Installation, Operation and Maintenance Manual

Fulton Ltd
INSTALLATION, OPERATION AND MAINTENANCE

MANUAL
J SERIES - DUAL FUEL

STEAM BOILER (Switchable Burner)
(including optional Fully Modulating Burner)
This manual must be available to the boiler operator at all times.
J DUAL FUEL MANUAL 02 2014 ISSUE 9
! CAUTION
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, whatever
the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been investigated
by a competent person and rectified.
For your safety!

The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
! WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel
injury or death to personnel. involved in the operation and maintenance of this
equipment to fully understand the WARNINGS,
! CAUTIONS must be observed to prevent damage CAUTIONS and NOTES by which hazards are to be
or destruction of equipment or loss of operating eliminated or reduced.
effectiveness.
Personnel must become familiar with all aspects of
NOTES: must be observed for essential and safety and equipment prior to operation or
effective operating procedures, conditions and as maintenance of the equipment.
a statement to be highlighted.
! WARNING
Steam boilers are a potential hazard, possibly fatal if not properly maintained.
! CAUTION
It is vitally important that the instructions
given in 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.
The Pressure System Safety Regulations 2000
Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
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.

LIST OF CONTENTS
INTRODUCTION 1 MAINTENANCE 4
General 1.1 Visual Checks 4.1
Technical Data 1.2 Water Level and Low Water Safety Controls 4.2
- Pump Test 4.2.1
INSTALLATION 2 - 1st Low Water Level Check 4.2.2
General 2.1 - 2nd Low Water Level Check 4.2.3
Siting 2.2 Main Blowdown 4.3
Ventilation 2.3 Water Column Blowdown 4.4
Flue Outlet 2.4 Water Level Gauge Blowdown 4.5
Water Supply (see also section 5.3) 2.5 Evapouration Checks 4.6
Blowdown Valves 2.6 Flame Sensor Test 4.7
Main Steam Valve 2.7 Draining the Boiler 4.8
Steam Safety Valves 2.8 Long Term Shutdown 4.9
Water Level Gauge Set (sight Glass) 2.9 Internal Inspection 4.10
Electrical Requirements 2.10 Schedule of Operator Tests and Checks 4.11
Gas Supply 2.11 - Daily 4.11.1
Oil Supply 2.12 - Weekly 4.11.2
Steam Pressure Gauge 2.13 - Three Monthly 4.11.4
Commissioning the Boiler 2.14 - Six Monthly 4.11.5
- Boiler Inspection and Initial Firing - Oil 2.14.1 - Annually 4.11.6
- Boiler Inspection and Initial Firing - Gas 2.14.2 Troubleshooting 4.12
Gas Monoblocs (Non Modulating Burners) 2.15 Maintenance Log 4.13
- Multibloc Gas Valve (Non Modulating Burners) 2.15.1 Daily and Weekly Test Log 4.14
- Multibloc Gas Valve (Fully Modulating Burner) 2.15.2

Setting The Burner Controls For 2.16 GENERAL DATA 5
Fully Modulating Models 30 - 60 Boiler Dimensions 5.1
Cleaning Steam Lines and Pressure Vessels 2.17
Boiler Specification 5.2
Recommended Water Conditions 5.3
OPERATION 3
General 3.1 APPENDIX Optional Variations (where fitted)
Boiler Controls 3.2
Water Level Probe Info A
Control Panel - Indicator Lights 3.3
Motorised High/Low Control B
Changing To The Alternative Fuel 3.4
Spirax High Intensity Level Controls C
Filling the Boiler - All Models 3.5
Starting the Burner - All Models - Gas 3.6
Electrical Diagrams (Supplied Separately)
Starting the Burner - All Models - Oil 3.7

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 ! WARNING
Do not try to do repairs or any other maintenance work you DANGER FROM HOT SURFACES
do not understand. Obtain a service manual from Steam boilers have high temperature surfaces, that if touched
Fulton Ltd or call a Fulton service engineer. may cause serious burns. Only competent and qualified
personnel should work on or in the locality of a steam boiler
! WARNING and ancillary equipment. Always ensure the working area and
It is the responsibility of the installer to ensure all parts floor are clear of potential hazards, work
supplied with the boiler are fitted in a correct and safe manner. slowly and methodically.
Do NOT store inflammable materials near the boiler.
! WARNING
Understand the electrical circuit before connecting or ! WARNING
disconnecting an electrical component. A wrong connection DANGER FROM INCOMPLETE COMBUSTION
can cause injury and or damage. The importance of correct burner adjustment to achieve low
emissions, safe, clean and efficient combustion is paramount.
! WARNING Poor combustion, where unburnt gas forms carbon monoxide
A defective boiler can injure you or others. Do not operate is both a health hazard, and the potential risk to the boiler
a boiler which is defective or has missing parts. Make sure from overheating, caused by re-burning of the
that all maintenance procedures are completed before using unburnt gas in the secondary flue passes.
the boiler.
! WARNING
! CAUTION The importance of correct boiler water and feedwater cannot
Obey all laws and local regulations which affect you and be over emphasised, see the relevant section in this manual.
your boiler.
! CAUTION
! WARNING LOW FEEDWATER TEMPERATURE
Do not change the boiler fuel without consulting the boiler Low feedwater temperature can result in thermal shock to the
manufacturer. boiler pressure vessel. Return the maximum amount of
condensate and if necessary preheat the feedwater. If in
! WARNING doubt consult Fulton Ltd.
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local ! CAUTION
regulations and is suitable for the job. You can be injured WATER SOFTENER and CHEMICAL TREATMENT
if you use faulty lifting equipment. Make sure the lifting The chemicals required to operate the water softeners and
equipment is in good condition. chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
! WARNING It is the responsibility of the operator to ensure adequate
Operating the boiler beyond its design limits can damage the supplies of chemical are available at all times
boiler, it can also be dangerous. (including commissioning).
Do not operate the boiler outside its limits. Costly repairs could be required should the plant operate
Do not try to upgrade the boiler performance by unapproved without chemicals or the wrong dosage of chemicals.
modifications.
! CAUTION
! WARNING HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Non-approved modifications can cause injury and damage. Hydraulic testing requires specialist equipment and is
Contact your Fulton dealer before modifying the boiler. normally only required by engineering surveyors / inspectors.
In order to ensure the material/ pressure vessel does not
! WARNING suffer from brittle fracture, hydraulic testing should not be
Only qualified persons should be allowed to operate carried out below 7°C.
and maintain the boiler and its equipment. Boilers should
always be drained through an approved blowdown vessel. WARNING
Prior to the commencement of any work requiring the
! WARNING removal of cover plates and the opening of control panel
The installation of gas appliances including the flue system box, the electrical supply to the boiler must be isolated.
should only be carried out by Gas Safe registered engineers.

LIST OF ILLUSTRATIONS
TITLE FIG. NO
Typical Dual Fuel Boiler 1
Major Fuel Components 2
Typical Installation 3
Boiler Flue Connection 4
Boiler Feed Water Arrangement 5
Boiler Blowdown (20-60) 6
Boiler Blowdown (6-15) 6A
Boiler Top Components 7
Control Box 8
Gas Supply 9
Oil Supply 10
Steam Pressure Gauge 11
Basic Burner Electrode Settings 12
Feedewater Stop Valve 13
Ignition Flame Detector 14
Main and Primary Air Controls 15
Burner Flame Observation Glass 16
Pressure Controller 17
6J - 30J Gas Valve Major Components (Non-Modulating Burner) 18
6J - 30J Gas Valve Major Components (Fully Modulating Burner) 19
Boiler Operation 20
Alarm and Indicator Lights 21
Boiler Maintenance 22
Pump Interrupt Switch 23
Main Boiler Blowdown Valve 24
Water Column 25
Water Level Gauge Operating Positions 26
Water Level Gauges (Sight Glasses) 27
Flame Sensor Removal 28
Automatic Blowdown Valve 29
Handhole 30
Feedwater Pipe Removal 31
Burner Assembly 32
Flue Cleaning 33
Fault Finding Check List 34
Boiler Dimensions 35
Water Level Probe Components 36
Angle Rajah Fitted To Probe 37
High/Low Control 38
Air Damper Motor 39
Control Panel Side 40

1
Monobloc Gas Steam Pressure Oil Pump Motor

Train Gauge
Water Column
Automatic TDS
Blowdown
Air Pressure
Switch
Water Level Motorised

Gauge Sets High / Low
Control
Operator Control
Panel
Control Box
Fuel Selector
Switch
Door Electrical
Isolator
Steam Pressure
Controllers
FIG. 1 TYPICAL DUAL FUEL BOILER
Page 6 J DUAL FUEL MANUAL 02 2014 ISSUE 9

1
SECTION 1 - INTRODUCTION
1.1 GENERAL
The Fulton J Series Dual Fuel 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. 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.
Dual Fuel boilers are supplied complete with all the components necessary to operate on either
Gas or Oil Fuel. The controls are arranged such that the change over from one fuel to another can
be achieved by selecting the required fuel on the control panel and isolating the off line fuel supply.
1.2 TECHNICAL DATA
For a full specification refer to Section 5.
! CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical

treatment equipment CAN BE SUPPLIED by Fulton Ltd.
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.
J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 7

2
Oil Feed Solenoid Oil Feed

Valves Lines
Oil Pump
Motorised
High / Low
Control
Monobloc Gas Feedwater Steam Outlet

Valve Inlet
Pressure
Gauge
Oil Solenoid
Gas Inlet
Valves
Safety Valve Oil Pump

Motor
Water Level Water Level Water Column

Gauge Sight Limiters and
Glass Water Level Probes
FIG. 2 MAJOR DUAL FUEL COMPONENTS

2
SECTION 2 - INSTALLATION
2.1 GENERAL
The installation of a J Series Dual Fuel 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.
The requirements and instructions contained in this section are for boilers being installed to operate
on Natural Gas or 35 sec. Fuel Oil.
2.2 SITING
(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication

1676, and in particular to Section 5, Location of Appliances).
The boiler house should be sufficiently sized to allow easy and safe access to all parts of the boiler
for operational and maintenance purposes.
Reference should be made to Section 5 - General Data to ascertain the relevant dimensions and
weights, special note should be taken of the required vertical clearance required for maintenance.
! WARNING
Maintenance on the burner assembly requires the area directly above
and to one side of the boiler must not be obstructed with pipework or
equipment which would interfere with the removal of the complete burner
unit. Care should be taken on installation of the boiler to ensure this
area remains clear of obstructions.
The flooring must be level, laid in a non-combustible material and be of sufficient strength to support
the boiler.
2.3 VENTILATION
Adequate fresh, clean air is necessary for safe and efficient combustion, and should be provided at
high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.
Note:
a) Ensure that there is adequate ventilation in the boiler room. Lack of ventilation will create a high
temperature and cause control lockout. There is a minimum ventilation requirement to supply the air for
combustion.
b) Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the
necessary boiler draught.
c) Do 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.
Note: see Section 5 for low and high level values.

