FULTON 10J Installation, Operation, Maintenance And Parts Manual Download Page 1

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INSTALLATION, OPERATION,

MAINTENANCE AND PARTS MANUAL

J OIL-E-10 2008

'J' SERIES - OIL FIRED

STEAM BOILERS (6J - 60J)

This Manual must be available to the boiler operator at all times.

Summary of Contents for 10J

Page 1: ...INSTALLATION OPERATION MAINTENANCE AND PARTS MANUAL J OIL E 10 2008 J SERIES OIL FIRED STEAM BOILERS 6J 60J This Manual must be available to the boiler operator at all times...

Page 2: ...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...

Page 3: ...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...

Page 4: ...raulic testing requires specialist equipment and is normally only required by engineering surveyors in spectors Thematerialtheboilerismanufacturedfrom has not been impact tested as it is not a require...

Page 5: ...ontrol Circuit 24 LC Level Control Circuit 25 TDS and Blowdown Control Circuit 26 6J 30J Burner Control Circuit 27 40J 60J Burner Control Circuit 28 SPARE PARTS Boiler GA A0 2 1 Boiler Shell and Fitti...

Page 6: ...1 Steam Supply Valve Oil Strainer Boiler Control Panel Oil Feed Return Lines Air Intake Manifold Oil Pump Water Column Probes 1 Water Column Cleanout Door flue passes and flame turn around Handhole P...

Page 7: ...liability 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...

Page 8: ...d Water and Check Valves Main Steam Valve Steam Pressure Gauge to Pressure Controllers TDS System Feed Water Supply Ignition Transformer Steam Valve Oil Feed Flame Detector Ignition Electrodes 2 Press...

Page 9: ...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 allow...

Page 10: ...MAKE U P SUPPL Y FEED WA TER PUMP NOTE A BREAK TANK MAY BE REQUIRED CHECK TH E LOCA L WA TER AUTHORITY BYE LAW S OVERFLOW TO DRAIN DRAIN STAINLESS STEEL TANK SET ISOLATING VA LVE STRAINER FU LTON BLO...

Page 11: ...ned 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 ch...

Page 12: ...upplied 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 shou...

Page 13: ...Valve Water Column Australian boilers only The valve is a three position isolation valve each position is indicated on a backing plate mounted with the valve the valve is shown in the blowdown positio...

Page 14: ...or Burner Assembly Water Level Probes Ignition Electrodes Steam Supply Pipe Flame Detector Location Oil Supply Connections Electrical Connection Box Ignition Transformer Oil Supply Valves Oil Pump Adj...

Page 15: ...the boiler These lines should 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 n...

Page 16: ...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...

Page 17: ...tight Reconnect the ignition leads and replace the sensor d Ensure all wiring connections are correct and all terminal screws are tight FIG 10 NOZZLE AND IGNITION ASSEMBLIES Burner Plate Electrodes E...

Page 18: ...Feed Water Line Main Steam Valve Oil Flow Return Pipes Control Box Isolator Switch Cleanout Door Cleanout Handhole Water Column Blowdown Valve Engineers Test Button PM5 Sight Gauge Blowdown Valves Oil...

Page 19: ...when the operation is stable DO NOT ALLOW THE PUMP TO RUN DRY h 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 sh...

Page 20: ...ure 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...

Page 21: ...sential 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 th...

Page 22: ...nted 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 Pu...

Page 23: ...e 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 e...

Page 24: ...s 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...

Page 25: ...gated before the boiler is used Ensure that all blowdown pipework is safe and discharged to a blowdown receptacle 3 6 1 Pump Check With the burner firing and the pump not running lower the water level...

Page 26: ...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 s...

Page 27: ...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...

Page 28: ...eset 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 23 3 7 BLOWDOWN PROCEDURES D...

Page 29: ...ose the blowdown isolation valve 3 Using a screwdriver located as shown A push up and make a quarter turn this will lock the button in position and open the blowdown valve 4 Using the blowdown isolati...

Page 30: ...uired Check settings adjust if required Check for cracks in porcelain if found replace 3 Main Air Adjustment Check air adjustment Air may be blowing flame away from the UV detector Open primary air un...

Page 31: ...detector 5 Faulty Air Switch 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 rep...

Page 32: ...ks 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...

Page 33: ...place the pump 5 Dirty Flue Check flue for Carbon build up or blockage Clean flue passages with brush 6 Pressure Control Disconnect all power to the controller Disconnect the wires from the controller...

Page 34: ...temperature if it is above 82O C 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 121O C 2 Block...

Page 35: ...obes 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...

Page 36: ...J OIL E 08 2008 3 MAINTENANCE LOG Date Action Remarks Sig This log should be completed regularly as a record of boiler maintenance 31 3...

Page 37: ...he 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 Sub...

