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Summary of Contents for FULTON 60E
- Page 1 Fulton Boiler Works (Great Britain) Ltd. OPERATOR, SERVICE & PARTS MANUAL SERIES 'E' - GAS FIRED STEAM BOILERS (6E - 60E) GFSE-Std-0202...
- Page 2 NOTE The Pressure system and Transportable Gas Containers Regulations 1989 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme and Section 40 of the Health and Safety at Work Act, 1974. Regular inspections are therefore required by a 'Competent Person' at intervals not exceeding 14 months.
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Page 3: Table Of Contents
LIST OF CONTENTS TITLE SECTION INTRODUCTION General Technical Data INSTALLATION General Siting Ventilation Flue Outlet Water Supply Blowdown Valves Main Steam Valve Steam Safety Valves Water Gauge Set Gas Supply 2.10 Electrical Requirements 2.11 Steam Pressure Gauge 2.12 Plumbing 2.15 Commissioning the Boiler 2.16 Cleaning the Steam Lines and Pressure Vessel... - Page 4 Do not try to do repairs or any other maintenance Do not change the boiler fuel without consulting the work you do not understand. Obtain a Service Manual boiler manufacturer. from Fulton or call a Fulton Service Engineer WARNING WARNING Understand the electrical circuit before connecting or Non-approved modifications can cause injury and disconnecting an electrical component.
- Page 5 Steam Pressure Gauge Burner Electrode Settings Commissioning the Boiler Monobloc Gas Valve L.P. Gas Train Boiler Operation Control Panel 6E/30E Control Panel 40E/60E Water Gauge Blowdown Sequence 14 & 14A Fault Finding Check List Boiler Maintenance Handhole Assembly Burner Assembly...
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Page 6: Gas Fired Steam Boiler
FIG.1 GAS FIRED STEAM BOILER GFSE-Std-0499... -
Page 7: Introduction
SECTION 1 General (Fig. 1) The Fulton Series E Gas Fired Steam Boiler is a vertical two pass boiler of simple and efficient design and construction. Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained. -
Page 8: General Arrangement
MODULAR PRESSURE GAS UNIT TEST POINT STEAM PRESSURE SCALE GAUGE TRAP MAIN STEAM VALVE AIR SAFETY STEAM SAFETY SWITCH VALVE WATER LEVEL PROBES BLOWER HOUSING BURNER MOTOR CONTROL PANEL WATER GAUGE CHECK WATER VALVE COLUMN STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN CLEAN OUT... -
Page 9: Installation
INSTALLATION SECTION 2 GENERAL (Figs. 2 and 3) The installation of a Series E Gas 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. -
Page 10: Typical Installation
PIPE SAFETY VALVE TO SAFE AREA, FITTING UNIONS AND DRAIN STEAM SUPPLY DRAFT STABILISER (WHERE FITTED) STANDARD BOILER TRIM SUPPLIED STAINLESS STEEL FEEDWATER MAKE-UP SUPPLY CLEAN-OUT TANK DOOR OVERFLOW BLOWDOWN SEPERATOR STOP CONDENSATE VALVE RETURN CHECK VALVE FEED PUMP MAIN BLOWDOWN F01762 STRAINER VALVE... -
Page 11: Flue Outlet
If the boiler is to be operated with little or no condensate return, consideration should be given to pre-heating the feedwater. If in doubt consult Fulton Boiler Works. The Feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight glass assembly. -
Page 12: Water Gauge Set
F02490 FIG. 3A TYPICAL FLUE CONNECTION STEAM WORKING WATER BLOWDOWN POSITION BLOWDOWN F03200 F03190 BLOWDOWN GAUGE GLASS FIG 4 WATER GAUGE SET GFSE-Std-0499... -
Page 13: 2.10 Gas Supply
STEAM SAFETY VALVES 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. The lift pressure is indicated on the safety valve. -
Page 14: Steam Pressure Gauge
STEAM PRESSURE GAUGE STEAM COCK SYPHON FIG. 5 STEAM PRESSURE GAUGE 2.12 STEAM PRESSURE GAUGE (Fig. 5) The steam pressure gauge assembly should be assembled in accordance with Fig. 5 using a suitable sealant on all joints. Screw the assembly into the top of the boiler and connect the copper tube from the control panel box to the nipple provided on the assembly. -
Page 15: 2.15 Plumbing
Conduct a feedwater analysis before operating the boiler. 2.16 COMMISSIONING THE BOILER (Fig. 7) 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. - Page 16 MODULAR GAS UNIT PRESSURE TEST POINT STEAM PRESSURE GAUGE GAS COCK MAIN STEAM VALVE SCALE TRAP AIR SAFETY SWITCH STEAM SAFETY VALVE BLOWER HOUSING WATER LEVEL PROBES BURNER MOTOR WATER GAUGE CONTROL PANEL CHECK VALVE WATER COLUMN STOP VALVE PRESSURE CONTROL MAIN BLOWDOWN...
