Fulton 15E, 8E, 6E, 40E, 10E OPERATOR, SERVICE & PARTS MANUAL

R

Fulton Boiler Works (Great Britain) Ltd.

OPERATOR, SERVICE

& P ARTS 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.

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 insurance company/broker

GFSE-Std-0499

LIST OF CONTENTS

TITLE SECTION

INTRODUCTION 1

General 1.1
Technical Data 1.2

INSTALLATION 2

General 2.1
Siting 2.2
Ventilation 2.3
Flue Outlet 2.4
Water Supply 2.5
Blowdown Valves 2.6
Main Steam Valve 2.7
Steam Safety Valves 2.8
Water Gauge Set 2.9
Gas Supply 2.10
Electrical Requirements 2.11
Steam Pressure Gauge 2.12
Plumbing 2.15
Commissioning the Boiler 2.16
Cleaning the Steam Lines and Pressure Vessel 2.17
L.P. Supplement - Gas Supply - Propane/Butane 2.18

OPERATION 3

General 3.1
Boiler Controls 3.2
Control Panel - Indicator Lights 3.3
Filling the Boiler - All Models 3.4
Starting the Burner - All Models 3.5
Daily Checks 3.6
Pump Check 3.6.1
1st. Low Water Check 3.6.4
Overiding Low Water Check 3.6.5
Blowdown Procedures 3.7
Evaporation Checks 3.8

MAINTENANCE 4

General 4.1
Weekly 4.2
Monthly 4.3
Three Monthly 4.4
Six Monthly 4.5

GENERAL DATA 5

SPARE PARTS 6

GFSE-Std-0499

SAFETY

The instructions provided for the operation and maintenance of the boiler MUST be observed.
Failure to do so could result in damage to the boiler and serious personal injury.

WARNING

It is the responsibility of the installer to ensure all
parts supplied with the boiler are fitted in a correct and

safe manner.

WARNING

Do not try to do repairs or any other maintenance
work you do not understand. Obtain a Service Manual
from Fulton or call a Fulton Service Engineer

WARNING

Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and or damage.

WARNING

A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing
parts. Make sure that all maintenance procedures are
completed before using the boiler.

CAUTION

Obey all laws and local regulations which affect you
and your boiler.

WARNING

The installation of Gas appliances including the flue
system should only be carried out by Corgi Regis­tered engineers.

CAUTION

HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and
is normally only required by engineering surveyors /
inspectors.The material the boiler is manufactured
from, has not been impact tested, as it is not a
requirement of BS2790 (boiler construction stand­ard). In order to ensure the material / pressure vessel
does not suffer from brittle fracture, hydraulic testing
should not be carried out below 5OC.

WARNING

The importance of correct boiler water and feed water
cannot be over emphasised, see the relevant section
in this manual.

CAUTION

LOW FEED WATER TEMPERATURE
Low feed water temperature can result in thermal
shock to the boiler pressure vessel. Return the maxi­mum amount of condensate and if necessary pre­heat the feed water. If in doubt consult FBW.

WARNING

Only qualified persons should be allowed to
operate and maintain the boiler and its equip­ment. Boilers should always be drained through an

approved Blowdown Vessel.

WARNING

Do not change the boiler fuel without consulting the

boiler manufacturer.

WARNING

Non-approved modifications can cause injury and
damage. Contact your Fulton dealer before modifying
the boiler.

WARNING

You can be injured if you use faulty lifting equipment.
Make sure the lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job

WARNING

Operating the boiler beyond its design limits can
damage the boiler, it can also be dangerous. Do not
operate the boiler outside its limits. Do not try to up
grade the boiler performance by unapproved modifica­tions.

WARNING

DANGER FROM HOT SURFACES
Steam Boilers have high temperature surfaces, that if
touched may cause serious burns. Only competant
and qualified personnel should work on or in the
locality of a steam boiler and ancillary equipment.
Always ensure the working area and floor are clear of
potential hazards, work slowly and methodically.

WARNING

DANGER FROM INCOMPLETE COMBUSTION
The importance of correct burner adjustment to achive
low emissions, safe, clean and efficient combustion
is paramount. Poor combustion, where unburnt gas
forms carbon monoxide is both a health hazard, and
the potential risk to the boiler from overheating,
caused by re-burning of the unburnt gas in the
secondary flue passes.

GFSE-Std-0499

TITLE FIG. NO.

Gas Fired Steam Boiler 1
General Arrangement 2
Typical Installation 3
Typical Flue Connection 3A
Water Gauge Set 4
Steam Pressure Gauge 5
Burner Electrode Settings 6
Commissioning the Boiler 7
Monobloc Gas Valve 9
L.P. Gas Train 10
Boiler Operation 11
Control Panel 6E/30E 12
Control Panel 40E/60E 13
Water Gauge Blowdown Sequence 14 & 14A
Fault Finding Check List 15
Boiler Maintenance 16
Handhole Assembly 17
Burner Assembly 18
Flue Cleaning 19
Boiler Dimensions 20
Level Controller - Type LC1 21

SPARE PARTS

See index in Spare Parts Section

GFSE-Std-0499

1 1

FIG.1 GAS FIRED STEAM BOILER

1

GFSE-Std-0499

INTRODUCTION

SECTION 1

1.1 General (Fig. 1)

The Fulton Series E Gas Fired Steam Boiler is a vertical two pass boiler of simple and efficient design
and construction. Every care has been taken in the manufacture of the boiler to ensure that quality
and reliability standards are maintained. However, satisfactory performance can only be ensured if
the installation recommendations, operating routines and maintenance schedules laid out in this
manual are adhered to.