2
STANDARD BOILER TRIM SUPPLIED FIT AN ISOLATING VALVE IN OIL RETURN
Page 10
WHEN ORDERING THE BOILER LINE ONLY IF OIL TANK OR PIPEWORK
IS ABOVE BURNER LEVEL
TO FUSIBLE LINK
SIGHT FIRE VALVE
GAUGE LINE
VENT
FILL
OIL RETURN LINE
PIPE SAFETY VALVE

STEAM TO SAFE AREA, FITTING OIL
SUPPLY UNIONS AND DRAIN STORAGE
STOP TANK ISOLATING OIL FILTER
VALVE
VALVE (METAL CARTRIDGE)
DRAUGHT CHECK
STABILISER VALVE OIL FEED
SLUDGE
(WHERE LINE
COCK
FITTED)
FLUE
FLANGE CLEAN-OUT
DOOR CONNECTIONS TO OIL STORAGE TANK
MAKE-UP SUPPLY
OVERFLOW
BOILER WATER LEVEL NOTE:- A BREAK TANK MAY BE
STAINLESS REQUIRED CHECK THE LOCAL
CONDENSATE

STEEL WATER AUTHORITY BYE-LAWS
RETURN
FIG. 3 TYPICAL INSTALLATION

FEEDWATER FLEXIBLE TANK SET
CHECK VALVE LINK
(TO BE INSTALLED
FULTON
BELOW BOILER BLOWDOWN
WATER LEVEL) SEPARATOR
MAIN BLOWDOWN
VALVE ISOLATING OVERFLOW
WATER
STRAINER VALVE TO DRAIN
COLUMN
BLOWDOWN
LINE
FEED PUMP CHECK
VALVES
DRAIN
Note: Both gas and oil fuel supply lines must be fitted with isolation valves with proof of closure microswitches
which must be electronically interlocked with the burner gas and oil control circuits.
2
2.4 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 1.5 x the diameter of the flue, and that it is of the
terminal cone type.
Note:
a) If the flue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required.
b) Avoid fitting 90° elbows whenever possible, if unavoidable compensate by increasing the flue diameter.
c) Ensure all flue pipes from the boiler to the main flue have a rising pitch.
FIG. 4 BOILER FLUE CONNECTION

2
2.5 WATER SUPPLY
The quality of the water used in the boiler will affect the life and performance of the boiler.
Feedwater contains solids and dissolved gases, these may 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.
Note: see Section 5.3 - Recommended Water Conditions.
Connect the feedwater pump discharge to the check valve inlet with 25mm. bore pipe (this may be
reduced to 15 mm, where the discharge pipe work is shorter than 4m in total. The pump suction
pipe work must remain at 25mm minimum diameter and be as short as possible). Install the stop
valve supplied between the boiler and the check valve. The check valve must be positioned so that
it is below the internal water level of the boiler, and should be installed at least 1m after the
feedwater pump. The reason for this placement position is that the check valve is designed to have
water on both sides to enable it to function correctly.
It is essential to protect the feedwater pump from damage by foreign matter, a strainer should
therefore be fitted in the pump suction pipework.
Care should be taken to ensure the pipe work is properly aligned and not placing any strain upon
the feedwater pump.
Note: The boiler feedwater pump may contain an inhibitor and this should be flushed from the pump prior to fit-
ting 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.
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 Ltd.
The feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight
glass assembly.
Feedwater stop valve
Feedwater Dip Pipe
Feedwater line
Check valve
FIG. 5 BOILER FEEDWATER ARRANGEMENT

2
2.6 BLOWDOWN VALVE
There are four blowdown valves on the boiler, the boiler blowdown valve at the rear of the boiler,
the water column blowdown valve and each of the water level gauge (sight glass) blowdown
valves.
All 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 Fulton Ltd.
FIG. 6 BOILER BLOWDOWN (models 20-60) FIG. 6A BOILER BLOWDOWN (models 6 - 15)
Note: 20J - 60J main blowdown connection is integral, via a boiler mounted flange.
Where possible the main blowdown pipework on 20 - 60J boilers should drop down to a union connection to allow
removal of the inspection flange without the necessity to remove the blowdown pipework.

2
Electrical Ignition Oil supply Flame detector

connection box transformer location
Adjustable Oil pump Oil supply

air control valves Ignition Secondary air
electrodes damper
Safety valve Burner assembly Flame detector Oil supply Steam supply
connections pipe
Water level Ignition electrodes

probes
FIG. 7 BOILER TOP COMPONENTS

2
2.7 MAIN STEAM VALVE
The main steam stop valve should be inserted in the steam line approximately 305mm from the top
of the boiler.
2.8 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.
Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806
clause 4.9.7. / BSEN 134801-1:2002
a) The 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 its design pressure.
c) Any system connected to the boiler not capable of accepting boiler pressure must be protected
by a separate safety valve set to the required pressure.
! WARNING
Factory fitted safety valves are preset to protect the boiler only and must not be used to protect any
other items not capable of accepting boiler pressure.
2.9 WATER GUAGE SET
(The design may vary from that illustrated) Numbers may vary due to individual country’s regulations.)
Boilers are normally supplied with two complete water level gauge sets. The water level gauge
blowdown cock should be connected to the auxiliary blowdown line from the water column blowdown
valve in 3/8 in. soft copper tubing.
2.10 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 TDS blowdown
on the rear inside wall of the control box controller
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 Recommended
to take the appropriate action should the water treatment
alarm be activated.
Unless otherwise specified, the alarms
supplied will be mains voltage models.
Unless otherwise specified all models are Fuel selector
supplied with burner motors and feed water
pump motors arranged for operation on a
three phase supply.
The power ratings and requirements are FIG. 8 CONTROL BOX
given in Section 5.2 - Boiler Specifications.
Note: It is advisable for dual fuel burners, that the offline fuel is manually isolated with a proof of closure microswitch
that is interlocked with the online control circuit.
e.g. gas supply proof of closure interlocked with the oil burner control circuit.
oil supply proof of closure interlocked with the gas burner control circuit.
2
2.11 GAS SUPPLY
Verify that the burner is suitable for the type of gas being supplied. Ensure that the piping from the
meter is the correct size, and that a gas cock is inserted in the line between the boiler and the meter.
To avoid pressure drops, eliminate all unnecessary bends and elbows in the pipework between the
gas meter and the boiler. A scale trap is provided on the gas train and should be used.
Burners suitable for operation on natural and manufactured gas are supplied with gas trains or a
modular gas head.
A minimum pressure of 18 mbar at the specified flow rate, is required at the gas train for natural gas
installations and a minimum pressure of 50 mbar is required at the gas train for manufactured/L.P
gas installations.
If the gas supply is in excess of 100 mbar for natural gas a suitable regulator is required before the
main gas valve.
Burners arranged for operation on L.P. gas are supplied with gas trains. It is essential that the
MAXIMUM p ressure of the gas at the gas train does not exceed 80 mbar and does not fall
below 50 mbar. A suitable regulator is required before the main gas valve.
To obtain these pressures, a pressure regulating device or service governor must be fitted to the
supply line from the storage tank to the boiler gas train.
Careful consideration must be given to the siting of LPG storage tanks to prevent over pressure
conditions arising, due to temperature rises caused by solar gain.
Main gas line isolating valve Main gas valve assembly
Pilot line Pilot line Pilot line

ball valve governor gas valves
FIG. 9 GAS SUPPLY

2
2.12 OIL SUPPLY
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 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 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.
Oil feed lines
Oil feed solenoid valves
Oil pump
Out In
FIG. 10 OIL SUPPLY

2
2.13 STEAM PRESSURE GAUGE
The steam pressure gauge assembly should be assembled in accordance with Fig. 11 using a
suitable sealant on all joints.
The gauge should be facing front 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.
Steam pressure gauge
Plug
Steam cock
Pressure controller
connection point
Syphon
F03210
FIG. 11 STEAM PRESSURE GAUGE

2
2.14 COMMISSIONING THE BOILER
Dual fuel boilers that use a common burner assembly and have a switch change over from one fuel
to another, have to be commissioned on the basis of a primary fuel (usually gas), with the secondary
fuel as a back-up. The primary fuel should be commissioned as 2.16 oil firing or 2.17 gas firing.
The secondary fuel then has to be commissioned using the air settings for the primary fuel. In practice
this means adjusting the fuel input of the secondary fuel to achieve acceptable combustion.
As more air is required for oil combustion the consequences are that when oil is the secondary fuel
there will be a small reduction in the fuel input rate.
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:
a. 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.
b. Smoke Test
With the flue capped, the drain stabiliser pipe (if fitted) blanked and a smoke generator inserted
into the flue, there 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 Ltd immediately.
Note: Flues that are designed to operate with positive pressure should be tested to the latest regulations.

2
196
141
89
Burner Plate
NOTES:
1. GAS ELECTRODE TIP SHOULD BE

POSITIONED 3mm FROM THE END
OF THE GAS SUPPLY PIPE TO ENABLE 205
IGNITION.
258
2. OIL ELECTRODE TIP SHOULD BE
POSITIONED 3mm FROM ONE OF 271.5
THE OIL NOZZLES.
Gas Ignition Oil Ignition

Electrode Electrodes
dimensions in mm
FIG. 12 BASIC BURNER ELECTRODE SETTINGS
Pilot gas
supply
Mains gas
supply
Ignition
electrodes
Flame detector
Feedwater
stop valve
FIG. 13 FEEDWATER STOP VALVE FIG. 14 IGNITION FLAME DETECTOR

2
2.14.1 BOILER INSPECTION AND INITIAL FIRING OIL
1. Ensure the boiler has been washed out after installation. It is advisble to conduct a water
analysis before operating the boiler.
Examine the probes in the water column and the boiler shell.
Replace any damaged probes.
2. Remove the burner and check that the electrodes have not been damaged. If the burner is
fitted with a flame detector, remove the detector and check for damage.
3. Check that the burner is the correct type for use in a dual fuel boiler. Replace the burner and
reconnect the copper oil lines to the oil nozzle assembly and gas connection, ensure these
connections are tight. Reconnect the ignition leads and replace the flame detector.
4. Ensure that the gas supply isolation valve is closed.
5. Check the rotation of the oil pump motor. Ensure that the oil supply flow and return valves
are open. Bleed the oil pump.
6. Ensure that all wiring connections are correct and that all terminal screws are tight.
7. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of - 0.01
in. to 0.02in. (0.025 mb to 0.05 mb) of water column pressure with the burner off.
8. Check that the visual flame signal display on the burner controller (5 LED bar) is fully
illuminated during pilot and main flame.
9. Open all the valves in the feedwater line. Switch on the feedwater pump motor and fill the
boiler, see Section 3 - Operation. 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 level sight
gauge is reading half 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 connections. Close the boiler blowdown
valve.
10. Start the burner as detailed in Section 3 - Operation. Allow time for the fuel pump to prime
itself.
11. After the burner has been firing for approximately five minutes, adjust the main air control
gate to obtain a clean combustion.
Main air adjusting screw
Main air adjustment plate Primary air adjustment

FIG. 15 MAIN AND PRIMARY AIR CONTROLS
2
11. 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.
12. Observe the flame through the eye glass in the burner plate. The desired flame shape is a full
swirling flame brushing the wall of the furnace. Adjust the air controls to achieve this shape.
13. Check the operation of the low water safety controls as detailed in Section 3 - Operation.
14. Adjust the steam pressure control to suit the boiler application. It should be borne in mind that
boilers are designed to operate most efficiently at their maximum operating pressure. 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 - Safety Valve setting.
Primary air
6mm Peep hole Adjustment
Main flame
observation glass
FIG. 16 BURNER FLAME OBSERVATION GLASS

2
2.14.2 BOILER INSPECTION AND INITIAL FIRING GAS
The commissioning procedures listed below must be 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 at maximum efficiency.
1. 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.
2. Remove the burner and check that the electrodes have not been damaged. If the burner is fitted
with an flame detector, remove the detector and check for damage.
3. Check that the burner is the correct type for use with the gas being supplied.
4. Ensure that the oil supply isolation valve is closed. Check that the gas supply valve is open.

