FULTON J Series User manual

INSTALLATION, OPERATION,
MAINTENANCE AND PARTS MANUAL
J OIL-E-10 2008
'J' SERIES - OIL FIRED
STEAM BOILERS (6J - 60J)
This Manual must be available to the boiler operator at all times.

J OIL-E-08 2008
NOTE
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ofce.
(c) Your Competent Person.
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 rectied.
WARNING
Steam Boilers are a potential hazard possibly fatal if not properly maintained.
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.
Continualimprovementinboilerdesignandttingsmayresultinsomeofthecomponentsusedbeingdifferent
to those in this manual, if in any doubt about individual components or their operation, contact Fulton Service
Department.

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LIST OF CONTENTS
TITLE SECTION
INTRODUCTION 1
General 1.1
Technical Data 1.2
INSTALLATION 2
General 2.1
Siting 2.2
Ventilation 2.3
Flue Outlet 2.4
Water Supply 2.5
Blowdown Valves 2.6
Main Steam Valve 2.7
Steam Safety Valve 2.8
Water Level Gauge Set 2.9
Oil Supply 2.10
Electrical Requirements 2.11
Steam Pressure Gauge 2.12
Commissioning the Boiler 2.16
Cleaning Steam Lines and Pressure Vessels 2.17
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
Overriding Low Water Check 3.6.5
Blowdown Procedures 3.7
Evaporation Checks 3.8
Draining the Boiler 3.9
Long Term Shut Down 3.10
Troubleshooting 3.11
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
SPARE PARTS 6

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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
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
It is the responsibility of the installer to ensure all parts
suppliedwiththeboilerarettedinacorrectandsafe
manner.
WARNING
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong con-
nection can cause injury and or damage.
WARNING
Adefective boiler caninjure youorothers.Donotoperate
a boiler which is defective or has missing parts. Make
sure that all maintenance procedures are completed
before using the boiler.
WARNING
Do not change the boiler fuel without consulting the
boiler manufacturer.
WARNING
LIFTING EQUIPMENT
Make sure that lifting tackle complies with all local
regulations and is suitable for the job
You 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 dam-
age 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modications.
WARNING
Non-approved modications can cause injury and
damage. Contact your Fulton dealer before modifying
the boiler.
WARNING
Only qualied persons should be allowed to
operate and maintain the boiler and its
equipment. Boilers should always be drained through
an approved Blowdown Vessel.
WARNING
HYDRAULIC TEST -
RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is
normally only required by engineering surveyors / in-
spectors. The material the boiler is manufactured from,
has not been impact tested, as it is not a requirement
of BS2790 (boiler construction standard). In order to
ensure the material / pressure vessel does not suffer
from brittle fracture, hydraulic testing should not be
carried out below 5OC.
WARNING
DANGER FROM HOT SURFACES
Steam Boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent
andqualiedpersonnelshouldworkonorinthelocal-
ity of a steam boiler and ancillary equipment. Always
ensuretheworkingareaandoorareclearofpotential
hazards, work slowly and methodically.
WARNING
DANGER FROM INCOMPLETE COMBUSTION
The importance of correct burner adjustment to achieve
lowemissions,safe,cleanandefcientcombustionis
paramount. Poor combustion, where unburnt oil 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
uepasses.
WARNING
The importance of correct boiler water and feed water
cannot be over emphasised, see the relevant section
in this manual.
CAUTION
LOW FEED WATER TEMPERATURE
Low feed water temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary pre-heat the
feed water. If in doubt consult FBW.
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.
CAUTION
Obey all laws and local regulations which affect you
and your boiler.

