INSTALLATION, OPERATION, MAINTENANCE

AND PARTS MANUAL

'J' SERIES - GAS FIRED

STEAM BOILERS (6J - 60J)
This Manual must be available to the boiler operator at all times.

JGAS-E-10 2008
 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, what so ever the cause, then the fuel supply to the boiler should be isolated immediately,
until such time that 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 injury or death to personnel.
CAUTIONS must be observed to prevent
damage or destruction of equipment or
loss of operating effectiveness.
NOTES must be observed for essential
and effective operating procedures,
conditions and as a statement to be
highlighted.
It is the responsibility and duty of all personnel involved in
the operation and maintenance of this equipment to
fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.

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 com-
petent 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.

J Gas 08 2008
 LIST OF CONTENTS

TITLE SECTION

INTRODUCTION 1
General 1.1
Technical Data (for a full specification refer to section 5) 1.2

INSTALLATION 2
General 2.1
Siting 2.2
Ventilation 2.3
Flue Outlet 2.4
Water Supply (see also Water Treatment in section 5) 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
Gas Valve, Pilot Gas (40 - 60 models & Australia) 2.10.1
Electrical Requirements 2.11
Steam Pressure Gauge 2.12
Commissioning the Boiler 2.16
Boiler Inspection and Initial Firing 2.16.1
Setting the Burner Controls for Low Fire/High Fire, Models 40-60 2.16.2
Multibloc Gas Valves 2.17
Cleaning Steam Lines and Pressure Vessel 2.18
Gas Supply - Propane/Butane 2.19

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 Operating Tests 3.6
Pump Check 3.6.1
First Low Water Level Check 3.6.4
Second Low Water Check 3.6.5
Blowdown Procedures 3.7
Evaporation Checks 3.8
Troubleshooting - Boiler 3.9
Troubleshooting - Burner Control Unit LFL - 1 3.10
Troubleshooting - Burner Control Unit TMG 740-3 3.11
Draining the Boiler 3.12
Long Term Shut Down 3.13

Maintenance Log

MAINTENANCE 4
General 4.1
Daily 4.2
Weekly 4.3
Monthly 4.4
Three Monthly 4.5
Six Monthly 4.6

GENERAL DATA 5
Boiler Dimensions
Boiler Specification
Recommended Water Conditions
Probe Lengths
Wiring Diagrams
Pressure Controller
Boiler Controls Test Log

J Gas 08 2008
 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 discon-
necting 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 us-
ing the boiler.
WARNING
The installation of Gas appliances including the flue system
should only be carried out by Corgi
Registered Enginee
WARNING
The importance of correct boiler water and feed water can-
not be over emphasised, see the relevant section in this
manual.
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.
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
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 pre-heat the feed water. If in
doubt consult FBW.
J Gas 08 2008
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
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local regu-
lations and is suitable for the jobYou can be injured if you
use faulty lifting equipment. Make sure the lifting equipment
is in good condition.
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
competent 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.
Do NOT store inflammable materials near the boiler.
CAUTION
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is nor-
mally 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 7OC.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and
chemical treatment plants are NOT SUPPLIED by Fulton.
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.
 Optional Variations (where fitted) Appendix

Motorised High / Low Control B

Spirax High Integrity Level Controls C
Automatic TDS Blowdown System D

Title Fig. No.

Gas Fired Steam Boiler 1

General Arrangement 2
Typical Installation 3
Boiler Flue Connection 4
Boiler Feed Water Arrangement 5
Boiler Blowdown (20 - 60) 6
Boiler Blowdown (6 - 15) 7
Water Column Blowdown Valve 8
Water Column Sequencing Valve 8A
Boiler Top Components 9
Steam Pressure Gauge 10
Burner Electrode Settings 11
6 - 30 Gas Valve 12
Pressure Controller 13
40 - 60 Gas Valve 14
Gas Valve Detail 15
Control Panel Facias 16
Boiler Blowdown Valve 17
Sequencing Blowdown Valve 18
Water Level Gauges 19
Boiler Maintenance 20
Removing/replacxing UV Detector 21
Handhole 22
Boiler Furnace 23
Ignition Electrode 24
Burner Plate 25
Burner Assembly 26
Flue Cleaning 27
Boiler Dimensions                    28

Electrical Circuits
Three Phase Supply Circuit 29
Three Phase Supply Circuit -  
Australian Boilers Only 30
Ancillary Control Circuit 31
Burner Control Circuit 32
Burner Control Circuit, Australian Boilers Only 33
Burner Control Circuit, High - Low Gas 34

PM5 Remote Panel / Typical boiler Connections 35

Tank Solid State Water Level and Alarm Circuits 36
Standard Single Boiler and
Ancillary Skid Electrical Connections 37
Spirax Level Control Circuit 38
LC Level Control Circuit 39
TDS and Blowdown Control Circuit 40

J Gas 08 2008
1 1

Supply Gas,
Pressure Test Point Steam
Monobloc Pressure
Gas Valve Gauge
Gas Supply Valve Feed Water Isolating
Ball Valve

Gas Inlet Feed Water

Non-return
Valve
Scale Trap
Steam Supply
Valve

Safety Valve

Air Pressure
Water Column Switch
containing
water level
probes

Air Intake
Manifold
containing
Main Air
Control

Sight Gauge Boiler Control

Blowdown Panel
Valves

Control Box
Water Column Door Lock
Blowdown Valve

Feed Water Pump

Isolator Switch

Control Box
Boiler Isolator Switch
Blowdown Valve

Steam Pressure
Control

Clean Out Handhole

(Water Jacket) Clean Out Door
(Gas turn around)

FIG.1 GAS FIRED STEAM BOILER

1 J Gas 08 2008
 1 1

INTRODUCTION
SECTION 1
1.1 General (Fig. 1)

The J Gas Service Manual is a generic publication, as such provides information on standard boiler
operation and maintenance.

The Fulton J Series 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.

1.2 Technical Data - Boiler Output

for a full specification refer to Section 5.

BOILER MODEL 6J 8J 10J 15J 20J 30J 40J 50J 60J

Output
kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960

CAUTION
WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and chemical treat-
ment plants are NOT SUPPLIED by Fulton.

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

cal 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 Gas 08 2008 2
2 2

Modular
Gas Unit Pressure
Test Point
Steam Pressure Gauge
Gas Cock
Feed Water Isolating
Ball Valve

Check Valve
Scale Trap
Main Steam
Valve

Steam Safety Air Safety

Valve Switch

Water Blower
Column Housing
with water containing
level probes Main Air
Control

Water Burner
Gauge Motor
Sets

Operator
Control
Panel

Blowdown
Valve

Water
Pressure
Column
Control
Blowdown
Valve

Main
Boiler
Blowdown
Valve
Clean Out Door
(Gas turn around)
Hand Hole
(Water Jacket)
FIG. 2 GENERAL ARRANGEMENT
3 J Gas 08 2008
2 2

INSTALLATION
SECTION 2
2.1 GENERAL

The installation of a J Series 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 ( Reference should be made to Utilization 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 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
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 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.

Note: see section 5 for Low and High Level values.

J Gas 08 2008 4
 5
2
Cowl

Pipe safety valve

to a safe area, H
using unions and
drain as required.
Standard boiler trim D D = Diameter of flue
Steam Supply Feed water isolation ball valve supplied with boiler
H = 1.5 X D
Feed water non-return valve

Flue

Draught stabiliser
(when fitted) Note: A break tank may be required depending
upon Local Water Authority By-laws

Clean-out door Overflow Make-up feed water supply

J Gas 08 2008
Stainless steel
Flue spigot
feed water and

FIG. 3 TYPICAL INSTALLATION

Flexible link
condensate Vent
Water column Flanged connection return tank
blowdown line 20 - 60J only Condensate return Blowdown
Separator
Feed water
pump
Overflow to
drain

Boiler blowdown valve Drain

F03164
Strainer Plugged drains
Isolating gate/ball valve
2
 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.
The height and type of flue will be subject to local
planning regulations and approvals. The following
information is only intended to provide assistance for
the installation of a simple flue.
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. FIG. 4 BOILER FLUE CONNECTION
Note:
1. If the flue layout is such that it may produce an excessive up-draught, a draught stabiliser
may be required.
2. Avoid fitting 90deg. elbows whenever possible, if unavoidable compensate by increasing the
flue diameter.
3. Ensure all flue pipes from the boiler to the main flue have a rising pitch.

2.5 Water Supply

The quality of the water used in the boiler will affect the life and performance of the boiler. Feed water
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. Isolating Check
Note: see Section 5 Water Treatment. Ball Valve Valve
Connect the feed water pump to the check valve
inlet with 25 mm. bore pipe (this may be reduced
to 15 mm. where the discharge pipework is shorter
than 4m in total), the pump suction pipe work must
remain at 25mm minimum diameter.) and insert the
stop valve supplied, between the boiler and the
check valve.
It is essential to protect the feedwater pump from
Feed
damage by foreign matter, a strainer should
Water
therefore be fitted in the pump suction pipework
Supply
Care should be taken to ensure the pipework is
properly aligned and not placing any strain upon
the feed water pump.
Note: FIG. 5 BOILER FEED WATER ARRANGEMENT
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.
J Gas 08 2008 6

2 2
2.6 BOILER Blowdown Valves

There are three blowdown valves on the boiler

(four if two water gauge sets are fitted), the
boiler blowdown 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 blow
down arrangements, consult your Fulton
agent.

Note: 6J - 15J main blowdown connection via branch

pipe 20J - 60J main blowdown connection is integral,
via a boiler mounted flange.

FIG. 6 BOILER BLOWDOWN (models 20-60)

(skid mounted boiler shown)

FIG. 7 BOILER BLOWDOWN (models 6 - 15)

(skid mounted boiler shown)

7 J Gas 08 2008
2 2

2.6.1 WATER COLUMN Blowdown Valve

The valve on the water column should be operated

daily to blowdown the column.

Water Column
Blowdown Valve

FIG. 8 WATER COLUMN BLOWDOWN VALVE

WATER COLUMN Blowdown Valve

(Australian boilers only).

The valve is a three position isolation valve,

each position is indicated on a backing
plate mounted with the valve,
(the valve is shown in the blowdown position).

FIG. 8A WATER COLUMN SEQUENCING and

BLOWDOWN VALVES
(Australian boilers only)
J Gas 08 2008 8
2 2

Flame (UV) Detector

Secondary Air Control

Secondary Air Control

Main Gas Valve Boiler Water Level Probes

Air Proving Switch

Water Feed Gas Train

with Stop Valve and with 360O rotation Note: Boiler illustrated is fitted with op-
Check Valve tional Self Monitoring Controls.

FIG. 9 BOILER TOP COMPONENTS

9 J Gas 08 2008
2 2

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.

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 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 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 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.The water gauge 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 DN8, 6mm (1/4in. BSP).

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. A minimum pressure of 7 in.
(17.5 mb) water column at the specified flow rate, 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.
If the gas supply is in excess of 100 mbar (6 - 30) or 200 mbar (40 - 60) a suitable regulator is required
before the main gas valve.

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.
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.

2.10.1 GAS VALVE, with pilot gas line.

(Models 40 - 60 and Australian boilers).

The main gas valve is fitted with a by-pass system (internal or external depending on the model)
the by-pass allows pilot pressure to be maintaned whilst the flame is verified.

J Gas 08 2008 10
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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 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 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 Technical Data - Section 5.

Steam Pressure Gauge

Plug

Steam Cock

Test Point

Syphon

F03210

FIG. 10 STEAM PRESSURE GAUGE

2.12 Steam Pressure Gauge

The steam pressure gauge assembly should be assembled in accordance with Fig. 10 using a
suitable sealant on all joints.

Screw the assembly into the top of the boiler and connect the copper tube from the pressure controller
to the nipple provided on the assembly. The gauge should be facing the electrical control box and/or the
boiler operator.

11 J Gas 08 2008
 2 2

2.16 Commissioning the Boiler

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:

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, the drain stabilizer 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 Boiler Works Immediately.

Note: Flues that are designed to operate with positive pressure should be tested to the requirements
of IGE/UP/10 March 2001.

2.16.1 BOILER INSPECTION and INITIAL FIRING

(a) Ensure the boiler has been washed out after installation.
It is advisable to conduct a water analysis before operating the boiler.
Examine the probes in the water column and the boiler shell and record their lengths.
Replace any damaged probes.

(b) If the burner is fitted with an ultraviolet or solid state detector, remove the detector and check
for damage.
Remove the burner and check that the electrodes have not been damaged and that their
setting corresponds to the appropriate drawing.

(c) Check that the burner is the correct type for use with the gas being supplied.

Main Gas Supply

Ultra-Violet Detector

Ignition Electrode
297.4mm

Primary Air
Blast Tube
12.7mm

3 mm min.
5 mm max.

50.8mm

FIG. 11 BURNER ELECTRODE SETTINGS

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2 2
Main Gas Valve Air Pressure Gauge

Feed Water
Check Valve

Safety Valve

Flue

FIG. 12 6 - 30J  MODELS GAS VALVE

(d) Ensure that all wiring connections are correct and that all terminal screws are tight.

(e) 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.

(f) Open all the valves in the feed water line.

Close the isolating valve on the discharge side of the feed water pump. Remove the priming plug
from the pump head and slowly fill the pump with water. Replace the priming plug and tighten
secuerly.
Note the correct rotation of the pump on the motor fan cover.

Start the pump and check the direction of rotation.

Vent the pump by means of the vent valve in the pump head. At the same time, open the discharge
isolating valve a little. Continue to vent the pump. At the same time, open the discharge isolating
valve a little more. Close the vent valve when a steady stream of water runs out of it.

Completly open the discharge isolating valve.

The bypass valve located in the drain plug may be opened during the filling procedure, close the
bypass when the operation is stable.

DO NOT ALLOW THE PUMP TO RUN DRY.

13 J Gas 08 2008
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(g) Open all the valves in the water feed line.

Switch on the feedwater pump motor and fill the boiler.

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 sight level gauge is reading two thirds 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.

For models 40 - 60 with an external pilot gas line, see 2.16.2.

(h) After purging the gas lines of air, start the burner.

Note: For Australian boilers only:
Prove the pilot flame by placing the PILOT HOLD / NORMAL switch into the Pilot Hold position,
this will hold the gas valve in the pilot gas position until the pilot flame has been verified.

(j) Check the Satronic burner control for a minimum of four indicator lights to verify the flame.
Adjust the gas input by reading the gas meter (if fitted).

(k) Adjust the main air control gate located on the burner scroll, to obtain a clean combustion.
Measure the levels of CO2 CO and O2 in the exhaust gas, record the results.
See typical combustion values in section 5.

(l) Observe the flame through the peephole between the electrodes and adjust the scondary air
control located on the top of the boiler, so that the flame cannot be seen 'backing up' the blast
tube.

(m) Check the operation of the low water safety controls.

(n) 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 boil-
ers 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.

If the pressure control is fitted with a differential scale:

(see OEM literature in section 5)

(i) Set the main scale pressure to the maximum

pressure required (system pressure).
Do not exceed the boiler operating pressure.

(ii) 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.

Note: When multiple boilers are fitted with a

sequence control:


(i) Set the main scale and differential scale
as above.