5. Ensure that all wiring connections are correct and that all terminal screws are tight.
6. Check that the visual flame signal display on the burner controller (5 LED bar) is fully illuminated
during pilot and main flame.
7. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of - 0.01 in.
to 0.02 in. (0.025 mb to 0.05 mb) of water column pressure with the burner off.
8. Open all the valves in the feedwater line. Switch on the feedwater pump motor and fill the boiler,
see Section 3 - Operation. The operation of the pump controls should be checked by using the
boiler blowdown valve (located at the rear of the boiler). 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 connections. Close the boiler blowdown valve.
9. After purging the gas lines of air. Start the burner as detailed in Section 3 - Operation. Check the
readings on the micro-ammeter for the pilot and main flames, adjusting the primary/secondary
air control to obtain the maximum readings.
10. After the burner has been firing for approximately five minutes. adjust the main air control gate
to obtain a clean combustion.
11. 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. Observe the flame through
the eye glass in the burner plate. The desired flame shape is a full swirling flamebrushing the
wall of the furnace. Adjust the air controls to achive this shape.
12. Check the operation of the low water safety controls as detailed in Section 3 - Operation.
13. Adjust the steam pressure control to suit the boiler application. It should be borne in mind that
boilers are designed to operate most efficiently at their maximum operating pressure. 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 - Safety Valve setting.

2
If the pressure control is fitted with a differential
scale: (see OEM literature in Section 5)
1. Set the main scale pressure to the maximum

pressure required (system pressure).
Do not exceed the boiler operating pressure.
2. Set the differential scale to it’s minimum

pressure. If the pressure control has a fixed
differential, i.e. no adjustable differential
scale, set the main scale to the maximum
pressure required.
When multiple boilers are fitted with a

sequence control:

1. Set the main scale and differential scale as
above.
FIG. 17 PRESSURE CONTROLLER
2. Set the setback pressure control to the
required set back pressure.
Note: In order to utilise 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.
2.15 GAS MONOBLOCS (NON MODULATING BURNERS)
Setting the gas pressure switch. - Models 6 - 30
1. Remove the adjustable gas pressure switch cover.
2. Set the pressure switch by rotating the setting wheel to the desired pressure.
Normally set to 2.5 mbar below the normal supply pressure with the boiler running.
Setting the pressure regulator. - Models 6 - 30
1. Remove the regulator cover.
2. Using a screwdriver, set the regulator to the desired pressure:

Clockwise to increase pressure. Anticlockwise to decrease pressure.
Gas pressure can be tested at the test point on top of the gas output flange.
Setting the main gas flow (V2) - Models 6 - 30. - factory set, would not normally be altered.
1. Loosen the security screw on the setting plate.
2. Turn the setting plate: Clockwise to reduce gas flow. Anticlockwise to increase gas flow.
Rapid stroke adjustment Model 6 - 30 - factory set, to slowest possible opening,

would not normally be altered.
1. Unscrew the adjustment cap from the hydraulic brake.
2. Invert the cap and use as a tool: Clockwise = slowest opening time.
Anticlockwise = fastest opening time.

2
2.15.1 MULTIBLOC GAS VALVES 6J - 30J MODELS (NON MODULATING BURNER)

(see attached manufacturers leaflets).
Output pressure
controller adjusting screw
Hydraulic Brake
Operating indicator
Main gas flow

adjustment Adjustable
pressure switch
Test point
connection Test point
connection
downstream
of Valve 1
Gas output
flange
Test point connection Test point connection Gas input

downstream of Valve 2 upstream of Valve 1 filter cover
Output pressure controller Hydraulic

adjusting screw brake
Main gas flow

adjustment
Test point
connection
downstream
Operating of Valve 1
indicator
Test point
Adjustable
connection
pressure switch
downstream of
Valve 2
Test point
Gas input connection
flange upstream of
Gas input filter cover Valve 1
FIG. 18 6J - 30J GAS VALVE: MAJOR COMPONENTS (NON-MODULATING BURNER)

2
Hydraulic brake
Main gas flow adjustment
Solenoid
Low fire
adjustment ring
Test point connection

downstream of valve 1

down stream of valve 2

upstream of valve 1
SETTING THE BURNER FOR LOW FIRE / HIGH FIRE, Models 40J, 50J AND 60J
(Non Modulating Burner)

The correct settings for low fire/high fire operation are obtained by making adjustments to the two
stage Multibloc valve and the high/low fire steam pressure control.
a) Set the gas input to the boiler for correct input on high fire. This should be done where possible
by using the gas meter. Adjust the main air gate and primary/secondary air adjustment to obtain
optimum combustion conditions.
b) Adjust the high/low fire steam control to cut out at approximately 5 psi below the setting of the
main steam pressure control.
c) Adjust the two-stage multibloc valve by rotating the low fire adjustment ring to obtain a low fire gas
input of approximately 80% of high fire. Leave the air gate adjustments as for high fire.

2
2.15.2 MULTIBLOC GAS VALVES 30J - 60J MODELS (FULLY MODULATING BURNER)
GAS ACTUATOR
Servo motor body
Valve coupling
GAS GOVERNOR & VALVE
Gas valve
Gas governor
Filter & main Electrical

housing connections
Gas in flange
Gas out
flange
Low gas
pressure switch
Filter caps
FIG. 19 30J - 60J GAS VALVE: MAJOR COMPONENTS (FULLY MODULATING BURNER)
2
2.16 SETTING THE BURNER CONTROLS FOR FULLY MODULATING MODELS 30 - 60
The correct setting for fully modulating operation are made by adjusting the parameters via the
Siemens LMV burner controller.
All adjustments need to be carried out by a suitably trained service engineer.
All parameter adjustments are password protected.
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.
1. Disconnect the condensate return pipe adjacent to the condensate return tank.
2. Direct the returns to a floor drain or other safe discharge point and make safe.
3. Leave in this position for one week to allow all impurities to flush through.
4. Drain the boiler completely each day.
5. 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.
! WARNING
Do not change the boiler fuel without
consulting the boiler manufacturer.

Monobloc gas valve steam outlet
Gas
supply inlet
Steam pressure gauge
Oil valves
Feedwater inlet Oil pump
Safety valve
Water level
limiters
Water level
gauges
Water
column
Motorised high /
low control
Pump interrupt /
pump run switch Operator control panel
TDS controller
High pressure
steam controller
High/Low steam
pressure controller
Door electrical isolator
Operating steam
pressure controller
Note: Control Boxes vary

with specification
FIG. 20 BOILER OPERATION

3
SECTION 3 - OPERATION
3.1 GENERAL
The following instructions are given for the guidance of the operator in the use of the J Series Dual
Fuel 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 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 the water is driven off by chemical reaction and the initial test firing,
the refractory is still ‘wet’ when the boiler is delivered. For a 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 drying process.
3.2 BOILER CONTROLS
The following brief description of the controls used on the J Series Dual Fuel 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.
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 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). Located on the control panel box and connected to the steam pressure
gauge assembly by copper tube, the 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.
Note: A set-back pressure controller is fitted when multi-boilers are fitted with a sequence control.
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 Multibloc gas valve will be
closed.
Air Pressure Switch. Mounted on the burner scroll, this switch is operated by the pressure of air
entering the burner through the throat of the scroll. Lack of air, or insufficient pressure, will prevent
the switch completing the circuit thus preventing the burner from operating.
Fuel Pump. Mounted on the burner scroll and driven by the burner motor, the fuel pump delivers oil to
the burner nozzels at the correct pressure to allow complete atomisation and therefore combustion.

CONTINUED...

3
3.2 BOILER CONTROLS - CONTINUED
Gas Head Assembly Consists of a multiblock located in the main gas line, incorporating an integral
governor, pressure switch and gas valves. The independent pilot line having a manual gas cock, a
governor and two electrically powered gas valves. The pilot governor maintain a constant pressure
of gas during the ignition sequence. The electrically powered gas valves are controlled by the burner
programmer.
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.
LOW GAS HIGH LOW BURNER POWER HIGH STEAM

PRESSURE FLAME FLAME ON IGNITION ON PRESSURE
FLAME
FAILURE PUMP START
GAS OFF OFF OIL

RESET
RESET PUMP & SECOND

BOILER LOW WATER
FIRING PILOT MAIN FIRING START MAIN & RESET 1st LOW
FLAME FLAME FLAME FLAME WATER
FIG. 21 ALARM AND INDICATOR LIGHTS
Note: Boilers fitted on skid units and in plant rooms are interlocked with the feedwater and condensate return
tank, after switching the boiler on at the boiler control box isolator switch, the reset button on the tank control box
must be reset. This reset must also be selected after any electrical outage.

3
3.3 INDICATOR LIGHTS
Indicator lights are fitted to the control panel as an 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 approximately 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 vaporised oil which could cause an explosion.
Oil Valve
The two lamps provide a visual indication that the magnetic oil valves have been energised.

Low Flame / Start and Main Flame
Models 40J and 60J are fitted with the following indicator lamps in place of the two oil valve indicator
lamps: The burners on models 40J and 60J are fitted with a two-stage combustion system. The low
flame start lamp indicates that the first stage of combustion is in progress and that the burner should
be firing. Once the second stage of combustion is reached (full firing position), the low flame start
lamp extinguishes and the main flame lamp illuminates.
This lamp will remain illuminated until the burner is shut down.

3
3.4 CHANGING TO THE ALTERNATIVE FUEL
1. S
witch OFF the electrical supply at the door isolator
switch. TDS
Blowdown
2. Isolate the supply lines of the fuel not required. control
3. Open the isolation valve on the required fuel supply.
4. Switch the fuel selector switch to the required fuel.

5. Switch ON the electrical supply to the boiler at
the door isolator.

6. Start the burner. Fuel
selector
switch
FIG. 22 BOILER MAINTENANCE
3.5 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:
1. Ensure that the main steam stop valve is OPEN.
2. Ensure that the steam pressure gauge isolating valve is OPEN.
3. Select the fuel to be used, ensure that the valves in the selected fuel line(s) are open, and the
alternative fuel lines are closed (see Section 3.4).
4. Ensure that all the valves in the feedwater line are OPEN.
5. Ensure that the main blowdown valve is CLOSED.
6. Ensure that the water level gauge isolating valve(s) is OPEN.
7. Ensure that the water level gauge blowdown valve(s) is CLOSED.
8. Ensure that the column blowdown valve is CLOSED.
9. Ensure that the boiler and pump switch is in the OFF position.
10. Ensure that all appropriate electrical isolators are switched ON.
11. Ensure the pump interrupt switch is switched OFF (PUMP RUN).
! 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.
12. Press the boiler/pump switch to the PUMP ONLY position.
Note: If 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
3.6 STARTING THE BOILER - ALL MODELS GAS
1. OPEN all the valves in the gas mains supply to the boiler.
2. OPEN the manual gas cocks on the Pilot and Main lines of the gas head.
CLOSE the steam stop valve.
CLOSE the oil supply isolation valve with the proof of closure microswitch.
3. Select the control switch to PUMP AND BOILER position, the low water alarm bells will sound, the
low water reset will illuminate.
4. Select the low water reset switch for two seconds maximum.
The alarms will stop, and the alarm lights extinguish.
The burner start sequence will commence.
5. After a maximum of two minutes the burner should be firing, and the main gas light be ON.
6. When the boiler has achieved the required (set) pressure, the main steam isolating valve should
be slowly opened allowing steam to enter the system distribution pipework.
! 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:
a) Crack open the main steam valve and allow the system to heat up slowly, (minimum
15 minutes) before fully opening the main steam valve.

b) 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.
If fitted, TDS Panel Mounted Controllers (BC3250) must be reset after any break in electrical supply to the unit.
3.7 STARTING THE BOILER - ALL MODELS OIL
1. OPEN all the valves in the oil supply line.
! CAUTION
Failure to open the oil supply line will damage the oil pump.
A pump damaged under these circumstances will not be replaced by warranty.
2. CLOSE the steam stop valve.

