therefore combustion PUMP CONTROL Pump Interrupt Pump Run Switch Fitted on the left side of the control panel used to override switch off the pump controls during evaporation tests Fulton START PUMP ONLY FLAME FAILURE CIRCUIT BURNE R IGNITION OIL _ O L W RESET PUMP amp BOILER FIG 17 JFS33 CONTROL PANEL 17 JFS Series Oil 01 2008 Fulton 3 3 3 INDICATOR LIGHTS Indicator lights are fitted to the control panel as an
6. 3 JFS Series 01 2008 2 1 2 2 2 3 INSTALLATION SECTION 2 GENERAL The installation of a JFS Series Oil Fired Steam Boiler should be carried out by competent personnel in accordance with all relevant safety regulations It is the responsibility of the installer to ensure that these regulations are complied with SITING The boiler house should be sufficiently large to allow easy and safe access to all parts of the boiler for installation operation and maintenance purposes Reference should be made to Section 5 General Data to ascertain the relevant dimensions and special note taken of the vertical clearance required for the removal of the burner The flooring must be level laid in a non combustible material and be of sufficient strength to support the boiler VENTILATION Adequate fresh clean air is necessary for safe and efficient combustion and should be provided at high and low level in accordance with IGE UP 10 Edition 2 It is essential that only fresh air is allowed to enter the combustion air system Foreign substances such as combustible and volatile materials in the combustion system can create hazardous conditions Note a Ensure there is adequate ventilation in the boiler room Lack of ventilation will create a high temperature and cause control lockout b Do not keep exhaust fans running with windows doors and vents closed this will interfere with the necessary boiler draught c Do
7. FIG 23 BOILER DIMENSIONS JFS Series Oil 01 2008 40 Fulton A WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted to the boiler in a correct and safe manner Connection Sizes DN F female M male All connections BSP Steam Outlet Feed Water Safety Valve discharge Main Boiler Blowdown Water Column Blowdown Sight Glass Blowdown Specification Output kg h F amp A 100 C Standard Working Pressure bar Firing Rates Input KW h Input BTU h x 1000 Input 35 sec oil US gal h Input 35 sec oil litre h Nozzle Size US gal h Nozzle Spray Angle Oil Pressure barg Oil Pressure psig Capacities and Weight Water Content litre Weight Empty kg Weight Operating kg Electrical Requirements FLC Amp 400V 3ph 50Hz Oil Boiler Combustion Values Model 22 32F 15M 32F 25F 20F 8F 160 10 34 124 425 11 4 2 25 809 S 13 1 189 450 1320 370 4 7 33 32F 15M 32F 25F 20F 8F 240 10 34 187 637 17 6 3 5 800 8 12 1 176 740 1900 740 4 7 CO range 11 5 12 596 less than 100ppm 5 4 Excess air 30 20 Smoke 3 max 55 32F 15M 32F 25F 20F 8F 320 10 34 250 849 23 5 5 2 809 5 10 6 154 1172 2925 1120 4 9 JFS Series 01 2008 Fulton 5 IMPORTANT Recommended Water Conditions It is very important that a strict water m
8. boiler performance by unapproved modifications N WARNING DANGER FROM HOT SURFACES Steam Boilers have high temperature surfaces that if touched may cause serious burns Only competent and qualified personnel should work on or in the local ity of a steam boiler and ancillary equipment Always ensure the working area and floor are clear of potential hazards work slowly and methodically N WARNING DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustmentto achieve low emissions safe clean and efficient combustion is paramount Poor combustion where unburnt oil forms carbon monoxide is both a health hazard and the potential risk to the boiler from overheating caused by re burning of the unburnt gas in the secondary flue passes N CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants are NOT SUPPLIED by Fulton It is the responsibility of the operator to ensure adequate supplies of chemical are available at all times including commissioning Costly repairs could be required should the plant operate without chemicals or the wrong dosage of chemicals JFS Series Oil 01 2008 Fulton Optional Variations where fitted Appendix Spirax High Integrity Level Controls C LIST OF ILLUSTRATIONS TITLE FIG NO Oil Fired Steam Boiler 1 General Arrangement 2 Typical Installation 3 Boiler Flue Connection 4 Boiler Feed Water Arra
9. Check for proper location of detector Check for faulty air switch by jumpering the two air switch leads at the terminal block If the boiler starts and runs with the jumper in place the air switch should be replaced Check the level control relays are securly mounted on their bases Check the power supply to each The relays may be checked by swopping positions and checking they are both functioning Check for clogged nozzle clean or replace Check voltage between transformer neutral at terminal block to be sure transformer is being powered Check voltage between pilot terminal and neutral and ignition terminal and neutral Check must be made before the control locks out on safety If no power replace control Disconnect all power to the controller Disconnect the wires from the controller connect an ohmmeter between the switch terminals Lower the set point of the controller the switch should make raise the set point and re check switch should break if the controller operates improperly replace it JFS Series Oil 01 2008 26 3 9 TROUBLESHOOTING continued Problem Cause Remedy Poor Combustion 1 Refractory Bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Stainless Steel Ring Check to ensure the ring is present and fits securely against the furnace wall 3 Main Air Adjustment Check air adjustment Open main air until fire brushes the furnace wall 4 S
10. Fulton Boiler Works Great Britain Ltd Broomhill Road Bristol BS4 4TU England Telephone 0117 972 3322 Fax 0117 972 3358 e mail uk info fulton com web site www fulton com Fulton FM 28400
11. Fulton representative CAUTION It is essential that regular checks are made to ensure that scale buildup is not taking place within the boiler Such checks will ensure that water treatment being applied to the boiler feed water is effective The lower hand hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined If scale or sludge build up is observed it should be removed and the water treatment supplier advised New gaskets must be fitted every time a handhole door is removed Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are observed Thereafter inspections should be carried out at three monthly intervals A WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be isolated Feed Water Feed Water Non Steam Pressure Ball Valve return Valve Gauge Flame Detector Steam Supply Ignition Electrodes UE T Line Oil Feed Line Safety valve nes Outlet Water Level Probes __ Water Column Level Probes P Fulton old o ol B FIG 19 BOILER MAINTENANCE JFS Series Oil 01 2008 32 Fulton 4 Wi Note 4 2 4 3 The following procedures are designed to prevent the buildup of scale silt or sludge in the bottom of the boiler water ga
12. Start 2 Bii 5mm 80 Spray oil supply nozzle Arrow B Nozzle Manifold 5mm Y 2 12mm 300mm 80 Spray View on arrow B 12mm High Fire Oil Supply OMA Low Fire Oil Supply F00870 SINGLE NOZZLE SINGLE STAGE LIGHT 40E 60E VERNE Note Always place the highest value nozzle engraved on the side of the nozzle into the low fire oil supply port in the manifold FIG 14 NOZZLE AND IGNITION ASSEMBLIES JFS Series Oil 01 2008 12 Feed Water Feed Water Non return Valve Stop Valve Steam Pressure Gauge Flame Detector Ignition Electrodes Main Steam Valve Oil Feed Line Safety Valve Water Level Probes Air Intake Manifold Boiler Control Panel Sight Gauge Blowdown Feed Water Pump Valves Isolator Switch Control Box Door Lock Water Column Blowdown Valve Control Box Isolator Switch Steam Pressure Control Boiler Blowdown Valve Cleanout Handhole Cleanout Door Water Jacket FIG 15 COMMISSIONING THE BOILER 13 JFS Series 01 2008 Fulton 2 2 16 COMMISSIONING THE BOILER continued A barometric type draught stabiliser if fitted in the flue should be set for a draught of 0 01in to 0 02in 0 025mb to 0 050 mb of water column pressure with the burner off Open all the valves in the water feed line Open all the valves in the feed water line FEED PUMP Close the isolating valve on the discharge side of the pump Remove