Page 38: ...own the Boiler 2 Blowdown the Water Column 3 Blowdown the Water Level Gauge 4 3 WEEKLY including daily WARNING Ensure the fittings around the steam safety valve s are secure The safety valve will be v...

Page 39: ...Using the special wrench tighten the nut a further quarter of a turn DO NOT OVER TIGHTEN d If the gasket leaks as the pressure is building up tighten the securing nut only sufficient to stop the leak...

Page 40: ...URNER ASSEMBLY Electrodes Oil Line Electrode Holder Photocell Oil Feed Pipe Burner Plate Burner Top Plate Ignition Leads Burner Motor Ignition Transformer Burner Scroll Fan Air Damper Air Gate Fuel Pu...

Page 41: ...water pump 21 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 22 Rem...

Page 42: ...J OIL E 08 2008...

Page 43: ...the water by evaporation Daily Test 1st Low Water 1 With the burner firing 2 Press and hold the 1st Low Water test button until minimum 15 seconds the low water alarm sounds and the low water indicato...

Page 44: ...ch the pump interrupt switch to the pump on position 5 The pump will start and restore the water level to the normal position and switch off 6 After approximately 17 seconds from restoring the second...

Page 45: ...1670 E 1670 1670 1760 1890 2070 2320 2320 2320 F 1845 1845 1950 2100 2310 2680 2680 2680 G 1550 1550 1640 1735 1915 2150 2150 2150 H 1500 1500 1565 1670 1820 2075 2075 2075 J 1810 1810 1900 2030 2210...

Page 46: ...10 34 10 34 10 34 10 34 10 34 10 34 10 34 10 34 Firing Rates Input kW h 75 100 124 187 250 373 501 622 746 Input BTU h x 1000 255 340 425 637 849 1273 1712 2122 2547 Input 35 sec oil US gal h 1 9 2 5...

Page 47: ...er Sodium Sulphite or Tannin 20 to 50mg kg Phosphate Less than 50 mg kg in the form of PO4 Total Alkalinity Less than 1000 mg kg Caustic Alkalinity Less than 300 mg kg as CaCO3 Total Dissolved Solids...

Page 48: ...UMP MOTOR CONTACTOR BURNER MOTOR FEED PUMP MOTOR M 3 M 3 9 8 7 OIL PUMP MOTOR CT1 IF FITTED OIL PUMP MOTOR CONTACTOR IF FITTED OIL PUMP MOTOR IF FITTED M 3 1 1 TRANSFORMER C CN 2A MCB 6J 60J SERIES PA...

Page 49: ...X BURNER ON PC AUX PUMP CT1 AUX PUMP INTERRUPT PC C A BC POWER ON OPC AUX IF FITTED OIL PUMP CT1 AUX IF FITTED R11 IF FITTED OPC IF FITTED OIL PUMP RUN IF FITTED CN TDS C CN FUSED TERMINAL R3 R2 R1 39...

Page 50: ...6 1st LOW WATER TEST BUTTON 1st LOW WATER LIGHT ALARM 2nd LOW WATER LP30 LC3000 2nd 9 101112 1 4 2 R2 2nd LOW WATER TEST BUTTON 2nd LOW WATER LIGHT ALARM 3 R2 R2 2nd LOW WATER RESET BUTTON OFF PUMP ON...

Page 51: ...HIGH WATER IF FITTED 52 PUMP ON 51 PUMP OFF HIGH WATER ALARM IF FITTED 1st LOW WATER R1 1st LOW WATER ALARM 2nd LOW WATER R2 LOW WATER RESET BUTTON 2nd LOW WATER ALARM R2 7 4 3 1 2 LW1 8 53 R2 7 4 3 1...

Page 52: ...CONTROL IF FITTED BLOWDOWN CONTROL BT1000 IF FITTED 82 83 84 85 86 87 88 89 PC A AUX SCREENED CABLE TDS PROBE TDS SOLENOID VALVE TDS CONTROLLER SUPPLY CLOSED SWITCH OPEN ALARM SOLENOID VALVE FUSED TER...

Page 53: ...IT CONTINUATION INSTRUCTION REFER TO DRAWING EJ060000 6J 30J SERIES PANEL BURNER CONTROL CIRCUIT FOR OIL BOILERS ONLY R8 AUTO MANUAL 97 98 MAIN VALVE OIL VALVE 4 1 HIGH PRESSURE RESET IF FITTED HIGH P...

Page 54: ...PRESSURE IF FITTED R2 40J 60J SERIES PANEL BURNER CONTROL CIRCUIT FOR OIL BOILERS ONLY R8 AUTO MANUAL 96 98 LOW FIRE VALVE TR 5 A HIGH PRESSURE RESET IF FITTED HIGH PRESSURE PS3 IF FITTED LC LW1 5 6 o...

Page 55: ...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...