CLOSE the gas supply isolation valve fitted with the proof of closure microswitch.
3. Select the control switch to PUMP AND BOILER position, the low water alarm bells will sound, the
LOW WATER RESET switch will illuminate.
4. Press the LOW WATER RESET switch for two seconds maximum.
The alarms will stop, and the alarm lights extinguish.
5. The burner start sequence will commence.
6. After a maximum of one minute the burner should be firing, and the BURNER ON lamp should
illuminate.

3
6. When the boiler has achieved the required (set) pressure, the main steam isolating valve should
be slowly opened allowing steam to enter the system distribution pipework.
! 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:
a) Crack open the main steam valve and allow the system to heat up slowly (minimum
15 minutes), before fully opening the main steam valve.

b) 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.
If fitted, TDS Panel Mounted Controllers (BC3250) must be reset after any break in electrical supply to the unit.

4
SECTION 4 - MAINTENANCE
Fulton Ltd recommends that these tests and checks are carried out on a regular basis to ensure that the boiler is
operating safely.
Tests should be carried out by a competent person trained to perform such tests. If any test shows that the
equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used.
Any rectification or repairs should be carried out by trained, competent service personnel.
4.1 VISUAL CHECKS
Inspect the steam and feedwater 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 any repairs.
Note: 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.
4.2 WATER LEVEL AND LOW WATER SAFETY CONTROLS
The following procedures ensure the correct functioning of the water level controls and the low water
safety controls.
4.2.1 PUMP TEST
a) If the boiler is not firing and not under steam pressure, lower the water level using the main
blowdown valve:
If the pump is running:
1. Observe the water level in the water level gauge (sight glass).
2. Verify that the pump continues to run until the Pump Off level is reached and then switches
off.
If the pump is not running:
1. Check that the water level in the water level gauge is between Pump On and Pump Off
levels.
2. Lower the water level by opening the main boiler blowdown valve.
3. Verify that the pump starts to run when the water level reaches the Pump On level.
4. Close the main boiler blowdown valve.
5. Continue to observe the water level in the water level gauge and verify that the pump
continues to run until the Pump Off level is reached and then switches off.

4
b) If the boiler is firing and under load, lower the water level by evaporation, observing a
pump cycle:
If the pump is running:
1. Observe the water level in the water level gauge.
2. Verify that the pump continues to run until the Pump Off level is reached and then switches
off.
If the pump is not running:
1. Check that the water level in the water level gauge is between Pump On and Pump Off
levels.
2. The water level will lower through natural evaporation.
3. Verify that the pump starts to run when the water level reaches the Pump On level.
4. Continue to observe the water level in the water level gauge and verify that the pump
continues to run until the Pump Off level is reached and then switches off.
4.2.2 1ST LOW WATER LEVEL CHECK
1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is
between Pump On and Pump Off.
2. Switch off the pump using the Pump Interrupt/Pump Run switch.
3. Allow the water level to lower by natural evaporation below the 1st Low Water level.
4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the
burner stops firing. Do not allow the water level to drop below the bottom of the water level
gauge (sight glass).
If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is
used.
5. Switch on the pump using the Pump Interrupt/Pump Run switch.
6. Verify that the pump runs and refills the boiler. When the water level rises above the 1st Low
Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silences
and the burner fire sequence starts.
7. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

4
4.2.3 2ND LOW WATER LEVEL CHECK
1. Ensure that the boiler is firing, the feedwater pump

is not running and that the water level is between
Pump On and Pump Off.
2. Switch off the pump using the

Pump Interrupt/Pump Run switch.
3. Allow the water level to lower by natural

evaporation to the 1st Low Water level.
4. Verify that the Low Water lamp illuminates,

the Low Water audible alarm sounds and that the
burner stops firing. Do not allow the water level to
drop below the bottom of the water level gauge
(sight glass).
If the test fails, turn the boiler off and ensure that
the fault is rectified before the boiler is used.
5. Allow the water level to lower further by

natural evaporation below the 2nd Low Water
level. Do not allow the water level to drop below
the bottom of the water level gauge. FIG. 23 PUMP INTERRUPT SWITCH
6. Verify that the Low Water Reset switch illuminates.
If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is
used.
7. Switch on the pump using the Pump Interrupt/Pump Run switch.
8. Verify that the pump runs and refills the boiler. When the water level rises above the
1st Low Water level, verify that the 1st Low Water lamp extinguishes but the burner fire
sequence does not start.
9. Press the Low Water Reset switch- Verify that the 2nd Low Water lamp and audible alarm
extinguishes and the burner starts.
10. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

4
4.3 MAIN BLOWDOWN
Keep the boiler, water level gauge (sight glass), water column and interconnecting pipework free
from sludge and scale build-up by blowing down in the following manner:
Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Ltd
Service Department regarding the appropriate blowdown procedure.
1. Start the boiler and generate not more

than 10 psi of steam (see note).
2. Shut off both the burner and the

pump.

Boiler Blowdown
1. Fully OPEN the boiler main blowdown valve

for not more than 5 seconds, or as
recommended by the water treatment
specialist.
2. CLOSE the valve.
Note: Where high levels of suspended solids are FIG. 24 MAIN BOILER BLOWDOWN VALVE
produced, longer and/or more frequent blowdown may
be required.
4.4 WATER COLUMN BLOWDOWN
Note: The water column contains the pump On/Off

probe, which is not safety interlocked.
1. Switch the pump off (pump interrupt)

at the Pump Interrupt/Pump Run
switch.
2. Open the water column blowdown

valve for 5 seconds.
3. Close the water column blowdown

valve and wait for 10 seconds for the
boiler to refill and the water to
stabilise in the vessel.
4. Switch the Pump Interrupt switch to

Pump Run.
Water column
blowdown valve
FIG. 25 WATER COLUMN BLOWDOWN VALVE

4
4.5 WATER GAUGE BLOWDOWN
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 are 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.
WORKING STEAM WATER

POSITION BLOWDOWN BLOWDOWN
B B B
C
C
A A A
FIG. 26 Water Level Gauge FIG. 27 Water Level Gauges

Operating Positions. (Sight Glasses)
4.6 EVAPOURATION 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 period for the LOW WATER
RESET switch to illuminate.
When the check is complete, proceed as follows:

c) Switch the pump ON at the pump interrupt / pump run switch.
d) 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.

4
4.7 FLAME SENSOR TEST
This test checks the operation of the flame

safeguard sensor.
1. Ensure that the burner is firing.
2. Remove the flame sensor from its tube

on the top of the burner.
3. Cover the sensor glass.
4. Verify that the burner goes out (the fan

will run on for a short time but the flame
should go out).
If the test fails, turn the boiler off and

ensure that the fault is rectified before
the boiler is used.
5. Return the flame sensor to its tube on the

top of the boiler.
6. Fire the burner to ensure correct

operation.
FIG. 28 FLAME SENSOR REMOVAL
4.8 DRAINING THE BOILER
! CAUTION
Your local regulations could state boiler water above 43OC must not be discharged into the drain.
ALWAYS check your local regulations.
Boilers with manual blowdown valves
1. Ensure the boiler is cold.

2. Isolate the boiler electrics at the isolator on the control box door.
3. Isolate the feedwater tank and the feedwater pump.
4. Open the main steam valve and the boiler drain valve.
5. Open the drain valve on the blowdown vessel.
6. Open all valves in the drain lines.
Boilers with automatic blowdown systems
1. The boiler should not be under pressure.

2. The boiler should be cold.
3. Close the blowdown isolation valve.
4. Using a screwdriver located as shown ‘A’ in FIG. 29, push up and make a quarter turn, this will
lock the button in position and open the blowdown valve.
5. Using the blowdown isolation valve to throttle the flow, drain the boiler.
Note: Skid units and plant rooms have internal drainage systems which require the same procedures.

4
FIG. 29 AUTOMATIC BLOWDOWN VALVE
4.9 LONG TERM SHUT DOWN
To store the boiler in a corrosion-free situation there are three practical solutions:
1. Fully flood the boiler to exclude as much air as possible.
2. Drain the boiler completely.

Remove all hand hole and manhole doors.
Open all gas/oil side access doors.
3. As (2) but also introduce a form of convection heating to the gas/oil and water side.
A very effective solution is to install a string of outdoor type waterproof light bulbs distributed
throughout the boiler.
4.10 INTERNAL INSPECTION
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 hand hole 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.
Hand Hole Cover Plate
Gasket
Crab
FIG. 30 HAND HOLE

4
4.11 SCHEDULE OF OPERATOR TESTS AND CHECKS
The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary
according to site risk assessment and/or specific requirements of the country/territory that the boiler
is installed in. Failure to maintain the boiler adequately may void the Fulton warranty.
Maintenance on gas related parts of a boiler must be carried out by competent, trained personnel
who are GAS SAFE/ACS registered, and who have the necessary equipment to check combustion.
If any fault is found during these operations, contact your Fulton representative.
! WARNING
Prior to the commencement of any work requiring the removal of cover plates and the opening of
control panel box, the electrical supply to the boiler must be isolated.
! WARNING
Ensure any residual pressure within the boiler is completely vented
before working on the pressure vessel
! 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 feedwater is
effective.
The following procedures are designed to prevent the buildup of scale, silt or sludge in the bottom
of the boiler, water level gauge (sight glass) and water column pipework, personnel involved in
doing this work must have received the appropriate training in all aspects of maintenance and
safety procedures.
In addition to these procedures, the advice of a water treatment specialist should be sought and
followed.
4.11.1 DAILY
1. Visually inspect the steam and feedwater 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.
2. Blowdown the Boiler (Refer to Section 4.3).
Note: If the boiler is being operated automatically on a time clock, the blowdown may be done once during the
working day and once at the end of the day when generating 10 psig or less, providing this is sufficient to
control the TDS level within limits.
3. Blowdown the Water Column (Refer to Section 4.4).
4. Blowdown the Water Level Gauge (sight glass), (Refer to Section 4.5).
4.11.2 WEEKLY (IN ADDITION)
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
1. Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe
blowdown point.
2. Pump Test (Refer to Section 4.2.1).
3. First Low Water Check (Refer to Section 4.2.2).
4. Second Low Water Check (Refer to Section 4.2.3).
5. Flame Sensor Test (Refer to Section 4.7).
4.11.3 MONTHLY (IN ADDITION)
WARNING
Ensure the main electrical supply is isolated before starting work.
6. Visually inspect the internal water space (Refer to Section 4.6).
7. Visually inspect the hand holes in the boiler. If any leakage is evident, the gasket needs
replacing.
8. Visually inspect the flanged joint covering the rear inspection port in which the blowdown valve
is fitted, if any leakage is evident, the gasket needs replacing.
9. Clean the water level gauges (sight glasses).

