FULTON J Series User manual

Fulton Ltd
J DUAL FUEL MANUAL 02 2014 ISSUE 9
J SERIES - DUAL FUEL
STEAM BOILER (Switchable Burner)
(including optional Fully Modulating Burner)
This manual must be available to the boiler operator at all times.
INSTALLATION, OPERATION AND MAINTENANCE
MANUAL

J DUAL FUEL MANUAL 02 2014 ISSUE 9
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 competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.
For further information contact:
(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) Health and Safety Executive local ofce.
(c) Your Competent Person.
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.
CAUTION
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, whatever
the cause, then the fuel supply to the boiler should be isolated immediately, until 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.
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.
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J DUAL FUEL MANUAL 02 2014 ISSUE 9
LIST OF CONTENTS
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 (see also section 5.3) 2.5
Blowdown Valves 2.6
Main Steam Valve 2.7
Steam Safety Valves 2.8
Water Level Gauge Set (sight Glass) 2.9
Electrical Requirements 2.10
Gas Supply 2.11
Oil Supply 2.12
Steam Pressure Gauge 2.13
Commissioning the Boiler 2.14
- Boiler Inspection and Initial Firing - Oil 2.14.1
- Boiler Inspection and Initial Firing - Gas 2.14.2
Gas Monoblocs (Non Modulating Burners) 2.15
- Multibloc Gas Valve (Non Modulating Burners) 2.15.1
- Multibloc Gas Valve (Fully Modulating Burner) 2.15.2
Setting The Burner Controls For
Fully Modulating Models 30 - 60
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
Changing To The Alternative Fuel 3.4
Filling the Boiler - All Models 3.5
Starting the Burner - All Models - Gas 3.6
Starting the Burner - All Models - Oil 3.7
MAINTENANCE 4
Visual Checks 4.1
Water Level and Low Water Safety Controls 4.2
- Pump Test 4.2.1
- 1st Low Water Level Check 4.2.2
- 2nd Low Water Level Check 4.2.3
Main Blowdown 4.3
Water Column Blowdown 4.4
Water Level Gauge Blowdown 4.5
Evapouration Checks 4.6
Flame Sensor Test 4.7
Draining the Boiler 4.8
Long Term Shutdown 4.9
Internal Inspection 4.10
Schedule of Operator Tests and Checks 4.11
- Daily 4.11.1
- Weekly 4.11.2
- Three Monthly 4.11.4
- Six Monthly 4.11.5
- Annually 4.11.6
Troubleshooting 4.12
Maintenance Log 4.13
Daily and Weekly Test Log 4.14
GENERAL DATA 5
Boiler Dimensions 5.1
Boiler Specication 5.2
Recommended Water Conditions 5.3
APPENDIX Optional Variations (where tted)
Water Level Probe Info A
Motorised High/Low Control B
Spirax High Intensity Level Controls C
Electrical Diagrams (Supplied Separately)

J DUAL FUEL MANUAL 02 2014 ISSUE 9
WARNING
Do not try to do repairs or any other maintenance work you
do not understand. Obtain a service manual from
Fulton Ltd 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 connection
can cause injury and or damage.
WARNING
A defective boiler can injure you or others. Do not operate
a boiler which is defective or has missing parts. Make sure
that all maintenance procedures are completed before using
the boiler.
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
WARNING
Do not change the boiler fuel without consulting the boiler
manufacturer.
WARNING
LIFTING EQUIPMENT
Make sure that lifting equipment 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 damage the
boiler, it can also be dangerous.
Do not operate the boiler outside its limits.
Do not try to upgrade 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
The installation of gas appliances including the ue system
should only be carried out by Gas Safe registered engineers.
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.
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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 locality of a steam boiler
and ancillary equipment. Always ensure the working area and
oor are clear of potential hazards, work
slowly and methodically.
Do NOT store inammable materials near the boiler.
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 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 ue passes.
WARNING
The importance of correct boiler water and feedwater cannot
be over emphasised, see the relevant section in this manual.
CAUTION
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock to the
boiler pressure vessel. Return the maximum amount of
condensate and if necessary preheat the feedwater. If in
doubt consult Fulton Ltd.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and
chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
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
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is
normally only required by engineering surveyors / inspectors.
In order to ensure the material/ pressure vessel does not
suffer from brittle fracture, hydraulic testing should not be
carried out below 7°C.
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.