FIG. 13 PRESSURE CONTROLLER

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2 2

Main Gas Valve Assembly

Main Gas Line Isolating

Pilot Line Ball Valve

  

Pilot Line Governor

Pilot Line Gas Valves Note: Australian Models are fitted

with a Gas Valve Closed Indicator
on the Main Gas Valve

FIG. 14 40 - 60J  MODELS GAS VALVE

15 J Gas 08 2008
2 2

(ii) Set the setback pressure control to the

required set back pressure.

2.16.2 SETTING THE BURNER CONTROLS FOR LOW FIRE / HIGH FIRE, MODELS 40 - 60

The correct setting for low fire/high fire operation are made by making adjustments to the two stage
solenoid
valve and the low fire steam pressure switch.

(a) Isolate the main gas valve by closing the valve in the gas input line.

(b) Screw the pilot gas governor fully down, (governor open).

(c) Start the burner and where possible meter the pilot gas rate, (ideally the pilot gas rate should be
10% of the full gas rate).

(d) Check the LED display on the Satronic control box (where fitted).
The pilot should produce a solid line of five illuminated LED's (four minimum).
Check the ignition and pilot stability several times.
Record the pilot gas pressure.

(e) Open the main gas isolating valve.

(f) Set the gas input to the boiler for correct input on high fire. This adjustment should be done
where possible by using the gas meter.
Adjust the main and secondary air gates to obtain optimum combustion conditions.

(g) Adjust the low fire steam pressure switch to cut-out at approximately 5 psi below the setting of
the main steam pressure control.

(h) Adjust the two-stage solenoid valve to obtain a low fire gas input of approximately 80% of high
fire.
Leave the air gates adjustments as for high fire.

J Gas 08 2008 16
2 2

2.17 GAS MULTIBLOCS (see attached manufacturers leaflets).

BOILER SIZE MULTIBLOC USED

Dungs:

6 - 30 MB-D(LE) 405-412 B01

6 - 30 Australian MB-D(LE) 405-412 B07

40 - 60 MB-ZRD(LE) 415-420 B01

L.P.G. MB-ZRD(LE) 405-412 BO1

Output pressure controller

Hydraulic brake adjusting screw
6 - 30 Models
Main gas flow Operating indicator
adjustment

Adjustable
pressure switch

Test point
connection Test point
connection
downstream
of valve 1

Gas input
filter cover

Gas output Test point Test point

flange connection connection
upstream of Output pressure controller Hydraulic
downstream of
valve 1 adjusting screw brake
valve 2
Main gas flow
adjustment
Operating indicator

Test point
connection
downstream of
Adjustable pressure switch valve 1

Test point
connection
Gas input flange downstream of
valve 2

Test point
connection
upstream of
valve 1

Gas input filter cover

FIG. 15 GAS VALVE - MAJOR COMPONENTS
17 J Gas 08 2008
2 2

2.17 GAS MULTIBLOCS (continued)

40 - 60 Models
(with pilot line fitted for Australia)

Hydraulic Brake
Main Gas Flow Adjustment

High Fire Solenoid

Output Pressure Controller
Adjusting Screw

Low Fire Flow

Adjustment
Operating Pressure Indicators

Input Gas Test Point

Adjustable Pressure
Switch

Test Point 1
Downstream
(internal leak test)

Test Point 2
Downstream

Gas Input Test Point 1

Mounting Flange Upstream

J Gas 08 2008 18
2 2

2.18 CLEANING STEAM LINES AND PRESSURE VESSEL

During the first week of boiler operation, clean all oil and dirt from the boiler, steam line and
condensate return line.

(a) Disconnect the condensate return pipe adjacent to the condensate return tank.

(b) Direct the returns to a floor drain or other safe discharge point and make safe.

(c) Leave in this position for one week to allow all impurities to flush through.

(d) Drain the boiler completely each day.

(e) 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.

L.P. GAS
2.19 GAS SUPPLY - PROPANE / BUTANE

WARNING
Do not change the boiler fuel without
consulting the boiler manufacturer.

Note: LPG Boilers should be installed to the requirements of IGE/UP/10 March 2001

An L.P. gas boiler is similar in design to a natural gas boiler, the main differences are important and
must be taken into account when installing the boiler and ordering spare parts.
When installing an L.P. 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. (80 mbar)
Water Column or less.

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.

Gas Pressure Alarm Indicator Light

For L.P.G. applications the inlet pressure switch is used to protect the system from over pressure
and should be set at 100 mbar.

19 J Gas 08 2008
3 3

OPERATION
SECTION 3
3.1 GENERAL

The following instructions are given for the guidance of the operator in the use of the J Series 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.

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 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.

Low Water Relays and Feedwater 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 enter-
ing 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.

Gas Head Assembly. Consists of a multibloc incorporating an integral governor, pressure switch and
gas valves or for larger boilers in addition to the internal components, an external pilot line with
it's own gas proving valves and governor.

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.

Australian Boilers only.

Pilot Hold/Normal switch, Mounted on the right hand side of the boiler control box, the switch is used
to hold the main gas valve at pilot pressure in order to verify the pilot flame.

J Gas 08 2008 20
3 3

6J - 30J

40J - 60J Standard and Australian

(standard boilers have the CPI
indicator blanked)

6J - 30J Australia

3.2 BOILER CONTROLS continued.

Note:
Boilers fitted on skid units and in plant rooms are interlocked with the feed water 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.

FIG. 16 CONTROL PANEL FACIAS

21 J Gas 08 2008
3 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:

CAUTION
The control circuit live light is dirived from a single phase. It is possible that with the control phase
down or a defective bulb the other phases could be live. Always isolate the supply before investigat-
ing any fault.

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 lock-out due to a low water condition. Once the water in
the boiler has been restored to a safe operating level, pressing the switch will reset the controls.

Circuit On. (Circuit Energised 40J - 60J) Indicates that power is being supplied to the control panel
box.

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. Indicates that the ignition transformer has been energised. This light will only be illuminated
for approximately 5 - 10 seconds during the ignition sequence.

Gas Pressure Alarm. This light will illuminate whenever the gas is off, or below minimum inlet
pressure required by the European Standard for gas burners EN676.
This switch is factory set and should not be adjusted after the boiler has been commissioned.

Start Gas. (40 - 60 models and Australian boilers)

This light indicates the gas valves in the pilot line are energised. 

Main Gas. This light illuminates when the Multibloc gas valve is energised.

Flame Failure / Reset. This switch will be illuminated when the burner has gone to a lock out
condition due to flame failure. The burner controller can be reset by pressing this switch.

Combustion Air. This light indicates that the burner motor contactor is energised.

Closed Position Indicator (C.P.I.). (Australian Boilers Only)

The lamp illuminates when the gas valve is in the closed (no gas) position.

ADDITIONAL INDICATOR LIGHTS ON MODELS 40J AND 60J

Low Flame.
This light indicates that the burner is operating in the low flame mode.
High Flame.
This light indicates that the burner is operating in the full firing mode.

J Gas 08 2008 22
3 3

3.4 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:

(a) Ensure the main steam stop valve is OPEN.

(b) Ensure the steam pressure gauge isolating valve is OPEN.

(c) Ensure all the valves in the main gas supply to the boiler are OPEN.

(d) Ensure all the valves in the water feed line are OPEN.

(e) Ensure the main boiler blowdown valve is CLOSED.

(f) Ensure water level gauge isolating valve(s) is OPEN.

(g) Ensure water level gauge blowdown valve(s) is CLOSED.

(h) Ensure water column blowdown valve is CLOSED.

(i) Ensure the Burner and Pump switch is in the OFF position.

(j) Ensure all appropriate electrical isolators are switched ON.

(k) 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.

(l) Press the control switch to the PUMP ONLY position.

Note: If the boiler water level is below its correct level, the feed 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.

23 J Gas 08 2008
3 3

3.5 STARTING THE BURNER

(a) CLOSE the main steam stop valve.

(b) Press the control switch to 'PUMP AND BOILER' position, the low water audible alarm will
sound, the low water reset and low water alarm lights will illuminate.

(c) Press the low water reset switch for two seconds maximum.
The alarms will stop, and the alarm lights extinguish.
The burner start sequence will commence.

(d) After a maximum of one minute the burner should be firing, and the main gas light ON.

(e) When the boiler has achived 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 achived by one of two methods.

1. Crack open the main steam valve and allow the system to heat up slowly, (minimum
15 minuets) before fully opening the main steam valve.

2. 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 achived.

Note: TDS Panel Mounted Controllers (BC3210 - BC3200) if fitted.

The controller must be reset after any break in electrical supply to the unit.

3.6 Daily OPERATING TESTS (3.6 - 3.7)

Visually inspect the steam and feed water 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. The following procedure should be carried out by a competent person
to ensure the correct functioning of the water level and low water safety controls. Where possible, the
boiler should not be under steam pressure during these tests, (see 3.6.5.g.2.).

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.

3.6.1. Pump check

With the burner firing and the pump not running, lower the water level in the boiler by opening the
main boiler blowdown valve.
As the water level falls, visible in the sight glass, and before the low water lock out position is reached
the water pump should start to run. When this happens close the main boiler blowdown valve.
The water pump should continue to run and re-fill the boiler to the correct level and stop.

J Gas 08 2008 24
3 3

3.6.4 First Low Water Level

(a) Ensure the following:

The burner is firing.

The water level is correct in the boiler.
The water pump is not running.

(b) Switch the pump off (Pump Interrupt) at the pump interrupt/pump run switch.

(c) OPEN the main blowdown valve.

(d) When the water level nears the bottom of the water level gauge sight glass, the low water alarm
should sound, the LOW WATER ALARM lamp should illuminate and the burner should stop
firing. When this happens, CLOSE the blowdown valve IMMEDIATELY.

(e) Switch the pump to RUN at the main pump interrupt/pump run switch. The pump should run
and refill the boiler. When the water level in the boiler rises above the first low water level, the
LOW WATER LEVEL lamp should extinguish, the audible alarm should silence and the burner
start sequence should commence automatically.
The pump should run until the boiler water level is correct and then stop.
3.6.5 Overriding (2nd) Low Water Check

(a) Ensure the following:

The burner is firing.

The water level is correct in the boiler.
The water pump is not running.

(b) Switch the pump off (Pump Interrupt) at the pump intrrupt / pump run switch.

(c) OPEN the main blowdown valve.

(d) When the water level nears the bottom of the water level gauge sight glass, the LOW WATER
ALARM lamp should illuminate, the low water audible alarm should sound and the burner
should stop firing.

(e) Continue to blow down the boiler. As the water level falls nearer the bottom of the water level
gauge sight glass, the LOW WATER RESET switch should illuminate and the second audible
low water alarm should sound.

(f) CLOSE the main blowdown valve and switch the pump to RUN at the pump interrupt/pump run
switch. The water pump should now start to run and refill the boiler. Once filled to the correct
level the pump should stop. The low water alarm should continue to sound, the LOW WATER
RESET switch and LOW WATER ALARM lamp should remain illuminated and the burner should
NOT start.

(g) When the water level in the boiler is correct, the burner can be restarted by depressing the
LOW WATER RESET switch for a maximum of 2 seconds.

1. The First and Overriding low water checks can be carried out in one operation to reduce
the blowdown time and possible interruption to the steam supply.

2. Where the water level tests are to be carried out at full pressure, evaporate the water
down to 1st. low level as in 3.8, blowdown the boiler from 1st. to 2nd. low water.
The purpose of adopting this procedure is to prevent steam and water being expelled
from the blowdown vessel vent because of prolonged blowdown.

25 J Gas 08 2008
3 3

3.7 BLOWDOWN PROCEDURES (DAILY TESTS)

Keep the boiler, water gauge, water column and interconnecting pipework free from sludge and scale
buildup by blowing down in the following manner:
Note: Where a boiler is operating continuously at steam pressure, advice should be sort from Fulton
regarding the appropriate blowdown procedure.

(a) Start the boiler and generate not more

than 10psi of steam.
(b) Shut off both the burner and the pump.

Boiler Blowdown

(a) Fully OPEN the boiler main blowdown

valve for not more than 10 seconds.
(b) CLOSE the valve. Water Column
Note: Where high levels of suspended solids are produced, Blowdown Valve
longer and/or more frequent blowdown may be required.

Water Column Blowdown

Note: The water column contains the pump
on/off probe, which is not safety interlocked.

(a) OPEN the ball valve in the water column, close after 5 seconds.

Australian Boilers only

Water Column Blowdown

1. Place the sequence valve lever into the

blowdown column position A.
A
2. Open the Column blowdown valve B for
5 seconds then CLOSE.

3. Place the sequence valve lever into the

blowdown leg position C. D

4. Open the Column blowdown valve B for

C
5 seconds then CLOSE.

5. Return the sequene lever to the working

A
B/DOWN COLUMN

C D
Operating handle shown
B/DOWN LEG WORKING
in the closed position.
POSITION

Fig. 17 BOILER BLOWDOWN VALVE Fig. 18 SEQUENCING BLOWDOWN VALVE

J Gas 08 2008 26
3 3
Water Gauge Blowdown

(a) 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 Water Level Gauge
Repeat for gauge set 2 Set 2

On completion of the blowdown procedure ensure

that all isolation valves are OPEN and all
blowdown valves CLOSED.
B
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 C Water Level
Gauge
A A A
A Set 1

Water Level Gauge Operating Positions

FIG. 19 WATER LEVEL GAUGES

3.8 EVAPORATION 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:

(a) Switch the pump to RUN at the pump interruptpump run switch.

(b) 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 re-started
from the beginning.
27 J Gas 08 2008
3 3

3.9 TROUBLESHOOTING

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 1. Power Supply Check fuse or Circuit breaker.

During 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 circuit. Tighten wiring connections.
8. Contact open on
Air Switch Adjust to the correct setting.
9. UV Detector wiring
reversed at control box. Change to the correct terminals.

Flame Failure 1. Power Supply Check fuse or circuit, reset or replace as

necesssary.
During 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.
3. UV Detector Check the detector is located correctly and clean.
4. Faulty Air Switch Check for faulty air switch.
5. Bad Combustion Check combustion readings.

J Gas 08 2008 28
3 3
3.9 TROUBLESHOOTING, continued.

Problem Cause Remedy

Burner Cut-off 6. Gas Valve Check filters in the valve block. Clean as required.
7. Weak Amplifier
(Honeywell Control Replace the amplifier.
Box Only)
8. Weak Pilot Adjust to larger pilot by adjusting pilot gas
pressure regulator.
9. Faulty Level Control Test level controls, adjust or replace as required.
10. Dirty or defective
UV detector Clean or replace.

Poor Combustion 1. Refractory Bricks Check refractories to see if they are plugged with
soot or broken in pieces. Clean or replace as
necessary.
2. Stainless Steel Ring Check the ring is present (40 - 60 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.
3. UV Detector Check the detector is located correctly and clean.
4. Draft Check draft with a gauge.
Draft should be -.05 to -.10mbar with the
burner off,
or -.10 to -.15mbar 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.

29 J Gas 08 2008
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3.9 TROUBLESHOOTING, continued.

Problem Cause Remedy

Boiler will not

maintain pressure 1. 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. 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 Surging 1. Steam traps
(Widely fluctuating blowing through. Check steam traps, clean or replace as required.
water level in 2. Contamination Empty boiler and feed tank.
sight glass) in boiler. Flush out and refill, if system operates but progressively
deteriorates, there is probably a leak somewhere in the
system.
3. Scale buildup or
lime deposits. Consult Fulton or call a water treatment specialist.
4. Too much compound
(water treatment
over dose). Dump contents of the return tank and flush the
in the system. 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 -.1mbar with the burner off.
A barometric damper may need to be installed.
3. Too much main air. Adjust main air gate.