If any leakage is evident, the gasket needs replacing.
10. Clean any water traps and strainers fitted in the feedwater line.
Check feedwater and boiler water quality against the values given in
Section 5.3 - Recommended Water Conditions.
11. Oil Burner: Remove, clean and adjust the oil nozzle and electrode assembly.
Note: Use only genuine Fulton replacement parts.
4.11.4 THREE MONTHLY (IN ADDITION)
12. Drain and isolate the boiler.
13. Remove the lower hand hole assemblies

and inspect the interior of the pressure
vessel for scale and sludge build up.
14. Remove the feedwater pipe from the

top of the boiler. Ensure the pipe is not
blocked, clean as required.
15. Gas Burner: Isolate the gas supply.

Disconnect the gas head from the
burner by unscrewing the union.
Remove the burner plate screws,
withdraw the burner assembly.
Clean the ignition electrodes and reset FIG. 31 FEEDWATER PIPE REMOVAL

4
Ignition Ignition leads Burner plate screws

transformer
Burner Burner motor

Photocell
scroll
Air gate
Electrodes
Fan
Oil feed pipe
Air damper
Burner plate
Burner top plate
Oil line
Rubber
spider
Oil
Coupling Electrode
nozzle
holder
Air
Deflector
Fuel pump
FIG. 32 BURNER ASSEMBLY
Cleaning
Remove cover
the Flues
plates and gasket
Remove the clean-out door

to the flue passes and to
the bottom of the boiler.
Oil boiler illustrated.
FIG. 33 FLUE CLEANING

4
4.11.5 SIX MONTHLY (IN ADDITION)
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 the forming of the
boiler insulation. This is normal and does not affect the efficiency or the life of the boiler in any
way.
16. 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 new gasket material and furnace cement to ensure a tight
seal, thus preventing the escape of hot gases.
17. Apply a small quantity of oil to the bearings of the burner motor and the feedwater pump
motor.
18. Drain and flush the feedwater tank. Clean any filters in the tank, in the feedwater line or in the
feedwater pump.
19. Remove and clean the water level 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
feedwater pump.
20. Remove the air gate and clean the fan.
21. 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, there should be no smoke
visible.
If either of these tests fail, shut down the boiler and contact Fulton Ltd immediately.

22. Remove components from all threaded stub pipes, clean and inspect, replace if required.
23. Remove the water level gauge (sight glass) and water column. Rod through the top
connections of both to ensure that the holes in the baffle plates (approx. 6 mm dia.) inside the
boiler are not obstructed.
24. Check the burner combustion to ensure that excess air and carbon monoxide values are
within normal limits (see combustion values in Section 5).
25. Check the condition of the gas valve filter (if fitted), renew as required.
4.11.6 ANNUALLY (IN ADDITION)
26. Fulton Ltd recommend replacement of all threaded stub pipes on the boiler OR to your
inspectors satisfaction.

4
4.12.1 TROUBLESHOOTING GAS BOILER
Problem Cause Remedy

Ignition Failure 1. Power Supply Check fuse or circuit breaker.
Reset or Replace as required.
2. Ignition Electrodes Check for cracks in porcelain,if found replace the
electrode. Check electrodes for carbon build-up.
Clean as required.
Check settings, adjust if required.
3. Transformer Check voltage between transformer leads at
terminal block to be sure transformer is live.
4. Burner Control Check voltage between ignition terminal and
neutral, this check must be made before the control
locks out. If no power, replace the control.
5. Air Settings Check main air adjustment and secondary air
adjustment.
6. Faulty Air Switch Check for faulty air switch.
7. Gas Valve Check filters in the valve block. Clean as
required.
8. Gas supply Check for gas pressure and intermittent supply
problems.
9. Loose wire connections Check connections to all components.
Flame Failure During 1. Power Supply Check fuse or circuit breaker.
Start-up Reset or replace as required.
2. Gas supply Check for gas pressure and intermittent supply
problems.
3. Air Settings Check main air adjustment and secondary air
adjustment.
4. Ignition Electrodes Check electrodes for carbon build-up.
Clean as required. Check for proper adjustment,
readjust if necessary. Check for cracks in porcelain,
if found replace the electrode.
5. UV Detector Check the detector is located correctly and clean.
6. Burner Control Check voltage between ignition terminal and
neutral, this check must be made before the control
locks out.
If no power, replace the control.
7. Loose wire at fuel valve Tighten wiring connections.
circuit.
8. Contact open on Air Switch Adjust to the correct setting.
9. UV Detector wiring reversed Change to the correct terminals.
at control box.
Flame Failure During 1. Power Supply Check fuse or circuit, reset or replace as necessary.
Normal Run 2. Gas Supply Check gas pressure coming into the gas train, if
low contact the gas supplier.
Check the setting on the gas valve regulator, adjust
as required.
4. Faulty Air Switch Check for faulty air switch.
5. Bad Combustion Check combustion readings.

4
4.12.1 TROUBLESHOOTING, CONTINUED. GAS BOILER

Burner Cut-off 1. Gas Valve Check filters in the valve block.
Clean as required.
2. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure
regulator.
3. Faulty Level Control Test level controls, adjust or replace as required.
4. Dirty or defective UV detector Clean or replace.
Poor Combustion 1. Refractory Bricks Check refractories to see if they are blocked with
soot or broken in pieces.
Clean or replace as necessary.
2. Stainless Steel Ring Check the ring is present (40J - 60J models) and
fits tightly against the furnace wall.
3. Main Air Adjustment Check air adjustment. Air/fuel mixture may be off.
Open main air gate until the flame brushes the
furnace wall.
4. Secondary Air Adjustment Check main air adjustment, reset as required and
secure in place.
Check CO2 and O2 levels.
5. Draft Check draft with a gauge. Readings will vary
between installations, if in doubt consult Fulton for
a draft value for your system.
6. Dirty Flue Check flue for carbon build-up or blockage.
Clean the flue.
7. Negative Room Pressure Ensure there are no exhaust fans running in the
boiler room.
8. Dirty Fan Check fan for obstructions, clean as required.
Burner Back Fires 1. Refractory Bricks Check refractories to see if they are plugged with
soot (Delayed Ignition) or broken in pieces.
Clean or replace as necessary.
2. Ignition Electrodes Check electrodes for carbon build-up.
Clean as required. Check for proper adjustment,
readjust if necessary.
Check for cracks in porcelain, if found replace the
electrode.
4. Draft Check draft with a gauge. Draft should be -.05 to
-.10 mbar with the burner off, or -.10 to -.15 mbar
when operating.
A barometric damper may need to be installed.
5. Negative Room Pressure Ensure there are no exhaust fans running in the
boiler room.
6. Air Adjustment Check Air Adjustment settings.
7. Gas Supply Check gas pressure coming into the gas train, if
low contact the gas supplier.
Check the setting on the gas valve regulator, adjust
as required.

4
4.12.1 TROUBLESHOOTING, CONTINUED. GAS BOILER

Boiler will 1. Gas Supply Check gas pressure coming into the gas train, if
not maintain low contact the gas supplier.
pressure Check the setting on the gas valve regulator, adjust
as required. If possible meter the flow rate.
2. Dirty Flue Check flue for carbon build-up or blockage.
Clean the flue.
3. Pressure Control Disconnect all power to the controller.
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,
the switch should break. If the controller operates
improperly, replace it.
4. Scale build-up in boiler Clean the pressure vessel.
5. Refractory Bricks. Check refractories to see if they are blocked with
soot or broken in pieces. Clean or replace as
necessary.
6. Steam traps blowing through. Check steam traps, clean or replace as required.
7. Boiler size. Boiler may be undersized.
8. Faulty Gas Valve. Check gas flow rate.
Boiler is 1. Steam traps blowing through. Check steam traps, clean or replace as required.
Surging (Widely 2. Contamination in boiler. Empty boiler and feed tank.
fluctuating water Flush out and refill, if system operates but
level in sight progressively deteriorates, there is probably a leak
glass) somewhere in the system.
3. Scale buildup or lime deposits. Consult Fulton or call a water treatment specialist.
4. Too much compound (water Dump contents of the return tank and flush the
treatment over dose). system. Test the water.
5. High Alkalinity (high pH). Have a water treatment specialist test the water.
6. Load exceeds boiler capacity. Check total system load against the output of the
boiler. Decrease the load required at any one time.
Boiler rumbles 1. Poor Combustion Check combustion readings.
and pulsates 2. Draft. Check draft with a gauge.
Draft should be -.05 to -.1 mbar with the burner off.
A barometric damper may need to be installed.
3. Too much main air. Adjust main air gate.
Boiler carrying 1. Steam Traps. Check steam traps, clean or replace as required.
over water with 2. Too much compound (water Dump contents of the return tank and flush the
the steam treatment over dose) in the system. system. Test the water.
system.
3. Contamination in boiler. Empty boiler and feed tank. Flush out and refill, if
system operates but progressively deteriorates,
there is probably a leak somewhere in the system.

4
4.12.2 TROUBLESHOOTING FEEDWATER PUMP

Feedwater Pump, 1. Supply failure. Connect the electricity supply.
Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers.
3. Motor contactor overload has Reactivate the motor protection.
tripped out.
4. Contactors not making Check, the coil is faulty or wiring loose.
5. Control circuit is defective. Repair the control circuit.
6. Motor is defective. Replace the motor.
Motor starter overload, 1. One fuse/automatic circuit breaker is Replace the fuse, reset the circuit
trips out immediately blown. breaker.
when supply is 2. Contacts in motor contactor overload Replace motor starter contacts.
switched on. are faulty.
3. Cable connection is loose or faulty. Tighten or replace the cable connection.
4. Motor winding is defective. Replace the motor.
5. Pump blocked. Remove the blockage.
6. Overload setting too low. Set the motor starter correctly.
Motor contactor 1. Overload setting is too low. Set the overload correctly.
overload trips out 2. Low voltage at peak times. Check the electricity supply.
occasionally.
Motor contactor has Check :
not tripped out but the Motor does not run when started:
pump does not run. items: 1, 2, 4, 5, 6,
Pump capacity not 1. Pump inlet pressure is too low Check the suction conditions.
constant. (cavitation).
2. Suction pipe/pump partly blocked. Clean the pump or suction pipe.
3. Pump draws in air. Check the suction conditions.
Pump runs but gives 1. Suction pipe/pump blocked. Clean the pump or suction pipe.
no water. 2. Foot or non-return valve blocked in Repair the foot or non-return valve.
closed position.
3. Leakage in suction pipe. Repair the suction pipe.
4. Air in suction pipe or pump. Check the suction conditions.
5. Pump rotates in the wrong direction. Change the direction of rotation of the
motor.
6. Boiler feedwater non-return valve Check and clean boiler feed water
letting water passed the valve seat, non-return valve, ensure it is seating
(normally and not allowing water
passed. accompanied by banging in the
feedwater tank).

