FULTON 60E Guide

OPERATOR,SERVICE
& PARTS MANUAL
Fulton Boiler Works (Great Britain) Ltd.
R
GFSE-Std-0202
SERIES 'E' - GAS FIRED
STEAM BOILERS (6E - 60E)

GFSE-Std-0499
WARNING
Steam Boilers are a potential hazard possibly
fatal if not properly maintained.
CAUTION
It is vitally important that the instructions given
in this manual are strictly adhered to.
Failure to carry out the daily, weekly, monthly and six monthly checks
could result in a drastic reduction in the life expectancy of the boiler.
NOTE
ThePressuresystemandTransportableGasContainersRegulations1989
Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme and
Section 40 of the Health and Safety at Work Act, 1974.
Regularinspectionsarethereforerequiredbya'CompetentPerson'atintervalsnotexceeding
14months.
The scope of the examination and the actual intervals between examinations is at the
discretionofthecompetentperson.
Itistheresponsibilityoftheusertoprovideawrittenschemeofexaminationforthoseparts
of the system in which a defect may give rise to danger.
Instructionsinthismanualareprovidedforthesafeoperationandmaintenanceoftheboiler
anddo not coverperiodic statutory inspections.
Forfurtherinformationcontact:-
(a) SAFed
SAFETYASSESSMENTFEDERATIONLimited.
NutmegHouse,
60GainsfordStreet,
ButlersWharf,
London,SE12NY
(b) HealthandSafetyExecutivelocaloffice.
(c) Yourinsurancecompany/broker

GFSE-Std-0499
LIST OF CONTENTS
TITLE SECTION
INTRODUCTION 1
General 1.1
Technical Data 1.2
INSTALLATION 2
General 2.1
Siting 2.2
Ventilation 2.3
Flue Outlet 2.4
Water Supply 2.5
BlowdownValves 2.6
Main Steam Valve 2.7
Steam Safety Valves 2.8
Water Gauge Set 2.9
Gas Supply 2.10
Electrical Requirements 2.11
Steam Pressure Gauge 2.12
Plumbing 2.15
Commissioning the Boiler 2.16
Cleaning the Steam Lines and Pressure Vessel 2.17
L.P. Supplement - Gas Supply - Propane/Butane 2.18
OPERATION 3
General 3.1
Boiler Controls 3.2
Control Panel - Indicator Lights 3.3
Filling the Boiler - All Models 3.4
Starting the Burner - All Models 3.5
Daily Checks 3.6
Pump Check 3.6.1
1st. Low Water Check 3.6.4
Overiding Low Water Check 3.6.5
BlowdownProcedures 3.7
Evaporation Checks 3.8
MAINTENANCE 4
General 4.1
Weekly 4.2
Monthly 4.3
Three Monthly 4.4
Six Monthly 4.5
GENERALDATA 5
SPAREPARTS 6