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TITLE FIG. NO.
Oil Fired Steam Boiler 1
Boiler Top View 2
Typical Installation 3
Boiler Flue Connection 4
Boiler Feedwater Arrangements 5
Boiler Blowdown (20-60) 6
Boiler Blowdown (6-15) 6A
Water Column Sequencing Valve 7
Boiler Top Components 8
Steam Pressure Gauge 9
Nozzle and Ignition Assembly 10
Commissioning the Boiler 11
Pressure Controller 12
Operator Control Panels 13
Sequencing Blowdown Valve 14
Water Level Sight Gauge Blowdown 15
Fault Finding Check List 16
Maintenance 17
Handhole 18
Burner Assembly 19
Flue Cleaning 20
Boiler Dimensions 21
Boiler Supply Circuit 22
Ancillary Control Circuit 23
Spirax level Control Circuit 24
LC Level Control Circuit 25
TDS and Blowdown Control Circuit 26
6J - 30J Burner Control Circuit 27
40J - 60J Burner Control Circuit 28
SPARE PARTS
Boiler GA A0-2-1
Boiler Shell and Fittings 6-15 A1-1-1
Boiler Shell and Fittings A1-2-1
Burner Assembly 6-15 B2-1-1
Burner Assembly 20-30 B2-2-1
Burner Assembly 40-60 B2-3-2
Burner Scroll 6-15 D2-1-1
Burner Scroll 20-30 D2-2-1
Burner Scroll 40-60 D2-3-1
Burner Scroll, Dual Fuel, 40-60 D2-5-1
Water Column E1-6-1
Water Level Gauge Assembly (300mm) 6-60 F1-3-1
Water Level Gauge Assembly (350mm) 6-60 F1-4-1
Control Box Assembly, Dual Fuel, 40-60 G1-10-1
Control Box Assembly 6-15 G2-1-1
Control Box Assembly 20-30 G2-2-1
Control Box Assembly 40-60 G2-3-1
Feed Water Pump H1-1-1
LIST OF ILLUSTRATIONS
Optional Variations (wheretted) Appendix
Spirax High Integrity Level Controls C

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FIG.1 OIL FIRED STEAM BOILER
1
1
Steam Supply Valve
Oil
Strainer
Boiler
Control
Panel
Oil
Feed /
Return
Lines
Air Intake Manifold
Oil
Pump
Water
Column
Probes
1
Water
Column
Cleanout Door
(uepassesand
ameturnaround)
Handhole
(Pressure Vessel
Inspection)
Feed Water to Boiler

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1
1
INTRODUCTION
SECTION 1
1.1 General
 TheFultonSeriesJOilFiredSteamBoilerisaverticaltwo-passboilerofsimpleandefcient 
design and construction. Every care has been taken in the manufacture of the boiler to ensure that
quality and reliability standards are maintained. Satisfactory performance can only be ensured if the
installation recommendations, operating routines and maintenance schedules laid out in this
manual are adhered to.
Particular attention should be paid to electrical installation and water treatment.
1.2 Technical Data
forafullspecicationrefertoSection5.
BOILER MODEL
6J 8J 10J 15J 20J 30J 40J 50J 60J
Performance
Output kg/h 96 160 160 240 320 480 640 800 960
(F & A 100oC)
2

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FIG. 2 BOILER TOP VIEWS
2
3
Feed
Water and
Check
Valves
Main
Steam
Valve
Steam
Pressure
Gauge
to
Pressure
Controllers
TDS
System
Feed Water
Supply
Ignition
Transformer
Steam Valve
Oil Feed
Flame
Detector
Ignition
Electrodes
2
Pressure
Gauge
Feed Water
Valves
Water Level
Probes

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INSTALLATION
SECTION 2
2.1 GENERAL
The installation of a Series J Oil 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.
2.2 SITING
 Theboilerhouseshouldbesufcientlylargetoalloweasyandsafeaccesstoallpartsoftheboilerfor
installation, operation and maintenance purposes. Reference should be made to Section 5 - General
Data to ascertain the relevant dimensions and special note taken of the vertical clearance required for
the removal of the burner.
 Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthtosupportthe
boiler.
2.3 VENTILATION
 Adequatefresh,cleanairisnecessaryforsafeandefcientcombustion,andshouldbeprovidedat
high and low level in accordance with IGE/UP/10 Edition 2. It is essential that only fresh air is allowed
to enter the combustion air system. Foreign substances, such as combustible and volatile materials in
the combustion system can create hazardous conditions.
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ueandcausetheburnertolockoutonamefailure.
Ventilation requirements
Boiler Model 6J 8J 10J 15J 20J 30J 40K 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
22