For Propane Boilers read Section 2.19 before proceeding.

1.2 Technical Data

BOILER MODEL

1

6E 8E 10E 15E 20E 30E 40E 50E 60E

Performance

lb/h (F & A 100oC) 210 280 350 525 700 1050 1400 1750 2100
kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960

Firing Rates

Approx. BTU input [phone] 424 637 849 1273 1360 2121 2546
Natural Gas 1035 BTU

cu.ft./h 246 328 410 615 820 1230 1700 2050 2461
cu.m/h 7 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6

Electrical Requirements

FLC (400V, 3ph, 50Hz) amps 4.7 4.7 4.7 4. 7 4.9 4.9 6. 9 6 .9 8.6
FLC (230V, 1ph, 50Hz) amps 12.7 12.7 12.7 12.7 14.9 14.9 19.3 19.3 19.3

The full load current (flc) of the feed water pump motor can vary with the type and duty
requirements of the pump supplied. The figures quoted above are given as a guide only.

Miscellaneous

Water Content (Imp Gal) 13 15 20 33 64 14 1 2 0 4 20 4 2 2 3
Water Content (Litres) 59 68 91 15 0 291 6 40 92 7 92 7 1022

Approx. Net Weight (lb) 1540 1590 1785 2130 3135 4480 6728 6728 6944
Approx. Net Weight (kg) 700 720 810 965 1420 2030 3050 3050 3150

Nat. Gas Head
Pipe Size (in.) 1 1 1 1.25 1.25 1.5 2 2 2

Required Vertical 2060 2160 2210 2365 2440 2745 2845 2845 3000
Clearance (mm)
(Floor to Ceiling)

2

GFSE-Std-0499

2 2

SCALE
TRAP

STEAM SAFETY
VALVE

WATER LEVEL
PROBES

MODULAR

GAS UNIT

PRESSURE

TEST POINT

STEAM

PRESSURE

GAUGE

MAIN STEAM

VALVE

AIR SAFETY

SWITCH

BLOWER

HOUSING

BURNER

MOTOR

WATER
GAUGE

CHECK
VALVE

STOP
VALVE

MAIN
BLOWDOWN
VALVE

CONTROL

PANEL

WATER

COLUMN

COLUMN

BLOWDOWN

VALVE

CLEAN OUT

DOOR

PRESSURE

HAND HOLE

FIG. 2 GENERAL ARRANGEMENT

3

GFSE-Std-0499

CONTROL

2 2

INSTALLATION

SECTION 2

2.1 GENERAL (Figs. 2 and 3)

The installation of a Series E Gas Fired Steam Boiler should be carried out by competent personnel in
accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these
regulations are complied with.

The requirements and instructions contained in this Section generally relate to the boilers being installed
to operate on natural or manufactured gas. Where the boiler is to operate on L.P. Gas, special reference
should be made to Section 2.10 - Gas Supply, and Section 2.18 L.P. Gas Supply.

2.2 SITING

The boiler house should be sufficiently large 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 special note taken of the required vertical clearance.

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.

Note:

(a) Ensure there is adequate ventilation in the boiler room. Lack of ventilation will create a high

temperature and cause control lockout.

(b) Do not keep exhaust fans running with windows, doors and vents closed, this will interfere

with the necessary boiler draught.

(c) Do 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.

Boiler Model 6E 8E 10E 15E 20E 30E 40E 50E 60E

High Level (cm2) 305 360 420 560 700 980 1260 1540 1820
Low Level (cm2) 610 720 835 1115 1395 1960 2520 3085 3645

GFSE-Std-0499

4

2 2

F01762

PIPE SAFETY VALVE

TO SAFE AREA,

FITTING

UNIONS AND DRAIN

STEAM SUPPLY

WATER
COLUMN
BLOWDOWN
VALVE

STOP
VALVE

DRAFT STABILISER

(WHERE FITTED)

CLEAN-OUT
DOOR

CHECK VALVE

MAIN BLOWDOWN

VALVE

STANDARD BOILER

OVERFLOW

CONDENSATE

RETURN

FEED PUMP

STRAINER

TRIM SUPPLIED

STAINLESS

STEEL

FEEDWATER

TANK

ISOLATING

VALVE

MAKE-UP SUPPLY

BLOWDOWN

SEPERATOR

PLUGGED

DRAIN

NOTE: A BREAK TANK MAY

BE REQUIRED - CHECK
THE LOCAL WATER

AUTHORITY BYE-LAWS

FIG. 3 TYPICAL INSTALLATION

5

GFSE-Std-0499

2 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 (see fig. 3A).
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 2ft (610 mm) higher than the nearest ridge to avoid down draughts. Where a chimney
cowl is fitted, care should be taken to ensure that the cross sectional area of the outlet is equal to at least

1.5 times the cross sectional area 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 90deg. elbows whenever possible, if unavoidable compensate by increasing the

flue diameter.