Boiler carrying over
water with 1. Steam Traps. Check steam traps, clean or replace as required.
the steam
2. Too much compound
(water treatment Dump contents of the return tank and flush the
over dose) in the system. system. Test the water.
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.

J Gas 08 2008 30
3 3
3.9 TROUBLESHOOTING, continued.

Problem Cause Remedy

FEED WATER PUMP

Pump will not run 1. Supply failure. Connect the electricity supply.
2. Fuses are blown. Replace fuses.
3. Motor contactor overload
has tripped out. Reactivate the motor protection.
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, trips out 1. One fuse/automatic circuit
immediately when breaker is blown. Replace the fuse.
supply is 2. Contacts in motor contactor
switched on. overload are faulty. Replace motor starter contacts.
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 overload
trips out occasionally. 1. Overload setting is too low. Set the overload correctly.
2. Low voltage at peak times. Check the electricity supply.

Motor contactor has not Check :

tripped out but the Motor does not run when started:
pump does not run. items: 1, 2, 4, 5, 6,

Pump capacity
not constant. 1. Pump inlet pressure is too
low (cavitation). Check the suction conditions.
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 no water. 1. Suction pipe/pump blocked. Clean the pump or suction pipe.
2. Foot or non-return valve
blocked in closed position. Repair the foot or non-return valve.
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 feed water non-return Check and clean boiler feed water
valve letting water passed non-return valve, ensure it is seating
the valve seat, (normally and not allowing water passed.
accompanied by banging in
the feed water tank).

31 J Gas 08 2008
3 3

3.9 TROUBLESHOOTING, continued.

Feed Water Pump

Problem Cause Remedy

Pump runs backwards

when switched off. 1. Leakage in suction pipe. Repair the suction pipe.
2. Foot or non-return valve is
defective. Repair the foot or non-return valve.

Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal.

Noise. 1. Cavitation occurs in the pump. Check the suction conditions.

2. Pump does not rotate freely
(frictional resistance)
because of incorrect
pump shaft position. Adjust the pump shaft.
3. Frequency converter
operation. See Grundfoss manual.
4. Boiler feed water non-return Check and clean boiler feed water
valve letting water passed non-return valve, ensure it is seating
the valve seat, (normally and not allowing water passed.
accompanied by banging in
the feed water tank).

Water pump will not 1. Scale on probes. Check and clean probes, replace as
come on at times. necessary.
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 As the boiler cools, it pulls water from the
with boiler off. system piping. To prevent this, add a
check valve on the steam gauge
assembly piping, which closes under
pressure and opens under vacuum.

J Gas 08 2008 32
3 3

3.10 TROUBLESHOOTING,
Burner Control Unit - LFL 1 (Landis and Staefa)

Symptom and Cause Remedy
Identification Symbol

No Start 1. No Power Check all fuses.

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 Moter fault Check overload.

Lockout 1. False flame detected Check for stray light (cell only).
Faulty cell or damaged flame probe.

Interruption of
start-up sequence 1. Air Damper Check fully open microswitch is made.

Lockout 1. Air Pressure Switch Check that switch is made.

P 2. Note: Any air pressure

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
start-up sequence 1. Air Damper Check low fire microswitch is made.

Lockout 1. No ignition spark Check supply ignitor.
1 Check electrode and HT leads
for damage.
2. No pilot flame Check gas supply.
Check electrode setting.
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 Check gas pressure is steady.
will cause a lockout Check the flame is being sensed, i.e.
condition (i) Check sensor for damage.
(ii) Check sensor can view flame.
(iii) Check flame signal,
see data sht. LFL1 - 7451

33 J Gas 08 2008
3 3

3.10 TROUBLESHOOTING,
Burner Control Unit - LFL 1 (Landis and Staefa)

Symptom and Cause Remedy

Identification Symbol

Lockout 1. No main flame Check supply to main valve(s).

2 Check functionality of main valve(s).
Check gas pressure at burner.
Check air pressure at burner.
Check flame signal strength,
refer to LFL1 data sht. 7451

Lockout 1. Flame failure Check flame signal.

l 2. Air pressure failure Check switch operation.

Lockout on completion
of control programme 1. Extraneous light Check flame extinguished.
sequence Check gas valves for leaks.
2. Faulty flame signal Check for aged/faulty UV cell.
Check flame supervision circuit.
3.11 TROUBLESHOOTING - Gas,
Burner Control Unit - TMG 740-3 (Satronic)
Routine Checks.

Test the safety of the flame detection system during

commissioning and after servicing, or if the system
has not been in operation for a long period.
Test 1 Test 2
1. Bridge the gas proving switch. 1. During normal boiler operation, remove the
flame detector and block light from the
2. Close the gas isolation valve. sensor. Lockout should occur within one
second.
3. After the first safety interval has elapsed,
the boiler should lockout.

Fault Finding
Fault finding is considerably simplified by making use of the coloured programme indicator. Irregularities
during commissioning, normal operation or a normal shutdown pause can be localised via the programme
indicator disc. If malfunction occurs, it is useful to note the exact position of the indicator before operating
the control switch or reset button. The following list is designed to assist with fault finding.
COLOUR WHERE WHAT REASON
Blue beginning does not start No power, break in control circuit, air proving switch not in
resting position.
continuous ventilation End switch 'MAX' air damper does not operate.
line lockout Air proving switch does not switch over or is too late.
end continuous ventilation End switch 'ignition position' , air damper does not operate.
anywhere lockout Stray light
Yellow end lockout No ignition, no spark, no gas or too little gas
too much or too little air.
Flame detector selector switch set incorrectly.
Red end lockout No flame signal current or too weak after end of
second safety interval (double fuel feed burner).
Green end lockout Loss of flame during operation, air pressure too low.
Black end lockout Stray light due to burning on, flame detector tube reached
end of life and activates shutoff, defect in flame
detector circuit.

J Gas 08 2008 34
3 3
3.12 DRAINING THE BOILER,
Boilers with manual blowdown valves
CAUTION
Your local regulations could state boiler water above 43OC must not be discharged into the drain.
ALWAYS check your local regulations.

1. Ensure the boiler is cold.

2. Isolate the boiler electrics at the isolator on the control box door.

3. Isolate the feed water tank and the feed water 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.

The boiler should be cold.

2. Close the blowdown isolation valve.

3. Using a screwdriver located as shown ‘A’, push up and make a quarter turn,
this will lock the button in position and open the blowdown valve.

4. Using the blowdown isolation valve to throttle the flow, drain the boiler.
Note: Skid units and plant rooms have internal drainage systems which require the same procedures.

3.13 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.

35 J Gas 08 2008
3 3
This log should be completed regularly as a record of boiler maintenance.

MAINTENANCE LOG

Date Action Remarks Sig.

J Gas 08 2008 36
4 4

Feed Water
Dip Pipe

Removing/replacing Water Level Probe

Safety Valve
Outlet

Water Level
Gauge Blowdown

Water Column
Blowdown

Boiler Blowdown

Handhole Feed Water Pump

FIG. 20 BOILER MAINTENANCE Interrupt Switch
37 J Gas 08 2008
 4 4

MAINTENANCE
SECTION 4
4.1 General

Maintenance on Gas appliances should only be carried out by competent, trained personnel who are
CORGI/ACS registered, and who have the necessary equipment to check combustion.
If any fault is found during these operations contact your Fulton representative.

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 feed water is effective.

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 handhole 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.

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.
The following procedures are designed to prevent the buildup of scale, silt or sludge in the bottom of
the boiler, water gauge and water column pipework, some of the routines form part of the normal boiler
operation as detailed in section 3.
In addition to these procedures, the advice of a water treatment specialist should be sought
and followed

4.2 DAILY.
Some of the following procedures should be carried out as part of the normal operating routines of the
boiler, others are required to be done as part of the boiler maintenance programme.
All boiler operating routines and tests should be recorded and kept as a boiler history.

1. Blowdown the Boiler.

2. Blowdown the Water Column.

3. Blowdown the Water Level Gauge.

4.3 WEEKLY (including daily)

WARNING
Ensure the fittings around the steam safety valve(s) are secure.
The safety valve will be very hot, do not operate the safety valve without protection.

4. Ensure that the pipes from the safety valve outlet is not damaged and that it continues to a safe
blowdown point.

5. The water level and safety cut-off controls must be tested under operating conditions by
interrupting the water feed supply.
To carry out this test, use the feed pump interrupt switch to isolate the feedwater pump and lower
the water level in the boiler by evaporation. Lower the water level passed both the 1st. and
2nd. low water levels (see section 3).
On completion of this test, switch off the pump interrupt switch and check that the water level
is restored to normal.

J Gas 08 2008 38
4 4

4.4 Monthly (including weekly)

6. Inspect the hand holes in the boiler. If any leakage is evident proceed as follows:
Note: Use only genuine Fulton replacement parts.

a). Using the special tee handle wrench, remove the handhole assembly.

b). Remove the old gasket and thoroughly clean the mating faces of the plate and boiler.

c). Fit the handhole assembly as follows:

1. Place the new gasket on the handhole plate and ensure that it is seating correctly.
Do not use any grease, lubricant or adhesive.

2. Position the plate in the boiler, set the crab and tighten the securing nut only
sufficiently to provide a snug fit. Verify the position of the plate in the boiler to
ensure that there is uniform space between the periphery of the door and the
boiler inspection opening. Tighten the nut hand tight only. Using the special
wrench, tighten the nut a further quarter of a turn. DO NOT OVERTIGHTEN.

d). If the gasket leaks as the pressure is building up, tighten the securing nut only
sufficient to stop the leakage.

7. Inspect the flanged joint covering the rear inspection port in which the blowdown valve is fitted,
if any leakage is evident replace the gasket.

8. Clean the sight glass. If any leakage is evident, renew the gasket.

Note: Isolate the gas supply.

9. Check and clean the ultra -violet cell (if fitted).

10. Check feedwater and boiler water quality (see Water Treatrment in section 5).

Handhole Cover
Plate

Gasket

Crab

FIG. 21 REMOVING/REPLACING UV FIG. 22 HANDHOLE

DETECTOR

39 J Gas 08 2008
4 4

4.5 THREE MONTHLY (including monthly)

11. Drain and isolate the boiler.

12. Remove the lower handhole assemblies and inspect the interior of the pressure vessel for
scale and sludge build up.

13. Remove the feedwater pipe from the top of the boiler. Ensure the pipe is not blocked,
clean as required.

Caution
Ensure the gas supply is isolated.

14. 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.

Insulating rope

Lower refractory
brick in place

FIG. 23 BOILER FURNACE FIG. 24 IGNITION ELECTRODE

FIG. 26 BURNER ASSEMBLY

FIG. 25 BURNER PLATE (suitable lifting equipment must be used to lift any heavy items)

J Gas 08 2008 40
4 4
4.6 SIX MONTHLY (including three monthly)

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.

15. 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.

16. Apply a small quantity of oil to the bearings of the burner motor and the feed water pump motor.

17. Drain and flush the feed water tank. Clean any filters in the tank, in the feed water line or in
the feed water pump.

18. 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 feed water pump.

19. Remove the air gate and clean the fan.

20. 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, their should be no smoke
visible. If either of these tests fail, shut down the boiler and contact Fulton Boiler Works
immediately.

21. Remove the water gauge and water column. Rod through the top connections of both to
ensure the holes in the baffle plates (approx.. 6mm dia.) inside the boiler are not obstructed.

22. Check the burner combustion to ensure that excess air and carbon monoxide values are within
normal limits (see combustion values in section 5).

23. Check the condition of the gas valve filter (if fitted), renew as required.

Cleaning
the Flues

Remove cover
plates and gasket Remove the cleanout door to
the flue passes and to the
bottom of the boiler.
Oil boiler illustrated.

FIG. 27 FLUE CLEANING

41 J Gas 08 2008
B B

Appendix ‘B’
Motorised High/Low Control

1.1 Description

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; two stage gas valve, motorized air damper unit and
two stage steam pressure switch.

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

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, 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.

J Gas 08 2008 42
B B
Motorised High/Low Control. continued.

2 Commissioning
(commissioning should only 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.

2.1 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 com-
bustion values.

2.2 Air Damper Motor - Factory Cam Settings (see 2.3 Setup procedure)

Terminal Position Degrees

N1 High Fire Motor Cam 45O
N2 Low Fire Motor Cam 10O
N5 High Fire Interlock Cam 40O
N6 Low Fire Interlock Cam 15O

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

Note: The high fire interlock cam should always be set approximately 5O lower than the high fire cam posi-
tion. The low fire interlock cam should always be set approximately 5O higher than the low fire cam position.

43 J Gas 08 2008
 B B
Motorised High/Low Control. continued.

2.3 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 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 con-
nection block.

5. The high fire CO2 constituent of the flue gases is 10 - 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 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 5O 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.

J Gas 08 2008 44
B B
Motorised High/Low Control. continued.

5.0 Spare Parts

Part No. Description Qty Model

10366 Casting, scroll 1 6 - 15

13195 Transformer, TRK2P COFI 1 15
14437 Switch, air pressure, DL5A 1 15
14485 Motor, damper, A30 045Y 1 15
14486 Inlet, scroll 1 15
14487 Fan, 200x40x16 1 15
14489 Coupling, air gate 1 15
5-10-000480 Airgate, high/low 1 15
11327 Switch, low fire hold 1 15
14493 Valve, gas, MB-ZRD(LE)410 B01 1 15

45 J Gas 08 2008
C C

Appendix ‘C’
Spirax High Integrity Level Controls
The daily testing of boiler water level controls is a mandatory requirement as defined in the Health & Safety
Executive Guidance Note PM5.
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 at-
tendant, but may be supervised during the silent hours and weekends by a Competent Person trained to re-
spond to an alarm.

Daily testing of the controls is required which can be by simulation, with a weekly test by interrupting the feed
water pump and lowering the water by evaporation.

Daily Test

1st. Low Water

1. With the burner firing

2. Press and hold the 1st. Low Water test button until (minimum 15 seconds) the low water alarm
sounds, and the low water indicator lamp illuminates, and the burner shuts down
3. Release the test button
4. After approximately 17 seconds the low water alarm will cancel, the low water lamp will
extinguish, and the burner will restart

2nd. Low Water

1. With the burner firing

2. Press and hold the 2nd. Low Water test button until (minimum 15 seconds) the low water alarm
sounds, and the second low water reset switch illuminates, and the burner shuts down
3. Release the test button
4. After approximately 17 seconds the second low water relay will reset.
5. To cancel the second low water level alarm and light, depress the second low water reset switch
6. The burner will restart.

HIGH INTEGRITY LEVEL LIMITERS

TEST TEST

1st. LOW WATER 2nd. LOW WATER

TEST:
with the boiler water at the normal working level,
press and hold each control for a minimum of
15 seconds, until the alarm sounds.