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FIG. 3 TYPICAL INSTALLATION
5
STANDARD BOILER TRIM SUPPLIED WHEN ORDERING THE BOILER
STEAM SUPPL Y
PIPE SAFETY VA LVE TO SAFE AREA, FITTING UNIONS AND DRAIN
DRAUGHT STABILISER (WHERE FITTED)
WA TER COLUM N BLOWDOWN LINE
BOILER BLOWDOWN VA LVE
CLEANOU T DOOR
FEED WA TER CHECK VA LVE
FLUE SPIGOT
CONDENS ATE RETURN
FLEXIBLE LINK
OVERFLOW
MAKE-U P SUPPL Y
FEED WA TER PUMP
NOTE: A BREAK TANK MA Y BE REQUIRED CHECK THE LOCA L WA TER AUTHORITY BYE-LAW S
OVERFLOW TO DRAIN
DRAIN
STAINLESS
STEEL
TANK
SET
ISOLATING
VA LVE
STRAINER
FU LTON BLOWDOWN SEP ARA TO R
CONNECTIONS TO OIL STORAGE T ANK
OIL FEED LINE
OIL FILTER
(METAL CART RIDGE)
FITAN ISOLATING VA LVE IN
OIL RETURN LINE ONLY
IF OILTANK OR PIPE WORK
ISABOVE BURNER LEVEL
VEN T
FILL OIL RETURN LINE
SIGHT GLASS
ISOLATING VA LVE
CHECK VA LVE
SLUDG E
COCK
BALL
VA LVE
FIRE VA LVE LINE
Cowl
Flue
D = Diameter of flue H = 1.5 XD
H
D
2
2

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2
6
2.4 FLUE OUTLET
 Theboilerissuppliedwithastainlesssteeluespigot 
 thatshouldbeinsertedintotheue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uewillgenerallybesubjectto
local planning regulations and approvals. The following
information is intended to provide assistance where the
 installationofasimpleueisrequired.
 Wheremulti-boileruesordifcultiesareexperienced,
specialist advice should be obtained.
 Theuediametermustbethesameorlargerthanthe
 ueange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tted,careshouldbetakento
ensure that the distance between the lowest point of
 thecowlandthetopoftheueis1.5Xthediameter
 oftheue,andthatitisoftheterminalconetype.
Note:
1. Iftheuelayoutissuchthatitmayproduceanexcessiveup-draught,adraughtstabiliser
may be required.
2. Avoidtting90deg.elbowswheneverpossible,ifunavoidablecompensatebyincreasingthe
  uediameter.
3. Ensurealluepipesfromtheboilertothemainuehavearisingpitch.
FIG. 4 BOILER FLUE CONNECTION
2

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2
7
2
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.
Note: see Section 5 Water Treatment.
Connect the feed water pump discharge to the check valve inlet with 25mm. bore pipe (this
may be reduced to 15 mm, where the discharge pipework is shorter than 4mm in total. the
pump suction pipework must remain at 25mm minimum diameter and be as short as possible.)
and insert the stop valve supplied, between the boiler and the check valve. It is essential to protect the
 feedwaterpumpfromdamagebyforeignmatter,astrainershouldthereforebettedinthepump
suction pipework.
Care should be taken to ensure the pipework is properly aligned and not placing any strain upon
the feed water pump.
Note:
1. Theboilerfeedwaterpumpmaycontainaninhibitorandthisshouldbeushedfromthepump
  priortotting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feedwater.IfindoubtconsultFultonBoilerWorks.
3. TheFeedwaterinletconnectiononsomeboilersislocatedonthelefthandsideoftheboiler
below the sight glass assembly.
FIG. 5 BOILER FEED WATER ARRANGEMENT
Feed
Water
Supply
Feed Water
Stop Valve
Check
Valve
Feed Water
Dip Pipe

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FIG. 6 BOILER BLOWDOWN (models 20-60) FIG. 6A BOILER BLOWDOWN (models 6 - 15)
2.6.1 BLOWDOWN VALVE - Water Column
(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. 7 WATER COLUMN SEQUENCING and
BLOWDOWN VALVES
(Australian boilers only)
2
8
2
2.6. BLOWDOWN VALVE