13. burner combustion to ensure that excess air and carbon monoxide values are within normal limits see combustion values in section 5 Cleaning the Flues 10 Remove the cleanout door to the flue pass es and to the bottom of the boiler Vi FG00200 FIG 22 FLUE CLEANING JFS Series Oil 01 2008 36 JFS Series 01 2008 Spirax High Integrity Level Controls The daily testing of boiler water level controls is a mandatory requirement as defined in the Health amp Safety Executive Guidance Note PM5 The level of supervision is dependent upon the type of level controls limiters fitted Boilers fitted with self monitoring high integrity controls limiters should be tested daily by a qualified boiler at tendant but may be supervised during the silent hours and weekends by a Competent Person trained to re spond to an alarm Daily testing of the controls is required which can be by simulation with a weekly test by interrupting the feed water pump and lowering the water by evaporation Daily Test 1st Low water1 With the burner firing 2 3 4 2nd Press and hold the 1st Low Water test button until minimum 15 seconds the low water alarm sounds and the low water indicator lamp illuminates and the burner shuts down Release the test button After approximately 17 seconds the low water alarm will cancel the low water lamp will extinguish and the burner will
14. leak in intake line and tighten Check for possible restricted intke line Replace 9 Loose Oil Fittings Check all fittings and tighten 10 Blocked Oil Filter Check and clean or replace 11 Blocked screen in Oil Pump Check and clean or replace 12 Blocked Flue Check flue is not blocked clean as required Check draft at flue 13 Vacuum on Pump Check for too high a vacuum on the pump Check oil lines and distance from tank to boiler Repaire or replace as necessary 14 Hole in suction line Check and replace as necessary 27 JFS Series Oil 01 2008 3 9 TROUBLESHOOTING continued Problem Boiler will not maintain pressure Cause 1 N 9 Oil tank empty Oil Nozzle Oil Valve Oil Pump Dirty Flue Pressure Control Scale buildup in boiler Refractory Bricks Steam Traps blowing through 10 Boiler size Remedy Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check for blocked nozzle Clean or replace Check voltage between oil valve leads at terminal block to be sure oil valve is getting power Check for blocked strainer or filter Remove and clean Check for slipping or broken coupling tighten or replace Check for seized pump shaft Replace the pump Check flue for Carbon build up or blockage Clean flue passages with brush Disconnect all power to the cont
15. pressure the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework A WARNING The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer This can be achieved by one of two methods 1 Crack open the main steam valve and allow the system to heat up slowly minimum 15 minuets before fully opening the main steam valve 2 Open the main steam valve when starting the boiler allowing the boiler and system to heat up together Note This can lead to water logging of the steam lines until full pressure is achieved DAILY OPERATING TESTS 3 6 3 7 Visually inspect the steam and feed water pipework valves and fittings for signs of leakage If leaks are suspected shut the system down and evacuate the system to atmospheric pressure before attempting to repair the leaks The following procedure should be carried out by a competent person to ensure the correct functioning of the water level and low water safety controls Where possible the boiler should not be under steam pressure during these tests see 3 6 5 9 2 Ensure that the water level is maintained during the pressure build up If any part of the equipment is not operating correctly the fault should be investigated before the boiler is used Ensure that all blowdown pipework is safe and discharged to a blowdown receptacle 3 6 1 3 6 4 Pump Check With the burn
16. promote encrustations of scale foaming priming surging corrosion and pitting or caustic embrittlement To prevent this happening it is strongly recommended that a reputable water treatment concern is consulted prior to commissioning the boiler see Section 5 Water Treatment Feed Water Feed Water Check Connect the feed water pump discharge to the Dip Pipe Stop Valve Valve check valve inlet with 25 mm bore pipe this may be reduced to 15 mm where the discharge pipework is shorter than 4m in total the pump suction pipework must remain at 25mm minimum diameter and be as short as possible insert the stop valve supplied between the boiler and the check valve It is essential to protect the feed water pump from damage by foreign matter a strainer should therefore be fitted in the pump suction pipework Care should be taken to ensure the pipework is properly aligned and not placing any strain upon the feed water pump FIG 5 BOILER FEED WATER ARRANGEMENT 1 The boiler feed water pump may contain an inhibitor and this should be flushed from the pump prior to fitting the pump to the boiler Failure to do so may result in water bounce or foaming due to the inhibitor forming a seal in the boiler 2 If the boiler is to be operated with little or no condensate return consideration should be given to pre heating the feed water If in doubt consult Fulton Boiler Works 3 The feed water inlet connection on some boilers is located on the lef
17. restart Low Water 1 With the burner firing Press and hold the 2nd Low Water test button until minimum 15 seconds the low water alarm sounds and the second low water reset switch illuminates and the burner shuts down Release the test button After approximately 17 seconds the second low water relay will reset To cancel the second low water level alarm and light depress the second low water reset switch The burner will restart JFS Series Oil 01 2008 38 Fulton C Spirax High Integrity Level Controls continued Weekly Test Daily test plus 1st Low Water 2nd ous G 8 1 With the burner firing 2 3 By evaporation lower the water level in the boiler until the first low water alarm sounds Switch the pump interrupt switch to the pump interrupt position and the low water indicator lamp illuminates and the burner shuts down 4 Switch the pump interrupt switch to the pump on position 5 6 After approximately 17 seconds from restoring the first low water level the low water alarm will The pump will start and restore the water level to the normal position and switch off cancel the low water lamp will extinguish and the burner will restart Low Water With the burner firing Switch the pump interrupt switch to the pump interrupt position By evaporation lower the water level in the boiler until the low water alarm sounds the second low w
18. valve is CLOSED i Ensure that the boiler and pump switch is in the OFF position j Ensure that all appropriate electrical isolators are switched ON k Ensure the pump interrupt switch is in the PUMP RUN position caution The feed pump seals are water cooled The pump must never be allowed to run whilst dry irreparable damage may result Ensure the pump is fully primed before energising the motor 1 Press the boiler pump switch to the PUMP ONLY position Note f the boiler water level is below its correct level the water pump will operate When the water reaches the correct level two thirds up the water level gauge sight glass the pump will stop If the water level is above the top of the water level gauge sight glass drain off until the level is in the middle of the water level gauge sight glass 3 5 STARTING THE BURNER a CLOSE the main steam stop valve b Press the control switch to the PUMP AND BOILER position The low water audible alarm will sound and the low water reset switch and low water alarm lamp will illuminate c Press the low water reset switch for 2 seconds maximum The audible alarm will silence and the alarm lamps will extinguish The burner start sequence will commence d After a maximum of one minute the burner should be firing and the burner on lamp should illuminate 19 JFS Series Oil 01 2008 3 5 3 6 Note STARTING THE BURNER continued e When the boiler has achieved the required set