- Page 17 If the pressure control has a fixed differential, i.e. no adjustable differential scale, set the main scale to the maximum pressure required. SETTING THE BURNER FOR LOW FIRE / HIGH FIRE, MODELS 50E AND 60E The correct settings for low fire/high fire operation are obtained by making adjustments to the two stage solenoid valve (Fig.
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Page 18: Monobloc Gas Valve
MONOBLOC GAS VALVES (FIG. 9) ADJUSTMENTS 6E - 30E (MBDLE 407/412 B07) (With in built pilot bypass valve) Pilot gas rate should be set to a maximum of 10% of the full fire gas throughput. ADJUSTMENTS ACTION Main and Pilot Gas Governor. Turn clockwise to increase gas pressure. -
Page 19: Cleaning The Steam Lines And Pressure Vessel
MONOBLOC GAS VALVES (FIG. 9) continued. ADJUSTMENTS 40E - 60E (MBZRDLE 415/420 BO1) ADJUSTMENTS ACTION Main Gas Governor. Turn clockwise to increase gas pressure. Range 4 - 20 mbar. First and second stage - initial lift adjuster, main gas valve. - Page 20 GFSE-Std-0499...
- Page 21 L.P. GAS WARNING 2.18 GAS SUPPLY - PROPANE / BUTANE Do not change the boiler fuel without consulting the boiler manufacturer. Note: LPG Boilers should be installed to the requirements of IGE/UP/10 March 2001 An L.P. gas boiler is similar in design to a natural gas boiler, the main differences are important and must be taken into account when installing the boiler and ordering spare parts.
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Page 22: Boiler Operation
MODULAR GAS UNIT STEAM PRESSURE GAUGE GAS COCK MAIN STEAM VALVE WATER LEVEL AIR SAFETY PROBES SWITCH WATER GAUGE CHECK VALVE STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN VALVE FIG. 11 BOILER OPERATION GFSE-Std-0499... -
Page 23: Operation
OPERATION SECTION 3 GENERAL The following instructions are given for the guidance of the operator in the use of the Series 'E' gas 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. - Page 24 MODULAR GAS UNIT STEAM PRESSURE GAUGE MAIN STEAM GAS COCK VALVE AIR SAFETY WATER LEVEL SWITCH PROBES WATER GAUGE CHECK VALVE STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN VALVE FIG.11 BOILER OPERATION GFSE-Std-0499...