J Gas 08 2008 46
C C
Spirax High Integrity Level Controls, continued.
Weekly Test (Daily test plus)

1st. Low Water

1. With the burner firing

2. Switch the pump interrupt switch to the pump interrupt position.
3. By evaporation lower the water level in the boiler until the first low water alarm sounds
and the low water indicator lamp illuminates, and the burner shuts down
4. Switch the pump interrupt switch to the pump on position.
5. The pump will start and restore the water level to the normal position and switch off.
6. After approximately 17 seconds from restoring the first low water level the low water alarm will
cancel, the low water lamp will extinguish, and the burner will restart

2nd. Low Water

1. With the burner firing

2. Switch the pump interrupt switch to the pump interrupt position
3. By evaporation lower the water level in the boiler until the low water alarm sounds, the second low
water reset switch illuminates, and the burner shuts down.
4. Switch the pump interrupt switch to the pump on position.
5. The pump will start and restore the water level to the normal position and switch off.
6. After approximately 17 seconds from restoring the second low water level the second low water
relay can be reset.
7. To cancel the second low water level alarm and light, depress the second low water reset switch
8. 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 second low water alarm will occur immediately after the burner has shut down on first 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 site glass before the alarm sounds. Should this happen the second low
water level alarm should be checked by lowering the water level slowly by partially opening the main blow-
down valve.

Pump Interrupt Switch

47 J Gas 08 2008
D D

Appendix ‘D’
Automatic TDS Blowdown System
The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS
level within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be
used to control suspended solids, and prevent the build up of sludge in the bottom of the boiler.

The method of operation is to take a sample of the boiler water at preset timed intervals, pass the sample over
an electrode which measures water conductivity (which is proportional to TDS for a given water chemistry),
and then compares the result with the control value (normally 2000ppm), which is set when the unit is com-
missioned.

If the sample value is higher than the control value the blowdown solenoid valve opens in a series of pulses until
the measured value corresponds to, or is lower than, the set value. When this is achieved blowdown finishes
until the next timed sample is taken when the process is repeated. Should the sample value be lower than the
set value, blowdown is deferred until the next timed sample.

For the system to function reliably, the control must be calibrated to a typical water sample that is representative
of the water conditions that are likely to prevail during normal running of the boiler and system.

Conductivity and as a consequence TDS, can vary significantly with water chemistry. Changes in condensate
return rates, alkalinity, chemical dosage, and suspended solids can all affect the performance of an Automatic
TDS Blowdown System.

Condensate return rates that vary greatly on a day to day basis can severely disrupt the reliability of the con-
ductivity measurement.

FIG. 1
e.g. A boiler with a 50% condensate return and a raw water TDS of 400
will have a boiler feed water TDS of 200 ppm.

J Gas 08 2008 48
D D

Automatic TDS Blowdown Systems, continued.

Systems that return for example very little condensate during the day, but a high proportion at night are almost
impossible to control with any real accuracy. At best a compromise calibration will be achieved, where too much
blowdown at times may be the penalty.

When installing and commissioning a new Automatic TDS Control Blowdown System, it must be accepted that
the calibration will be a reiterative process, requiring continual sampling, testing, and re-calibration until stable
system operating conditions are achieved.

When purchasing an Automatic TDS Control Blowdown System from Fulton Boiler Works (Great Britain)
Ltd, the equipment would normally be supplied with the controller wired and fitted to the boiler control
panel, with all the other parts supplied loose for piping and wiring on site by others, unless agreed
otherwise in our order acknowledgement.

The purchase price of the system supplied fully or part fitted includes for one single visit to commission the
system once installed. Part of the commissioning process will be the initial calibration of the TDS sensor to the
water conditions prevailing at the time.
Further re-calibration will be required until the water treatment regime has been established, and “typical” water
conditions have been achieved. Routine calibration checks will be required as part of the site maintenance and
water treatment monitoring.

The equipment, staff training required to carry out TDS sampling, and calibration can be provided by Fulton
Boiler Works (Great Britain) Ltd. if required. In order to achieve the maximum benefit from the installation of an
Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the neces-
sary equipment, and training in order for them to fully understand the function of the system, and the possible
consequences of their actions.

Note:- Where Automatic TDS Blowdown systems are provided as part of a skid mounted or packaged plant
room unit, they will be fully installed piped and wired.

e.g. Hourly blowdown rate required to maintain a boiler TDS of 2000

with a feed water TDS of 200 = 12%

For a 1000kg/h boiler 125kg/h (125l/h) of blowdown is required.

49 J Gas 08 2008
5 5
GENERAL DATA
SECTION 5

Steam H Feed Water Inlet

Outlet Gas Inlet Flue Connection
L (dia)
J

H P 360O
A
G1 M
B F N
C E
D Boiler Q
Blowdown

FIG. 28 BOILER DIMENSIONS

Model 6J 8J 10J 15J 20J 30J 40J 50J 60J

A** 2300 2300 2300 2460 2600 2800 3100 3100 3100
B 1840 1840 1840 1990 2060 2240 2490 2490 2490
C 1060 1060 1060 1215 1285 1465 1710 1710 1710
D 1025 1025 1025 1175 1245 1385 1670 1670 1670
E 1670 1670 1670 1820 1890 2070 2320 2320 2320
F 1845 1845 1845 2010 2100 2310 2680 2680 2680
G1 2045 2045 2045 2225 2330 2510 2820 2820 2820
H 1500 1500 1500 1625 1670 1820 2075 2075 2075
J 1810 1810 1810 1960 2030 2210 2460 2460 2460
K 380 380 380 380 390 390 395 395 395
L 152 152 152 203 255 305 305 305 305
M 715 715 715 760 985 1175 1390 1390 1390
N 1025 1025 1025 1060 1400 1595 1850 1850 1850
P 265 265 265 265 265 265 265 265 265
Q 270 270 270 270 270 270 265 265 265
Dimensions (mm)

Standard Boiler Trim. Quantity

Main Steam Valve 1

Steam Safety Valve 1
GAS COMBUSTION VALUES
Steam Pressure Gauge Assembly 1
Boiler Blowdown Valve 1
Water Level Gauge Set 1 or 2* CO2 range 9.5 - 10.5%
Feedwater Check Valve 1 CO less than 50ppm
Feedwater Stop Valve 1 O2 4.3 - 2.5%
Flue Spigot 1
Excess air 25 - 15%
Audible Alarm 1 or 2*
Flue Brush 1 Smoke -
Tee Handle Wrench 1

J Gas 08 2008 50
5 5

Specification

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

Output kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960
Std. working pressure. (bar). 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34
Boilers at higher pressures are available as special orders

Firing Rates
Gas (m3/h) 7.0 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6

The mains gas supply pressure must be between 18.5mb and 50mb.

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 - - - -

Water Content (litres) 91 91 91 205 291 640 1022 1022 1022

Weight dry (approx. kg) 810 810 810 1190 1420 2030 3150 3150 3150

Weight full (approx. kg) 900 900 900 1395 1711 2670 4172 4172 4172

Connection Sizes (DN) (F=female, M=male) (all connections BSP)

Steam Outlet 20F 20F 25F 32F 32F 40F 50F 50F 50F
Feed Water 15M 15M 15M 15M 15M 15M 15M 15M 15M
Safety Valve (discharge) 20F 20F 20F 20F 20F 20F 32F 32F 32F
Blowdown (Boiler) 20F 20F 20F 20F 25F 25F 25F 25F 25F
Blowdown (Water column) 20F 20F 20F 20F 20F 20F 20F 20F 20F
Blowdown (Sight Glass) 8F 8F 8F 8F 8F 8F 8F 8F 8F
Gas Inlet 20F 20F 20F 32F 32F 32F 50F 50F 50F

Ventilation - High and Low levels

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

High Level (cm2) 305 360 420 560 700 980 1260 1540 1820

Low Level (cm2) 610 720 835 1115 1395 1960 2520 3085 3645

51 J Gas 08 2008
issue1
5 5

IMPORTANT

Recommended Water Conditions

It is very important that a strict water management program is followed

to ensure trouble free boiler operation.
The following are recommended for feedwater and for boiler water.

FEEDWATER (water entering boiler)

pH Value 8.5 to 9.5 tested at room temperature.

Hardness less than 2.0mg/kg in the form of CaCO3
Suspended Solids None
Chloride Less than 50mg/kg
Organic Matter Less than 5mg/kg
Oil None

BOILER WATER (water inside boiler)

pH Value 9.5 - 11.5, tested at room temperature

Hardness Not detectable
Suspended Solids Less than 100 mg/kg
Chloride Less than 500 mg/kg
Oxygen Scavenger,
Sodium Sulphide or Tannin 20 to 50 mg/kg
Phosphate Less than 50mg/kg, in the form of PO4
Total Alkalinity Less than 1000 mg/kg
Caustic Alkalinity Less than 300 mg/kg as CaCO3

Total Dissolved Solids (TDS) Less than 2000ppm
Iron Less than 1 mg/kg
Silica Less than 180 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 9.5 -11.5.

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 achive the required conditions.

J Gas 08 2008 52
5 5
PROBE LENGTHS (TI65)

DATUM:
underside of
probe hex.head Top of Sockets /
Shell / Furnace

High Water Probe

216
2nd Low Water
1st Low Water

Pump Off

Pump On
430
405

216

241
Centre
of
Glass

1st Low Water

2nd Low Water

Note: 350 Sight Glass

Probe Lengths Probe Lengths

High Level 216 Pump Off 216
1st Low Water 405 Pump On 241
2nd Low Water 430 measurements in mm

’J SERIES’ BOILER PROBE LENGTHS

53 J Gas 08 2008
 5

INTERLOCKED DOOR ISOLATOR 1:1 TRANSFORMER

L1 C
L2 2A MCB 2A MCB
L3

N
2A MCB

PE
PE SINGLE PHASE SUPPLY

L1
L2
L3
FEED PUMP MOTOR
BURNER MOTOR CT1 CT1 OIL PUMP MOTOR CT1 (IF FITTED)
N

J Gas 08 2008
BURNER MOTOR CONTACTOR FEED PUMP OIL PUMP MOTOR
MOTOR CONTACTOR CONTACTOR (IF FITTED)

1.
2.
6.

3.
5.
9.

7.
8.

4.

FIG. 29 THREE PHASE SUPPLY CIRCUIT

M M M
3 3 3
CN
BURNER MOTOR FEED PUMP MOTOR OIL PUMP MOTOR
(IF FITTED) 6J-60J SERIES PANEL

NOTE:
~ ~ ~ SUPPLY CIRCUIT
FOR CIRCUIT CONTINUATION INSTRUCTION REFER TO DRAWING EJ060000. (FOR GAS, OIL & DUAL FUEL BOILERS) EJ06 0001-1

54
5
55
5
INTERLOCKED DOOR
ISOLATOR MCB

L1 C
L2
L3

N
PE

BURNER MOTOR CTI FEED PUMP

2 2
MOTOR CTI

BURNER MOTOR FEED PUMP MOTOR

CONTACTOR CONTACTOR

J Gas 08 2008
1
6
5

2
3
4

M M
3 3
~ CN
BURNER FEED PUMP
~
MOTOR MOTOR
NOTE:

FIG. 30 THREE PHASE SUPPLY CIRCUIT - AUSTRALIAN BOILERS ONLY

FOR SINGLE PHASE PANELS ONLY 'L1' WILL BE WIRED.

FOR CIRCUIT CONTINUATION INSTRUCTION REFER TO DRAWING FOR ISSUE EDITS, REFER TO NUMBER IN CIRCLE: #
EJ060000. 6J-60J SERIES PANEL
3-PHASE SUPPLY CIRCUIT EJ06 0011-2
5

(FOR BOILERS WITHOUT TRANSFORMER)

56 J Gas 08 2008
FIG. 31 ANCILLARY CONTROL CIRCUIT
C

CN

REMOTE
13
TC (IF FITTED) STOP 14
2

TC R7
4

{ (IF FITTED) (IF FITTED)

15
BC AUX BCT1 AUX
BURNER RUN BURNER ON
CHEMICAL 16
DOSING 17 PC AUX PUMP CT1
AUX
FUSED TERMINAL

WATER SOFTENER 18
19
CONDENSATE TANK 20
21
PC PUMP INTERRUPT
TANK LOW WATER PUMP
22
INTERRUPT
23 PL1 (3)
OIL/GAS
24 R11 (IF FITTED)
SELECTOR
SWITCH
PM5 CONNECTIONS 26
(IF FITTED)
27 R5
{ R11A (IF FITTED)
5

25 R6
5

25
REMOTE PANEL
BOILER TESTING 28
29
SW/1
30
1st LOW
31 R1
WATER
32
33
2nd LOW

{
34 R2
WATER
35
36
FLAME

{
37 R3
FAILURE
38

NO VOLT CONTACTS
39
OIL HIGH PRESSURE

{
40 R4
FIRING (IF FITTED)

6J-60J SERIES PANEL

41

ANCILLARY CONTROL CIRCUIT

R7
REMOTE STOP

{ 42

(FOR GAS, OIL & DUAL FUEL BOILERS)

(IF FITTED) 43
GAS R8
SEQUENCE
FIRING 44
CONTROL
45

SWITCH
OIL/GAS
(IF FITTED)

SELECTOR
OPC AUX OIL PUMP CT1 AUX
OIL PUMP RUN
(IF FITTED) (IF FITTED)
POWER ON (IF FITTED)
BC

EJ06 0002-5
OPC (IF FITTED) R11 (IF FITTED)

(17)
A
C

CN
TDS
5 5
 57
5

CC CC
NOTES:
A

1. IF USING PROPANE GAS, THE LIGHT WILL

BE FED FROM THE NORMALLY 'OPEN' SIDE
HIGH PRESSURE
OF THE PRESSURE SWITCH, AND SATRONIC
PS4 SET BACK PRESS RESET
TERMINAL 10 WILL BE FED FROM THE IF LC LEVEL CONTROLS FITTED,
AUTO MANUAL SWITCH (IF FITTED) (IF FITTED)
NORMALLY 'CLOSED' SIDE OF THE SWITCH. USE: LW1 (5, 6)
or (IF FITTED)
1st SPIRAX LEVEL CONTROLS FITTED,
2. FOR CIRCUIT CONTINUATION INSTRUCTION USE: (6+7) R8
REFER TO DRAWING EJ060000. R2

2nd SPIRAX
2 R5 (6+7)
(IF FITTED)
PS1
R4 (IF FITTED)

19 20 9
PS3

SATRONIC TMG 740-3

(IF FITTED)

5 8 1 14 15 16 17 18 11 7 3 2 6 21 10

J Gas 08 2008
PS2
R4

R3

FIG. 32 BURNER CONTROL CIRCUIT

6/30 ONLY
IGNITION

MAIN GAS
MAIN GAS

40/60 ONLY
40/60 ONLY
40/60 ONLY
40/60 ONLY

START GAS
LOW FLAME

HIGH FLAME
R4 (IF FITTED)

HIGH PRESSURE

FLAME FAILURE RESET

61
71

60
67
68

63
65
66

58
62
70
69

64
73
72

59
74

GAS VALVE FLAME IGNITION PILOT GAS MAIN GAS VALVE

(6-30 ONLY) SENSOR P VALVE (40-60 ONLY) GAS PRESSURE
(40-60 ONLY) P SWITCH
(SEE NOTE 1)