19. a Blowdown the water gauge set 1 1 Open the gauge glass blowdown valve A 2 Close for approx 3 seconds the top gauge valve B 3 Open valve B 4 Close for approx 3 seconds the bottom gauge valve C 5 Open valve C 6 Close valve A Repeat for gauge set 2 On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves CLOSED Note Where a Boiler is operating continuously at steam pressure advice should be taken from a Fulton agent as to the appropriate blowdown procedure Water Level Gauge Set 2 WORKING STEAM WATER POSITION BLOWDOWN BLOWDOWN art AU LP F03200 Water Level Gauge operating positions n 1 ater Level Gauge Set 1 Fig 18 WATER LEVEL SIGHT GAUGE BLOWDOWN 23 JFS Series Oil 01 2008 3 8 EVAPORATION CHECKS With the boiler running under normal load conditions and the pump stopped having just completed a refill cycle a Ensure that the boiler water level is correct b Switch the pump OFF at the pump interrupt pump run switch The water level in the boiler will lower through natural evaporation When the level nears the bottom of the water level gauge sight glass the first low water alarm will sound the low water alarm lamp will illuminate and the burner will shut down If it is required to check the second low water alarm wait a further peri
20. additional aid to the operator The meaning and operating sequence of these lights is as follows Start Low Water Reset This switch is used to start the boiler and to reset the low water alarm When the switch is pressed to initiate the start up sequence the low water alarm lamp also illuminates and the low water audible alarm sounds Keeping the switch depressed for approximately 2 seconds cancels the low water alarm and initiates the burner start sequence Illumination of this switch and sounding of the audible alarm at any other time other than at switch on indicates that the boiler has gone to a lockout safe condition due to low water Once the water in the boiler has been restored to a safe operating level pressing the switch will reset the controls Circuit On Indicates that power is being supplied to the control panel Low Water Alarm 1st low water This light will energise when the boiler is switched on and the water level is between 1st low water and 2nd low water A light will illuminate and a pulsing alarm sound Low Water Reset 2nd low water The 1st low water light and alarm are replaced by the 2nd low water light and a continuous alarm indicated by the low water reset switch The second alarm must be reset the first alarm will be automatically reset by the return to normal water level Ignition This lamp indicates the ignition transformer has been energised it will remain illuminated for 5 10 seconds appr
21. anagement program is followed to ensure trouble free boiler operation The following are recommended for feedwater and boiler water FEEDWATER water entering boiler pH Value 8 5 to 9 5 tested at room temperature Hardness less than 2 0mg kg in the form of CaCO Suspended Solids None Chloride Less than 50mg kg Organic Matter Less than 5mg kg Cil None BOILER WATER water inside boiler pH Value 9 5 11 5 tested at room temperature Hardness Not detectable Suspended Solids Less than 100mg kg Chloride Less than 500mg kg Oxygen Scavenger Sodium Sulphite or Tannin Phosphate Total Alkalinity Caustic Alkalinity Total Dissolved Solids TDS Iron Silica Dissolved Oxygen mg kg CaCO PO SiO 1 Grain hardness therefore 7 For practical purposes mg kg 20 to 50mg kg Less than 50mg kg in the form of PO Less than 1000mg kg Less than 300mg kg as CaCO Less than 2000ppm Less than 1mg kg Less than 150mg kg in the form of SiO None Milligrams per Kilogram Calcium Carbonate Phosphate Silica 17 118ppm 4 10 grains hardness ppm It is critical that the boiler water pH be alkaline 9 5 11 5 whenever water is in the boiler Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids TDS Consult your Water Treatment specialist to establish the frequency and duration of blowdown required to achieve the required water conditions JFS Serie
22. ater reset switch illuminates and the burner shuts down Switch the pump interrupt switch to the pump on position The pump will start and restore the water level to the normal position and switch off After approximately 17 seconds from restoring the second low water level the second low water relay can be reset To cancel the second low water level alarm and light depress the second low water reset switch The burner will restart Note These tests can be carried out consecutively however it is possible that if the boiler is under load conditions the second low water alarm will occur immediately after the burner has shut down on first low water without the apparent loss of any more water The reason is the collapse of the steam bubbles at the water level surface when the heat is removed The degree of collapse could be such that the water level will disappear from the bottom of the site glass be fore the alarm sounds Should this happen the second low water level alarm should be checked by lowering the water level slowly by partially opening the main Pump Interrupt Switch 39 JFS Series Oil 01 2008 Fulton 5 GENERAL DATA SECTION 5 440 1750 1955 2295 390 2060 1880 985 310 220 152 1295 950 2800 350 440 2065 2395 2640 390 2455 2225 1175 425 220 203 1600 1235 3250 350 440 2175 2500 2795 390 2610 2380 1390 500 220 305 1890 1600 3500 350
23. cient design and construction incorporating a larger heat transfer surface than standard boilers it meets the peak demand for steam over a relatively short period of time ideal for applications such as sterilisers and autoclaves The larger steam release surface area results in a more stable water level under peak load conditions producing higher quality steam Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained Satisfactory performance can only be ensured if the installation recommendations operating routines and maintenance schedules laid out in this manual are adhered to Particular attention should be paid to electrical installation and water treatment Technical Data for a full specification refer to Section 5 JFS Series Oil 01 2008 Feed Water Steam Pressure Isolation Gauge Ball Valve Red alee Flame Detector Non return Valve Ignition Electrodes VB Safety Valve J ks Main Steam Valve ae Oil Feed Water Column Oil Pump Probes Main Air 3 Intake B manifold FI Boiler Control Panel Sight Gauge Feed Water Pump Blowdown Valve Isolator Switch LT Control Box Door Lock Water Column Blowdown Valve Control Box 530 Isolator Switch e Steam Pressure Control Boiler Blowdown Valve Cleanout Handhole Cleanout Door Water Jacket flame turn around FIG 2 GENERAL ARRANGEMENT
24. e should be no smoke visible from the flue If either of these tests fail or at any time during boiler operation there is doubt about the integrity of the flue shut down the boiler and contact Fulton Boiler Works Immediately 11 JFS Series Oil 01 2008 2 Fulton 2 Wi 2 16 COMMISSIONING THE BOILER continued INSPECTION a Ensure the boiler has been washed out after installation Conduct a water analysis before operating the boiler Examine the probes in the water column and the boiler shell Replace any damaged probes b Remove the burner and check the electrodes have not been damaged and that their settings are correct If the burner is fitted with a photocell remove it and check for damage c Replace the burner and reconnect the cooper oil line s to the oil nozzle assembly ensuring these connections are tight Reconnect the ignition leads and replace the sensor d X Ensure all wiring connections are correct and all terminal screws are tight Fire Oil Supply Low Fire Start Burner Plate cg Supply B Electrodes Electrodes View on ERA arrow omm des uta ra oo 12m NA OO Electrode settings 22 0 relative to nozzles 130mm 5mm Fuel Nozzle Electrode Tips Bent to align with 300mm 212 Low Flame