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9
2
FIG. 8 BOILER TOP COMPONENTS
Safety Valve
Flame Detector
Burner Assembly
Water Level
Probes Ignition Electrodes
Steam Supply
Pipe
Flame Detector
Location
Oil Supply
Connections
Electrical
Connection Box
Ignition
Transformer
Oil Supply
Valves
Oil Pump
Adjustable
Air Control
Oil Supply
Ignition
Electrodes
Secondary Air
Damper
2

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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tted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.
(a) The lift pressure is indicated on the safety valve. (Do not adjust).
 (b) Thesafetyvalvetted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.
 (d) Longradiusttingstobeusedwithaminimumof6diameterstothersttting.
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 6mm (0.25in.).
2.10 OIL SUPPLY
The positioning of the oil storage tank will be dependent on site conditions and local regulations. The
burner fuel pump is of the bypass type requiring the installation of feed and return lines between the oil
storage tank and the boiler. These lines should be in tubing of a minimum bore of 10 mm.
 Arevalve,stopvalveandcheckvalvesshouldbeinsertedintheoilfeedline.
 Toavoidblockagesinthefuelpumpandburnernozzle,ametalcartridgeoilltershouldbetted.
Fibrouscartridgeltersarenotrecommended.
 Thenalconnectionsbetweenthefuelpumpandthefeedandreturnlinesshouldbemadewith
theexiblefuellinessupplied.Iftheoilstoragetankispositionedhigherthantheboiler,anon-return
valveshouldbettedtothereturnline.
To overcome suction problems at the fuel pump, all vertical lifts in the feed pipe should be made as
close to the boiler as possible. The burner fuel pump pressure is preset at the factory and should not
require adjustment.
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specication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specied,thealarmssuppliedwillbemainsvoltagemodels.Unlessotherwise 
 specied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.
WARNING
Factory tted 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.
10
22