AIR SWITCH
CN CN

6J-60J SERIES PANEL EJ06 0006-3

BURNER CONTROL CIRCUIT

(FOR GAS BOILERS ONLY)
5
 5
CC CC
A
NOTES: 1. IF USING PROPANE GAS, THE LIGHT WILL HIGH PRESSURE
BE FED FROM THE NORMALLY 'OPEN' SIDE RESET
OF THE PRESSURE SWITCH, AND LANDIS (IF FITTED)
TERMINAL 4 WILL BE FED FROM THE
NORMALLY 'CLOSED' SIDE OF THE SWITCH.
PS1
2. FOR CIRCUIT CONTINUATION INSTRUCTION
REFER TO DRAWING EJ060000. LW1 R2
R4 (IF FITTED)

7 1 6 8 5
PS3

LANDIS LFL-1-335
(IF FITTED)

G 2 23 13 4 12 14 21 3 16 18 19 4

PILOT
HOLD
PS2

J Gas 08 2008
R4

R3

CPI
IGNITION
MAINS GAS

START GAS

FLAME FAILURE RESET

40/60 ONLY

40/60 ONLY

63
62
64
LOW FLAME

HIGH FLAME
R4 (IF FITTED)

HIGH PRESSURE

CPI SWITCH

E
60
67
68

65
66
73
72
74

GAS

FIG. 33 BURNER CONTROL CIRCUIT - AUSTRALIAN

PRESSURE
FLAME IGNITION PILOT MAIN

FLAME FAILURE
SWITCH
SENSOR P AIR SWITCH GAS VALVE GAS VALVE
(SEE
P
NOTE 1)

CN CN

6J-60J SERIES PANEL

BURNER CONTROL CIRCUIT EJ06 0012-1
(FOR AUSTRALIAN BOILERS ONLY)
5

58
 59
5
CC CC

R5 2nd SPIRAX (6+7)

C (IF
BC AUX R9 FITTED) LW1 (5+6) LC R2 AUTO/MANUAL
'A' 4
3
or SWITCH
3
1st SPIRAX (6+7) (IF FITTED)

19 20 14 9
2 SATRONIC TMG 740-3
(IF FITTED)

AUTO
13 8 1 16 17 18 15 11 7 3 2 6 12 21 10

MANUAL
5
R8
PRESSURE
( IF FITTED )

PS4 SET BACK

HIGH STEAM PRESSURE RESET

PS2
PS1

RESET
IGNITION
MAIN GAS

START GAS
5
R9

FLAME FAILURE
R4 (IF FITTED)

R12 R10

LOW
2 PS3

FLAME
5 (IF FITTED)
R10 R9 R3

J Gas 08 2008
R4

HIGH FLAME
R12 (IF FITTED) R10
5 R4
R9

GAS 2 2

71

61
68
67
73

70
72

69

65
66
74

60
63
62
64
101
107

100
105
106

103
102
104
PRESSURE
FLAME IGNITION START MAIN LOW (IF (FITTED)
2 1 6 22 7 5 N
SENSOR GAS GAS VALVE FIRE
HIGH STEAM PRESSURE (IF (FITTED)

AIR DAMPER MOTOR

HOLD GAS PRESSURE

FIG. 34 HIGH - LOW, BURNER CONTROL CIRCUIT

P SWITCH
P

AIR
(SEE NOTE 1)

SWITCH
CN CN
FOR ISSUE EDITS, REFER TO NUMBER IN CIRCLE: #
NOTES:
1. IF USING PROPANE GAS, THE LIGHT WILL BE FED FROM THE
6J-60J SERIES PANEL EJ060010-6
NORMALLY 'OPEN' SIDE OF THE PRESSURE SWITCH, AND
SATRONIC TERMINAL 10 WILL BE FED FROM THE NORMALLY
'CLOSED' SIDE OF THE SWITCH.
BURNER CONTROL CIRCUIT
2.FOR CIRCUIT CONTINUATION INSTRUCTION REFER TO (FOR HIGH/LOW GAS BOILERS ONLY)
DRAWING EJ060000.
5
 5

2A MCB 240./24.V 2A MCB

MAINS SUPPLY BOILER ALARM
FUSE

2A MCB

FUSED ISOLATOR 'A' 'B' 'C'

MUTE

'A' 'B' 'C'

NOTE: N L Q1 Q2 Q3 Q4
USE SAME TERMINAL CONNECTIONS FOR BOILER 'B' & 'C' AS
LOGO
FOR 'A', & CONNECT TO THEIR RELEVANT PM5 REMOTE PANEL
TERMINALS. I1 I4 I2 I5 I3 I6 I7

EMERGENCY STOPS
6
7
8

2
9

3
5

4
10

1
1
1
11
11
11

'A' 'B' 'C' 'A' 'B' 'C' 'A' 'B' 'C' 'A' 'B' 'C'

J Gas 08 2008
27
28
27
28
27
28

37
38
37
38
37
38

26
26
26

33
35
33
35
33
35

29
29
29

36
36
36

24
24
24

34
34
34

25
25
25
25
25
25

24V SUPPLY BOILER 24V SUPPLY BOILER 24V SUPPLY BOILER

2nd LOW FLAME 2nd LOW FLAME 2nd LOW FLAME
FROM PM5 TESTING FROM PM5 TESTING FROM PM5 TESTING
WATER FAILURE WATER FAILURE WATER FAILURE

FIG. 35 PM5 REMOTE PANEL / TYPICAL BOILER CONNECTIONS

BOILER 'A' BOILER 'B' (SEE NOTE) BOILER 'C' (SEE NOTE)
EAC06 0001-2
PM5 REMOTE PANEL & TYPICAL BOILER CONNECTIONS
(FOR GAS, OIL & DUAL FUEL BOILERS).

60
5
5 5

FIG. 36 TANK SOLID STATE WATER LEVEL AND ALARM CIRCUITS

61 J Gas 08 2008
 5
AUXILLARY SKID PLUG & SOCKET BOILER TERMINALS BOILER TERMINALS BOILER SKID

E E E
L1
1 1 4 82
L2

SWITCH
CLOSED
2 2 5 83

PUMP
PUMP
L3
3 3 6 84
L

OPEN
VALVE
ALARM
4 4 16 85
N

DOSAGE
5 5 17 86

CHEMICAL
L
6 6 18 87
N
SOLENOID VALVE

WATER
7 7 19 78
BOTTOM BLOWDOWN

SOFTENER
TDS

L
VALVE

8 8 20 79
SOLENOID

TANK
TDS & BOTTOM BLOWDOWN CONNECTION (REF.)

FEED
9 9 21

J Gas 08 2008
10 10 22
RED

PUMP
RELAY
11 11 23 1 RED

INTERRUPT
YELLOW
12 12 - 2
BLUE
(REF.)

13 13 - 3 BLUE
TDS PROBE

GREEN
14 14 - 4
TDS PROBE CONNECTION

15 SCREENED CABLE
15 13

LINK
STOP
16

REMOTE
16 14
NOTE:
STANDARD SINGLE BOILER PUMP MAYBE FITTED ON THE BOILER SKID OR ANCILLARY SKID.

FIG. 37 STANDARD SINGLE BOILER AND ANCILLARY SKID ELECTRICAL CONNECTIONS

& ANCILLARY SKID
ELECTRICAL CONNECTIONS
5

62
(FOR GAS, OIL & DUAL FUEL BOILERS) EAC06 0003-1
63
5

C CC
SWITCH PUMP PUMP & R2
SELECTOR ONLY BOILER
OFF

1 R2 1 3
3
LC3000 LC3000
2nd

R6
7 2 7 2 1st
6 4 4
1 2nd LOW WATER
3 HL1 4 3 RESET BUTTON
(IF FITTED) PL1
5 8
1 8
6 5 2 5 2
1 9101112 1 9 101112

R1
R2

J Gas 08 2008
BUTTON

BUTTON

(IF FITTED)
LP30

51
LP30

50
52
1st LOW WATER TEST
2nd LOW WATER TEST

HIGH WATER ALARM

1st LOW 2nd LOW
HIGH PUMP PUMP WATER WATER
WATER OFF ON

FIG. 38 SPIRAX LEVEL CONTROL CIRCUIT

(IF FITTED)
2nd LOW WATER LIGHT & ALARM

1st LOW WATER LIGHT & ALARM

PL1 (3)
CN CN
1 DENOTES LOCATION OF CHANGES FOR ISSUE NUMBER
NOTE:
FOR CIRCUIT CONTINUATION INSTRUCTION
REFER TO DRAWINGS: EGP06 0001-2
EJ060000 (FOR 'J' SERIES BOILERS); SPIRAX LEVEL CONTROL PANEL CIRCUIT
ERB060000 (FOR RBC BOILERS). (FOR GAS, OIL & DUAL FUEL BOILERS)
5
 5

C CC

SWITCH SELECTOR PUMP PUMP &

BOILER
R2
ONLY
OFF
RESET

LOW WATER
1
RESET BUTTON
2nd LOW WATER

R6
7 2 7 2 7 2 7 2
6 4 4 4
R2
3 HL1 4 3 3 3
(IF FITTED) PL1 LW1 LW2
5 8 8 8
1 8
6 5 6 5
1 1 1

R1
R2

J Gas 08 2008
(IF FITTED)
HIGH WATER ALARM
1st LOW WATER ALARM

51
2nd LOW WATER ALARM

53

52
54

50

FIG. 39 LC LEVEL CONTROL CIRCUIT

HIGH WATER PUMP PUMP 1st LOW 2nd LOW
(IF FITTED) OFF ON WATER WATER

PL1 (3)
CN CN
EGP06 0002-1
LC LEVEL CONTROL PANEL CIRCUIT
(FOR GAS, OIL & DUAL FUEL BOILERS)

64
5
65
5

CC CC

PC 'B' AUX
(If fitted)

SCREENED CABLE
RED
1
YELLOW PC 'A' AUX
2
BLUE
3
GREEN
4 1
2
20 BLOWDOWN 3
TDS 19 CONTROL 4
CONTROL 18 BT1000 6
(IF FITTED) 17 (IF FITTED) 8
16 10
15 12

PC 'B' AUX
(If fitted)

J Gas 08 2008
PC 'A' AUX
RED BLUE
TDS PROBE
89
88

80

79
81
87
86

85

83
82
84

78
TDS CLOSED OPEN SOLENOID
TDS SWITCH ALARM VALVE
SOLENOID

FIG. 40 TDS AND BLOWDOWN CONTROL CIRCUITS

VALVE CONTROLLER
SUPPLY
TDS (17)

CN CN

TDS & BLOWDOWN CONTROL PANEL CIRCUIT

FUSED TERMINAL EGP060003-1
(FOR GAS, OIL & DUAL FUEL BOILERS)
5
5 5

J Gas 08 2008 66
 STANDARD BOILER CONTROLS TESTS - LOG Boiler No.
The following tests are to be performed in accordance with the maintenance schedule in the Fulton Service Manual.
DAILY TEST WEEKLY TEST
Date Date

Water gauge blowdown

test satisfactory Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Flame failure
device tested
Water Level (by sight)
1st. gauge
2nd. gauge

Water Level Control

Feed pump, start/stop Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
Test by lowering water level
1st. low water alarm
Burner cut out
and alarm sounded Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
2nd. low water alarm

J Gas 08 2008
Burner lock out
and alarm sounded Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No

Main boiler blowdown

duration/seconds
Time test carried out
Pressure gauge reading
Boiler water test
TDS
pH
Water treatment
Softened water Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No
Brine level correct Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No Yes/No

Signature of operator
6 6
SPARE PARTS
SECTION 6

Using the appropriate information as completed below,

order spare parts from the Fulton Spare Parts Manual
provided with the boiler

In order to ensure spare parts are correct, please complete the

details below and have them at hand when ordering parts or
making enquires regarding the boiler.

1. Boiler number

2. Boiler type

3. Type of fuel used

5. Wiring Diagram No.

6. Commissioning Date

WARNING
The type, size and lift pressure of the safety valve fitted to a boiler is specific to that boiler.
When ordering new safety valves it is important that, as well as the information requested
above, the following additional information is given:

Boiler design pressure (located on the boiler data plate).

Make and type (eg fig no.) of safety valve fitted.

J Gas 08 2008 68
A0-1-1 GAS BOILER - MAJOR COMPONENTS

2
4

J Gas 08 2008
 A0-1-1 GAS BOILER - MAJOR COMPONENTS

Item Part Number Qty Description Remarks Size

1 1 Boiler Shell & fittings see A1-1-1 4 - 15

1 Boiler Shell & fittings see A1-2-1 20 - 60
2 1 Burner assembly see B1-1-1 6 - 15
1 Burner assembly see B1-2-1 20 - 30
1 Burner assembly see B1-3-1 40 - 60
1 Burner assembly see B1-4-1, Aus. 40 - 60
1 Gas train assy, monobloc see C1-8-1 6 - 15
1 Gas train assy, monobloc see C1-9-1 20 - 30
1 Gas train assy, monobloc see C1-11-1 40 - 60
1 Gas train assy, monobloc see C1-12-1, Aus. 40 - 60
1 Gas train assy, monobloc see C1-13-1, LPG 6 - 60
1 Gas train assy, m,bloc, Aus. see C1-14-1, LPG 40 - 60
4 1 Burner scroll assembly see D1-1-1 6 - 10
1 Burner scroll assembly see D1-1-2 15
1 Burner scroll assembly see D1-2-1 20 - 30
1 Burner scroll assembly see D1-3-1 40 - 60
1 Burner scroll assy, dual fuel. see D2-5-1 40 - 60
5 1 Water column see E1-3-1, Aus. 6 - 60
1 Water column see E1-6-1 6 - 60
6 A/R Water level gauge see F1-4-1 6 - 60
7 1 Control box see G1-1-1 6 - 15
1 Control box see G1-3-1 40 - 60
1 Control box see G1-5-1, Aus. 6 - 15
1 Control box see G1-6-1, Aus. 20 - 30
1 Control box see G1-7-1, Aus. 40 - 60
not illustrated 1 Feed water pump see H1-1-1 6 - 60

J Gas 08 2008
A1-1-1 BOILER SHELL AND FITTINGS, 6 - 15
(UK and Australia)

2 3

13 4
21
6
5
4
20
15

22
7

28 27

23
18 17 19
19 17

16

26 8 1
25

14

24

11

12
10

A1-1-1, 6-15

J Gas 08 2008
 A1-1-1 BOILER SHELL AND FITTINGS, 6 - 15
(UK and Australia)
Item Part Number Qty Description Remarks Size
1 10535 1 Valve, steam stop DN20 6-8
10536 1 Valve, steam stop DN25 10
10537 1 Valve, steam stop DN32 15
2 10566 1 Gauge, pressure 4in. x 250psi 6 - 15
3 SA0001 1 Gauge, pressure assy. 6 - 15
4 10565 2 Tee 6 - 15
5 10548 1 Valve 6 - 15
6 10655 1 Plug 6 - 15
7 10564 1 Syphon, pigtail 6 - 15