25. econdary Air Adjustment Check main air adjustment to see if it has moved Adjust as necessary and tighten in position Check CO and O level 5 Draft Check draft is neutral Consider installing a barometric damper if the draft is too strong 6 Dirty Flue Check flue for Carbon build up or blockage Clean flue passages with brush 7 Negative Room Pressure Ensure no exhaust fans are running in the boiler room 8 Oil Nozzle Check for blocked nozzle clean or replace as necessary 9 Oil Pump Check for blocked strainer or filter Remove or clean Check for slipping or broken coupling Tighten or replace Check for seized pump shaft Replace Burner back fires 1 Refractory Bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Ignition Electrodes Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace 3 UV Detector Check for dirt on scanner clean as required Check for proper location of detector 4 Draft Problem Check draft is neutral Consider installing a barometric damper if the draft is too strong 5 Negative Room Pressure Ensure no exhaust fans are running in the boiler room 6 Primary Air Adjustment Check air adjustment Air may be blowing fire away from flame detector 7 Oil Valve s Check for leaking oil valve s and replace 8 Loss of Oil Prime Check all lines for possible air
26. eekly 6 WARNING Ensure the main electrical supply is isolated before starting work Inspect the hand holes in the boiler If any leakage is evident proceed as follows Note Use only genuine Fulton replacement parts 4 5 10 11 12 13 14 a Using the special tee handle wrench remove the handhole assembly b Remove the old gasket and thoroughly clean the mating faces of the plate and boiler C Fit the handhole assembly as follows 1 Place the new gasket on the handhole plate and ensure that it is seating correctly Do not use any grease lubricant or adhesive 2 Position the plate in the boiler set the crab and tighten the securing nut only sufficiently to provide a snug fit Verify the position of the plate in the boiler to ensure that there is uniform space between the periphery of the door and the boiler inspection opening Tighten the nut hand tight only Using the special wrench tighten the nut a further quarter of a turn DO NOT OVERTIGHTEN d If the gasket leaks as the pressure is building up tighten the securing nut only sufficient to stop the leakage Inspect the flanged joint covering the rear inspection port in which the blowdown valve is fitted if any leakage is evident replace the gasket Clean the sight glass If any leakage is evident renew the gasket Clean any strainers in the feed water line Check and clean the UV detector Clean any water traps and strainers fitted in the fu
27. el line Check the operation of any steam traps fitted on the condensate return system Check boiler and feedwater quality see water treatment in section 5 Remove clean and adjust the oil nozzle and electrode assembly THREE MONTHLY including monthly 15 16 17 Drain and isolate the boiler Remove the lower hand hole assemblies and inspect the interior of the pressure vessel for scale and sludge build up Remove the feedwater pipe from the top of the boiler Ensure the pipe is not blocked clean as required JFS Series Oil 01 2008 34 gt gt Handhole Cover Plate FIG 20 HANDHOLE Ignition n Transformer Ignition Leads Burner Plate Screws Burner Burner Motor Scroll Photocell Air Gate UMN Ls Cc Electrodes Fan Oil Feed Pipe Air Damper N Pie ae 7 JE Burner Plate Burner Top Plate Oil Line Spider Electrode Holder Coupling Deflector Plate Fuel Pump F00850 FIG 21 BURNER ASSEMBLY 35 JFS Series Oil 01 2008 46 SIX MONTHLY including three monthly It should be noted that after a Fulton boiler has been in operation for several months pieces of burned metal will be found in the space at the bottom of the boiler These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation This is normal and does not affect the efficiency or the li
28. er Ensure the boiler room doors are closed and the recommended vents are clear Dirty probes clean or replace as required Check relay is secure on its base if so replace the relay Check for tightness and clean As the boiler cools it pulls water from the system To prevent this add an anti vacuum valve on the steam gauge assembly piping this valve closes under pressure and opens under vacuum JFS Series 01 2008 Fulton 3 Ignition Flame Burner Burner Boiler Boiler Failure Failure Cutoff Combustion Back will not will not Fires Maintain Maintain Pressure Water Power Supply Oil Supply Refractories Ignition Electrodes Main Air Adjustment Oil Valves Photoelectric Cell Low Water Probes Low Water Control Pressure Controller Burner Programmer Draught Transformer Sec Air Adjustment Loss of Priming Oil Steam Overload Feed water Pump Bad Traps Dirty Flues FIG 16 FAULT FINDING CHECK LIST JFS Series Oil 01 2008 30 3 Fulton 3 This log should be completed regularly as a record of boiler maintenance MAINTENANCE LOG am umm 9 31 JFS Series Oil 01 2008 4 4 1 MAINTENANCE SECTION 4 GENERAL To ensure the efficiency of the boiler carry out the regular maintenance instructions detailed below If any fault is found during these operations contact your
29. er firing and the pump not running lower the water level in the boiler by opening the main boiler blowdown valve As the water level falls visible in the sight glass and before the low water lock out position is reached the water pump should start to run When this happens close the main boiler blowdown valve The water pump should continue to run and re fill the boiler to the correct level and stop First Low Water Level for boilers fitted with Spirax High Integrity Level Controls see Appendix a Ensure the following The burner is firing The water level is correct in the boiler The water pump is not running b Switch the pump off Pump Interrupt at the pump interrupt pump run switch c OPEN the main blowdown valve d When the water level nears the bottom of the water level gauge sight glass the low water alarm should sound the low water alarm lamp should illuminate and the burner should stop firing When this happens CLOSE the blowdown valve IMMEDIATELY e Switch the pump to RUN at the main pump interrupt pump run switch The pump should run and refill the boiler When the water level in the boiler rises above the first low water level the low water level lamp should extinguish the audible alarm should silence and the burner start sequence should commence automatically The pump should run until the boiler water level is correct and then stop JFS Series Oil 01 2008 20 3 6 5 2nd Low Water Check for b
30. fe of the boiler in any way 18 19 20 21 22 23 Remove the cover plates and clean out door Clean out the flue passes Check the refractories for soot or breakage inspect the stainless steel ring When replacing the cover plates and clean out door use furnace cement to ensure a tight seal thus preventing the escape of hot gases Apply a small quantity of oil to the bearings of the burner motor and the feed water pump motor Drain and flush the feed water tank Clean any filters in the tank in the feed water line or in the feed water pump Remove and clean the water probes take care not to crack the porcelain After replacement of the probes check the operation of the low water cutoff relay and of the feed water pump Remove the air gate and clean the fan Test the flue using the following procedure Visual inspection Check joints between all flue sections for quality of seals Where the flue passes through the structure of the building use your judgement as to the integrity of this section of the flue Smoke test With the flue capped and a smoke generator inserted into the flue their should be no smoke visible If either of these tests fail shut down the boiler and contact Fulton Boiler Works immediately 24 26 Remove the water gauge and water column Rod through the top connections of both to ensure the holes in the baffle plates approx 6mm dia inside the boiler are not obstructed Check the