Page 56: ...J OIL E 08 2008 A0 2 1 BOILER OIL 1 2 3 4 5 6 December 12 2004...

Page 57: ...0 3 1 Burner scroll assembly See D2 1 1 6 15 1 Burner scroll assembly See D2 2 1 20 30 1 Burner scroll assembly See D2 3 1 40 60 4 1 Column water assembly See E1 3 1 Australian 6 60 1 Column water ass...

Page 58: ...J OIL E 08 2008 A1 1 1 BOILER SHELL AND FITTINGS 6 15 UK and Australia 10 1 2 3 4 4 5 6 7 8 9 11 12 13 14 15 16 17 17 18 19 19 21 22 23 24 25 26 20 27 28 A1 1 1 6 15 oil December 2004...

Page 59: ...lue flange 6 10 10120 1 Flue flange 15 21 10417 1 Probe water level 6 15 11882 1 Probe water level 6 8 11774 1 Probe water level 10 15 22 099E9360 2 Basket probe 6 15 23 10558 2 Valve steam safety 3 4...

Page 60: ...J OIL E 08 2008 A1 2 1 BOILER SHELL AND FITTINGS 20 60 UK and Australia 6 7 3 3 4 4 5 2 1 8 9 28 27 10 11 12 13 14 15 16 18 20 19 26 22 23 24 22 25 21 17 A1 2 1 20 60 June 07 December 2004...

Page 61: ...14 13568 3 Clip connector 20 60 15 13544 1 Plate flue cover 20 13545 1 Plate flue cover 30 13546 1 Plate flue cover 40 60 16 10136 Roll Gasket flue cover plate 20 60 17 10023 1 Wrench tee 20 60 18 11...

Page 62: ...J OIL E 08 2008 B2 1 1 12 2004 B2 1 1 BURNER ASSEMBLY OIL 6 15 December 2004 1 6 7 8 4 5 3 2 20 28 27 22 13 26 14 26 24 25 21 31 18 29 30 17 12 11 32 33 34 28 23 27 19 15 9 16 35 10 21 24 25...

Page 63: ...eye glass 6 15 14 10319 1 Glass eye Pyrex 6 15 15 10382 1 Plate top 6 15 16 SA0022 1 Deflector 6 15 17 10580 1 Nipple pipe 6 15 18 10716 1 Elbow 1 8in BSP x 1 4in 6 15 19 10785 6 Bolt 1 4in x 3 4in U...

Page 64: ...L E 08 2008 B2 2 1 BURNER ASSEMBLY OIL 20 30 December 2004 B2 2 1 Oil 20 30 10 2008 6 7 8 1 5 3 2 4 21 36 37 38 34 35 20 14 23 30 27 26 15 31 16 31 9 10 35 24 28 29 25 24 28 29 17 39 11 27 33 32 22 13...

Page 65: ...1 Spring eye glass 20 30 16 10319 1 Glass eye Pyrex 20 30 17 10325 7 Clip 1 2in 20 30 18 10383 1 Plate top 20 30 19 SA0023 1 Deflector was 10396 20 30 20 10581 1 Nipple pipe 1 8in x 12in 20 30 21 107...

Page 66: ...E 08 2008 B2 3 2 BURNER ASSEMBLY OIL 40 60 December 2004 B2 3 2 Oil 40 60 12 2004 1 4 5 3 9 24 33 31 26 11 30 12 30 32 27 31 18 8 38 13 14 32 23 27 34 25 29 28 15 34 37 35 10 19 6 7 38 36 2 20 21 22 1...

Page 67: ...14 10327 1 Spinner 40 60 15 10350 2 Nipple pressure test 40 60 16 10384 1 Plate top 40 60 17 10397 1 Deflector 40 60 18 10402 1 Control damper 40 60 19 10581 1 Nipple pipe 1 8in x 12in 40 60 20 10595...

Page 68: ...J OIL E 08 2008 D2 1 1 BURNER SCROLL ASSEMBLY OIL 6 15 December 2004 D2 1 1 Oil 6 15 12 2004 14 23 21 19 26 2 9 20 24 22 16 5 25 12 8 11 8 11 4 10 19 23 14 17 18 21 24 15 22 6 7 13 3 1...

Page 69: ...BSP 6 15 9 10366 1 Casting scroll 6 15 10 10373 1 Casting damper 6 15 11 10578 A R Nipple pipe 1 8in x 3in 6 15 12 10720 1 Elbow 6 15 13 10755 1 Box conduit 75 x 75 x 37mm 6 15 14 10786 4 Bolt set 6...

Page 70: ...J OIL E 08 2008 D2 2 1 BURNER SCROLL ASSEMBLY OIL 20 30 December 2004 D2 2 1 oil 20 30 12 2004 1 18 21 15 24 22 17 10 4 11 8 11 8 12 6 7 23 14 19 16 24 22 20 25 5 9 26 14 23 21 19 3 2 13...