8 10001 1 Refractory, furnace Top 6 - 10

12037 1 Refractory, furnace Top 15
9 12040 1 Refractory, furnace Bottom 6 - 15

10 10006 1 Door, cleanout 6 - 15

11 13764 A/R Handhole assembly Bottom 6 - 15
10009 A/R Handhole assembly Top 6-8
10010 A/R Handhole assembly Top 10
10011 A/R Handhole assembly Top 15
12 10017 A/R Gasket, handhole 6 - 15
13 10023 1 Wrench, tee Handhole 6 - 15
14 11524 1 Valve, blowdown 6 - 15
15 14257 1 Valve, feed water stop 6 - 15
16 SA0002 1 Valve, check assembly 6 - 15
17 11824 2 Gasket 6 - 15
18 14126 1 Valve, check 6 - 15
19 11825 2 Flange 6 - 15
20 10417 1 Probe, water level 6 - 15
11882 1 Probe, water level 6-8
11774 1 Probe, water level 10 - 15
21 099E9360 2 Basket, probe 6 - 15
22 10558 2 Valve, steam safety 3/4in.Bir.130psi 6 - 15
11504 1 Valve, steam safety 3/4in.N.V.130psi 6 - 15
11609 2 Valve, steam safety 3/4in.Bir.125psi 6 - 15
11952 1 Valve, steam safety Superseded 6 - 15
11953 1 Valve, steam safety Superseded 6 - 15
14187 1 Valve, steam safety 1/2in. 165psi 6 - 15
14433 1 Valve, steam safety 1/2in. 125psi 6 - 15
23 10135 A/R Gasket, flue cover 6 - 15
24 10022 1 Brush, flue 6 - 15
25 13508 1 Connector, flue, male 6in. 6 - 10
13510 1 Connector, flue, male 8in. 15
13509 1 Connector, flue, female 6in. 6 - 10
13511 1 Connector, flue, female 8in. 15
26 13568 3 Clip, flue connector 6 - 15
27 SA0045 1 Pipe, feed water dip 6 - 15
SA0040 1 Pipe, feed water dip for TDS systems 6 - 15
28 010E 9520 2 Cover, shell flue 6 - 10
015E9520 2 Cover, shell flue 15

Note: In order to comply fully with safety regulations it is essential that the correct safety valves are used. If in
any doubt please contact Fulton Service Department for assistance.
J Gas 08 2008
A1-2-1 BOILER SHELL AND FITTINGS, 20 - 60
(UK and Australia)

21 26

17 22
19
23
24
22
20
6
18
25

15 7

16
4 3
3 4 5

14 27 1
13

12

28

10

11
9

A1-2-1 20/60
June 07

J Gas 08 2008
 A1-2-1 BOILER SHELL AND FITTINGS, 20 - 60

(UK and Australia)
Item Part Number Qty Description Remarks Size

1 10537 1 Valve, steam stop DN32 20

10538 1 Valve, steam stop DN40 30
10539 1 Valve, steam stop DN50 40 - 60
2 SA0044 1 Valve, check assembly 20 - 60
3 11825 2 Flange 20 - 60
4 11824 2 Gasket 20 - 60
5 14126 1 Valve, check 20 - 60
6 14257 1 Valve, feed water stop DN15 20 - 60
7 SA0045 1 Pipe, feed water 20 - 60
8 13732 1 Brush, flue 20 - 60
9 10006 1 Door, cleanout 20 - 60
10 13764 A/R Handhole assembly Bottom 20 - 60
10012 A/R Handhole assembly Top 20
10013 A/R Handhole assembly Top 30
10014 A/R Handhole assembly Top 40 - 60
11 10017 A/R Gasket, handhole 20 - 60
12 11525 1 Valve, blowdown 20 - 60
14497 1 Valve, blowdown Australia only 40 - 60
13 13512 1 Connector, flue 10in. 20
13514 1 Connector, flue 12in. 30 - 60
14 13568 3 Clip, connector 20 - 60
15 13544 2 Plate, flue cover 20
13545 2 Plate, flue cover 30
13546 2 Plate, flue cover 40 - 60
16 10136 Roll Gasket, flue cover plate 20 - 60
17 10023 1 Wrench, tee 20 - 60
18 11952 1 Valve, steam safety 3/4in. 140psi Birket 20 - 30
14187 1 Valve, steam safety 1/2in. 165psi 20 - 30
11953 1 Valve, steam safety 3/4in. 165psi Birkett 40 - 60
19 SA2200 1 Basket, probe 20 - 60
20 10417 1 Probe, water level 20 - 60
11774 1 Probe, water level 20 - 60
10418 1 Probe, water level Spirax only 20 - 60
11541 1 Probe, water level Spirax only 20 - 60
21 SA0001 1 Gauge, pressure assy. 20 - 60
22 10565 2 Tee 20 - 60
23 10655 1 Plug 20 - 60
24 10548 1 Valve DN8 20 - 60
25 10564 1 Syphon, pigtail 20 - 60
26 10566 1 Gauge, pressure 4in. x 250psi 20 - 30
10567 1 Gauge, pressure 6in. x 300psi 40 - 60
27 10002 1 Refractory, furnace Top 20
12038 1 Refractory, furnace Top 30
12149 1 Refractory, furnace Top 40
12039 1 Refractory, furnace Top 50 - 60
28 12041 1 Refractory, furnace Bottom 20 - 30
12148 1 Refractory, furnace Bottom 40
10003 1 Refractory, furnace Bottom 50 - 60
29 12597 2 Body, probe LP30 high not illustrated 40 - 60
30 13033 2 Tip, probe LP30 not illustrated 40 - 60

Note: In order to comply fully with safety regulations it is essential that the correct safety valves are used. If in
any doubt please contact Fulton Service Department for assistance.
J Gas 08 2008
B1-1-1 BURNER ASSEMBLY, GAS, 6 - 15

4
5

18
14

3
11 2
13
12
13

10

15

16
17

J Gas 08 2008 B1-1-1, gas, 6-15, 05 2005

 B1-1-1 BURNER ASSEMBLY, GAS, 6 - 15

Item Part Number Qty Description Remarks Size

1 006EG330 1 Burner, assy, Nat. gas see note 6

006EP330 1 Burner, assy, LP gas see note 6
008EG330 1 Burner, assy, Nat. gas see note 8
008EP330 1 Burner, assy, LP gas see note 8
010EG330 1 Burner, assy, Nat. gas see note 10
010EP330 1 Burner, assy, LP gas see note 10
015EG330 1 Burner, assy, Nat. gas see note 15
015EP330 1 Burner, assy, LP gas see note 15
2 10330 1 Tube, orifice Natural gas 6
10332 1 Tube, orifice Natural gas 8
10334 1 Tube, orifice Natural gas 10
10340 1 Tube, orifice Natural gas 15
10333 1 Tube, orifice L.P.G. 6
10335 1 Tube, orifice L.P.G. 8
10336 1 Tube, orifice L.P.G. 10
10341 1 Tube, orifice L.P.G. 15
3 010EG430 1 Plate, burner 6 - 10
015EG430 1 Plate, burner 15
4 10251 1 Electrode, ignition 6 - 15
5 SA0004 1 Adaptor, sensor not required 6 - 15
SA0031 1 Adaptor, sensor not required 6 - 15
6 14297 1 Detector, UV April 2003 onward 6 - 15
10292 1 Detector, UV up to April 2003 6 - 15
11507 1 Detector, UV up to July 2001 6 - 15
7 10385 1 Casting, top plate 6 - 10
13967 1 Casting, top plate 15
8 SA0025 1 Tube, blast 6 - 15
9 11547 1 Plate, deflector 6 - 15
SA0048 1 Plate, deflector 15
10 SA0005 1 Gas assembly, sec. air 6 - 15
11 10318 1 Spring, retaining 6 - 15
12 10319 1 Glass, eye 6 - 15
13 10977 2 Washer 6 - 15
14 11633 1 Lens 6 - 15
15 10838 1 Nut, dome 6 - 15
16 10839 1 Rod, actuating 6 - 15
17 10843 1 Locknut 6 - 15
18 11662 1 Sensor, adaptor not required 6 - 15

Note: When ordering complete assembly, you must order items 5 and 6 seperatly,
specifying the sensor model.
J Gas 08 2008
B1-2-1 BURNER ASSEMBLY, GAS, 20 - 30
1

5
4

19
18

3
14
2
16
15
16

8
11
12

13
17

10

20

B1-2-1, gas, 20-30

J Gas 08 2008
 B1-2-1 BURNER ASSEMBLY, GAS, 20 - 30

Item Part Number Qty Description Remarks Size

1 020EG330 1 Burner, assy, Nat. gas N/S see note 20

020EP330 1 Burner, assy, LP gas N/S see note 20
030EG330 1 Burner, assy, Nat. gas N/S see note 30
030EP330 1 Burner, assy, LP gas N/S see note 30
2 10342 1 Tube, orifice Natural gas 20
10343 1 Tube, orifice L.P.G. 20
10344 1 Tube, orifice Natural gas 30
10345 1 Tube, orifice L.P.G. 30
3 015EG430 1 Plate, burner 20
030EG430 1 Plate, burner 30
4 10251 1 Electrode, ignition 20 - 30
5 SA0004 1 Adaptor, sensor Satronic 20 - 30
SA0031 1 Adaptor, sensor not used 20 - 30
6 10292 1 Detector, UV up to April 2003 20 - 30
14297 1 Detector, UV April 2003 onward 20 - 30
7 10386 1 Casting, top plate 20 - 30
8 SA0026 1 Tube, blast 20 - 30
9 SA0006 1 Plate, deflector 20 - 30
10 10144 1 Rope, insulation 20 - 30
11 SA0005 1 Gate assembly, sec. air 20 - 30
12 10838 1 Nut, dome 20 - 30
13 10839 1 Rod, actuating 20 - 30
14 10318 1 Spring, retaining 20 - 30
15 10319 1 Eye, glass 20 - 30
16 10977 2 Washer 20 - 30
17 10843 1 Locknut 20 - 30
18 11633 1 Lens 20 - 30
19 11662 1 Sensor, adaptor 20 - 30
20 11131 1 Ring, combustion 20 - 30

Note: When ordering a complete assembly, you must order items 5 and 6
separately specifying the detector model.
J Gas 08 2008
B1-3-1 BURNER ASSEMBLY, GAS, 40 - 60
1

13
19

10

12

18 11

17 12

16

14 15

B1-3-1, gas 40 - 60, 05 2005

J Gas 08 2008
 B1-3-1 BURNER ASSEMBLY, GAS, 40 - 60

Item Part Number Qty Description Remarks Size

1 040EG330 1 Burner, assy, Nat. gas N/S see note 40

040EP330 1 Burner, assy, LP gas N/S see note 40
050EG330 1 Burner, assy, Nat. gas N/S see note 50
050EP330 1 Burner, assy, LP gas N/S see note 50
060EG330 1 Burner, assy, Nat. gas N/S see note 60
060EP330 1 Burner, assy, L.P. gas N/S see note 60
2 12150 1 Tube, orifice Natural gas 40
10344 1 Tube, orifice L.P. gas 40
10346 1 Tube, orifice Natural gas 50
10347 1 Tube, orifice L.P. gas 50
10348 1 Tube, orifice Natural gas 60
10349 1 Tube, orifice L.P. gas 60
3 050EG430 1 Plate, burner 40 - 60
4 10251 1 Electrode, ignition 40 - 60
5 10384 1 Plate, top 40 - 60
6 SA0027 1 Tube, blast 40 - 60
7 SA0007 1 Plate assembly, deflector 40 - 60
8 10328 1 Spinner 40 - 60
9 SA0008 1 Gate assembly 40 - 60
10 10318 1 Spring, retaining 40 - 60
11 10319 1 Eye, glass 40 - 60
12 10977 2 Washer 40 - 60
13 14297 1 Detector, UV 40 - 60
10292 1 Detector, UV up to April 2003 40 - 60
11507 1 Detector, UV up to July 2001 40 - 60
14 11133 1 Ring, combustion stainless steel 40 - 60
15 10144 A/R Rope, insulation 40 - 60
16 10402 1 Damper, control 40 - 60
17 11633 1 Lens 40 - 60
18 11662 1 Detector, adaptor 40 - 60
19 SA0004 1 Adaptor assembly, detector 40 - 60

Note: When ordering a complete assembly, you must order items 13 and 18
separately specifying the detector model.
J Gas 08 2008
B1-4-1 BURNER ASSEMBLY, GAS, 40 - 60, Australian
1

13

19

18

17
3

10

12

11

12

5
8

16

14 15

B1-4-1, gas, 40-60,

J Gas 08 2008
 B1-4-1 BURNER ASSEMBLY, GAS, 40 - 60, Australian

Item Part Number Qty Description Remarks Size

1 040EG330AU 1 Burner, assembly Natural gas 40
050EG330AU 1 Burner, assembly Natural gas 50
060EG330AU 1 Burner, assembly Natural gas 60
2 12150 1 Tube, orifice Natural gas 40
10346 1 Tube, orifice Natural gas 50
10348 1 Tube, orifice Natural gas 60
3 050EG430 1 Plate, burner 40 - 60
4 10251 1 Electrode, ignition 40 - 60
5 10384 1 Plate, top 40 - 60
6 SA0027 1 Tube, blast 40 - 60
7 SA0007 1 Plate assembly, deflector 40 - 60
8 10328 1 Spinner 40 - 60
9 SA0008 1 Gate assembly 40 - 60
10 10318 1 Spring, retaining 40 - 60
11 10319 1 Eye, glass 40 - 60
12 10977 2 Washer 40 - 60
13 11507 1 Sensor, UV Landis 40 - 60
14 11133 1 Ring, combustion stainless steel 40 - 60
15 10144 A/R Rope, insulation 40 - 60
16 10402 1 Damper, control 40 - 60
17 11633 1 Lens 40 - 60
18 11662 1 Sensor, adaptor 40 - 60
19 SA0004 1 Adaptor assembly, sensor 40 - 60

Note: When ordering a complete assembly, you must order items 22 and 34
separately specifying the detector model.
J Gas 08 2008
C1-8-1 GAS TRAIN ASSEMBLY, MONOBLOC, 6 -15

10

C1-8-1, gas, 6-15

J Gas 08 2008
 C1-8-1 GAS TRAIN ASSEMBLY, MONOBLOC, 6 -15

Item Part Number Qty Description Remarks Size

1 006EG350UK 1 Gas Train assembly 6 - 10
006EG350AU 1 Gas Train assembly Australia 6 - 10
020EG350UK 1 Gas Train assembly 15
015EG350AU 1 Gas Train assembly Australia 15
2 13064 1 Valve assembly Superseded 6 - 10
13082 1 Valve assembly MBDLE 407 B01 6 - 10
12022 1 Valve assembly Australia 6 - 10
13065 1 Valve assembly MBDLE 410 B01 15
11536 1 Valve assembly Australia 15
3 10550 1 Valve Superseded 6 - 10
11640 1 Valve DN20 6 - 10
12024 1 Valve Australia 6 - 10
10552 1 Valve Superseded 15
11712 1 Valve 15
14508 1 Valve Australia 15
4 10635 1 Cap 6 - 10
10637 1 Cap 15
5 12136 1 Indicator Australia 6 - 15

J Gas 08 2008
C1-9-1 GAS TRAIN ASSEMBLY, MONOBLOC, 15 - 30

Illustration to follow

J Gas 08 2008
 C1-9-1 GAS TRAIN ASSEMBLY, MONOBLOC, 15 - 30

Item Part Number Qty Description Remarks Size

1 020EG350UK 1 Monobloc assembly 15 - 20
030EG350UK 1 Monobloc assembly 30
015EG350AU 1 Monobloc assembly Australia 15 - 20
030EG350AU 1 Monobloc assembly Australia 30
2 10350 1 Nipple, pressure test 15 - 30
3 11712 1 Valve, ball DN32 15 - 20
11707 1 Valve, ball DN40 30
14508 1 Valve, ball, Auatralia 1 1/4in. 15 - 20
4 13065 1 Valve, gas MBDLE 410 B01 15 - 20
13066 1 Valve, gas MBDLE 412 B01 30
11536 1 Valve, gas, Australia MBDLE 410 B07 15 - 20
5 12136 1 Indicator, valve closed Australia 15 - 20
6 10296 2 Valve, gas, alcon GB4 S not illustrated 30 Aus
7 10302 1 Valve, 1 1/2in. GS4010-2000 not illustrated 30 Aus
8 10303 1 Valve, gas not illustrated 30 Aus
9 10308 1 Governor, 1/2in. not illustrated 30 Aus
10 10315 1 Governor, 1 1/2in. not illustrated 30 Aus
11 10329 1 Tube, pilot orifice, 1/2in. not illustrated 30 Aus