31. ff Remedy Check traps clean or replace as required Call water treatment company and consult the factory Dump the return tank and flush the system Test the water treatment Check total equipment load against the boiler output Decrease amount of equipment being used Check draft is neutral Consider installing a barometric damper if the draft is too strong Adjust main air Check tank and lines for water or leaks Check traps Clean or replace as required Dump the return tank and flush the system Test the water treatment Clean or replace as required Check relay is secure on its base if so replace the relay Check for tightness and clean Allow system to cool down check steam traps and check to be sure return lines are not insulated Check return tank temperature if it is above 82 vapour locking of the pump will occur Inspect check valves Clean and replace as needed Replace pump with multi stage centrifugal pump able to cope with 1219C Check feed water line is not blocked clean as required Check probes clean as required Check to ensure the contactor is live Check to ensure the contactor coil is being pulled in Replace as required Check the pump circuit is live If the circuit is live but the pump is not running replace the pump Check the valve is opening and closing Clean or replace as required Check the draft with a gauge should read neutral May need to install a barometric damp
32. ing Tests 3 6 Pump Check 3 6 1 First Low Water Level Check 3 6 4 2nd Low Water Check 3 6 5 Blowdown Procedures 3 7 Evaporation Checks 3 8 Troubleshooting 3 9 Maintenance Log MAINTENANCE 4 General 4 1 Daily 4 2 Weekly 4 3 Monthly 4 4 Three Monthly 4 5 Six Monthly 4 6 GENERAL DATA 5 SPARE PARTS 6 JFS Series Oil 01 2008 Fulton SAFETY The instructions provided for the operation and maintenance of the boiler MUST be observed Failure to do so could result in damage to the boiler and serious personal injury WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner WARNING Do not try to do repairs or any other maintenance work you do not understand Obtain a Service Manual from Fulton or call a Fulton Service Engineer WARNING Understand the electrical circuit before connecting or disconnecting an electrical component A wrong con nection can cause injury and or damage N WARNING Adefective boilercan injure you or others Do not operate a boiler which is defective or has missing parts Make sure that all maintenance procedures are completed before using the boiler N WARNING HYDRAULIC TEST RISK OF BRITTLE FRACTURE Hydraulic testing requires specialist equipment and is normally only required by engineering surveyors in spectors The materialthe boileris manufactured from has not been impact tested as it is no
33. ings to be used with a minimum of 6 diameters to the first fitting A EE FIG 8 SAFETY VALVE WATER GAUGE SET The design may vary from that illustrated Numbers may vary due to individual countries regulations Boilers are normally supplied with two complete water gauge sets The water gauge blowdown cock should be connected to the auxiliary blowdown line from the water column blowdown valve in soft copper tubing The connection to the gauge cock is 6mm 0 25in A WARNING Factory fitted safety valves are preset to protect the boiler only and must not be used to protectany other items not capable of accepting boiler pressure FIG 9 WATER GAUGES JFS Series Oil 01 2008 2 Fulton 2 Oil supply Flame detector Ignition i location Electrical Transformer Connection Box p Oil Supply Valves Oil Pump Adjustable Ignition Secondary air Air Control electrodes damper FIG 10 OIL SUPPLY FIG 11 IGNITION ELECTRODES Flame Detector Safety Valve Burner Assembly Cover Oil Supply Steam Supply Connections Pipe Water Level Probes Ignition Electrodes FIG 12 BOILER TOP COMPONENTS 9 JFS Series 01 2008 2 10 OIL SUPPLY 2 11 The positioning of the oil storage tank will be dependent on site conditions and local regulations The burner fuel pump is of the bypass type requiring the installation of feed and return lines between the oil storage tank and the boiler These lines shou
34. inutes adjust the main air control gate to obtain a clean combustion Observe the flame through the peephole between the electrodes and adjust the primary air control so that the flame cannot be seen backing up the blast tube Adjust the air main control to obtain a full swirling flame shape brushing the wall of the furnace by observing the flame through the eye glass in the burner plate Check the operation of the low water safety controls as detailed in Section 3 Operation JFS Series Oil 01 2008 14 Fulton 2 N Wi 2 16 COMMISSIONING THE BOILER continued n Adjust the steam pressure control to suit the boiler application It should be borne in mind that boiler are designed to operate most efficiently at their maximum operating temperature When boilers are to be operated below a pressure of 80 psi 5 5 bar consideration should be given to the fitting of a pressure reducing set see Section 2 8 Steam Safety Valves If the pressure control is fitted with a differential scale see OEM literature in section 5 i Set the main scale pressure to the pressure indicated on the boiler data plate ii Set the differential scale to it s minimum pressure If the pressure control has a fixed differential e g no adjustable differential scale set the main scale to the maximum pressure required Note When boilers are fitted with a sequence control i Set the main scale and differential scale as above ii Se
35. ld be in tubing of a minimum bore of 10 mm A fire valve stop valve and check valves should be inserted in the oil feed line To avoid blockages in the fuel pump and burner nozzle a metal cartridge oil filter should be fitted Fibrous cartridge filters are not recommended The final connections between the fuel pump and the feed and return lines should be made with the flexible fuel lines supplied If the oil storage tank is positioned higher than the boiler a non return valve should be fitted to the return line To overcome suction problems at the fuel pump all vertical lifts in the feed pipe should be made as close to the boiler as possible The burner fuel pump pressure is preset at the factory and should not require adjustment ELECTRICAL REQUIREMENTS An individual wiring diagram for the boiler is located on the inside cover of the control box When referring to the electrical specification of the boiler the reference number located on the rear inside wall of the control box and the wiring diagram number should be quoted The audible alarms provided are mounted on the side of the control panel if not audible they should be repositioned where they can be heard by a person competent to take the appropriate action should the alarm be activated Unless otherwise specified the alarms supplied will be mains voltage models Unless otherwise specified all models are supplied with burner motors and feed water pump motors arranged for opera