J DUAL FUEL MANUAL 02 2014 ISSUE 9
TITLE FIG. NO
Typical Dual Fuel Boiler 1
Major Fuel Components 2
Typical Installation 3
Boiler Flue Connection 4
Boiler Feed Water Arrangement 5
Boiler Blowdown (20-60) 6
Boiler Blowdown (6-15) 6A
Boiler Top Components 7
Control Box 8
Gas Supply 9
Oil Supply 10
Steam Pressure Gauge 11
Basic Burner Electrode Settings 12
Feedewater Stop Valve 13
Ignition Flame Detector 14
Main and Primary Air Controls 15
Burner Flame Observation Glass 16
Pressure Controller 17
6J - 30J Gas Valve Major Components (Non-Modulating Burner) 18
6J - 30J Gas Valve Major Components (Fully Modulating Burner) 19
Boiler Operation 20
Alarm and Indicator Lights 21
Boiler Maintenance 22
Pump Interrupt Switch 23
Main Boiler Blowdown Valve 24
Water Column 25
Water Level Gauge Operating Positions 26
Water Level Gauges (Sight Glasses) 27
Flame Sensor Removal 28
Automatic Blowdown Valve 29
Handhole 30
Feedwater Pipe Removal 31
Burner Assembly 32
Flue Cleaning 33
Fault Finding Check List 34
Boiler Dimensions 35
Water Level Probe Components 36
Angle Rajah Fitted To Probe 37
High/Low Control 38
Air Damper Motor 39
Control Panel Side 40
LIST OF ILLUSTRATIONS

J DUAL FUEL MANUAL 02 2014 ISSUE 9
Page 6
1
Steam Pressure
Gauge
Oil Pump Motor
Air Pressure
Switch
Water Column
Water Level
Gauge Sets
Operator Control
Panel
Control Box
Door Electrical
Isolator
Fuel Selector
Switch
Automatic TDS
Blowdown
Motorised
High / Low
Control
Monobloc Gas
Train
Steam Pressure
Controllers
FIG. 1 TYPICAL DUAL FUEL BOILER

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 7
1
SECTION 1 - INTRODUCTION
The Fulton J Series Dual Fuel 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.
Dual Fuel boilers are supplied complete with all the components necessary to operate on either
Gas or Oil Fuel. The controls are arranged such that the change over from one fuel to another can
be achieved by selecting the required fuel on the control panel and isolating the off line fuel supply.
1.1 GENERAL
1.2 TECHNICAL DATA
For a full specication refer to Section 5.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical
treatment equipment CAN BE SUPPLIED by Fulton Ltd.
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.
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Page 8
2
FIG. 2 MAJOR DUAL FUEL COMPONENTS
Monobloc Gas
Valve
Gas Inlet
Feedwater
Inlet
Steam Outlet
Safety Valve
Pressure
Gauge
Water Level
Limiters
Water Level
Gauge Sight
Glass
Oil Pump
Motor
Oil Solenoid
Valves
Water Column
and
Water Level Probes
Oil Feed Solenoid
Valves
Oil Pump
Motorised
High / Low
Control
Oil Feed
Lines

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 9
2
SECTION 2 - INSTALLATION
2.1 GENERAL
2.2 SITING
2.3 VENTILATION
The installation of a J Series Dual Fuel 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 are for boilers being installed to operate
on Natural Gas or 35 sec. Fuel Oil.
The ooring must be level, laid in a non-combustible material and be of sufcient strength to support
the boiler.
(Reference should be made to Utilisation 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 sufciently sized 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.
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Adequate fresh, clean air is necessary for safe and efcient 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 that there is adequate ventilation in the boiler room. Lack of ventilation will create a high
temperature and cause control lockout. There is a minimum ventilation requirement to supply the air for
combustion.
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.
Note: see Section 5 for low and high level values.