GFSE-Std-0499
SAFETY
TheinstructionsprovidedfortheoperationandmaintenanceoftheboilerMUSTbeobserved.
Failure to do so could result in damage to the boiler and serious personal injury.
WARNING
Do not try to do repairs or any other maintenance
workyoudonotunderstand.ObtainaServiceManual
from Fulton or call a Fulton Service Engineer
WARNING
It is the responsibility of the installer to ensure all
partssuppliedwiththeboilerarefittedinacorrectand
safemanner.
WARNING
Understandtheelectricalcircuitbeforeconnectingor
disconnecting an electrical component. A wrong
connection can cause injury and or damage.
WARNING
A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing
parts.Makesurethatallmaintenanceproceduresare
completedbeforeusingtheboiler.
CAUTION
Obey all laws and local regulations which affect you
andyourboiler.
WARNING
Do not changetheboilerfuel without consulting the
boilermanufacturer.
WARNING
Youcanbeinjuredifyouusefaultyliftingequipment.
Makesuretheliftingequipmentisingoodcondition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job
WARNING
Operating the boiler beyond its design limits can
damage the boiler, it can also be dangerous. Do not
operate the boiler outside its limits. Do not try to up
gradetheboilerperformancebyunapprovedmodifica-
tions.
WARNING
Non-approved modifications can cause injury and
damage.ContactyourFultondealerbeforemodifying
theboiler.
WARNING
Only qualified persons should be allowed to
operate and maintain the boiler and its equip-
ment. Boilers should always be drained through an
approvedBlowdownVessel.
WARNING
Theinstallation of Gas appliances including the flue
system should only be carried out by Corgi Regis-
teredengineers.
CAUTION
HYDRAULICTEST-RISKOFBRITTLEFRACTURE
Hydraulictesting requires specialistequipment and
isnormallyonlyrequiredbyengineeringsurveyors/
inspectors.The material the boiler is manufactured
from, has not been impact tested, as it is not a
requirement of BS2790 (boiler construction stand-
ard).Inordertoensurethematerial/pressurevessel
doesnotsufferfrombrittlefracture,hydraulictesting
should not be carried out below 5OC.
WARNING
DANGERFROMHOTSURFACES
SteamBoilershavehightemperaturesurfaces,thatif
touched may cause serious burns. Only competant
and qualified personnel should work on or in the
locality of a steam boiler and ancillary equipment.
Alwaysensuretheworkingareaandfloorareclearof
potential hazards, work slowly and methodically.
WARNING
DANGERFROMINCOMPLETECOMBUSTION
Theimportanceofcorrectburneradjustmenttoachive
low emissions, safe, clean and efficient combustion
is paramount. Poor combustion, where unburnt gas
formscarbonmonoxideisbotha health hazard, and
the potential risk to the boiler from overheating,
caused by re-burning of the unburnt gas in the
secondaryfluepasses.
WARNING
Theimportanceofcorrectboilerwaterandfeedwater
cannotbeoveremphasised,seetherelevantsection
in this manual.
CAUTION
LOWFEEDWATERTEMPERATURE
Low feed water temperature can result in thermal
shocktotheboilerpressurevessel.Returnthemaxi-
mum amount of condensate and if necessary pre-
heat the feed water. If in doubt consult FBW.

GFSE-Std-0499
TITLE FIG. NO.
Gas Fired Steam Boiler 1
General Arrangement 2
Typical Installation 3
Typical Flue Connection 3A
Water Gauge Set 4
Steam Pressure Gauge 5
Burner Electrode Settings 6
Commissioning the Boiler 7
MonoblocGasValve 9
L.P. Gas Train 10
Boiler Operation 11
Control Panel 6E/30E 12
Control Panel 40E/60E 13
Water Gauge Blowdown Sequence 14 & 14A
Fault Finding Check List 15
Boiler Maintenance 16
Handhole Assembly 17
Burner Assembly 18
Flue Cleaning 19
Boiler Dimensions 20
Level Controller - Type LC1 21
SPAREPARTS
See index in Spare Parts Section

GFSE-Std-0499
FIG.1 GAS FIRED STEAM BOILER
1 1
1

GFSE-Std-0499
1
INTRODUCTION
SECTION 1
1.1 General (Fig. 1)
TheFultonSeriesEGasFiredSteam Boiler is a vertical two passboilerofsimpleandefficientdesign
and construction. Every care has been taken in the manufacture of the boiler to ensure that quality
and reliability standards are maintained. However, satisfactory performance can only be ensured if
the installation recommendations, operating routines and maintenance schedules laid out in this
manual are adhered to.
For Propane Boilers read Section 2.19 before proceeding.
1.2 Technical Data
BOILER MODEL
6E 8E 10E 15E 20E 30E 40E 50E 60E
Performance
lb/h (F & A 100oC) 210 280 350 525 700 1050 1400 1750 2100
kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960
Firing Rates
Approx. BTU input [phone] 424 637 849 1273 1360 2121 2546
Natural Gas 1035 BTU
cu.ft./h 246 328 410 615 820 1230 1700 2050 2461
cu.m/h 7 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6
Electrical Requirements
FLC (400V, 3ph, 50Hz) amps 4.7 4.7 4.7 4.7 4.9 4.9 6.9 6.9 8.6
FLC (230V, 1ph, 50Hz) amps 12.7 12.7 12.7 12.7 14.9 14.9 19.3 19.3 19.3
The full load current (flc) of the feed water pump motor can vary with the type and duty
requirements of the pump supplied. The figures quoted above are given as a guide only.
Miscellaneous
Water Content (Imp Gal) 13 15 20 33 64 141 204 204 223
Water Content (Litres) 59 68 91 150 291 640 927 927 1022
Approx. Net Weight (lb) 1540 1590 1785 2130 3135 4480 6728 6728 6944
Approx. Net Weight (kg) 700 720 810 965 1420 2030 3050 3050 3150
Nat. Gas Head
Pipe Size (in.) 1 1 1 1.25 1.25 1.5 2 2 2
Required Vertical 2060 2160 2210 2365 2440 2745 2845 2845 3000
Clearance (mm)
(Floor to Ceiling)
2

