FULTON J Series User manual

This manual must be available to the boiler operator at all times. JGASUK-IOMM-2015-2
INSTALLATION, OPERATIONAND MAINTENANCE MANUAL
J Series (UK)
Gas Fired Steam Boiler
(including optional fully modulating burner)

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TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Technical Data 1
SECTION 2 - INSTALLATION
2.1 General 3
2.2 Siting 3
2.3 Ventilation 4
2.4 Flue Outlet 4
2.5 Water Supply 6
2.6 Blowdown Valve 7
2.7 Main Steam Valve 8
2.8 Steam Safety Valves 8
2.9 Water Level Gauge Set (sight glass) 8
2.10 Gas Supply 8
2.10.1 Gas Valve with Pilot Gas Line 9
2.11 Electrical Requirements 9
2.12 Steam Pressure Gauge 9
2.13 Commissioning the Boiler 11
2.13.1 Boiler Inspection and Initial Firing 11
2.13.2 SettingBurnerControls-low/highre(40J-60J) 14
2.13.3 SettingBurnerControls-fullymodulating(30J-60J) 14
2.14 Multi Bloc Gas Valves 15
2.15 Cleaning Steam Lines and Pressure Vessels 18
SECTION 3 - OPERATION
3.1 General 19
3.2 Boiler Controls 19
3.3 Indicator Lights 21
3.4 Filling the Boiler-all models 22
3.5 Starting the Burner-all models 23
SECTION 4 - MAINTENANCE
4.1 Visual Checks 25
4.2 Water Level and Low Water Safety Controls 25
4.2.1 Pump Test 25
4.2.2 1st Low Water Level Check 26
4.2.3 2nd Low Water Level Check 27
4.3 Main Blowdown 28
4.4 Water Column Blowdown 28
4.5 Water Level Gauge Blowdown 29
4.6 Evaporation Checks 30
4.7 Flame Sensor Test 30
4.8 Draining the Boiler 31
4.9 Long Term Shut Down 32
4.10 Internal Inspection 32
4.11 Schedule of Operator Tests and Checks 33
4.11.1 Daily 34
4.11.2 Weekly-in addition 34
4.11.3 Monthly-in addition 34
4.11.4 Three Monthly-in addition 35
4.11.5 Six Monthly-in addition 35
4.11.6 Annually-in addition 37
4.12.1 Troubleshooting-boiler 38
4.12.2 Troubleshooting-feedwater pump 41
4.12.3 Troubleshooting-burner control unit-LFL1 43
4.13 Maintenance Log 45
APPENDIX A - TI SHEETS
APPENDIX B - WATER LEVEL PROBE INFO
APPENDIX C - MOTORISED HIGH/LOW CONTROL
1.1 General 57
1.2 Operation 57
1.3 Additional Controls 58
1.4 Commissioning 58
1.4.1 Fuel Input Rates 58
1.4.2 Air Damper Motor - Factory Cam Settings 58
1.4.3 Setup Procedure 59
1.5 Spare Parts 59
APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL
CONTROLS
1.1 Daily Tests 61
1.1.1 1st Low Water-daily 61
1.1.2 2nd Low Water-daily 61
1.2 Weekly Test-in addition 62
1.2.1 1st Low Water-weekly in addition 62
1.2.2 2nd Low Water-weekly in addition 62
APPENDIX E - AUTOMATIC TDS BLOWDOWN
SYSTEM
1.1 General 63
Electrical diagrams supplied separately

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WARNINGS
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
SAFETYASSESSMENT 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
system and increase the possibility of re, explosion, property damage, personal injury or loss of life.
!
!

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WARNINGS
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 heater 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 Ltd or call a Fulton service engineer.
It is the responsibility of the installer to ensure all parts
suppliedwiththeboilerarettedinacorrectandsafe
manner.
Understand the electrical circuit before connecting
or disconnecting an electrical component. A wrong
connection can cause injury and or damage.
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.
Do not change the boiler fuel without consulting the
boiler manufacturer.
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.
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.
Non-approvedmodicationscancauseinjuryand
damage. Contact your Fulton dealer before modifying
the boiler.
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.
The installation of gas appliances including the
uesystemshouldonlybecarriedoutbyGasSafe
registered engineers.
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.
The importance of correct boiler water and feedwater
cannot be over emphasised, see the relevant section in
this manual.
!
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
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.
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.
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
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.
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.
!

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Figure. 1 - Non-Modulating Gas Fired Steam Boiler
Monobloc gas valve
Low water level probes
Water column containing
water level probes
Water column
blowdown valve
Water level gauge
(sight glass)
Water level gauge
blowdown valves
Steam pressure limiter
Clean out handhole
(water jacket)
Steam pressure control
Pressure gauge
Air pressure
switch
Air intake
Boiler control
panel
Control box
door lock
Control box
isolator switch
Clean out door
(furnace)

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INTRODUCTION - 1
SECTION 1 - INTRODUCTION
1.1 GENERAL
TheFultonJSeriesgasredsteamboilerservicemanualisagenericpublication,providing
informationonstandardboileroperationandmaintenance.TheJSeriesgasredsteamboileris
averticaltwo-passboilerofsimple,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.
1.2 TECHNICAL DATA
ForafullspecicationrefertoAppendix A - TI-117-J Series Dimensions & Specication.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical treatment plants
CAN BE 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.
!