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2
FIG. 3 TYPICAL INSTALLATION
STANDARD BOILER TRIM SUPPLIED WHEN ORDERING THE BOILER
STEAM
SUPPLY
WATER
COLUMN
BLOWDOWN
LINE
PIPE SAFETY VALVE
TO SAFE AREA, FITTING
UNIONS AND DRAIN
STOP
VALVE
FEEDWATER
CHECK VALVE (TO BE INSTALLED BELOW BOILER WATER LEVEL)
FLUE
FLANGE CLEAN-OUT
DOOR
DRAUGHT
STABILISER
(WHERE
FITTED)
MAIN BLOWDOWN
VALVE
FEED PUMP
STRAINER
CONDENSATE
RETURN
OVERFLOW
OIL
STORAGE
TANK
SLUDGE
COCK
FILL
VENT
FLEXIBLE
LINK
ISOLATING
VALVE
CHECK
VALVES
DRAIN
STAINLESS
STEEL
TANK SET
ISOLATING
VALVE
CHECK
VALVE
SIGHT
GAUGE
FIRE VALVE
LINE
OIL RETURN LINE
FIT AN ISOLATING VALVE IN OIL RETURN
LINE ONLY IF OIL TANK OR PIPEWORK
IS ABOVE BURNER LEVEL
OIL FILTER
(METAL CARTRIDGE)
OIL FEED
LINE
MAKE-UP SUPPLY
CONNECTIONS TO OIL STORAGE TANK
FULTON
BLOWDOWN
SEPARATOR
OVERFLOW
TO DRAIN
TO FUSIBLE LINK
Note: Both gas and oil fuel supply lines must be tted with isolation valves with proof of closure microswitches
which must be electronically interlocked with the burner gas and oil control circuits.
NOTE:- A BREAK TANK MAY BE
REQUIRED CHECK THE LOCAL
WATER AUTHORITY BYE-LAWS
BOILER WATER LEVEL

J DUAL FUEL MANUAL 02 2014 ISSUE 9 Page 11
2
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.
FIG. 4 BOILER FLUE CONNECTION
2.4 FLUE OUTLET
Note:
a) If the ue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required.
b) Avoid tting 90° elbows whenever possible, if unavoidable compensate by increasing the ue diameter.
c) Ensure all ue pipes from the boiler to the main ue have a rising pitch.

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2
Feedwater stop valve
Check valve
Feedwater Dip Pipe
Feedwater line
The quality of the water used in the boiler will affect the life and performance of the boiler.
Feedwater 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 5.3 - Recommended Water Conditions.
Connect the feedwater pump discharge to the check valve inlet with 25mm. bore pipe (this may be
reduced to 15 mm, where the discharge pipe work is shorter than 4m in total. The pump suction
pipe work must remain at 25mm minimum diameter and be as short as possible). Install the stop
valve supplied between the boiler and the check valve. The check valve must be positioned so that
it is below the internal water level of the boiler, and should be installed at least 1m after the
feedwater pump. The reason for this placement position is that the check valve is designed to have
water on both sides to enable it to function correctly.
It is essential to protect the feedwater pump from damage by foreign matter, a strainer should
therefore be tted in the pump suction pipework.
Care should be taken to ensure the pipe work is properly aligned and not placing any strain upon
the feedwater pump.
Note: The boiler feedwater pump may contain an inhibitor and this should be ushed from the pump prior to t-
ting 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.
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 Ltd.
The feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight
glass assembly.
FIG. 5 BOILER FEEDWATER ARRANGEMENT
2.5 WATER SUPPLY

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2
FIG. 6A BOILER BLOWDOWN (models 6 - 15)FIG. 6 BOILER BLOWDOWN(models 20-60)
2.6 BLOWDOWN VALVE
There are four blowdown valves on the boiler, the boiler blowdown valve at the rear of the boiler,
the water column blowdown valve and each of the water level gauge (sight glass) blowdown
valves.
All of these valves must be connected to a blowdown receptacle of approved design. Regulations
exist covering such items and care must be taken to ensure compliance with these regulations.
If in doubt regarding blowdown arrangements, consult Fulton Ltd.
Note: 20J - 60J main blowdown connection is integral, via a boiler mounted ange.
Where possible the main blowdown pipework on 20 - 60J boilers should drop down to a union connection to allow
removal of the inspection ange without the necessity to remove the blowdown pipework.