36. n 3 8 blowdown the boiler from 1st to 2nd low water The purpose of adopting this procedure is to prevent steam and water being expelled from the blowdown vessel vent because of prolonged blowdown 21 JFS Series 01 2008 Fulton 3 3 7 BLOWDOWN PROCEDURES Daily tests Keep the boiler water gauge water column and interconnecting pipework free from sludge and scale buildup by blowing down in the following manner Note Where a boiler is operating continuously at steam pressure advice should be sort from Fulton regarding the appropriate blowdown procedure a Start the boiler and generate not more than 10psi of steam b Shut off both the burner and the pump Boiler Blowdown a Fully OPEN the boiler main blowdown valve for not more than 5 seconds b CLOSE the valve Note Where high levels of suspended solids are produced longer and or more frequent blowdown may be required Water Column Blowdown Note The water column contains the pump ON OFF probe which is not safety locked a Switch the pump off at the pump interrupt pump run switch b Open the water column blowdown valve for 5 seconds c Close the water column blowdown valve Wait for 10 seconds for the water in the boiler to stabilise after blowdown d Switch the pump on at the pump interrupt pump run switch JFS Series Oil 01 2008 22 3 Fulton 3 7 BLOWDOWN PROCEDURES Daily tests continued Water Gauge Blowdown
37. ngements 5 Boiler Blowdown 6 Main Steam Valve 7 Safety Valve 8 Water Gauges 9 Oil Supply 10 Ignition Electrodes 11 Boiler Top 12 Steam Pressure Gauge 13 Nozzle and Ignition Assembly 14 Commissioning the Boiler 15 Pressure Control 16 JFS33 Control Panel 17 Sight Gauges 18 Boiler Maintenance 19 Handhole 20 Burner Assembly 21 Flue Cleaning 22 Boiler Dimensions 23 Supply Circuit 24 Ancillary Supply Circuit 25 Spirax Level Control Circuit 26 LC Level Control Circuit 27 TDS and Blowdown Control Circuit 28 JFS 6J 30J Burner Control Circuit 29 SPARE PARTS Refer to Fulton for required spare parts JFS Series Oil 01 2008 Steam Feed Water Pressure Isolation Feed Water Gauge Ball Valve Non return Valve Ultraviolet Flame Detector Ignition Electrodes Steam Supply Val ges 5875 Ha Oil Feed Line Safety Valve a i al Water Level Probes Water Column Oil Pump Probes Main Air Intake Manifold Boiler Control Panel Sight Gauge Blowdown Valves Feed Water Water Column Blowdown valves KIL Pump Isolator Switch Control Box Isolator Switch Steam Pressure Control Boiler Blowdown Valve Cleanout Handhole Cleanout Door Water Jacket flame turn around FIG 1 OIL FIRED STEAM BOILER 1 JFS Series Oil 01 2008 1 1 1 2 INTRODUCTION SECTION 1 General The Fulton JFS Series Oil Fired Steam Boiler is a vertical two pass boiler of simple and effi
38. not store chemicals such as perclorethylene in the boiler house the fumes may damage the boiler and flue and cause the burner to lock out on flame failure Ventilation requirements Boiler Model 22 33 55 High Level cm 420 560 700 Low Level cm 835 1115 1395 JFS Series Oil 01 2008 4 HAT WA ONILIVIOSTI WINIVHLS MOL Vuvdss NOLTOA OL I HL VM 000007 155 FLY SNYGNOO S MNWL ALIHOHLOV UAL WMT vor THHLS SNTI HHL MOHHO ud SSHINIWLS ANVIL V ALON ATddOS d L SOVHGLS IIO OL SNOLLOYNNOD HAT VA ANIT adaa TIO FATWA SNIIVTOSI HOCIU IO TVLIEN TIO SSV ID LHOIS ANIT NHOLWH TIO YYNENE XAOSVSI YO MNVIIO 4I ANIT SAIYA HIA ANO ANIT NYNLYY TIO NI SXAIVASNIJA IOSI Hood L NONWH TO 3202 DANTS HATVA MOHHO VM dada AAT YA NMOGMOTH X IIOGH G3LLI4 HAT VA TIvd HAS ITIGVLS pol 5 14405 WWALS LHOnVud NIVHGQ ANY SNOINN WILLI VsHVH4VS OL HATVA ALHAVS WWIIOgH FHL DNIYYTYO NAHM WILL HW IIOH GQHVOINVILS 30 ANIT NMOGMO IH KNTOD VM FIG 3 TYPICAL INSTALLATION JFS Series Oil 01 2008 Fulton 2 2 4 Note
39. observed DRYING OUT TIME The refractory casing of the boiler is made from a material that uses a high proportion of water in the mixing process Whilst some of this water is driven off by chemical reaction and the initial test firing the refractory is still wet when the boiler is delivered For the first few days after the boiler is commissioned and in service water will be seen running from the bottom of the casing and from around some branch pipes This is perfectly normal and part of the final drying process BOILER CONTROLS The following brief description of the controls used on the JFS Series oil fired boiler is intended to provide the operator with a basic understanding of the operating principles which is essential for the continued efficient operation of the boiler WARNING The control circuit live light is derived from a single phase It is possible that with the control phase down or a defective bulb the other phase could be live Always Isolate the supply before investigating any fault Note All the controls are of the fail safe type and are wired in series failure of any one will automatically shut down the boiler Low Water Safety Relays and Feed Water Pump relays These relays operate in conjunction with probes suspended in the boiler and water column to automatically maintain the level of water in the boiler and to cut off the burner should the water level fall to an unsafe level Steam Pressure Control s
40. od for the LOW WATER RESET Switch to illuminate When the check is complete proceed as follows a Switch the pump ON at the pump interrupt pump run switch b Press the low water reset switch The pump will start to refill the boiler If the pump starts to run at any time during the test then the test must be abandoned and restarted from the beginning JFS Series Oil 01 2008 24 3 9 TROUBLESHOOTING Problem Ignition Failure Flame Failure see note Cause 1 Oi Oil tank empty Power Supply Ignition Electrodes Transformer UV Detector Loose wire connection Burner Control Oil nozzle clogging Faulty Oil Pump Power Supply Ignition Electrodes Main Air Adjustment UV Scanner Contact open on air safety switch Scanner wiring reversed at panel Oil Supply Oil Valve Oil Pump 10 Loss of Oil Prime Remedy Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check voltage between transformer leads at terminal block to be sure transformer is live Check for ignition interference Check connections to all components
41. oilers fitted with Spirax High Integrity Level Controls see Appendix Ensure the following The burner is firing The water level is correct in the boiler The water pump is not running Switch the pump OFF at the pump override switch OPEN the main blowdown valve When the water level nears the bottom of the water level gauge sight glass the LOW WATER ALARM lamp should illuminate the low water audible alarm should sound and the burner should stop firing Continue to blow down As the water level falls nearer the bottom of the water level gauge sight glass the LOW WATER RESET switch should illuminate and the second audible low water alarm should sound CLOSE the main blowdown valve and switch the pump ON at the pump override switch The water pump should now start to run and refill the boiler Once filled to the correct level the water pump should stop The low water alarm should continue to sound the LOW WATER RESET switch and LOW WATER ALARM lamp should remain illuminated and the burner should NOT start When the water level in the boiler is correct the burner can be restarted by depressing the LOW WATER RESET switch for a maximum of 2 seconds 1 The First and Overriding low water checks can be carried out in one operation to reduce the blowdown time and possible interruption to the steam supply 2 Where the water level tests are to be carried out at full pressure evaporate the water down to 1st low level as i
42. oximately during the ignition sequence Burner On This lamp indicates that the burner is running and that the flame is being monitored by the burner programmer Flame Failure Alarm reset This switch will illuminate if the burner goes to a lockout condition due to flame failure Pressing the switch will reset the burner controller WARNING No more than two attempts should be made to start the boiler by resetting the flame failure alarm reset Further attempts could cause the boiler and flue system to fill with vaporized oil which could cause an explosion Oil Valve The two lamps provide a visual indication that the magnetic oil valves have been energised JFS Series Oil 01 2008 18 3 4 FILLING THE BOILER ALL MODELS Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down a Ensure that the main steam stop valve is OPEN b Ensure that the steam pressure gauge isolating valve is OPEN c Ensure that the oil flow and return valves are OPEN that there is an adequate oil supply in the oil tank and that the burner oil pump has been vented d X Ensure that all the valves in the water feed line are OPEN e Ensure that the main blowdown valve is CLOSED f Ensure that the water level gauge isolating valve s is OPEN g Ensure that the water level gauge blowdown valve s is CLOSED h Ensure that the column blowdown