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Figure. 2 - Fully Modulating Gas Fired Steam Boiler
Steam pressure
limiter
Clean out handhole
(water jacket)
Pressure transducer
Air intake
containing main air
control
Boiler control panel
Control box
door lock
Control box isolator
switch
Clean out door
(furnace)
AZL burner control
RWF40
PID Controller
BT1050
Boiler blowdown
timer(iftted)
BC3150
Blowdown controller
(iftted)
LC3050
Level limiters
(iftted)
Low water level
probes
Water column
containing water
level probes
Water column
blowdown valve
Water level gauge
(sight glass)
Water level gauge
blowdown valves
Pressure gauge
Air pressure
switch

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INSTALLATION - 2
2.1 GENERAL
TheinstallationofaJSeriesgasred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 2.16 L.P. Gas
Supply.
2.2 SITING
(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 Appendix A - TI-117-J Series Dimensions & Specication 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.
!
SECTION 2 - INSTALLATION
Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto
support the boiler.

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INSTALLATION - 2
2.4 FLUE OUTLET
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 BS 6644 1991 and IGE/UP/10 Part 1 Communication
1676.
Note: 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.
Note: Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the
necessary boiler draught.
Note: 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 Appendix A - TI-117-J Series Dimensions & Specication for low and high level values.
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besubjecttolocalplanningregulationsandapprovals.
The following information is only intended to provide assistance for the installation of a simple
ue.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 metre 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: If the ue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required.
Note: Avoid tting 90° elbows whenever possible, if unavoidable compensate by increasing the ue diameter.
Note: Ensure all ue pipes from the boiler to the main ue have a rising pitch.
Figure. 3 - Boiler Flue Connection

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Figure. 4 - Typical Installation
F03164
Boiler blowdown valve
D
H
Drain
Overflow to
drain
Blowdown
Separator
Vent
Make-up feedwater supply
Stainless steel
feedwater and
condensate
return tank
Note: A break tank may be required depending
upon Local Water Authority bylaws
Overflow
Flexible
connector
Condensate return
Feedwater
pump
Feedwater
non-return
valve
(to be installed below
boiler water level)
Flanged connection
20J - 60J only
Clean-out door
Draught stabiliser
(when fitted)
Standard boiler trim
supplied with boiler
Flue
Cowl
D = Diameter of flue
H = 1.5 X D
Feedwater isolation ball valve
Pipe safety valve
to a safe area,
using unions and
drain as required.
Steam supply
Flue spigot
Water column
blowdown line
Strainer
Isolating gate/ball valve
Plugged drains
Boiler Water Level
Vent to
Atmosphere

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INSTALLATION - 2
2.5 WATER SUPPLY
Figure. 5 - Boiler Feedwater Arrangement
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 Appendix A - TI-139-Recommended Water Conditions.
Connect the feedwater pump discharge to the check valve inlet with 25 mm bore pipe (this may
be reduced to 15 mm, where the discharge pipework is shorter than 4 m in total. The pump
suction pipework must remain at 25 mm 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
1 m 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 pipework 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 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.
Note: 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.
Note: The feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight
glass assembly.
Feedwater
stop valve
Check valve
Feedwater
dip pipe
Feedwater line

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INSTALLATION - 2
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 two 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: 8J - 15J main blowdown connection is via a branch pipe.
Note: 20J - 60J main blowdown connection is integral, via a boiler mounted ange.
Where possible the main blowdown pipework on 20J - 60J boilers should drop down to a union connection to
allow removal of the inspection ange without the necessity to remove the blowdown pipework.
Figure. 6 - Boiler Blowdown- models 8J - 15J (skid
mounted boiler shown) Figure. 7 - Boiler Blowdown- models 20J - 60J (skid mounted boiler shown)

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INSTALLATION - 2
2.7 MAIN STEAM VALVE
The main steam stop valve should be inserted in the steam line approximately 305 mm from the
top of the boiler.
2.8 STEAM SAFETY VALVES
Safetyvalvesarefactoryttedandpre-set,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.
WARNING
Factory tted safety valves are pre-set to protect the boiler only and must not be used to protect any
other items not capable of accepting boiler pressure.
!
2.9 WATER LEVEL GAUGE SET (SIGHT GLASS)
Boilers are normally supplied with two complete water level gauge sets (sight glasses). The water
level gauge blowdown cock should be connected to the auxiliary blowdown line from the water
column blowdown valve by 3/8 in. soft copper tubing.
2.10 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.