(c) Ensure all pipework from the boiler to the main flue has a rising pitch of not less than 15deg.

2.5 WATER SUPPLY

The quality of the water used in the boiler will affect the life and performance of the boiler. It is strongly
recommended that a reputable water treatment concern is consulted prior to commissioning the boiler.
The following water conditions represent those which are considered essential in the boiler.

Total hardness of feedwater in terms of CaCo3 (mg/L) Max 2.
Caustic alkalinity of boiler water in terms of CaCo3 (mg/L) 300 ppm max.
Total dissolved solids in boiler water (mg/L) 2000 ppm max.
pH value of boiler water 9.5 to 11.5

Connect the feed water pump to the boiler with 1in. bore pipe and insert the stop valve and check valve
supplied. It is essential to protect the feedwater pump from damage by foreign matter. A strainer should
therefore be inserted in the pump suction pipework.

Note: 1. The boiler feedwater pump may contain an inhibitor and this should be flushed from the pump

prior to fitting the pump to the boiler. Failure to do so may result in water bounce or foaming
due to the inhibitor forming a seal in the boiler.

2. If the boiler is to be operated with little or no condensate return, consideration should be given
to pre-heating the feedwater. If in doubt consult Fulton Boiler Works.

3. The Feedwater inlet connection on some boilers is located on the left hand side of the boiler
below the sight glass assembly.

2.6 BLOWDOWN VALVES

There are three blowdown valves on the boiler (four if two water gauge sets are fitted), the main valve at
the rear of the boiler, the water column blowdown valve and the water gauge blowdown valve. 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 your Fulton agent.

2.7 MAIN STEAM VALVE

The main steam stop valve should be inserted in the steam line approximately 12in. (305 mm) from the
top of the boiler.

GFSE-Std-0499

6

2 2

F02490

WORKING

POSITION

FIG. 3A TYPICAL FLUE CONNECTION

STEAM

BLOWDOWN

WATER

BLOWDOWN

F03200

F03190

BLOWDOWN

GAUGE GLASS

FIG 4 WATER GAUGE SET

7

GFSE-Std-0499

2 2

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.

(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 it's 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 pre-set to protect the boiler only

and must not be used protect any other items !

2.9 WATER GAUGE SET (The design may vary from that illustrated)

Numbers may vary due to individual countries regulations.
Boilers are normally supplied with two complete water gauge sets. These gauges should be fitted as

shown in main view Fig. 4. The water gauge glass blowdown cock should be connected to the auxiliary
blowdown line from the water column blowdown valve in soft copper tubing. The connection to the
gauge cock is 1/8 in. BSP for conventional gauge glasses and 3/8 in. for reflex type gauges, (all
connections female).
Mounting manifolds 'C' are only supplied for conventional tubular gauge glasses.

2.10 GAS SUPPLY

Verify that the burner is suitable for the type of gas being supplied. Ensure 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 which are fitted with pressure regulating governors. No additional pressure
regulating devices should be required. A minimum pressure of 7 in. (17.5 mb) water column is
required at the gas train for natural gas installations and a minimum pressure of 5 in. (12.5 mb) water
column is required at the gas train for manufactured gas installations.

Burners arranged for operation on L.P. gas are supplied with gas trains which include a pressure
regulating governor. It is essential that the MAXIMUM pressure of the gas at the gas train does not
exceed 32 in. (80 mb) water column and does not fall below 20 in. (50 mb) water column. 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.

2.11 ELECTRICAL REQUIREMENTS

An individual wiring diagram for the boiler is located on the inside cover of the control box.
When referring to the electrical specification of the boiler, the reference number located on the rear
inside wall of the control box and the wiring diagram number should be quoted.

The audible alarm bells supplied are mounted on the side of the control panel, if not audible they
should be repositioned where they can be heard by a person competent to take the appropriate
action should the alarm be activated. Unless otherwise specified, the alarms supplied will be mains
voltage models. Unless otherwise specified all models are supplied with burner motors and feed
water pump motors arranged for operation on a three phase supply.
The power ratings and requirements are given in Section 1.2 - Technical Data.

GFSE-Std-0499

8

2 2

STEAM PRESSURE

GAUGE

STEAM COCK

SYPHON

FIG. 5 STEAM PRESSURE GAUGE

2.12 STEAM PRESSURE GAUGE (Fig. 5)

The steam pressure gauge assembly should be assembled in accordance with Fig. 5 using a
suitable sealant on all joints.

Screw the assembly into the top of the boiler and connect the copper tube from the control panel box to
the nipple provided on the assembly.

9

GFSE-Std-0499