J Gas 08 2008
C1-11-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60
(without pilot gas lines)

Illustration to follow

J Gas 08 2008
 C1-11-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60
(without pilot gas lines)

Item Part Number Qty Description Remarks Size

1 040EG350UK 1 Monobloc assembly 40 - 60
2 10350 2 Nipple, pressure test 40 - 60
3 10639 1 Cap MI 2in. 40 - 60
4 11708 1 Valve, ball DN50, K64808 40 - 60
5 13067 1 Valve, gas MBZRDLE420B01 40 - 60

J Gas 08 2008
C1-12-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60
(with pilot gas lines)

ˇ1

C1-12-1, gas, 40-60, aus, Dec 04

J Gas 08 2008
 C1-12-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60
(with pilot gas lines)

Item Part Number Qty Description Remarks Size

1 040EG350PL 1 Monobloc assembly Standard 40 - 60
040EG350AU 1 Monobloc assembly Australia 40 - 60
040EG351UK 1 Monobloc assembly 110V 40 - 60
2 10296 2 Valve, gas 40 - 60
11014 2 Valve, gas 110V 40 - 60
3 10308 1 Governor 40 - 60
4 11550 1 Valve, ball Australia 40 - 60
11639 1 Valve, ball 40 - 60
5 12136 1 Indicator, valve closed Australia 40 - 60
6 13067 1 Valve, gas 40 - 60
14295 1 Valve, gas 110V 40 - 60
7 14510 1 Valve, ball Australia. 40 - 60
11708 1 Valve, ball 40 - 60
8 14629 1 Switch, pressure, NB50 A2 not illustrated, Australia 40 - 60

J Gas 08 2008
C1-13-1 GAS TRAIN ASSEMBLY, MONOBLOC, 6 - 60, LPG

C1-13-1, gas, 6-60

J Gas 08 2008
 C1-13-1 GAS TRAIN ASSEMBLY, MONOBLOC, 6 - 60, LPG

Item Part Number Qty Description Remarks Size

1 006EP350UK 1 Gas Train assembly 6 - 40

050EP350UK 1 Gas Train assembly 50 - 60
2 13063 1 Valve assembly MBDLE 405 B01 6 - 40
13064 1 Valve assembly MBDLE 407 B01 50 - 60
3 10550 1 Valve Superseded 6 - 60
11640 1 Valve DN20 6 - 60
4 10635 1 Cap 6 - 60

J Gas 08 2008
C1-14-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60,
PROPANE/BUTANE, Australia

7
4

C1-14-1, gas, 40-60

J Gas 08 2008
 C1-14-1 GAS TRAIN ASSEMBLY, MONOBLOC, 40 - 60,
PROPANE/BUTANE, Australia

Item Part Number Qty Description Remarks Size

1 050EP350AU 1 Gas Train assembly 40 - 60
2 13064 1 Valve assembly MBDLE 407 B01 40 - 60
3 12024 1 Valve 40 - 60
4 11550 1 Valve 40 - 60
5 10308 1 Governor 40 - 60
6 10296 2 Valve, gas GB4 S 40 - 60
7 10635 1 Cap 40 - 60
8 12136 1 Indicator 40 - 60

J Gas 08 2008
D1-1-1 BURNER SCROLL ASSEMBLY, GAS, 6 - 10

18
2
14
17
4
15
3

16
13

5 6

12
7
11

8
14

10
9

15
13

D1-1-1, gas, 6-10

J Gas 08 2008
 D1-1-1 BURNER SCROLL ASSEMBLY, GAS, 6 - 10

Item Part Number Qty Description Remarks Size

1 006EG340 1 Scroll assembly 6-8
010EG340 1 Scroll assembly 10
2 10237 1 Transformer, ignition standard 6 - 10
13195 1 Transformer, ignition electronic 6 - 10
3 10241 1 Motor, burner 1ph. 6 - 10
10247 1 Motor, burner 3ph. 6 - 10
4 10270 1 Switch, air 6 - 10
5 10271 1 Fan, burner 6 1/4in. X 1 1/2in. 6-8
10272 1 Fan, burner 10
6 10366 1 Casting, scroll 6 - 10
7 10376 1 Gate, air 6 - 10
8 10379 1 Damper, air 6 - 10
9 10796 4 Bolt 6 - 10
10 10842 4 Washer 6 - 10
11 10850 4 Washer, spring 6 - 10
12 10833 4 Nut 6 - 10
13 10786 8 Bolt 6 - 10
14 10831 3 Washer 6 - 10
15 10849 8 Washer, spring 6 - 10
16 10841 7 Washer 6 - 10
17 10146 A/R Gasket 6 - 10
18 13202 2 Screw 6 - 10

J Gas 08 2008
D1-1-2 BURNER SCROLL ASSEMBLY, GAS, 15

18
2
14
17
4
15
3

16
13

5 6

12
7
11
8
14

10
9

15
13

D1-1-2, gas, 15

J Gas 08 2008
 D1-1-2 BURNER SCROLL ASSEMBLY, GAS, 15

Item Part Number Qty Description Remarks Size

1 015JG340 1 Scroll assembly 15
2 10237 1 Transformer, ignition standard 15
13195 1 Transformer, ignition electronic 15
3 10241 1 Motor, burner 1ph. 15
10247 1 Motor, burner 3ph. 15
4 10270 1 Switch, air 15
5 10274 1 Fan, burner 8 3/8in. x 1 1/2in. 15
6 13963 1 Casting, scroll 15
7 10376 1 Gate, air 15
8 10379 1 Damper, air 15
9 10796 4 Bolt 15
10 10842 4 Washer 15
11 10850 4 Washer, spring 15
12 10833 4 Nut 15
13 10786 6 Bolt 15
14 10831 3 Washer 15
15 10849 6 Washer, spring 15
16 10841 5 Washer 15
17 10146 A/R Gasket 15
18 13202 2 Screw 15

J Gas 08 2008
D1-2-1 BURNER SCROLL ASSEMBLY, GAS, 20 - 30

23
2
14
17
4
15
3

16
13

5 6

12
7
11

8
14

10
9

15
13

D1-2-1, gas, 20-30, dec 04

J Gas 08 2008
 D1-2-1 BURNER SCROLL ASSEMBLY, GAS, 20 - 30

Item Part Number Qty Description Remarks Size

1 020EG340 1 Scroll assembly 20
030EG340 1 Scroll assembly 30
2 10237 1 Transformer, ignition standard 20 - 30
13195 1 Transformer, ignition electronic 20 - 30
3 10242 1 Motor, burner 1ph. 20 - 30
10248 1 Motor, burner 3ph. 20 - 30
4 10270 1 Switch, air 20 - 30
5 10273 1 Fan, burner 7 11/16in. x 1 1/2in. 20
10276 1 Fan, burner 8 3/8in. x 2in. 30
6 10367 1 Casting, scroll 20 - 30
7 10377 1 Gate, air 20 - 30
8 10380 1 Damper, air 20 - 30
9 10796 4 Bolt 20 - 30
10 10842 4 Washer 20 - 30
11 10850 4 Washer, spring 20 - 30
12 10833 4 Nut 20 - 30
13 10786 A/R Bolt 20 - 30
14 10831 3 Washer 20 - 30
15 10849 6 Washer, spring 20 - 30
16 10841 A/R Washer 20 - 30
17 10146 A/R Gasket 20 - 30

J Gas 08 2008
D1-3-1 BURNER SCROLL ASSEMBLY, GAS, 40 - 60

12
13
2
14
12 16
15
3 13

4 14
10

25

Fu
l 33
5

7
23
11 8
6
9 21
19 24

18 22

20
17

D1-3-1, gas, 40-60

J Gas 08 2008
 D1-3-1 BURNER SCROLL ASSEMBLY, GAS, 40 - 60

Item Part Number Qty Description Remarks Size

1 050EG340 1 Scroll assembly 40 - 50
060EG340 1 Scroll assembly 60
060EG340 1 Scroll assembly 110V 40 - 60
2 10237 1 Transformer, ignition Superseded 40 - 60
13195 1 Transformer, ignition TRK2P COFI 40 - 60
10238 1 Transformer, ignition 110V 40 - 60
3 050E9451 1 Motor, burner 40 - 60
11975 1 Motor, burner 3ph. 40 - 60
4 11643 1 Switch, air 40 - 60
5 10278 1 Fan, burner 9 3/16in. x 2 1/2in. 40 - 50
10277 1 Fan, burner 10in. x 2 1/2in. 60
6 10368 1 Casting, scroll 40 - 60
7 SA0010 1 Mesh, gate, air 40 - 60
8 11897 1 Damper, air Superseded 40 - 60
10375 1 Damper, air Nov 2001 40 - 60
9 10371 1 Gate, air 40 - 60
10 11835 4 Screw 40 - 60
11 11147 1 Wingnut 40 - 60
12 10786 4 Bolt 40 - 60
13 10849 4 Washer, spring 40 - 60
14 10841 4 Washer 40 - 60
15 10831 2 Washer 40 - 60
16 10146 A/R Gasket 40 - 60
17 10796 1 Bolt 40 - 60
18 10850 1 Washer, spring 40 - 60
19 10842 1 Washer 40 - 60
20 11419 4 Screw, countersunk 40 - 60
21 11418 4 Washer, serrated 40 - 60
22 10844 4 Washer 40 - 60
23 10851 4 Washer, spring 40 - 60
24 10800 4 Locknut 40 - 60
25 11687 1 Box, electric 40 - 60
26 10350 A/R Nipple, pressure test 40 - 60

J Gas 08 2008
D1-4-1 BURNER SCROLL ASSEMBLY, GAS, 60
High / Low

Illustration to follow

J Gas 08 2008
 D1-4-1 BURNER SCROLL ASSEMBLY, GAS, 60
High / Low
Item Part Number Qty Description Remarks Size
1 060EG340HL 1 Scroll assembly 60
2 10275 1 Fan 9 15/16 x 1 1/2in. 60
3 10350 1 Nipple, pressure test 60
4 10368 1 Casting, scroll 50/60HP 60
5 11643 1 Switch, pressure GW10A6 60
6 11975 1 Motor 1.5kW 60
7 13195 1 Transformer TRK2P 60
8 14440 1 Scoop, fan 10in. 60
9 14485 1 Damper, motor A30 045Y 60
10 14489 1 Coupling, air gate 60
11 14520 1 Gate, air 60 

J Gas 08 2008
D2-5-1 BURNER SCROLL ASSEMBLY, DUAL FUEL, 40 - 60

5 3 2

8 4 7 14
9

11

6
12

10

13

15

16

18

17

18

18

D2-5-1, DF, 40-60, dec 04

J Gas 08 2008
 D2-5-1 BURNER SCROLL ASSEMBLY, DUAL FUEL, 40 - 60

Item Part Number Qty Description Remarks Size

1 050ED340 1 Scroll assembly 40 - 60
060ED340 1 Scroll assembly 40 - 60
2 10237 1 Transformer, ignition, gas up to June 2004 40 - 60
13195 1 Transformer, ignition, gas June 2004 onward 40 - 60
3 13521 1 Transformer, ignition, oil up to June 2004 40 - 60
10239 1 Transformer, ignition, oil June 2004 onward 40 - 60
4 11975 1 Motor, burner 1.5kW 40 - 60
5 11643 1 Switch, air pressure 40 - 60
6 10755 1 Box, electric 40 - 60
7 11687 1 Box, electric 40 - 60
8 10279 1 Fan, burner up to June 2004 40 - 60
10277 1 Fan, burner, 10 x 2 1/2in. June 2004 onward 50
10279 1 Fan, burner, 10 x 3in. June 2004 onward 60
9 SA0010 1 Mash, air gate 40 - 60
10 11897 1 Damper, air 40 - 60
11 10371 1 Gate, air 40 - 60
12 10350 1 Nipple, pressure test 40 - 60
13 10368 1 Burner, scroll 40 - 60
14 10146 A/R Gasket 40 - 60
15 10282 1 Spider 40 - 60
16 10281 1 Coupling 40 - 60
17 10268 1 Pump, oil 40 - 60
18 10286 3 Valve, oil 40 - 60
19 11038 1 Terminal 40 - 60
20 11039 1 Cover, terminal 40 - 60

J Gas 08 2008
E1-3-1 WATER COLUMN, 6 - 60, Australian

E1-3-1, water col, aus

J Gas 08 2008
 E1-3-1 WATER COLUMN, 6 - 60, Australian

Item Part Number Qty Description Remarks Size

1 14067 1 Casting, water column 6 - 60
2 SA0017 1 Valve, 3way with handle 6 - 60
3 11517 1 Plate, indicator 6 - 60
4 10542 1 Valve, column blowdown 6 - 60
5 11541 1 Probe, pump on 6 - 60
6 14133 1 Plug 6 - 60
7 10418 1 Probe, pump off 6 - 60
8 10729 1 Connector, conduit 6 - 60
9 099E9370 1 Basket 6 - 60
10 10250 A/R Shroud Rajah 6 - 60
11 11523 4 Flange 6 - 60
12 11522 2 Gasket 6 - 60

J Gas 08 2008
E1-6-1 WATER COLUMN, 6 - 60

3
1

E1-6-1 12 2004

J Gas 08 2008
 E1-6-1 WATER COLUMN, 6 - 60

Item Part Number Qty Description Remarks Size

1 14067 1 Casting, water column 6 - 60
2 11541 1 Probe, pump on 6 - 60
3 10418 1 Probe pump off 6 - 60
5 11640 1 Valve, ball superseded 6 - 60
11524 1 Valve, ball, DN20 6 - 60
6 099E9370 1 Basket 6 - 60

J Gas 08 2008
F1-4-1 WATER LEVEL GAUGE ASSEMBLY
350mm and 300mm (Clifton) 6 - 60

J Gas 08 2008
 F1-4-1 WATER LEVEL GAUGE ASSEMBLY
350mm and 300mm (Clifton) 6 - 60
Item Part Number Qty Description Remarks Size
1 12444 A/R Gauge, water level assy 350mm centres 6 - 60
12207 A/R Gauge, water level assy 300mm centres 6 - 60
2 12199 2 Valve, LH 300 & 350 6 - 60
12377 2 Valve, RH 300 & 350 6 - 60
3 12210 1 Valve, blowdown 300 & 350 6 - 60
4 10621 1 Bush 300 & 350 6 - 60
5 11895 1 Glass 350 6 - 60
12200 1 Glass 300 6 - 60
6 11893 2 Gasket 350 6 - 60
12201 2 Gasket 300 6 - 60
7 12208 10 Bolt 300 & 350 6 - 60
8 10850 10 Washer, spring 300 & 350 6 - 60
9 10842 10 Washer 300 & 350 6 - 60
10 12227 3 Plug 300 & 350 6 - 60