4
4.12.2 TROUBLESHOOTING, CONTINUED. FEEDWATER PUMP

Pump runs 1. Leakage in suction pipe. Repair the suction pipe.
backwards when 2. Foot or non-return valve is Repair the foot or non-return valve.
switched off. defective.
Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal.
Noise. 1. Cavitation occurs in the Check the suction conditions.
pump.
2. Pump does not rotate Adjust the pump shaft.
freely (frictional resistance
because of incorrect pump
shaft position.
3. Frequency converter See Grundfos manual.
operation.
4. Boiler feed water non-return Check and clean boiler feedwater non-return valve,
valve letting water passed ensure it is seating and not allowing water passed.
the valve seat, (normally
accompanied by banging
in the feed water tank).
Water pump will 1. Scale on probes. Check and clean probes, replace as
not come on at necessary.
times. 2. Faulty pump contactor Check the contactor has power. Check the
contactor is pulling in.
Replace if necessary.
3. Faulty pump motor. Check the pump has power.
If the pump has power but is not running, replace it.
4. Faulty Level Control Relay Check the relay has power and is secure on it’s
base. Replace if faulty.
Low fuel pressure. 1. Gas pressure regulator Check and replace.
Boiler flooding 1. Pump does not shut off. Dirty probes. Clean or replace as necessary.
2. Relay failed. Ensure the relay is secure on its base.
If so replace the water level relay.
3. Earth connection. Clean and tighten as required.
4. Vacuum created with boiler As the boiler cools, it pulls water from the system
off. piping. To prevent this, add a check valve on the
steam gauge assembly piping, which closes under
pressure and opens under vacuum.

4
4.12.3 TROUBLESHOOTING BURNER CONTROL UNIT-LFL 1 (SIEMENS)
Symptom and Cause Remedy

Identification Symbol
No Start 1. No Power Check all fuses/circuit breakers
Check for correct wiring.
2. External Interlocks Check all external interlocks are made.
3. Air Pressure Switch Check that the switch is in ‘No Air’ position.
4. CPI switch If fitted, must be made.
5. Air Damper If fully closing damper fitted, check relevant micro
switch on damper.
6. Burner Motor fault Check overload.
Lockout 1. False flame detected Check for stray light (cell only). Faulty cell or
damaged flame probe.
Interruption of 1. Air Damper Check fully open microswitch is made.
start-up sequence
Lockout 1. Air Pressure Switch Check that switch is made.

2. Note: Any air pressure
P failure after this time will
cause a lockout condition.
Lockout 3. Flame supervision Check for stray light (cell only).
Faulty cell or damaged flame probe.
Interruption of 1. Air Damper Check low fire microswitch is made.
start-up
sequence
Lockout 1. No ignition spark Check supply ignitor.

Check electrode and HT leads for damage.
2. No pilot flame Check gas supply.
Check electrode setting.
1 Check functionality of pilot gas valve(s).
Check pressure gas downstream of pilot valve(s).
3. Pilot lights then extinguishes Check flame stability with ignition off.
Note: Any flame signal Check air pressure at burner.
failure after this stage will Check gas pressure is steady.
cause a lockout condition Check the flame is being sensed, i.e.
(i) Check sensor for damage.
(ii) Check sensor can view flame.
(iii) Check flame signal,
see data sht. LFL1 - 7451

4
4.12.3 TROUBLESHOOTING BURNER CONTROL UNIT-LFL 1 (SIEMENS)
Symptom and Cause Remedy

Identification Symbol
Lockout 1. No main flame Check supply to main valve(s)
Check functionality of main valve(s).
Check gas pressure at burner.
2 Check air pressure at burner.
Check flame signal strength,
refer to LFL1 data sht. 7451
Lockout 1. Flame failure Check flame signal.
2. Air pressure failure Check switch operation.
l
Lockout on 1. Extraneous light Check flame extinguished.
completion of control Check gas valves for leaks.
programme sequence 2. Faulty flame signal Check for aged/faulty UV cell.
Check flame supervision circuit.

4
4.12.4 TROUBLESHOOTING OIL BOILER

Ignition Failure 1. Oil Tank Empty 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.
2. Power Supply Check fuse or Circuit breaker. Reset or replace as
required.
3. Ignition Electrodes Check electrodes for carbon build-up, clean if
required. Check settings adjust if required. Check
for cracks in porcelain, if found, replace.
4. Transformer Check voltage between transformer leads at
terminal block to be sure transformer is live.
5. UV Detector Check for ignition interference.
6. Loose wire connection Check connections to all components.
7. Burner Control 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.
8. Oil nozzle clogging Check oil nozzle(s), clean or replace as necessary.
9. Faulty Oil Pump Check to see if oil is being pumped to the boiler
nozzle. Repair or replace as necessary.
Flame Failure 1. Power Supply Check fuse or Circuit breaker. Reset or replace as
(see note) required.
3. Main Air Adjustment Check air adjustment. Air may be blowing flame
away from the UV detector. Open primary air until
fire
brushes the furnace wall.
4. UV Scanner Check for dirt on scanner, clean as required. Check
for proper location of detector.
5. Contact open on Adjust to proper setting air safety switch.
6. Scanner wiring reversed at panel Change to correct terminals.
` 7. Oil Supply 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.
8. Oil Valve Check the voltage between oil valve neutral at
terminal block to be sure oil valve is getting power.
9. Oil Pump Check for clogged strainer or filter. Remove
and clean. Check for slipping or broken coupling.
Tighten or replace. Check for seized pump shaft.
Replace.
10. Loss of Oil Prime Check all lines for possible air leak in intake line
and tighten. Check the intake line is not restricted.
Replace.

4
4.12.4 TROUBLESHOOTING, CONTINUED. OIL BOILER
Note: One of the most common causes of flame failure is dirt/sediment in the oil filter, oil lines, solenoid valves
or nozzle, 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.

Boiler fails to 1. No Power Check fuse or circuit breaker. Reset or replace as
start necessary.
2. Pressure 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.
Burner Cut-off 1. Oil tank empty 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.
2. Power Supply Check fuse or Circuit breaker. Reset or replace as
required.
4. UV Detector Check for dirt on detector, clean as required. Check

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 replaced.
6. Faulty Level Control Check the level control relays are securely
mounted on their bases. Check the power supply
to each. The relays may be checked by swopping
positions and checking they are both functioning.
7. Oil Nozzle Check for clogged nozzle, clean or replace.
8. Transformer Check voltage between transformer neutral at
terminal block to be sure transformer is being
powered.
9. Burner Control 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.
the wires from the controller. Connect an ohmmeter
of the controller, the switch should make raise the
set point and re-check, switch should break. If the
controller operates improperly, replace it.

4

Poor 1. Refractory Bricks Check the bricks are not plugged with soot or
Combustion 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. Secondary Air Adjustment. Check main air adjustment to see if it has moved.
Adjust as necessary and tighten in position. Check
CO2 and O2 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 1. Refractory Bricks Check the bricks are not plugged with soot or
fires broken into pieces. Clean and replace as required.
3. UV Detector Check for dirt on scanner, clean as required. Check
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 leak in intake line
and tighten. Check for possible restricted intake
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.
Repair or replace as necessary.
14. Hole In Suction Line Check and replace as necessary.

4

Boiler will 1. Oil Tank Empty Refill the oil tank. A slight delay in the re-priming of
not maintain the fuel pump may cause the burner programmer
pressure to require resetting before the boiler operates
satisfactorily.
2. Oil Nozzle Check for blocked nozzle. Clean or replace.
3. Oil Valve Check voltage between oil valve leads at terminal
block to be sure oil valve is getting power.
4. Oil Pump 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.
5. Dirty Flue Check flue for Carbon build-up or blockage. Clean
flue passages with brush.
the wires from the controller. Place an OHM meter
of the controller, the switch should make. Raise
the set point and recheck, switch should break.
If the controller operates improperly, replace
it.
7. Scale Buildup In Boiler Consult Fulton.
8. Refractory Bricks Check the bricks are not plugged with soot,
cracked or broken into pieces. Clean and replace
as required.
9. Steam Traps Blowing Through Check traps, clean or replace as required.
10. Boiler Size Boiler may be under sized.

4

Boiler is Surging 1. Steam Traps blowing through. Check traps, clean or replace as required.
2. Scale buildup or lime deposits. Call water treatment company and consult the factory.
3. Too much water treatment Dump the return tank and flush the system. Test the
water treatment.
4. Too much of a load. Check total equipment load against the boiler output.
Decrease amount of equipment being used.
Boiler Rumbles 1. Draft Problem Check draft is neutral. Consider installing a barometric
damper if the draft is too strong.
2. Too much main air. Adjust main air.
3. Air or water in the oil. Check tank and lines for water or leaks.
Boiler pushing 1. Steam Traps Check traps. Clean or replace as required.
steam
2. Too much water treatment. Dump the return tank and flush the system. Test the
water treatment.
Pump will not cut 1. Dirty Probes. Clean or replace as required
off
2. Relay failed. Check relay is secure on its base, if so, replace the relay.
3. Earth connection. Check for tightness and clean.
Pump runs but 1. Vapour locking of pump. Allow system to cool down, check steam traps of pump.
does not put and check to be sure return lines are not insulated.
water in the boiler Check return tank temperature, if it is above 82OC 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 121OC.
2. Blocked feed water line Check feed water line is not blocked, clean as required.
Water pump runs 1. Scale on probes. Check probes, clean as required.
intermittently
2. Bad pump contactor. Check to ensure the contactor is live. Check to ensure
the contactor coil is being pulled in. Replace as required.
3. Pump Motor damaged. Check the pump circuit is live. If the circuit is live but the
pump is not running, replace the pump.
Boiler continues 1. Oil Valve defective Check the valve is opening and closing.
after shut down
Oil fumes coming 1. Bad draft condition Check the draft with a gauge, should read neutral. May
out around the oil need to install a barometric damper.
pump housing
2. Venting of room Ensure the boiler room doors are closed on shut down
and the recommended vents are clear.
Boiler flooding 1. Pump does not shut off. Dirty probes, clean or replace as required.
2. Relay failed. Check relay is secure on its base, if so replace the relay.
3. Earth connection. Check for tightness and clean.
4. Vacuum created with the boiler off. 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.

4
Boiler Boiler
Burner
Fault Ignition Flame Burner Poor
Back
will not will not
Cause Failure Failure Cutoff Combustion Maintain Maintain
Fires
Pressure Water
Supply
Oil Supply
Refractories
S.S. Ring
Ignition Electrodes
Oil Nozzle
Main Air Adjustment
Oil Valves
Oil Pump
Photoelectric Cell
Low Water Probes
Low Water Control
Pressure Controller
Burner Programmer
Draught
Transformer
Sec. Air Adjustment
Loss of Priming Oil
Steam Overload
Feedwater Pump
Bad Traps
Dirty Flues
FIG. 34 FAULT FINDING CHECK LIST

4
4.13 MAINTENANCE LOG

This log should be completed regularly as a record of boiler maintenance.
Date Action Remarks Sig.