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Ignition
transformer
Flame detector Steam supply
pipe
Burner assembly Oil supply
connections
Safety valve
Water level
probes
FIG. 7 BOILER TOP COMPONENTS
Electrical
connection box
Oil supply
valves
Adjustable
air control
Oil pump
Ignition
electrodes
Secondary air
damper
Flame detector
location
Oil supply
Ignition electrodes

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2
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.
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 Section 5.2 - Boiler Specications.
2.7 MAIN STEAM VALVE
2.8 STEAM SAFETY VALVES
The main steam stop valve should be inserted in the steam line approximately 305mm from the top
of the boiler.
2.9 WATER GUAGE SET
(The design may vary from that illustrated) Numbers may vary due to individual country’s regulations.)
Boilers are normally supplied with two complete water level gauge sets. The water level gauge
blowdown cock should be connected to the auxiliary blowdown line from the water column blowdown
valve in 3/8 in. soft copper tubing.
2.10 ELECTRICAL REQUIREMENTS
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. / BSEN 134801-1:2002
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 its 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.
FIG. 8 CONTROL BOX
Fuel selector
Recommended
water treatment
TDS blowdown
controller
Note: It is advisable for dual fuel burners, that the ofine fuel is manually isolated with a proof of closure microswitch
that is interlocked with the online control circuit.
e.g. gas supply proof of closure interlocked with the oil burner control circuit.
oil supply proof of closure interlocked with the gas burner control circuit.
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FIG. 9 GAS SUPPLY
2.11 GAS SUPPLY
Verify that the burner is suitable for the type of gas being supplied. Ensure that 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.
A minimum pressure of 18 mbar at the specied ow rate, is required at the gas train for natural gas
installations and a minimum pressure of 50 mbar is required at the gas train for manufactured/L.P
gas installations.
If the gas supply is in excess of 100 mbar for natural gas a suitable regulator is required before the
main gas valve.
Burners arranged for operation on L.P. gas are supplied with gas trains. It is essential that the
MAXIMUM pressure of the gas at the gas train does not exceed 80 mbar and does not fall
below 50 mbar. A suitable regulator is required before the main gas valve.
To obtain these pressures, a pressure regulating device or service governor must be tted 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.
Main gas valve assembly
Main gas line isolating valve
Pilot line
ball valve
Pilot line
governor
Pilot line
gas valves

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FIG. 10 OIL SUPPLY
Oil feed solenoid valves
Oil pump
Oil feed lines
Out In
2.12 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.

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Steam pressure gauge
Plug
Steam cock
Pressure controller
connection point
Syphon
F03210
The steam pressure gauge assembly should be assembled in accordance with Fig. 11 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. 11 STEAM PRESSURE GAUGE
2.13 STEAM PRESSURE GAUGE

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2.14 COMMISSIONING THE BOILER
Dual fuel boilers that use a common burner assembly and have a switch change over from one fuel
to another, have to be commissioned on the basis of a primary fuel (usually gas), with the secondary
fuel as a back-up. The primary fuel should be commissioned as 2.16 oil ring or 2.17 gas ring.
The secondary fuel then has to be commissioned using the air settings for the primary fuel. In practice
this means adjusting the fuel input of the secondary fuel to achieve acceptable combustion.
As more air is required for oil combustion the consequences are that when oil is the secondary fuel
there will be a small reduction in the fuel input rate.
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:
a. 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.
b. Smoke Test
With the ue capped, the drain stabiliser 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 Ltd immediately.
Note: Flues that are designed to operate with positive pressure should be tested to the latest regulations.

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FIG. 12 BASIC BURNER ELECTRODE SETTINGS
Flame detector
Mains gas
supply
Pilot gas
supply
Ignition
electrodes
FIG. 13 FEEDWATER STOP VALVE FIG. 14 IGNITION FLAME DETECTOR
Feedwater
stop valve
NOTES:
1. GAS ELECTRODE TIP SHOULD BE
POSITIONED 3mm FROM THE END
OF THE GAS SUPPLY PIPE TO ENABLE
IGNITION.
2. OIL ELECTRODE TIP SHOULD BE
POSITIONED 3mm FROM ONE OF
THE OIL NOZZLES.
Oil Ignition
Electrodes
Gas Ignition
Electrode
Burner Plate
205
258
271.5
89
141
196
dimensions in mm