GFSE-Std-0499
FIG. 2 GENERAL ARRANGEMENT
2 2
3
MODULAR
GAS UNIT PRESSURE
TEST POINT
MAIN STEAM
VALVE
STEAM SAFETY
VALVE
WATER LEVEL
PROBES
AIR SAFETY
SWITCH
BLOWER
HOUSING
BURNER
MOTOR
WATER
COLUMN
STEAM
PRESSURE
GAUGE
SCALE
TRAP
CHECK
VALVE
STOP
VALVE
WATER
GAUGE
CONTROL
PANEL
COLUMN
BLOWDOWN
VALVE
PRESSURE
CONTROL
HAND HOLE
CLEAN OUT
DOOR
MAIN
BLOWDOWN
VALVE

GFSE-Std-0499
2 2
INSTALLATION
SECTION 2
2.1 GENERAL (Figs. 2 and 3)
The installation of a Series E Gas Fired Steam Boiler should be carried out by competent personnel in
accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these
regulations are complied with.
The requirements and instructions contained in this Section generally relate to the boilers being installed
to operate on natural or manufactured gas. Where the boiler is to operate on L.P. Gas, special reference
should be made to Section 2.10 - Gas Supply, and Section 2.18 L.P. Gas Supply.
2.2 SITING
The boiler house should be sufficiently large to allow easy and safe access to all parts of the boiler for
operational and maintenance purposes. Reference should be made to Section 5 - General Data to
ascertain the relevant dimensions and special note taken of the required vertical clearance.
The flooring must be level, laid in a non-combustible material and be of sufficient strength to support the
boiler.
2.3 VENTILATION
Adequate fresh, clean air is necessary for safe and efficient combustion, and should be provided at high
and low level in accordance with BS 6644 1991.
Note:
(a) Ensure there is adequate ventilation in the boiler room. Lack of ventilation will create a high
temperature and cause control lockout.
(b) Do not keep exhaust fans running with windows, doors and vents closed, this will interfere
with the necessary boiler draught.
(c) Do not store chemicals such as perclorethylene in the boiler house, the fumes may damage
the boiler and flue and cause the burner to lock out on flame failure.
4
Boiler Model 6E 8E 10E 15E 20E 30E 40E 50E 60E
HighLevel(cm2) 305 360 420 560 700 980 1260 1540 1820
LowLevel(cm2) 610 720 835 1115 1395 1960 2520 3085 3645

GFSE-Std-0499
2 2
5
F01762
STEAMSUPPLY
PIPE SAFETY VALVE
TO SAFE AREA,
FITTING
UNIONSANDDRAIN
DRAFTSTABILISER
(WHEREFITTED)
CLEAN-OUT
DOOR
STOP
VALVE CHECKVALVE
MAINBLOWDOWN
VALVE
WATER
COLUMN
BLOWDOWN
VALVE
FEEDPUMP
STRAINER ISOLATING
VALVE PLUGGED
DRAIN
BLOWDOWN
SEPERATOR
STAINLESS
STEEL
FEEDWATER
TANK
OVERFLOW
FIG. 3 TYPICAL INSTALLATION
MAKE-UPSUPPLY
CONDENSATE
RETURN
STANDARDBOILER
TRIMSUPPLIED
NOTE: A BREAK TANK MAY
BEREQUIRED-CHECK
THELOCALWATER
AUTHORITYBYE-LAWS