4
Vertical Steam Boiler - Daily and Weekly Tests Boiler Number:
Page 62
Model: Fuel:
4.14
Day
1 2 3 4 5 6 7
Date
1. Visual Inspection of pipework and fittings for signs of leakage Y-N Y-N Y-N Y-N Y-N Y-N Y-N
2. Pump Check, Feed pump, start/stop Y-N Y-N Y-N Y-N Y-N Y-N Y-N
3. First Low Water Level, Burner cut-out and alarm sound Y-N Y-N Y-N Y-N Y-N Y-N Y-N Note: *Additional tests to be completed on the 7th day
4. Second Low Water Level, Burner cut-out alarm sound. Y-N Y-N Y-N Y-N Y-N Y-N Y-N *10. Flame failure device tested. Y-N
Duration seconds.
5. Blowdown, Boiler Self Monitoring Controls (if fitted)
Test Time.
Duration seconds. *11. First Low Water Level Y-N
6. Blowdown, Water Column Burner cut-out and alarm sound
Test Time.
DAILY AND WEEKLY TEST LOG
Duration seconds. *12. Second Low Water Level Y-N

7. Blowdown, Water Level Gauge Burner cut-out alarm sound
Test Time.
Pressure gauge reading for blowdown tests. *13. Pressure gauge reading.
Boiler water and water treatment values must be
within known tolerances of the datum.
8. Boiler Water. datum value. TDS. reading
datum value. PH reading

9. Water Treatment. datum value. reading
Operator Signature:
Test Results and actions taken
Day 1. sig. Day 5. sig.

2. sig. 6. sig.
3. sig. 7. sig.
4. sig. 7+. sig.
Log examined by: Date:

5
SECTION 5 - GENERAL DATA
5.1 BOILER DIMENSIONS
360°
V
G
A K C
W
L J
U M D X
T E N
P B
S
FIG. 35 BOILER DIMENSIONS
MODEL: J SERIES 6J/8J/10J 15J 20J 30J 40J/50J/60J

A Minimum Clearance 2300 2400 2600 2800 3100
B Overall Width 980 1030 1250 1440 1655
C Overall Depth 1025 1060 1400 1595 1850
D Overall Height 1745 1835 1990 2170 2440
E Boiler Height 1670 1760 1890 2070 2320
F Boiler Diameter 715 765 985 1175 1390
G Height to Top of Fan 1810 1900 2030 2210 2460
H Gas Train Length 425 555 555 570 940
J Gas Inlet Height 2045 2165 2330 2510 2820
K Oil Inlet Height 1550 1640 1735 1915 2150
L Safety Valve Discharge Height 1840 1930 2060 2240 2490
M Steam Outlet Height 1845 1950 2100 2310 2680
N Feedwater Inlet Height 1810 1900 2030 2210 2460
P Flue Outlet Height 1500 1565 1670 1820 2075
R Flue Diameter 152 203 255 305 305
S Main Boiler Blowdown Height 380 380 390 390 395
T Control Column Blowdown Height 1025 1115 1245 1385 1670
Water Level Gauge (Sight Glass)
U 1060 1155 1285 1465 1710
Blowdown Height
V Water Level Gauge Stand Off 265 265 265 265 265
W Control Column Stand Off 270 270 270 270 265
X Fan Stand Off 330 330 440 480 500
Dimensions mm
Dimensions are approximate and only intended as a guide to aid installation
Note:
* Recommended height for service & maintenance
Information from TI 117 Issue 7

5
5.2 BOILER SPECIFICATION
! 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.
CE marked to PED, EMC, LVD & Machinery Directive, constructed to BS2790 (PD2790) Class 1 as
standard (other code specifications available).
MODEL: J SERIES UNIT 6J 8J 10J 15J 20J 30J 40J 50J 60J
CE marked to PED, EMC & LVD, constructed to BS2790 as standard (other code specifications available).
General
Steam Output F & A 100 °C kg/h 96 128 160 240 320 480 640 800 960
kW Rating kW 60 80 100 150 200 300 400 500 600
Operating Pressure ** barg 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34
Weight
Shipping Weight kg 977 977 977 1090 1620 2270 3400 3400 3400
Operational Weight kg 1067 1067 1067 1290 1910 2910 4420 4420 4420
Water Content L 90 90 90 200 290 640 1020 1020 1020
Efficiencies
Gross % 80 80 80 80 80 80 80 80 80
Net % 89 89 89 89 89 89 89 89 89
Gas Pressures
Min. Natural Gas Modulating*** mbar - - - - - 30 30 30 30
Min. Natural Gas On/Off mbar 18 18 18 18 18 18 18 18 18
Max. Natural Gas mbar 100 100 100 100 100 100 100 100 100
Min. LPG mbar 50 50 50 50 50 50 50 50 50
Max. LPG mbar 80 80 80 80 80 80 80 80 80
Firing Rate
Gas **** m3/h 7.0 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6
Oil L/h 7.1 9.4 11.8 17.6 23.6 35.2 47.1 58.9 70.4
LPG/Propane m3/h 2.9 3.9 4.8 7.2 9.6 14.4 19.2 24.1 28.9
Ventilation Requirements for Combustion Purposes (Free Area)
Low Level inlet cm2 670 800 920 1250 1570 2220 2870 3530 4170
High Level Outlet cm2 335 400 460 625 785 1110 1435 1765 2085
Electrical Requirements
FLC 400 V 3 ph 50 Hz A/ph 4.7 4.7 4.7 4.7 4.9 4.9 6.9 6.9 6.9
FLC 230 V 1 ph 50 Hz A 12.7 12.7 12.7 12.7 14.9 - - - -
Connection Sizes All threads BSP F= Female, M=Male
Steam Outlet DN 20 F 20 F 25 F 32 F 32 F 40 F 50 F 50 F 50 F
Safety Valve Discharge DN 25 F 25 F 25 F 25 F 25 F 25 F 32 F 32 F 32 F
Feedwater Inlet DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F
Feedwater Pump Inlet DN 25 F 25 F 25 F 25 F 25 F 25 F 25 F 25 F 25 F
Blowdown, Boiler DN 20 F 20 F 20 F 20 F 25 F 25 F 25 F 25 F 25 F
Blowdown, Water Column DN 20 F 20 F 20 F 20 F 20 F 20 F 20 F 20 F 20 F
Blowdown, Water Level Gauge
DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F
(Sight Glass)
Blowdown, TDS DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F
Water Sample Outlet DN 15 M 15 M 15 M 15 M 15 M 15 M 15 M 15 M 15 M
Flue Outlet in. 6 6 6 8 10 12 12 12 12
Gas Inlet DN 20 F 20 F 20 F 32 F 32 F 40 F 50 F 50 F 50 F
Oil Connection in. Flexible hoses provided 1/4 in. BSP all models.
Note:
** Boilers at higher pressure, available to special order.
*** Modulating control available at lower gas pressures, to special order.
**** Natural Gas - Group H.
Information from TI 117 Issue 7
5
5.3 RECOMMENDED WATER CONDITIONS
! IMPORTANT
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 (water entering boiler)

pH Value 8.5 to 9.5 tested at room temperature.
Hardness less than 2.0 mg/kg in the form of CaCO3.
Suspended Solids None.
Chloride Less than 50 mg/kg.
Organic Matter Less than 5 mg/kg.
Oil None.
Minimum Temperature 85°C
BOILER WATER (water inside boiler)
pH Value 10.5 - 12.0, tested at room temperature.
Hardness Not detectable.
Suspended Solids Less than 200 mg/kg.
Chloride Less than 500 mg/kg.
Oxygen Scavenger, Sodium Sulphite or Tannin 30 to 70 mg/kg.
Phosphate Less than 50 mg/kg, in the form of PO4.
Total Alkalinity Less than 1000 mg/kg.
Caustic Alkalinity 300 mg/kg as minimum as CaCO3.
Total Dissolved Solids (TDS) Less than 3500 ppm.
Iron Less than 1 mg/kg.
Silica Less than 150 mg/kg, in the form of SiO2.
Dissolved Oxygen None.
mg/kg = Milligrams per Kilogram

CaCO3= Calcium Carbonate
PO4 = Phosphate
SiO2 = Silicon Dioxide
1 Grain hardness = 17.118 ppm

therefore 70 ppm = 4.10 grains hardness.
For practical purposes mg/kg = ppm
It is critical that the boiler water pH be alkaline in the range 10.5 -12.0

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 conditions.

A
APPENDIX A
WATER LEVEL PROBE INFO
u Terminal & Securing Nuts must not be adjusted.

! IMPORTANT
u Only Angle Rajah are to be used to connect wire
to the probes.
The “Terminal & Securing Nuts” are tightened to a specified torque during manufacture which causes the
“PTFE Insulation” to seal against the probe body. Therefore these nuts must not be adjusted because the
seal will be broken which may cause the probe to leak. (See FIG. 36)
“Angle Rajah” ONLY must be used to connect wire to the probes because they clip directly to the “Terminal
Nut”. Spade Connectors must NOT be used because the “Terminal Nut” would require adjustment and
therefore cause the probe to leak. (See FIG. 37)
N.B. The “Probe Rod Grub Screw and Lock Nut” are suitably tightened during manufacture, meaning the
probe is ready to be installed without any adjustment.
The ONLY instance a spanner should be used, is to turn the “Probe Body” in order to remove or reinstall
the entire probe.
Terminal nut
Securing nuts
Probe wire
Probe body
Angle rajah
Terminal nut
PTFE
Insulation
Probe rod
grub screw
Probe body
Probe rod
Probe rod lock nut
FIG. 36 WATER LEVEL PROBE COMPONENTS FIG. 37 ANGLE RAJAH FITTED TO PROBE
B
APPENDIX B
MOTORISED HIGH / LOW CONTROL
1.1 GENERAL
The Fulton motorised high/low control is designed to improve the efficiency of the boiler by switching
the firing rate from high fire (when there is low steam pressure in the boiler) to low fire (when the
boiler reaches a high steam pressure). The systems major components comprises of; two stage gas
valves, motorised air damper unit and two stage steam pressure switches.
! CAUTION
The adjustment of the air gate control motor or the two stage
gas valve should only be carried out by qualified personnel,
incorrect adjustment could result in damage to the pressure
vessel and/or the production of harmful combustion gases.
Air Damper Housing
High/Low Fire Cams
Air Damper Motor
FIG. 38 HIGH/LOW CONTROL
1.2 OPERATION
With the steam pressure switch preset to the high and low fire operational requirements of the system,
and the boiler operating normally, steam pressure will gradually increase until the high pressure limit
is reached, the pressure switch will then switch the two stage gas valve and the air damper motor to
the low fire position.
The boiler will continue to operate at low fire until the steam pressure falls to the low pressure limit
setting on the pressure switch. At this point, the gas valve and the air damper will switch the boiler
into high fire mode and the sequence of high fire / low fire is regulated automatically with no routine
maintenance required.
Note: Should the boiler attain the off setting of the on/off control pressure switch, the burner will switch off on
low fire and then restart in the normal way on high fire.
1.3 ADDITIONAL CONTROLS
Low Fire Hold Switch - Used to maintain the boiler in the low fire mode during commissioning.
B
1.4 COMMISSIONING
Commissioning should be carried out by a qualified Fulton Service Engineer.
To achieve the ideal combustion efficiency and gas input rates, a gas flow rate meter is required to
measure the fuel input to the boiler.
1.4.1 FUEL INPUT RATES
Model 6 8 10 15 20 30 40 50 60
Low Fire
m3/h 3.5 4.7 5.8 8.7 11.6 11.6 23.2 29.0 34.8
ft3/min. 2.1 2.8 3.4 5.1 6.9 10.3 13.7 17.1 20.5
High Fire
m3/h 7.0 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6
ft3/min. 4.1 5.5 6.8 10.2 13.7 20.5 27.3 34.2 41.0
Note: Boilers are pre-commissioned before leaving the factory to ensure optimum gas input rates and
combustion values.
1.4.2 AIR DAMPER MOTOR - FACTORY CAM SETTINGS

(see 2.3 Setup procedure)
Terminal Position Degrees

N1 High Fire Motor Cam 45°
N2 Low Fire Motor Cam 10°
N5 High Fire Interlock Cam 40°
N6 Low Fire Interlock Cam 15°
Blue cam N7 not used
Red cam N6
Red cam N5
Red cam N4 not used
Red cam N3 not used
Yellow cam N2
Yellow cam N1
FIG. 39 AIR DAMPER MOTOR

Note: The high fire interlock cam should always be set approximately 5° lower than the high fire cam position.
The low fire interlock cam should always be set approximately 5° higher than the low fire cam position.
B
1.4.3 SETUP PROCEDURE
1. Set the cams on the air damper motor to the initial position.
Start the boiler and wait until the motor and gas valve have driven to high fire.
Adjust the main (primary) air gate to achieve the best combustion with the least buffeting in the
furnace.
2. Using the low fire hold switch, hold the boiler in low fire.
The air damper motor should move to its low fire position and the high fire light on the
control panel should extinguish, indicating the gas and air input rates have been reduced to
approximately half the high fire input rate.