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Page 25: Control Panel 6E/30E
Circuit On. (Circuit Energised 40E - 60E) Indicates that power is being supplied to the control panel box. 1st. Low Water Alarm. This light will energise, when the boiler is switched on and the water level is between 1st. -
Page 26: Filling The Boiler - All Models
MAIN HIGH FLAME FIG. 13 CONTROL PANEL 40E / 60E 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: Ensure the main steam stop valve is OPEN. -
Page 27: 3.6.1. Pump Check
STARTING THE BURNER CLOSE the main steam stop valve. Press the control switch to 'PUMP AND BOILER' position, the low water audible alarm will sound, the low water reset and low water alarm lights will illuminate. Press the low water reset switch for two seconds maximum. The alarms will stop, and the alarm lights extinguish. -
Page 28: Overiding Low Water Check
3.6.4 First Low Water Level 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 overide switch. OPEN the main blowdown valve. 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. -
Page 29: Blowdown Procedures
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. (refer to 3.6.5. (g) 1 - 2). Water Level Gauge Set 2 STEAM... -
Page 30: Evaporation Checks
EVAPORATION CHECKS With the boiler running under normal load conditions, and the pump stopped having just completed a refill cycle: Ensure that the boiler water level is correct. Switch the pump OFF at the pump override 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. - Page 31 Burner will Flame Low Water Poor Boiler will not not start Failure Alarm Combustion Maintain Pressure Power Supply Gas Supply Refractories Ignition Electrode Pri Air Adjustment Sec Air Adjustment Transformer Low Water Probes U/V Cell Low Water Safety Relay Water Level Relay Pressure Control Draught Steam Overload...
- Page 32 MAINTENANCE LOG Date Action Remarks Sig. GFSE-Std-0499...
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Page 33: Maintenance
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 Fulton representative. Note: It is essential that regular checks are made to ensure that scale build-up is not taking place within the boiler. -
Page 34: Weekly
Blow down the boiler and water column completely. Inspect the hand holes in the boiler. If any leakage is evident proceed as follows: Use only Fulton genuine replacement parts. Using the special tee handle wrench, remove the handhole assembly. (ii) Remove the old gasket and thoroughly clean the mating faces of the plate and boiler. -
Page 35: Three Monthly
HANDHOLE COVER PLATE GASKET CRAB FIG. 17 HANDHOLE THREE MONTHLY (Monthly tests plus) Drain and isolate the boiler. Remove the lower handhole 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. Check the pipes and out are clear and free from debris. -
Page 36: Six Monthly
SIX MONTHLY (Three monthly tests plus) 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. -
Page 37: General Data
1095 2320 1390 470 1730 1435 3100 dimensions mm FIG. 20 BOILER DIMENSIONS Note:- Standard Working Pressure 6E - 30E, 8.6bar. 40E - 60E, 10.34bar. 15mm Water Sample point located on Water Column if fitted. Gas Train can rotate through 360 GFSE-Std-0499... - Page 38 STANDARD TRIM ITEMS Additions and Optional items should be requested when ordering the boiler 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 manor. Standard Boiler Trim.
- Page 39 MAINS SENSING INTERNAL SCHEMATIC INTERNAL BASE WIRING Note: A common base is supplied for type A & B controller bases. Links must be fitted as per Fig. 21. FIG. 21 TYPE LC1 LEVEL CONTROLLER GFSE-Std-0499...
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Page 40: Boiler Water
IMPORTANT Recommended Water Conditions It is very important that a strict water management program is followed to ensure trouble free boiler operation. The following are recommended for feedwater and for boiler water. FEEDWATER pH Value 8.5 to 9.5 Tested at room temperature. Hardness less than 2.0mg/kg In the form of CACO... -
Page 41: Spare Parts
SPARE PARTS SECTION 6 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 WARNING The type, size and lift pressure of the safety valve fitted to a boiler is specific to that boiler. - Page 42 GFSE-Std-0499...
- Page 43 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.
- Page 44 Fulton Fulton Boiler Works (Great Britain) Ltd. Broomhill Road Bristol BS4 4TU England Telephone 01179 723 322 Fax: 0117 9723358 'e'-mail: uk-info@fulton.com FM 28400 Web site: www.fulton.com GFSE-Std-0499...
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What is the minimum clearance to a 1 hour fire rated ceiling of frame construction above a 10E boiler
The minimum clearance required to a 1-hour fire-rated ceiling for a FULTON 60E boiler is not specified in the provided context.
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