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F03210
2
11
Steam Pressure Gauge
Steam Cock
Syphon
Plug
2.12 STEAM PRESSURE GAUGE
The steam pressure gauge assembly should be assembled in accordance with Fig. 9 using a suitable
sealant on all joints.
The gauge should be facing front towards the electrical control box and/or the operator of the boiler.
Screw the assembly into the top of the boiler and connect the copper tube from the pressure controller
located on the side of the control box to the nipple provided on the assembly.
FIG. 9 STEAM PRESSURE GAUGE
Test Point
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efciency.
FLUE COMMISSIONING
Priortoinitialringoftheboiler,theuemustbecheckedforleaks.
This is done by BOTH of the following methods:
Visual Inspection
Checkjointsbetweenalluesectionsforqualityofseals.Wheretheuepassesthroughthe
   structureofthebuildinguseyourjudgementastotheintegrityofthissectionoftheue.
Smoke Test
Withtheuecapped,thedrainstabilizerpipe(iftted)blankedandasmokegenerator 
   insertedintotheue,thereshouldbenosmokevisiblefromtheue.
If either of these tests fail or at any time during boiler operation, there is doubt about the
   integrityoftheue,shutdowntheboilerandcontactFultonBoilerWorksImmediately.
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2.16 COMMISSIONING THE BOILER - continued
INSPECTION
(a) Ensure the boiler has been washed out after installation.
Conduct a water analysis before operating the boiler.
Examine the probes in the water column and the boiler shell.
Replace any damaged probes.
(b) Remove the burner and check the electrodes have not been damaged and that their settings
  arecorrect.Iftheburneristtedwithaphotocell,removeitandcheckfordamage.
(c) Replace the burner and reconnect the cooper oil line(s) to the oil nozzle assembly, ensuring
these connections are tight. Reconnect the ignition leads and replace the sensor.
(d) Ensure all wiring connections are correct and all terminal screws are tight.
FIG. 10 NOZZLE AND IGNITION ASSEMBLIES
Burner Plate
Electrodes Electrodes
Electrode Tips
Bent to align with
Low Flame (Start)
oil supply nozzle
80OSpray
80OSpray
Fuel Nozzle
5mm
300mm
300mm
5mm
5mm
DOUBLE NOZZLE
TWO-STAGE LIGHT
40E - 60E
SINGLE NOZZLE
SINGLE-STAGE LIGHT
10E - 30E
130mm
High Fire Oil Supply
Low Fire (Start)
Oil Supply
Low Fire Oil Supply
12mm
High Fire Oil Supply
View on
arrow 'A' 5mm
12mm
Electrode settings
relative to nozzles
View on arrow 'B'
Arrow 'B'
12mm
Note: Always place the highest value nozzle
(engraved on the side of the nozzle) into the low
reoilsupplyportinthemanifold.
Nozzle Manifold
Arrow 'A'
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FIG. 11 COMMISSIONING THE BOILER
13
Oil Supply Pipes
Feed Water
Line Main Steam Valve
Oil
Flow /
Return
Pipes
Control Box
Isolator Switch
Cleanout Door Cleanout Handhole
Water Column
Blowdown
Valve
Engineers Test
Button (PM5)
Sight Gauge
Blowdown
Valves
Oil Strainer
Water Level
Sight Gauges
Boiler
Data
Plate
Main Air Intake
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2.16 COMMISSIONING THE BOILER - continued
 (e) Abarometrictypedraughtstabiliser(ifttedintheue)shouldbesetforadraughtof
- 0.01in. to - 0.02in. (- 0.025mb to - 0.050 mb) of water column pressure with the burner off.
(f) Open all the valves in the water feed line.
(g) Open all the valves in the feed water line.
FEED PUMP
Close the isolating valve on the discharge side of the pump. Remove the priming plug from the
pumpheadandslowlyllthepumpwithwater.Replacetheprimingplugandtightensecuerly.
See the correct rotation of the pump on the motor fan cover. Start the pump and check the direc-
tion 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.
Completely open the discharge isolating valve.
  Thebypassvalvelocatedinthedrainplugmaybeopenedduringthellingprocedure,closethe
bypass when the operation is stable.
DO NOT ALLOW THE PUMP TO RUN DRY.
(h) Open all the valves in the water feed line.
  Switchonthefeedwaterpumpmotorandll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 connec-
tions.
Close the boiler blowdown valve.
(i) Close the boiler blowdown valve.
(j) Start the burner as detailed in Section 3 - Operation. Allow time for the fuel pump to prime itself.
 (k) Aftertheburnerhasbeenringforapproximatelyveminutes,adjustthemainaircontrolgate
to obtain a clean combustion.
 (l) Observetheamethroughthepeepholebetweentheelectrodesandadjusttheprimaryair
  controlsothattheamecannotbeseen'backingup'theblasttube.Adjusttheairmaincontrol
  toobtainafullswirlingameshapebrushingthewallofthefurnacebyobservingtheame 
through the eye glass in the burner plate.
(m) Check the operation of the low water safety controls as detailed in Section 3 - Operation.
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2.17 CLEANING STEAM LINES AND PRESSURE VESSELS
 Duringtherstweekofboileroperation,cleanalloilanddirtfromtheboiler,thesteamlineand
condensate return line.
(a) Disconnect the condensate return pipe adjacent to the condensate return tank.
 (b) Directthereturnstoaoordrainorothersafedischargepointandmakesafe.
 (c) Leaveinthispositionforoneweektoallowallimpuritiestoushthrough.
(d) Drain the boiler completely each day.
 (e) Aftertheweekiscompleted,drainandushthecondensatereturntank,removingallinstallation
sediment. Reconnect the condensate return pipe to the condensate return tank.
2.16 COMMISSIONING THE BOILER - continued
(n) Adjust the steam pressure control to suit the boiler application. It should be borne in mind that
  boileraredesignedtooperatemostefcientlyattheirmaximumoperatingtemperature.When
boilers are to be operated below a pressure of 80 psi (5.5 bar) consideration should be given to
  thettingofapressurereducingset(seeSection2.8-SteamSafetyValves).
If the pressure control is tted with a differential scale:
(see OEM literature in section 5)
(i) Set the main scale pressure to the pressure
indicated on the boiler data plate.
(ii) Set the differential scale to it's minimum pressure.
  Ifthepressurecontrolhasaxeddifferential,
e.g. no adjustable differential scale, set the main
scale to the maximum pressure required.
Note: When boilers are tted with a sequence control:
(i) Set the main scale and differential scale as above.
(ii) Set the set-back pressure control to the required
set-back pressure. FIG. 12 PRESSURE CONTROLLER
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