43. peuos eui eouepJoooe eq oj 559 BUIMOJ OJ eu 901 51541 S TOMLINOO 43711049 QHVONVIS ON Fulton 6 SPARE PARTS SECTION 6 Consult Fulton Boiler Works for spare parts for the JFS Range of Boilers tel 0117 9723322 In order to ensure spare parts are correct please complete the details below and have them at hand when ordering parts or making enquires regarding the boiler Boiler number Boiler type Type of fuel used Wiring Diagram No Commissioning Date The type size and lift pressure of the safety valve fitted to a boiler is specific to that boiler When ordering new safety valves it is important that as well as the information requested above the following additional information is given Boiler design pressure located on the boiler data plate Make and type e g fig no of safety valve fitted JFS Series Oil 01 2008 Material amp Workmanship Warranty On the Fulton Boiler Pressure Vessel Fulton Boiler Works Great Britain Ltd will repair or replace FoB factory any Fulton pressure vessel which within five 5 years of the date of delivery is found to be defective in workmanship or material provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the Manufacturer s Handbook This Warranty does not cover damage or failure
44. roller Disconnect the wires from the controller Place an OHM meter between the switch terminals Lower the set point of the controller the switch should make Raise the set point and recheck switch should break If the controller operates improperly replace it Consult Fulton Check the bricks are not plugged with soot cracked or broken into pieces Clean and replace as required Check traps clean or replace as required Boiler may be undersized JFS Series Oil 01 2008 28 TROUBLESHOOTING continued Problem Boiler is Surging Boiler Rumbles Boiler pushing water with steam Pump will not cutoff Pump runs but does not put water in the boiler Water pump runs intermittently Boiler contiues after shut down Oil fumes coming out around the oil pump housing on shut down Boiler flooding Cause Steam Traps blowing through Scale buildup or lime deposits Too much water treatment Too much of a load Draft Problem Too much main air Air or water in the oil Steam Traps Too much water treatment Dirty Probes Relay failed Earth connection Vapour locking of pump Blocked feed water line Scale on probes Bad pump contactor Pump Motor damaged Oil Valve defective Bad draft condition Venting of room Pump does not shut off Relay failed Earth connection Vacuum created with the boiler o
45. s Oil 01 2008 42 rem SAIOA Tria 2 110 SVD 304 070009073 OL 8343 NOLLOTINL SNI NOLLVNNILNOO UNDYED SIRIS faa HO LOM dnd HOLOW 334 HO LOM HINN 1 o 031115 30 HOLOYINOD HOLDVLNOD NOLOMI d d CH234 MBOLDVINOO HOLORN 03114 30 119 SOLON FO LLI C34 HIMHOJSNYUL IOSI CEDIOO THALNI WD JFS Series Oil 01 2008 Fulton 5 E GE EN E mi 2 ME i MM TE Mk rm BERRE F a E m n mi anam ER FIG 23 ANCILLARY CONTROL CIRCUIT JFS Series Oil 01 2008 44 TRE E Bb E SEE T mews i I i OF ATES _ 4 Pug FIG 24 SPIRAX LEVEL CONTROL CIRCUIT 45 JFS Series Oil 01 2008 NC z Y B E ME 15 2 4 01 E AL dg 4 i E 1 I i inl bt FIG 25 LC LEVEL CONTROL CIRCUIT 46 JFS Series Oil 01 2008 Tib h OTOL dad OR EDU
46. s that can be attributed to corrosion scale or dirt accumulation or to low water conditions This Warranty is good only in the United Kingdom of Great Britain and Northern Ireland This Warranty does not include labour or delivery charges of any kind General Warranty The Fulton general Guarantee is given in lieu of and in exclusion of any warranty expressed or implied statutory or otherwise as to the state condition performance quality or fitness of the goods Save thereunder we shall be under no obligation or liability of any kind to you in regard to the goods In the case of new goods manufactured and supplied by us we will make good any defect developing therein under proper use within 12 months of delivery provided that after investigation in our sole discretion we are satisfied that the defect arose from faulty design materials or workmanship and from no other Defective goods or parts must be returned to us as soon as possible after discovery of the defect Costs of carriage and of detaching and incorporating parts will be borne by you In all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to be incurred by us in respect of gauge or sight glasses packing glands or electric motors or any goods or accessories not of our manufacture But so far as we are able we shall let you have the benefit of any guarantee or warranty given to us in respect thereof
47. ssure System Safety Regulations 2000 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme Regular inspections are therefore required by Competent Person The scope of the examination and the actual intervals between examinations is at the discretion of the com petent person It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which a defect may give rise to danger Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover periodic statutory inspections For further information contact a SAFed SAFETY ASSESSMENT FEDERATION Limited Nutmeg House 60 Gainsford Street Butlers Wharf London SE1 2NY b Health and Safety Executive local office c Your Competent Person JFS Series 01 2008 LIST OF CONTENTS TITLE SECTION INTRODUCTION 1 General 1 1 Technical Data 1 2 INSTALLATION 2 General 2 1 Siting 2 2 Ventilation 2 3 Flue Outlet 24 Water Supply 2 5 Blowdown Valves 2 6 Main Steam Valve 2 7 Steam Safety Valve 2 8 Water Level Gauge Set 2 9 Oil Supply 2 10 Electrical Requirements 2 11 Steam Pressure Gauge 2 12 Commissioning the Boiler 2 16 Cleaning Steam Lines and Pressure Vessels 2 17 OPERATION 3 General 3 1 Boiler Controls 3 2 Control Panel Indicator Lights 3 3 Filling the Boiler All Models 3 4 Starting the Burner All Models 3 5 Daily Operat
48. t a requirement of BS2790 boiler construction standard In order to ensure the material pressure vessel does not suffer from brittle fracture hydraulic testing should not be carried out below 5 C N WARNING The importance of correct boiler water and feed water cannot be over emphasised see the relevant section in this manual A CAUTION LOW FEED WATER TEMPERATURE Low feed water temperature can resultin thermal shock to the boiler pressure vessel Return the maximum amount of condensate and if necessary pre heat the feed water If in doubt consult FBW N CAUTION Obey all laws and local regulations which affect you and your boiler NWARNING Only qualified persons should be allowed to operate and maintain the boiler and its equipment Boilers should always be drained through an approved Blowdown Vessel NWARNING Do not change the boiler fuel without consulting the boiler manufacturer WARNING Non approved modifications can cause injury and damage Contact your Fulton dealer before modifying the boiler N WARNING LIFTING EQUIPMENT Make sure that lifting tackle complies with all local regulations and is suitable for the job You can be injured if you use faulty lifting equipment Make sure the lifting equipment is in good condition N WARNING Operating the boiler beyond its design limits can dam age the boiler it can also be dangerous Do not operate the boiler outside its limits Do not try to up grade the