GFSE-Std-0499
2 2
2.4 FLUE OUTLET
The boiler is supplied with a stainless steel flue spigot that should be inserted into the flue outlet in the
back of the boiler and secured with the three angle clips supplied loose in the trim box (see fig. 3A).
The height and type of flue will generally be subject to local planning regulations and approvals. The
following information is intended to provide assistance where the installation of a simple flue is required.
Where multi-boiler flues or difficulties are experienced, specialist advice should be obtained.
The flue diameter must be the same or larger than the flue flange provided with the boiler and the outlet
should be at least 2ft (610 mm) higher than the nearest ridge to avoid down draughts. Where a chimney
cowl is fitted, care should be taken to ensure that the cross sectional area of the outlet is equal to at least
1.5 times the cross sectional area of the flue, and that it is of the terminal cone type.
Note:(a) If the flue layout is such that it may produce an excessive up-draught, a draught stabiliser
may be required.
(b) Avoidfitting90deg.elbowswheneverpossible,ifunavoidablecompensatebyincreasingthe
flue diameter.
(c) Ensureallpipeworkfromtheboiler tothemainfluehasarisingpitchofnot lessthan15deg.
2.5 WATER SUPPLY
The quality of the water used in the boiler will affect the life and performance of the boiler. It is strongly
recommended that a reputable water treatment concern is consulted prior to commissioning the boiler.
The following water conditions represent those which are considered essential in the boiler.
Total hardness of feedwater in terms of CaCo3(mg/L) Max 2.
Causticalkalinity of boiler water in terms of CaCo3(mg/L) 300 ppm max.
Total dissolved solids in boiler water (mg/L) 2000 ppm max.
pHvalueofboilerwater 9.5 to 11.5
Connect the feed water pump to the boiler with 1in. bore pipe and insert the stop valve and check valve
supplied. It is essential to protect the feedwater pump from damage by foreign matter. A strainer should
therefore be inserted in the pump suction pipework.
Note: 1. Theboilerfeedwaterpumpmaycontainaninhibitorandthisshouldbeflushedfromthepump
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. Iftheboileristobeoperatedwithlittleornocondensatereturn,considerationshouldbegiven
to pre-heating the feedwater. If in doubt consult Fulton Boiler Works.
3. TheFeedwater inlet connectionon some boilers is located on the left hand side of the boiler
below the sight glass assembly.
2.6 BLOWDOWN VALVES
There are three blowdown valves on the boiler (four if two water gauge sets are fitted), the main valve at
therearof the boiler, thewater column blowdown valveand the water gaugeblowdownvalve. All of these
valvesmustbeconnectedtoa blowdown receptacle of approved design. Regulationsexistcoveringsuch
itemsandcaremustbetakentoensurecompliancewiththeseregulations.Ifindoubtregardingblowdown
arrangements, consult your Fulton agent.
2.7 MAIN STEAM VALVE
The main steam stop valve should be inserted in the steam line approximately 12in. (305 mm) from the
top of the boiler.
6

GFSE-Std-0499
FIG 4 WATER GAUGE SET
7
2 2
FIG. 3A TYPICAL FLUE CONNECTION
F02490
F03200
F03190
WORKING
POSITION STEAM
BLOWDOWN WATER
BLOWDOWN
BLOWDOWN
GAUGEGLASS