Note: If gas flow rate equipment is available, the low fire gas input rate should be adjusted to the correct value
(see fuel input rates table) by rotating the black 1st stage partial adjustment ring located below the 2nd stage
solenoid.
3. The ideal low fire CO2 constituent of the flue gases is 8 - 10.5%.
Place an exhaust gas analyser into the flue, reduce or increase the amount of air entering the
boiler as required, by adjusting the low fire cam (N2) position.
Note: The reaction of the motor to a change in cam positions is:
Reduced air: adjust the cam to reduce the amount of air entering the boiler, the reaction of the
motor will be immediate.
Increased air: adjust the cam to increase the amount of air entering the boiler, switch the low fire hold
switch off. When the motor has driven back to high fire turn the low fire hold switch
on, the damper will drive back to its new low fire position. Adjust the cams until the
correct CO2 figure is achieved.
Note: Any adjustment to the cam positions requires an adjustment to its interlock cam position.
4. Switch off the low fire hold switch.
Note: if gas flow rate equipment is available, the high fire gas input rate can now be set (see fuel input
rates table) by adjusting the pressure control screw located under a protective cover on the black electrical
connection block.
5. The high fire CO2 constituent of the flue gases is 10 - 10.5%.

Place an exhaust gas analyses into the flue, reduce or increase the amount of air entering the
boiler as required, by adjusting the high fire cam (N1) position.
To reduce the amount of high fire air, the damper will have to be driven to its low fire position
and back again, before it takes up its new position. Ensure that the high fire interlock cam N5 is
always set approximately 5° below the high fire motor position cam N1.
Record all cam settings and the high and low fire final gas elbow pressures for future reference.
6. Adjust the pressure switch (PS2) to the high/low switch over point.
1.5 SPARE PARTS
Part No. Description Qty Model

13195 Transformer, ZT931 1 40 - 60
11643 Switch, air pressure 1 40 - 60
14485 Motor, damper, A30 045Y 1 40 - 60
12075 Fan 1 40 - 60
14489 Coupling, air gate 1 40 - 60

C
APPENDIX C
SPIRAX HIGH INTEGRITY LEVEL CONTROLS
1.1 DAILY TESTS
The daily testing of boiler water level controls is a mandatory requirement as defined in the Health &
Safety Executive Guidance Note BG01, Arrangements 2 and 3.
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 attendant, but may be supervised during the silent hours and weekends by a
competent person trained to respond to an alarm.
Daily testing of the controls is required which can be by simulation, with a weekly test by interrupting
the feedwater pump and lowering the water by evaporation.
1.1.1 1ST LOW WATER DAILY
With the burner firing:
1. Press and hold the 1st Low Water test button 5 - 6 seconds, the Low Water alarm sounds, and
the Low Water indicator lamp illuminates, and the burner shuts down.
2. Release the test button.
3. After approximately 17 seconds the Low Water alarm will cancel, the Low Water lamp will
extinguish, and the burner will restart
1.1.2 2ND LOW WATER DAILY
1. Press and hold the 2nd Low Water test button for 5 - 6 seconds, the Low Water alarm sounds,
and the 2nd Low Water Reset switch illuminates, and the burner shuts down.
2. Release the test button.
3. After approximately 17 seconds the 2nd Low Water Relay will reset.
4. To cancel the 2nd Low Water level alarm and light, depress the 2nd Low Water Reset switch.
The burner will restart.

C
1.2 WEEKLY TESTS (IN ADDITION)
1.2.1 1ST LOW WATER WEEKLY (IN ADDITION)

1. Switch the Pump Interrupt switch to the Pump Interrupt position.
2. By evaporation lower the water level in the boiler until the 1st Low Water alarm sounds and the
Low Water indicator lamp illuminates, and the burner shuts down.
3. Switch the Pump Interrupt switch to the Pump On position.
4. The pump will start and restore the water level to the normal position and switch off.
5. After approximately 17 seconds from restoring the 1st Low Water level the Low Water alarm will
cancel, the Low Water lamp will extinguish, and the burner will restart.
1.1.2 2ND LOW WATER WEEKLY (IN ADDITION)
1. Switch the Pump Interrupt switch to the Pump Interrupt position
2. By evaporation lower the water level in the boiler until the Low Water alarm sounds, the 2nd
Low Water Reset switch illuminates, and the burner shuts down.
3. Switch the Pump Interrupt switch to the Pump On position.
4. The pump will start and restore the water level to the normal position and switch off.
5. After approximately 17 seconds from restoring the 2nd Low Water level the 2nd Low Water
Relay can be reset.
6. To cancel the 2nd Low Water Level alarm and light, depress the 2nd Low Water Reset switch.
7. 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 2nd Low Water
alarm will occur immediately after the burner has shut down on 1st
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 sight glass
before the alarm sounds. Should this happen, the 2nd Low Water
Level alarm should be checked by lowering the water level slowly by
partially opening the main blowdown valve.
Pump Interrupt Switch
FIG. 40 CONTROL PANEL SIDE

Material & Workmanship Warranty
5 Year
Warranty
On the Fulton Boiler Pressure Vessel
Fulton Ltd will repair or replace EXW 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
failures 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.
Fulton Ltd
General Warranty
The Fulton general Guarantee is given in lieu of Defective goods or parts must be returned to
and in exclusion of any warranty expressed or us as soon as possible after discovery of the
implied, statutory or otherwise, as to the state, defect, Costs of carriage and of detaching and
condition, performance, quality or fitness of the incorporating parts will be borne by you. In all
goods. Save thereunder we shall be under no cases at the termination of such 12 months all
obligation or liability of any kind to you in regard liability on our part will cease.
to the goods. In the case of new goods No liability whatsoever is to be incurred by us
manufactured and supplied by us we will make in respect of gauge or sight-glasses, packing
good any defect developing therein under glands or electric motors or any goods or
proper use within 12 months of delivery, accessories not of our manufacture. But so
provided that after investigation in our sole far as we are able, we shall let you have the
discretion we are satisfied that the defect arose benefit of any guarantee or warranty given to
from faulty design, materials or workmanship us in respect thereof.
and from no other cause whatsoever.

www.fulton.co.uk
Fulton Ltd
5 Fernhurst Road
Fishponds
Bristol BS5 7FG
England
Telephone: +44 (0) 117 972 3322

Fax: +44 (0) 117 972 3358
Email: sales@fulton.co.uk 003
FM 28400

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Fulton Ltd

INSTALLATION, OPERATION AND MAINTENANCE

J SERIES - DUAL FUEL

For your safety!

The Pressure System Safety Regulations 2000

For further information contact:

(b) Health and Safety Executive local office.

(c) Your Competent Person.

J DUAL FUEL MANUAL 02 2014 ISSUE 9

General 2.1 - 2nd Low Water Level Check 4.2.3

Siting 2.2 Main Blowdown 4.3

Ventilation 2.3 Water Column Blowdown 4.4

Flue Outlet 2.4 Water Level Gauge Blowdown 4.5

Blowdown Valves 2.6 Flame Sensor Test 4.7

Main Steam Valve 2.7 Draining the Boiler 4.8

Steam Safety Valves 2.8 Long Term Shutdown 4.9

Electrical Requirements 2.10 Schedule of Operator Tests and Checks 4.11

Gas Supply 2.11 - Daily 4.11.1

Oil Supply 2.12 - Weekly 4.11.2

Steam Pressure Gauge 2.13 - Three Monthly 4.11.4

Commissioning the Boiler 2.14 - Six Monthly 4.11.5

- Boiler Inspection and Initial Firing - Oil 2.14.1 - Annually 4.11.6

- Boiler Inspection and Initial Firing - Gas 2.14.2 Troubleshooting 4.12

Gas Monoblocs (Non Modulating Burners) 2.15 Maintenance Log 4.13

- Multibloc Gas Valve (Fully Modulating Burner) 2.15.2

J DUAL FUEL MANUAL 02 2014 ISSUE 9

J DUAL FUEL MANUAL 02 2014 ISSUE 9

J DUAL FUEL MANUAL 02 2014 ISSUE 9

Monobloc Gas Steam Pressure Oil Pump Motor

Water Level Motorised

FIG. 1 TYPICAL DUAL FUEL BOILER

Page 6 J DUAL FUEL MANUAL 02 2014 ISSUE 9

1.2 TECHNICAL DATA

For a full specification refer to Section 5.

The chemicals required to operate the water softeners and chemical

It is the responsibility of the operator to ensure adequate supplies of

Costly repairs could be required should the plant operate without

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 7

Oil Feed Solenoid Oil Feed

Monobloc Gas Feedwater Steam Outlet

Safety Valve Oil Pump

Water Level Water Level Water Column

FIG. 2 MAJOR DUAL FUEL COMPONENTS

Page 8 J DUAL FUEL MANUAL 02 2014 ISSUE 9

(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication

Note: see Section 5 for low and high level values.

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 9

PIPE SAFETY VALVE

J DUAL FUEL MANUAL 02 2014 ISSUE 9

FIG. 3 TYPICAL INSTALLATION

2.4 FLUE OUTLET

FIG. 4 BOILER FLUE CONNECTION

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 11

2.5 WATER SUPPLY

Note: see Section 5.3 - Recommended Water Conditions.

Feedwater stop valve

Feedwater Dip Pipe

FIG. 5 BOILER FEEDWATER ARRANGEMENT

Page 12 J DUAL FUEL MANUAL 02 2014 ISSUE 9

2.6 BLOWDOWN VALVE

If in doubt regarding blowdown arrangements, consult Fulton Ltd.

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 13

Electrical Ignition Oil supply Flame detector

2.15.1 MULTIBLOC GAS VALVES 6J - 30J MODELS (NON MODULATING BURNER)