49. t hand side of the boiler below the sight glass assembly JFS Series Oil 01 2008 6 2 6 BLOWDOWN VALVES There are three blowdown valves on the boiler four if two water gauge sets are fitted the boiler blowdown valve at the rear of the boiler the water column blowdown valve and the water gauge blowdown valve of these valves must be connected to a blowdown receptacle of approved design Regulations exist covering such items and care must be taken to ensure compliance with these regulations If in doubt regarding blowdown arrangements consult your Fulton agent FIG 6 BOILER BLOWDOWN 27 MAIN STEAM VALVE The main steam stop valve should be inserted in the steam line approximately 12in 305 mm from the top of the boiler FIG 7 MAIN STEAM VALVE 7 JFS Series Oil 01 2008 2 8 STEAM SAFETY VALVES 2 9 Safety Valves are factory fitted and preset they MUST NOT be adjusted The discharge outlet should be piped to a safe discharge point and the piping so arranged that any condensate trapped in the pipework will drain away from the valve a lift pressure is indicated on the safety valve Do not adjust b The safety valve fitted to the boiler is designed to prevent the boiler exceeding it s design pressure c system connected to the boiler not capable of accepting boiler pressure must be protected by a separate safety valve set to the required pressure d Long radius fitt
50. the priming plug from the pump head and slowly fill the pump with water Replace the priming plug and tighten securely See the correct rotation of the pump on the motor fan cover Start the pump and check the direc tion of rotation Vent the pump by means of the vent valve in the pump head At the same time open the discharge isolating valve a little Continue to vent the pump At the same time open the discharge isolating valve a little more Close the vent valve when a steady stream of water runs out of it Completely open the discharge isolating valve The bypass valve located in the drain plug may be opened during the filling procedure close the bypass when the operation is stable DO NOT ALLOW THE PUMP TO RUN DRY Open all the valves in the water feed line Switch on the feed water pump motor and fill the boiler The operation of the pump controls should be checked by using the boiler blowdown valve located at the rear of the boiler When the water sight level gauge is reading two thirds full the pump will stop Open the boiler blowdown valve and slowly drain the boiler When the water level falls below the PUMP ON probe the pump should start If the pump does not start check the probe connec tions Close the boiler blowdown valve Close the boiler blowdown valve Start the burner as detailed in Section 3 Operation Allow time for the fuel pump to prime itself After the burner has been firing for approximately five m
51. tion on a three phase supply The power ratings and requirements are given in Technical Data Section 5 JFS Series Oil 01 2008 10 Steam Pressure Gauge Plug Steam Cock E Co Test Point Syphon F03210 FIG 13 STEAM PRESSURE GAUGE 2 12 STEAM PRESSURE GAUGE The steam pressure gauge assembly should be assembled in accordance with Fig 9 using a suitable sealant on all joints The gauge should be facing towards the electrical control box and or the operator of the boiler Screw the assembly into the top of the boiler and connect the copper tube from the pressure controller located on the side of the control box to the nipple provided on the assembly 2 16 COMMISSIONING THE BOILER It is essential that the commissioning procedures listed below are carried out by a Fulton Service Engineer who will have the necessary experience and testing equipment to ensure that the installation is not only correct but is operating safely and at optimum efficiency FLUE COMMISSIONING Prior to initial firing of the boiler the flue must be checked for leaks This is done by BOTH of the following methods Visual Inspection Check joints between all flue sections for quality of seals Where the flue passes through the structure of the building use your judgement as to the integrity of this section of the flue Smoke Test With the flue capped the drain stabilizer pipe if fitted blanked and a smoke generator inserted into the flue ther
52. tthe set back pressure control to the required set back pressure FIG 16 PRESSURE CONTROLLER Note In order to utilize the maximum flash steam capability of the boiler it is essential that the boiler is operated at the maximum working pressure 10 34 bar and then pressure reduced down to the required system pressure 2 17 CLEANING STEAM LINES AND PRESSURE VESSELS During the first week of boiler operation clean all oil and dirt from the boiler the steam line and condensate return line a Disconnect the condensate return pipe adjacent to the condensate return tank b Direct the returns to a floor drain or other safe discharge point and make safe c Leave in this position for one week to allow all impurities to flush through d Drain the boiler completely each day e After the week is completed drain and flush the condensate return tank removing all installation sediment Reconnect the condensate return pipe to the condensate return tank 15 JFS Series Oil 01 2008 3 3 1 3 2 OPERATION SECTION 3 GENERAL The following instructions are given for the guidance of the operator in the use of the JFS Series oil fired boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health Where original equipment Service Manuals are supplied they must be read and understood in conjunction with this manual All Warnings and Cautions must be
53. uge and water column pipework In addition to these procedures the advice of a water treatment specialist should be sought and followed for boilers fitted with Spirax High Integrity Level Controls see Appendix DAILY Some of the following procedures should be carried out as part of the normal operating routines of the boiler others are required to be done as part of the boiler maintenance programme All boiler operating routines and tests should be recorded and kept as a boiler history 1 Blowdown the Boiler 2 Blowdown the Water Column 3 Blowdown the Water Level Gauge WEEKLY including daily WARNING Ensure the fittings around the steam safety valve s are secure The safety valve will be very hot do not operate the safety valve without protection 4 Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point 5 The water level and safety cut off controls must be tested under operating conditions by interrupting the water feed supply To carry out this test use the feed pump interrupt switch to isolate the feedwater pump and lower the water level in the boiler by evaporation Lower the water level passed both the1st and 2nd low water levels see section 3 On completion switch off pump run the pump interrupt switch and check that the water level is restored to normal 33 JFS Series 01 2008 Fulton 4 4 4 MONTHLY including w
54. zzle caused by a new delivery of oil If the oil tank level is allowed to fall near to the bottom of the tank it is highly probable that sediment on the bottom of the tank will be disturbed and mixed in with the new oil delivery especially if the delivery rate is too fast 25 JFS Series 01 2008 Fulton 3 TROUBLESHOOTING continued Problem Boiler Fails to Start Burner Cut off Cause 1 No Power 2 Pressure Control 1 Oil tank empty 2 Power Supply 3 Ignition Electrodes 4 UV Detector 5 Faulty Air Switch 6 Faulty Level Control N Oil Nozzle 8 Transformer 9 Burner Control 10 Pressure Control Remedy Check fuse or circuit breaker Reset or replace as necessary Disconnect all power to the controller Disconnect the wires from the controller connect an ohmmeter between the switch terminals Lower the set point of the controller the switch should make raise the set point and re check switch should break if the controller operates improperly replace it Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check for dirt on detector clean as required
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