GFSE-Std-0499 8
WARNING
Factory fitted safety valves are pre-set to protect the boiler only
and must not be used protect any other items !
2.8 STEAM SAFETY VALVES
Safety Valves are factory fitted and preset, they MUST NOT be adjusted. The discharge outlet
should be piped to a safe discharge point and the piping so arranged that any condensate trapped
in the pipework will drain away from the valve.
(a) The lift pressure is indicated on the safety valve. (Do not adjust).
(b) The safety valve fitted to the boiler is designed to prevent the boiler exceeding it's design
pressure.
(c) Any system connected to the boiler not capable of accepting boiler pressure must be
protected by a separate safety valve set to the required pressure.
2.9 WATER GAUGE SET (The design may vary from that illustrated)
Numbers may vary due to individual countries regulations.
Boilers are normally supplied with two complete water gauge sets. These gauges should be fitted as
showninmainview Fig.4.Thewatergaugeglassblowdowncockshouldbeconnectedtotheauxiliary
blowdown line from the water column blowdown valve in soft copper tubing. The connection to the
gauge cock is 1/8 in. BSP for conventional gauge glasses and 3/8 in. for reflex type gauges, (all
connections female).
Mounting manifolds 'C' are only supplied for conventional tubular gauge glasses.
2.10 GAS SUPPLY
Verify that the burner is suitable for the type of gas being supplied. Ensure the piping from the meter
is the correct size, and that a gas cock is inserted in the line between the boiler and the meter. To
avoid pressure drops, eliminate all unnecessary bends and elbows in the pipework between the gas
meter and the boiler. A scale trap is provided on the gas train and should be used.
Burners suitable for operation on natural and manufactured gas are supplied with gas trains or a
modular gas head which are fitted with pressure regulating governors. No additional pressure
regulating devices should be required. A minimum pressure of 7 in. (17.5 mb) water column is
required at the gas train for natural gas installations and a minimum pressure of 5 in. (12.5 mb) water
column is required at the gas train for manufactured gas installations.
Burners arranged for operation on L.P. gas are supplied with gas trains which include a pressure
regulating governor. It is essential that the MAXIMUM pressure of the gas at the gas train does not
exceed 32 in. (80 mb) water column and does not fall below 20 in. (50 mb) water column. To obtain
these pressures a pressure regulating device or service governor must be fitted to the supply line
from the storage tank to the boiler gas train.
2.11 ELECTRICAL REQUIREMENTS
An individual wiring diagram for the boiler is located on the inside cover of the control box.
When referring to the electrical specification of the boiler, the reference number located on the rear
inside wall of the control box and the wiring diagram number should be quoted.
The audible alarm bells supplied are mounted on the side of the control panel, if not audible they
should be repositioned where they can be heard by a person competent to take the appropriate
action should the alarm be activated. Unless otherwise specified, the alarms supplied will be mains
voltage models. Unless otherwise specified all models are supplied with burner motors and feed
water pump motors arranged for operation on a three phase supply.
The power ratings and requirements are given in Section 1.2 - Technical Data.
2 2

GFSE-Std-0499
2.12 STEAM PRESSURE GAUGE (Fig. 5)
The steam pressure gauge assembly should be assembled in accordance with Fig. 5 using a
suitable sealant on all joints.
Screw the assembly into the top of the boiler and connect the copper tube from the control panel box to
the nipple provided on the assembly.
2 2
9
STEAM PRESSURE
GAUGE
STEAM COCK
SYPHON
FIG. 5 STEAM PRESSURE GAUGE