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INSTALLATION - 2
Models 40J - 60J
Themaingasvalveisttedwithabypasssystem(internalorexternaldependingonthemodel)
thebypassallowspilotpressuretobemaintainedwhilsttheameisveried.
2.10.1 GAS VALVE WITH PILOT GAS LINE
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feedwaterpumpmotorsarrangedfor
operation on a three phase supply.
The power ratings and requirements are given in Appendix A - TI-117-J Series Dimensions &
Specication.
2.11 ELECTRICAL REQUIREMENTS
2.12 STEAM PRESSURE GAUGE
The steam pressure gauge assembly should be assembled in accordance with Figure. 8 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.
Test Point
Steam Pressure Gauge
Steam Cock
Syphon
Plugged
Figure. 8 - Steam Pressure Gauge

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INSTALLATION - 2
Secondary air
control
Low level water
probes
Air proving
switch
Gas train with
360° rotation
Note: Boiler illustrated is tted with optional Self Monitoring Controls.
TDS system
Feedwater
stop valve
Feedwater
check valve
Burner scroll
Steam safety
valve
Pressure gauge
Feedwater
line
Figure. 9 - Boiler Top Components (non modulating burner)
Gas train with
360° rotation
Air pressure
switch
Air actuator TDS system
Feedwater line
Steam out
Burner scroll
Steam pressure
gauge
Figure. 10 - Boiler Top Components (fully modulating burner)

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INSTALLATION - 2
2.13 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:
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.
2.13.1 BOILER INSPECTION AND INITIAL FIRING
1. Ensure that 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.
2. Iftheburneristted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.
3. Check that the burner is the correct type for use with the gas being supplied.
50.8 mm
3 mm min.
5 mm max
12.7 mm
297.4 mm
Ultraviolet Detector
Main Gas Supply
Ignition Electrode
Primary Air
Blast Tube
Figure. 11 - Burner Electrode Settings CONTINUED ON NEXT PAGE

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INSTALLATION - 2
4. Ensure that all wiring connections are correct and that all terminal screws are tight.
5. Abarometrictypedraughtstabiliser,ifttedintheue,shouldbesetforadraughtof
- 0.025 mbar to - 0.05 mbar of water column pressure with the burner off.
6. Open all the valves in the feedwater line.
Close the isolating valve on the discharge side of the feedwater pump. Remove the priming
plugfromthepumpheadandslowlyllthepumpwithwater.Replacetheprimingplugand
tighten securely.
7. Check 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.
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.
8. Open all the valves in the water feed line.
Switchonthefeedwater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 level gauge (sight glass) is reading two
thirds full, the pump will stop.
WARNING
Gas purging by qualied persons only.
!
9. After purging the gas lines of air, start the burner.
Formodels40J-60Jwithanexternalpilotgasline,seeSection 2.13.2 - Setting the burner
controls.
Note: Prove the pilot ame 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 ame has been veried.
10.Check the burner control is in the run position.
11.Adjust the gas and main air control gate located on the burner scroll, to obtain a clean
combustion. Measure the levels of CO2CO and O2 in the exhaust gas and record the results.
See typical combustion values given in Appendix A - TI 117.
12.Observetheamethroughtheeyeglassandadjustthesecondaryaircontrollocatedonthe
topoftheboiler,sothattheamecanbeseenpassingdowntheblasttube.
13.Check the operation of the low water safety controls.
14.Adjust the steam pressure control to suit the boiler application. It should be borne in mind that
boilersaredesignedtooperatemostefciently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ttingofapressurereducingset.

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INSTALLATION - 2
If the pressure control is tted with a differential scale:
1. Set the main scale pressure to the maximum pressure required (system pressure).
Do not exceed the boiler operating pressure.
2. Setthedifferentialscaletoit’sminimumpressure.Ifthepressurecontrolhasaxed
differential, i.e. no adjustable differential scale, set the main scale to the maximum pressure
required.
When multiple boilers are tted with a sequence control:
1. Set the main scale and differential scale as above.
2. Set the setback pressure control to the required set back pressure.
Figure. 12 - Pressure Controller

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INSTALLATION - 2
2.13.2 SETTING THE BURNER CONTROLS LOW/HIGH FIRE (40J - 60J)
Thecorrectsettingforlowre/highreoperationismadebymakingadjustmentstothetwostage
solenoidvalveandthelowresteampressureswitch.
1. Isolate the main gas valve by closing the valve in the gas input line.
2. Screw the pilot gas governor fully down (governor open).
3. Start the burner and where possible meter the pilot gas rate (ideally the pilot gas rate should
be 10% of the full gas rate).
4. Check the ignition and pilot stability several times.
Record the pilot gas pressure.
5. Open the main gas isolating valve.
6. Setthegasinputtotheboilerforcorrectinputonhighre.Thisadjustmentshouldbedone
where possible by using the gas meter.
Adjust the main and secondary air gates to obtain optimum combustion conditions.
7. Adjustthelowresteampressureswitchtocutoutatapproximately5psibelowthesettingof
the main steam pressure control.
8. Adjustthetwo-stagesolenoidvalvetoobtainalowregasinputofapproximately80%ofhigh
re.
Leavetheairgateadjustmentsasforhighre.
2.13.3 SETTING THE BURNER CONTROLS FULLY MODULATING (30J - 60J)
The correct setting for fully modulating operation is made by adjusting the parameters via the
Siemens LMV burner controller.
All adjustments need to be carried out by a suitably trained service engineer.
All parameter adjustments are password protected.