Page 71: ...solenoid 1 8in BSP 20 30 9 10367 1 Casting scroll 20 30 10 10374 1 Casting damper 20 30 11 10578 2 Nipple pipe 1 8in x 3in 20 30 12 10720 1 Elbow 20 30 13 10755 1 Box conduit 75 x 75 x 37mm 20 30 14...

Page 72: ...IL E 08 2008 D2 3 1 BURNER SCROLL ASSEMBLY OIL 40 60 D2 3 1 Oil 40 60 12 2004 1 20 27 24 31 11 2 5 9 17 3 18 24 26 21 22 34 32 10 29 23 19 28 25 33 6 7 4 14 13 8 12 15 12 8 16 16 12 8 16 30 December 2...

Page 73: ...in 40 60 14 10655 2 Plug 1 4in 40 60 15 10692 1 Tee 1 8in 40 60 16 10720 3 Elbow 40 60 17 10755 1 Box conduit 75 x 75 x 37 40 60 18 10786 2 Bolt set 6 x 16mm plated 40 60 19 10800 4 Nut M10 plated 40...

Page 74: ...J OIL E 08 2008 E1 6 1 WATER COLUMN 6 60 December 2004 E1 6 1 12 2004 1 11 6 4 2 9 10 4 6 4 5 3 8 7...

Page 75: ...0 3 10592 1 Nipple 3 4in 6 60 4 10598 3 Nipple 1in 6 60 5 10627 1 Bush 6 60 6 10670 2 Union 6 60 7 10696 1 Tee 1in 6 60 8 11524 1 Valve ball DN20 6 60 9 11541 1 Probe pump on 8 1 2in 6 60 10 14067 1 C...

Page 76: ...J OIL E 08 2008 F1 4 1 WATER LEVEL GAUGE ASSEMBLY 6 60 350mm and 300mm Clifton December 2004...

Page 77: ...60 2 12199 2 Valve 300 350 6 60 3 12210 1 Valve blowdown 300 350 6 60 4 10621 1 Bush 300 350 6 60 5 11895 1 Glass 350 6 60 12200 1 Glass 300 6 60 6 11893 2 Gasket 350 6 60 12201 2 Gasket 300 6 60 7 12...

Page 78: ...J OIL E 08 2008 G2 1 1 CONTROL BOX ASSEMBLY OIL 6 15 December 2004 G2 1 1 6 15 oil 12 2004 1 6 28 30 29 7 29 10 21 22 9 14 8 15 16 24 23 32 27 33 11 20 26 31 25 2 17 18 34 4 3 5 12 13 19...

Page 79: ...relay 11 pin DIN 6 15 17 11941 1 Breaker circuit 3ph only 1 0 1 6A 6 15 12019 1 Breaker circuit 1ph only 4 0 6 3A 6 15 18 11942 1 Breaker circuit 3ph only 1 6 2 5A 6 15 11962 1 Breaker circuit 1ph on...

Page 80: ...J OIL E 08 2008 G2 2 1 CONTROL BOX ASSEMBLY OIL 20 30 December 2004 1 6 27 29 28 7 28 10 11 20 21 8 9 12 13 18 33 14 15 23 22 19 25 26 32 31 30 24 2 17 16 4 3 5...

Page 81: ...LC3 20 30 15 11904 3 Base relay 11 pin 20 30 16 11942 1 Breaker circuit 3ph only 1 6 2 5A 20 30 12019 1 Breaker circuit 1ph only 4 0 6 3A 20 30 17 11943 1 Breaker circuit 3ph only 2 5 4 0A 20 30 11962...

Page 82: ...J OIL E 08 2008 G2 3 1 CONTROL BOX ASSEMBLY OIL 40 60 1 December 2004 11 27 29 28 7 28 6 17 18 8 9 15 24 12 13 20 19 16 31 26 32 25 30 21 2 10 22 23 14 4 3 5 33...

Page 83: ...11943 2 Breaker circuit 3ph only 2 5 4 0A 40 60 12019 1 Breaker circuit 1ph only 4 0 6 3A 40 60 11962 1 Breaker circuit 1ph only 6 3 10A 40 60 15 11971 1 Base burner control 40 60 16 12016 1 Switch ha...

Page 84: ...J OIL E 08 2008 H1 1 1 PUMP FEED WATER 1 December 2004...

Page 85: ...20 14286 1 Pump assy 3ph 150psi 10 34bar 30 40 14288 1 Pump assy 3ph 150psi 10 34bar 50 60 14287 1 Pump assy 1ph 125psi 8 6bar 6 15 14289 1 Pump assy 1ph 125psi 8 6bar 20 30 14289 1 Pump assy 1ph 150p...

Page 86: ......

Page 87: ...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 g...

Page 88: ...FM 28400 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...

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