GFSE-Std-0499 10
2 2
FIG.6 BURNERELECTRODESETTINGS
2.15 PLUMBING
(a) Fitthecheckvalvesupplied,betweenthefeedwaterpumpandtheboilerfeedwaterstopvalve.
(b) Ensure that the boiler is washed out after installation and before it is put into service.
(c) Conductafeedwateranalysisbeforeoperatingtheboiler.
2.16 COMMISSIONINGTHEBOILER(Fig.7)
It is essential that the commissioning procedures listed below are carried out by a Fulton service
engineerwhowillhave the necessary experience and testingequipmenttoensure that the installation
is not only correct, but is operating safely and at optimum efficiency.
FLUECOMMISSIONING
Priorto initialfiring ofthe boiler,the fluemust bechecked forleaks. Thisis doneby BOTHof thefollowing
methods:
VisualInspection
Checkjointsbetween all flue sectionsforquality of seals. Wherethe flue passes throughthe
structure of the building use your judgement as to the integrity of this section of the flue.
Smoke Test
Withthefluecapped,thedrainstabilizerpipe(iffitted)blankedandasmokegeneratorinserted
into the flue, their should be no smoke visible from the flue.
Ifeitherofthesetestsfailoratanytimeduringboileroperation,thereisdoubtabouttheintegrityoftheflue,
shut down the boiler and contact Fulton Boiler Works Immediately.
Note: Fluesthataredesignedtooperatewithpositivepressureshouldbetestedtotherequirements of IGE/UP/
10March2001.
BOILERINSPECTION
(a) Ensurethe boiler has beenwashed out after installation.
Conductawateranalysisbeforeoperatingtheboiler.
Examine the probes in the water column and the boiler shell.
Replaceanydamagedprobes.
(b) If the burner is fitted with an ultraviolet sensor,removethesensorandcheckfordamage.
Removetheburnerandcheckthattheelectrodeshavenotbeendamagedandthattheirsetting
correspondstotheappropriatedrawing(refertoFig.6).
(c) Check that the burner is the correct type for use with the gas being supplied.
MAIN GAS SUPPLY ULTRAVIOLET
CELL
IGNITION
ELECTRODE
PRIMARYAIR
BLASTTUBE
3 mm MIN.
5 mm MAX.
297.4mm
12.7mm
50.8mm

GFSE-Std-0499
2 2
FIG. 7 COMMISSIONING THE BOILER
11
GAS COCK
MODULAR
GAS UNIT PRESSURE
TEST POINT
MAIN STEAM
VALVE
STEAM SAFETY
VALVE
WATER
LEVEL
PROBES
AIR SAFETY
SWITCH
BLOWER
HOUSING
BURNER
MOTOR
WATER
COLUMN
STEAM
PRESSURE
GAUGE
SCALE
TRAP
CHECK
VALVE
STOP
VALVE
WATER
GAUGE
CONTROL
PANEL
COLUMN
BLOWDOWN
VALVE
PRESSURE
CONTROL
HAND HOLE
CLEANOUT
DOOR
MAIN
BLOWDOWN
VALVE

GFSE-Std-0499
2 2
12
(d) Ensure that all wiring connections are correct and that all terminal screws are tight.
(e) Insertamicro-ammeterintothemeter jack (if fitted) on the burnerprogrammer.Thistaskshouldbe
undertaken by a qualified service engineer.
(f) Abarometrictypedraughtstabiliser,iffittedintheflue,shouldbesetforadraughtof-0.01in.to0.02
in. (0.025 mb to 0.05 mb) of water column pressure with the burner off.
(g) Open all the valves in the water feed line.
Switch on the feedwater pump motor and fill the boiler, see Section 3 - Operation.
Theoperationofthepump controls should be checked byusingtheboiler blowdown valve (located
at the rear of the boiler). When the water sight level gauge is reading half full, the pump will stop.
Open the boiler blowdown valve and slowly drain the boiler. When the water level falls below the
PUMP ON probe, the pump should start. If the pump does not start check the probe connections.
Close the boiler blowdown valve.
(h) After purging the gas lines of air, start the burner as detailed in Section 3 - Operation. Check the
readings on the micro-ammeter for the pilot and main flames, adjusting the primary air control to
obtain the maximum readings.
(j) Adjust the main air control gate to obtain a clean combustion.
(k) Observe the flame through the peephole between the electrodes and adjust the primary air
control so that the flame cannot be seen 'backing up' the blast tube.
(l) Check the operation of the low water safety controls as detailed in Section 3 - Operation.
(m) Adjustthesteampressurecontroltosuittheboilerapplication.Itshouldbeborneinmindthatboilers
are designed to operate most efficiently at their maximum operating pressure. When boilers are to
be operated below a pressure of 80 psi (5.5 bar) consideration should be given to the fitting of a
pressure reducing set. See 2.8 Safety Valve setting.
If the pressure control is fitted with a differential scale:
(i) Set the main scale to the maximum pressure required.
(ii) Set the differential scale to give the required pressure differential between the boiler cutting out
andrestarting. Ifthepressurecontrolhasafixeddifferential,i.e.noadjustable differentialscale,set
the main scale to the maximum pressure required.
SETTING THE BURNER FOR LOW FIRE / HIGH FIRE, MODELS 50E AND 60E
The correct settings for low fire/high fire operation are obtained by making adjustments to the two stage
solenoid valve (Fig. 8) and the low fire steam pressure switch.
(a) Set the gas input to the boiler for correct input on high fire. This should be done where possible by
using the gas meter. Adjust the main air gate and top damper adjustment to obtain optimum
combustion conditions.
(b) Adjust the low fire steam pressure switch to cut out at approximately 5 psi below the setting of the
main steam pressure control (See Section 2.16 (m)).
(c) Adjust the two-stage solenoid valve to obtain a low fire gas input of approximately 80% of high fire.
Leave the air gate adjustments as for high fire.
(d) Refer to the adjusting procedure below on the two-stage solenoid valve.