J Gas 08 2008
G1-1-1 CONTROL BOX ASSEMBLY, GAS 6 - 30
1

34 27 29 28 9 28 27 28 8

12

20
21

3
7
5

4 10
11
18 (6 - 15J)
33 (20 - 30J)

17 (6 - 15J)
18 (20 - 30J) 14
15

13

16

19
24 23

30

22
25

26 31
32
(3 phase control box illustrated)

J Gas 08 2008
 G1-1-1 CONTROL BOX ASSEMBLY, GAS 6 - 30

Item Part Number Qty Description Remarks Size

1 006EG324UK 1 Control Box assy (3 phase) 240V/3/50 6 - 30
006EG322UK 1 Control Box assy (1 phase) 400V/1/50 6 - 30
2 10448 1 Switch, isolator 25A 6 - 30
3 10486 1 Control, satronic TMG 6 - 30
4 10496 2 Contactor, CI 9 220 - 240V 6 - 30
5 10507 2 Contactor block n/open 6 - 30
6 11327 1 Switch, single pole 6 - 30
7 11344 1 Base, control S-720G 6 - 30
8 11527 1 Switch, rocker red 6 - 30
9 11587 1 Switch, rocker black 6 - 30
10 11596 3 Relay, miniture 4 pole 6 - 30
11 11597 3 Base, miniture relay 4 pole 6 - 30
12 11688 1 Facia 6 - 30
13 11737 2 CTI aux. contact CBA 10 6 - 30
14 11869 3 Relay LC3 240V 6 - 30
15 11904 3 Base LC relay 11 pin 6 - 30
16 11940 1 Busbar for CTI trip 6 - 30
17 11941 1 Breaker, circuit 1.0 - 1.6A 6 - 15
18 11942 1 Breaker, circuit 1.6 - 2.5A 6 - 30
19 12016 1 Handle, switch IP65 red 6 - 30
20 12854 4 Fuse, 2A 6 - 30
21 12855 4 Holder, fuse 6 - 30
22 13380 1 Alarm, audible continuous 6 - 30
23 13381 1 Alarm, audible pulsating 6 - 30
24 13560 1 Shaft, extension 180mm 6 - 30
25 14215 1 Control, pressure 4 - 12 bar 6 - 30
26 14330 3 Holder, fuse deleted june 06 6 - 30
27 14332 2 Lamp, indicator red 6 - 30
28 14333 3 Lamp, indicator amber 6 - 30
29 14334 1 Lamp, indicator green 6 - 30
30 14335 1 Cover, top pressure control 6 - 30
31 14367 1 Transformer 250VA Siemens 6 - 30
32 14368 3 Fuse, 1A cartridge superseded june 06 6 - 30
14806 3 MCB, 2A june 06 onward 6 - 30
33 11943 1 Breaker, circuit 2.5 - 4.0A 20 - 30
34 11526 1 Switch, rocker amber 6 - 30

J Gas 08 2008
G1-3-1 CONTROL BOX ASSEMBLY, GAS 40 - 60
(standard control box illustrated)

9 28 27 29 11 10

20
21

3
8

4
12
26 13
32
18

15
30 16
25

14
17

2
23
19
24

30
22

25

31

J Gas 08 2008
 G1-3-1 CONTROL BOX ASSEMBLY, GAS 40 - 60
(standard and 110V with spirax level controls)

Item Part Number Qty Description Remarks Size

1 050EG324UK 1 Control Box assy 400V/3/50 40 - 60
040EG321SX 1 Control Box assy 110V/3/50 40 - 60
2 10448 1 Switch, isolator 25A 40 - 60
3 10486 1 Control, TMG Satronic 40 - 60
11339 1 Control, TMG Satronic, 110V 40 - 60
4 10496 2 Contactor CI 9 220 - 240V 40 - 60
13672 2 Contactor LC1-DO9F7 110V 40 - 60
5 10507 2 Contactor, block n/open 40 - 60
6 10921 1 Facia 40 - 60
7 11327 1 Switch, single pole 40 - 60
8 11344 1 Base, control 40 - 60
9 11526 1 Switch, rocker amber 40 - 60
10 11527 1 Switch, rocker red 40 - 60
11 11587 1 Switch, rocker black 40 - 60
12 11596 A/R Relay, miniture 4 pole 40 - 60
12151 A/R Relay, miniture 4 pole, 110V 40 - 60
13 11597 A/R Base, miniture realy 4 pole 40 - 60
14 11737 2 CTI aux, contact CBA-10 40 - 60
15 11869 A/R Relay LC3 240V 40 - 60
10469 A/R Relay, spirax 110V 40 - 60
16 11904 3 Base, LC relay 11 pin 40 - 60
17 11940 1 Busbar 40 - 60
18 11943 2 Breaker, circuit 2.5 - 4.0A 40 - 60
19 12016 1 Switch, handle IP65 red 40 - 60
20 12854 4 Fuse, 2A 40 - 60
21 12855 4 Holder, fuse 40 - 60
22 13380 1 Alarm, audible continuous 40 - 60
23 13381 1 Alarm, audible pulsating 40 - 60
24 13560 1 Shaft, extension 180mm 40 - 60
25 14215 2 Control, pressure 4 - 12 bar 40 - 60
14215 1 Control, pressure set-back only fitted with sequence control
26 14330 3 Holder, fuse deleted, june 06 40 - 60
27 14332 2 Lamp, indicator red 40 - 60
13102 2 Lamp, indicator red, 110V 40 - 60
28 14333 5 Lamp, indicator amber 40 - 60
13101 5 Lamp, indicator amber, 110V 40 - 60
29 14334 1 Lamp, indicator green 40 - 60
13103 1 Lamp, indicator green 40 - 60
30 14335 2 Cover, top pressure control 40 - 60
31 14367 1 Transformer 250VA Siemens 40 - 60
32 14368 3 Fuse, 1A cartridge superseded june 06 40 - 60
14806 3 MCB, 2A june 06 onward 40 - 60
33 13120 2 Controller, LC3000 110V, not illustrated 40 - 60

J Gas 08 2008
G1-5-1 CONTROL BOX ASSEMBLY, GAS 6 - 15
Australian

10 32 12 31 11

6 5

30
22
23

7
7

8
9

4
16
20 17
19

15

18
13
14
2

25
26

33 24

21

29

27
28

J Gas 08 2008
 G1-5-1 CONTROL BOX ASSEMBLY, GAS 6 - 15
Australian
Item Part Number Qty Description Remarks Size
1 006EG324AU 1 Control Box assy 400V/3/50 6 - 15
2 10448 1 Switch, isolator 25A 6 - 15
3 10496 2 Contactor, CI 9 220 - 240V 6 - 15
4 10507 2 Contactor, block n / open 6 - 15
5 10575 1 Bell, 4in. 200/250V 50/60Hz 6 - 15
6 10920 1 Facia 6 - 15
7 11327 2 Switch, single pole 6 - 15
8 11506 1 Control, burner Landis 6 - 15
9 11511 1 Base, burner control 6 - 15
10 11526 1 Switch, rocker amber 6 - 15
11 11527 1 Switch, rocker red 6 - 15
12 11587 1 Switch, rocker black 6 - 15
13 11596 3 Relay, miniture 4 pole 6 - 15
14 11597 3 Base, miniture relay 4 pole 6 - 15
15 11737 2 Contact, aux CBA-10 6 - 15
16 11869 3 Relay, LC3 240V 6 - 15
17 11904 3 Base, relay LC 11 pin 6 - 15
18 11940 1 Busbar BBC25 6 - 15
19 11941 1 Breaker, circuit 1.0 - 1.6A 6 - 15
20 11943 1 Breaker, circuit 2.5 - 4.0A 6 - 15
21 12016 1 Handle, switch IP65 red 6 - 15
22 12854 5 Fuse, 2A 6 - 15
23 12855 5 Holder, fuse 6 - 15
24 13380 1 Alarm, audible continuous 6 - 15
25 13381 1 Alarm, audible pulsating 6 - 15
26 13560 1 Shaft, extension 180mm 6 - 15
27 14368 1 Fuse, 1A superseded june 06 6 - 15
14806 1 MCB, 2A june 06, onward 6 - 15
28 14330 1 Holder, fuse deleted june 06 6 - 15
29 14215 1 Control, pressure 4 - 12 bar 6 - 15
30 14332 2 Lamp, indicator red 6 - 15
31 14333 5 Lamp, indicator amber 6 - 15
32 14334 1 Lamp, indicator green 6 - 15
33 14335 1 Cover, top pressure control 6 - 15

J Gas 08 2008
G1-6-1 CONTROL BOX ASSEMBLY, GAS 20 - 30
Australian
1

9 31 30 11 10

5 4

29

6 6

7
8
21
22

3
15
16
18
19

14

17

25 24

23
32

20

28

26 12
27 13

J Gas 08 2008
 G1-6-1 CONTROL BOX ASSEMBLY, GAS 20 - 30
Australian
Item Part Number Qty Description Remarks Size
1 020EG324AU 1 Control Box assy 400V/3/50 20 - 30
2 10448 1 Switch, isolator 25A 20 - 30
3 10496 2 Contactor, CI 9 220 - 240V 20 - 30
4 10575 1 Bell, 4in. 200 / 250V, 50/60Hz 20 - 30
5 10920 1 Facia 20 - 30
6 11327 2 Switch, single pole 20 - 30
7 11506 1 Control, burner Landis 20 - 30
8 11511 1 Base, burner control Landis 20 - 30
9 11526 1 Switch, rocker amber 20 - 30
10 11527 1 Switch, rocker red 20 - 30
11 11587 1 Switch, rocker black 20 - 30
12 11596 3 Relay, miniture 4 pole 20 - 30
13 11597 3 Base, miniture relay 4 pole 20 - 30
14 11737 2 Contact, aux. CBA - 10 20 - 30
15 11869 3 Relay, LC3 240V 20 - 30
16 11904 3 Base, LC relay 11 pin 20 - 30
17 11940 1 Busbar BBC25 20 - 30
18 11942 1 Breaker, circuit 1.6 - 2.5A 20 - 30
19 11943 1 Breaker, circuit 2.5 - 4.0A 20 - 30
20 12016 1 Switch, handle, IP65 red 20 - 30
21 12854 5 Fuse, 2A 20 - 30
22 12855 5 Holder, fuse 20 - 30
23 13380 1 Alarm, audible continuous 20 - 30
24 13381 1 Alarm, audible pulsating 20 - 30
25 13560 1 Shaft, extension 180mm 20 - 30
26 14330 1 Holder, fuse deleted june 06 20 - 30
27 14368 1 Fuse, 1A superseded june 06 20 - 30
14806 1 MCB 2A june 06 onward 20 - 30
28 14215 1 Control, pressure 4 - 12 bar 20 - 30
29 14332 2 Lamp, indicator red 20 - 30
30 14333 5 Lamp, indicator amber 20 - 30
31 14334 1 Lamp, indicator green 20 - 30
32 14335 1 Cover, top pressure control 20 - 30

J Gas 08 2008
G1-7-1 CONTROL BOX ASSEMBLY, GAS, 40 - 60
Australian

10 31 12 30 11

6 5

29

21
22 7

4 8
9
3

18
20 16
17

2
25 24

32

23

19

28 15 26 13
27 14

J Gas 08 2008
 G1-7-1 CONTROL BOX ASSEMBLY, GAS, 40 - 60
Australian
Item Part Number Qty Description Remarks Size
1 050EG324AU 1 Control, box 40 - 60
2 10448 1 Switch, isolator 40 - 60
3 10496 2 Contactor, CI9 220 240V 40 - 60
4 10507 2 Block, contactor n / open 40 - 60
5 10575 1 Bell, 4in. 200 / 240V 40 - 60
6 10921 1 Facia 40 - 60
7 11327 2 Switch, single pole 40 - 60
8 11506 1 Control, burner Landis 40 - 60
9 11511 1 Base, control Landis 40 - 60
10 11526 1 Switch, rocker amber 40 - 60
11 11527 1 Switch, rocker red 40 - 60
12 11587 1 Switch, rocker black 40 - 60
13 11596 3 Relay, miniture 4 pole 40 - 60
14 11597 3 base, miniture relay 4 pole 40 - 60
15 11737 2 Contact, aux. CBA-10 40 - 60
16 11869 3 Relay, LC3 40 - 60
17 11904 3 Base, relay 11 pin 40 - 60
18 11943 1 Breaker, circuit 2.5 - 4.0A 40 - 60
19 12016 1 Switch, handle IP65 red 40 - 60
20 12019 1 Breaker, circuit 4.0 - 6.3A 40 - 60
21 12854 5 Fuse, 2A 40 - 60
22 12855 5 Holder, fuse 40 - 60
23 13380 1 Alarm, audible continuous 40 - 60
24 13381 1 Alarm, audible pulsating 40 - 60
25 13560 1 Shaft, extension 180mm 40 - 60
26 14330 1 Holder, fuse deleted june 06 40 - 60
27 14368 1 Fuse, 1A superseded june 06 40 - 60
14806 1 MCB, 2A june 06 onward 40 - 60
28 14215 2 Control, pressure 4 - 12 bar 40 - 60
12510 2 Control, pressure, EP16 200 psi 40 - 60
29 14332 2 Lamp, indicator red 40 - 60
30 14333 7 Lamp, indicator amber 40 - 60
31 14334 1 Lamp, indicator green 40 - 60
32 14335 2 Cover, pressure control KPI36 40 - 60

J Gas 08 2008
H1-1-1 PUMP, FEED WATER

J Gas 08 2008
 H1-1-1 PUMP, FEED WATER

Item Part Number Qty Description Remarks Size

1 14284 1 Pump CR1s-17 125 psi, 8.6 bar 6 - 15

14285 1 Pump CR1s-23 125 psi, 8.6 bar 20 - 30

14285 1 Pump CR1s-23 150 psi, 10.34 bar 6 - 20

14286 1 Pump CR1s-27 150 psi, 10.34 bar 30 - 40

14288 1 Pump CR1-23 150 psi, 10.34 bar 50 - 60

14287 1 Pump CR1s-17 125 psi, 8.6 bar 6 - 15

14289 1 Pump CR1s-21 125 psi, 8.6 bar 20 - 30

14289 1 Pump CR1s-21 150 psi, 10.34 bar 6 - 20

14296 1 Pump CR1s-27 150 psi, 10.34 bar 30 - 40

14292 1 Pump CR1-23 150 psi, 10.34 bar 50 - 60

J Gas 08 2008
J Gas 08 2008
 Material & Workmanship Warranty

5 Year
Warranty
On the Fulton Boiler Pressure Vessel

Fulton Boiler Works (Great Britain) Ltd. will repair or replace FoB factory any Fulton pressure
vessel which within five (5) years of the date of delivery is found to be defective in workmanship,
or material, provided this equipment is operated and maintained by the buyer for the purpose
for which it was designed and in accordance with the Manufacturer’s Handbook. 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 Boiler Works, (Great Britain) Ltd.

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

J Gas 08 2008
 Fulton

Fulton Boiler Works (Great Britain) Ltd.

Broomhill Road
Bristol BS4 4TU
England
Telephone 0117 9772563, 9723322
Fax: 0117 9723358
'e'-mail: uk-info@fulton.com
Web site: www.fulton.com FM 28400