User manual FULTON 60E

[. . . ] R Fulton Boiler Works (Great Britain) Ltd. OPERATOR, SERVICE & PARTS MANUAL SERIES 'E' - GAS FIRED STEAM BOILERS (6E - 60E) GFSE-Std-0202 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 daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy of the boiler. NOTE The Pressure system and Transportable Gas Containers Regulations 1989 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme and Section 40 of the Health and Safety at Work Act, 1974. Regular inspections are therefore required by a 'Competent Person' at intervals not exceeding 14 months. The scope of the examination and the actual intervals between examinations is at the discretion of the competent person. [. . . ] gas boiler is similar in design to a natural gas boiler, the main differences are important and must be taken into account when installing the boiler and ordering spare parts. gas boiler, the feed from the bulk tank supply must be fitted with a supply governor which is set to reduce the supply feed pressure to the boiler governor to 30 in. For PROPANE:-The boiler governor must be adjusted to give a firing pressure of 10 in. (25 mb) water column at the test point provided at the elbow on the gas train. For BUTANE:-The boiler governor must be adjusted to give a firing pressure of 8 in. (20 mb) water column at the test point provided at the elbow on the gas train. applications the inlet pressure switch is used to protect the system from over pressure and should be set at 100 mbar. PILOT BALL VALVE GAS PILOT ORIFICE TUBE GOVERNOR GAS START VALVE GAS STOP VALVE MAIN GAS FIG. GAS TRAIN MONOBLOC ADJUSTMENTS LPG Boilers (MBZRDLE 405/412 BO1) A F E B D C ADJUSTMENTS A Main Gas Governor. C Main gas throughput D E F Gas supply test point Boiler side test point High gas pressure switch ACTION Turn clockwise to increase gas pressure. Range 4 - 50 mbar. Slacken locking screw, turn fluted knob anticlockwise to increase, clockwise to decrease. GFSE-Std-0499 16 3 3 MODULAR GAS UNIT STEAM PRESSURE GAUGE GAS COCK MAIN STEAM VALVE WATER LEVEL PROBES AIR SAFETY SWITCH WATER GAUGE CHECK VALVE STOP VALVE COLUMN BLOWDOWN VALVE MAIN BLOWDOWN VALVE FIG. 11 BOILER OPERATION 17 GFSE-Std-0499 3 3 OPERATION SECTION 3 3. 1 GENERAL The following instructions are given for the guidance of the operator in the use of the Series 'E' gas fired boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health. 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. 3. 2 BOILER CONTROLS The following brief description of the controls used on the Series E gas fired boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient operation of the boiler. 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. 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. 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. 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 `lock-out' and both main and pilot gas valves will be closed. 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. Consists of pilot and main gas supply lines, each line having a manual gas cock, a governor and electrically powered gas valves. [. . . ] 19 FLUE CLEANING 31 GFSE-Std-0499 5 5 GENERAL DATA SECTION 5 A 6E 8E 10E 15E 20E 30E 40E 50E 60E 480 480 480 480 510 510 510 510 510 B C D E F 840 840 840 840 870 870 G H J 345 345 310 290 415 K 300 300 240 260 250 250 250 250 250 L 150 150 150 205 255 305 305 305 305 M 825 825 975 N 725 825 725 P 2000 2100 2150 2300 2500 1295 1535 1960 380 1395 1635 2060 380 1445 1685 2110 380 1570 1835 2260 380 1625 1955 2430 405 1850 2205 2690 405 1930 2290 2900 400 1930 2290 2900 400 2080 2440 3050 400 1460 665 1560 665 1610 715 1760 765 1840 985 1025 875 1235 955 2090 1175 420 1435 1205 2750 1730 1285 2950 1730 1285 2950 1730 1435 3100 1095 2170 1390 470 1095 2170 1390 470 1095 2320 1390 470 dimensions mm FIG. Gas Train can rotate through 360O. GFSE-Std-0499 32 5 STANDARD TRIM ITEMS Additions and Optional items should be requested when ordering the boiler 5 WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted to the boiler in a correct and safe manor. Standard Boiler Trim. Main Steam Valve Steam Safety Valve Steam Pressure Gauge Assembly Boiler Blowdown Valve Water Level Gauge Set Feedwater Check Valve Feedwater Stop Valve Flue Spigot Audible Alarm Flue Brush Tee Handle Wrench Quantity 1 1 1 1 2 1 1 1 1 or 2* 1 1 Items marked * vary according to boiler specification. BOILER TRIM Steam Safety Valve (Discharge side) (DN) Steam Outlet Valve Feed Water Stop Valves Feed Water Check Valve Boiler Blowdown Valves Water Column Blowdown Valves Sight Glass Blowdown Valve 6E 8E 10E 15E 20E 30E 40E 50E 60E 32 32 32 32 32 32 32 32 32 (DN) 20 20 25 32 32 40 50 50 50 (DN) 25 25 25 25 25 25 25 25 25 (DN) 25 25 25 25 25 25 25 25 25 (DN) 20 20 20 20 25 25 25 25 25 (DN) 20 20 20 20 20 20 20 20 20 (DN) 6 6 6 6 6 6 6 6 6 GFSE-Std-0499 33 5 5 MAINS SENSING INTERNAL SCHEMATIC INTERNAL BASE WIRING Note: A common base is supplied for type A & B controller bases. 21 TYPE LC1 LEVEL CONTROLLER GFSE-Std-0499 34 IMPORTANT Recommended Water Conditions It is very important that a strict water management program is followed to ensure trouble free boiler operation. [. . . ]