GFSE-Std-0499
2 2
13
ADJUSTMENTS ACTION
AMainandPilotGas Governor. Turn clockwise to increase gas pressure. Range 4 - 20 mbar.
BFirst and second stage -
initial liftadjuster, main gas valve.
CMaingasthroughput Slacken locking screw, turn fluted knob anticlockwise
to increase, clockwise to decrease.
DGas supply test point
EBoiler side test point
FLowgaspressure switch
B
E
FC
D
ADJUSTMENTS ACTION
AMainandPilotGas Governor. Turn clockwise to increase gas pressure. Range 4 - 20 mbar.
BPilot gas range. Turn anticlockwise to increase and clockwise to decrease rate.
CFirst and second stage -
initialliftadjuster,main gas valve.
DMaingasthroughput Slacken locking screw, turn fluted knob anticlockwise to
increase, clockwise to decrease.
EGas supply test point
FBoiler side test point
C
D
B
E
F
MONOBLOCGASVALVES(FIG.9)
ADJUSTMENTS6E-30E(MBDLE407/412B07)
(With in built pilot bypass valve)
Pilot gas rate should be set to a maximum of 10% of the full fire gas throughput.
A
A
ADJUSTMENTS6E-30E(MBDLE407/412BO1)
TheMonoblockgasvalveoperatesintwostagesthroughtwomainshut-offvalves:-
Stage 1. Thefirstvalveopensfullyandthe second valve opens slowly such that the
maximum gas flowrate during the start gas provingperiod does not exceed 30% of the full
firingrate.
Stage 2. Thesecondvalveisfullyopen.
NOTE: The time taken to open fully is set by the adjustment of the first and second stage initial lift adjuster.

GFSE-Std-0499
2 2
14
MONOBLOCGASVALVES (FIG. 9) continued.
ADJUSTMENTS40E-60E(MBZRDLE415/420BO1)
AB
F
D
C
E
G
ADJUSTMENTS ACTION
AMainGasGovernor. Turn clockwise to increase gas pressure. Range 4 - 20 mbar.
BFirst and second stage -
initialliftadjuster,main gas valve.
CHighflamethroughput Slacken locking screw, turn fluted knob anticlockwise to
increase, clockwise to decrease.
DLowflamethroughput. Turn fluted knobanticlockwisetoincrease,
clockwise to decrease.
EGas supply test point
FBoiler side test point
GLowgaspressure switch
2.17 CLEANINGSTEAMLINESANDPRESSUREVESSEL
During the first week of boiler operation, clean all oil and dirt from the boiler, steam line and condensate
returnline.
(a) Disconnectthe condensatereturn pipe adjacentto 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) Afterthe weekis completed, drain and flushthe condensate return tank, removing all installation
sediment.Reconnect the condensatereturn pipe to the condensate return tank.

GFSE-Std-0499
15
22