Instruction, Operation Model Number and Maintenance Manual ... · Introduction This manual is provided as a guide to the correct operation and mainte-nance of your Fulton Electric

Fulton Electric SteamBoilers

12 kW to 1000 kW 1.2 to 100 HP

Instruction, Operation and Maintenance Manual

Serial Number

Model Number

CO Number

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Date

Introduction

This manual is provided as a guideto the correct operation and mainte-nance of your Fulton Electric SteamBoiler, and should be permanentlyavailable to the staff responsible forthe operation of the electric boiler.These instructions must not be con-sidered as a complete code of prac-tice, nor should they replace exist-ing codes or standards which maybe applicable.

The installation of the FultonElectric Steam Boiler should becarried out by competent person-nel in accordance with all relevantsafety regulations. A completelist of all safety precautions maybe found in the safety summary atthe conclusion of Section 1. It isthe responsibility of the installerto ensure that the installation is incompliance with these regulations.

The requirements and instructionscontained in this section generallyrelate to the standard Fulton ElectricSteam Boiler. When installing apackaged unit, this entire sectionshould be read to ensure that theinstallation work is carried out correctly.

Prior to shipment the following testswere made to assure the customerthe highest standards of manufacturing:

a) Material inspections.b) Manufacturing process inspections.c) ASME welding inspections.d) ASME hydrostatic test inspection.e) Electrical components inspection.f) Operating test.g) Crating inspection.

Note

If it is necessary to store the boil-er for a prolonged period of timeprior to installation, the boilershould be stored at a minimum 40degree F in an atmosphere inwhich excessive moisture cannotdamage the controls or the steelcasing. If the storage is to be oversixty days, one element should beremoved. Place several bags ofdry dessicant inside the boiler.Bolt a blank flange over the element mounting plate to sealthe boiler. If handholes are provid-ed, these can be used to providean opening versus an element toplace the dessicant.

Contents

Section Page No.

Safety Warnings & Precautions 21Description/Instructions 42 Locating the BoilerDimensions & Specifications 1.2-3.6 BHPDimensions & Specifications 5-20 BHPDimensions & Specifications 30-100 BHPBoiler, Condensate Tank, and Blow off Separator Piping Feed Water PipingBlow off ValveMain Steam ValveSteam Safety Valve Electrical RequirementsBoiler ControlsWater Control RelaysWater Gauge Glass & Gauge Glass InstallationWater SupplyRecommended Water TreatmentGlossary of Water Supply Corrosives & InhibitorsInstallation Check PointsCleaning the Pressure Vessel

Operation 203 IntroductionStarting the BoilerBoiler ControlsThermostatSight Glass Isolation Valves

Maintenance 244 IntroductionRecommended Daily MaintenanceDaily blow off SequenceRecommended Monthly MaintenanceRecommended Six Month MaintenanceRecommended Annual MaintenanceTroubleshooting

Parts 305 Spare Parts Ordering InstructionsParts List

Warranty 366Component Data Sheets 387

1-ES 4-00 Fulton Boiler Works, Inc.

Safety Warnings/Precautions

1

Fulton Boiler Works, Inc. 2-ES 4-00

Safety Warnings/Precautions

Safety Warnings Cautions &Notes

The following WARNINGS , CAU-TIONS, and NOTES appear in vari-ous chapters of this manual. Theyare repeated on these safety sum-mary pages as an example and foremphasis.

WARNINGS must be observed toprevent serious injury, or death topersonnel.

CAUTIONS must be observed toprevent damage or destruction ofequipment or loss of operatingeffectiveness.

NOTES must be observed for essen-tial and effective operating proce-dures, conditions, and as a state-ment to be highlighted.

lt is the responsibility and duty of allpersonnel involved in the operationand maintenance of this equipmentto fully understand the WARNINGS,CAUTIONS, and NOTES by whichhazards are to be reduced oreliminated. Personnel must becomethoroughly familiar with all aspectsof safety and equipment prior tooperation or maintenance of theequipment.

Warning

Improper installation or maintenanceof gauge glass and connections cancause immediate or delayed breakageresulting in bodily injury and/or prop-erty damage.

Warning

When stopping the boiler for anyextensive repairs, shut off main powerswitch and pull main disconnectswitches on both the boiler side aswell as the feed water side.

Warning

Prior to the commencement of anywork requiring the removal of coverplates and the opening of the controlpanel box, the electrical supply to theboiler must be disconnected.

Caution

Do not downsize piping below safetyvalve size.

Caution

Unless otherwise specified, the steamsafety valve supplied with the boiler ispre-set. This valve is provided as asafety device for the boiler andshould not be used as the sole pro-tection for other equipment usingsteam from the boiler. Do not tamperwith the setting (It could accidentallybe set at a pressure higher than thedesign pressure of the boiler and,therefore ,create a hazardous condi-tion.

Caution

Do not exceed pressure rating on boiler.

Caution

In general, ensure that the boiler areais in conformance with establishedboiler room requirements. Reviewnational and local codes.

Caution

Do not tamper with the safety featuresof the low water safety cut out.

Caution

Keep boiler area clear and free fromcombustible materials, gasoline, andother flammable vapors and liquids.

Caution

Do not use harsh compounds that willinjure the feed water pump or ele-ments.

Caution

Do not clean the gauge or gaugeglass while pressurized or in opera-tion.

Caution

Prior to performing the “try lever”test, be certain to take precautions asa loud noise and high velocity steamwill discharge freely from dischargeport and through drain hole providedin the side of the valve body.

Note

If it is necessary to store the boiler fora prolonged period of time prior toinstallation, the boiler should bestored at a minimum 40 degree F inan atmosphere in which excessivemoisture cannot damage the controlsor the steel casing. If the storage is tobe over sixty days, one elementshould be removed. Place severalbags of dry dessicant inside the boil-er. Bolt a blank flange over the ele-ment mounting plate to seal the boil-er. If handholes are provided, thesecan be used to provide an opening

versus an element to place the dessi-cant.

Note

Where a condensate return tank is tobe fitted, this should:a) Be vented andb) Have a capacity sufficient to satis-fy boiler consumption as well asmaintain proper return tank tempera-ture andc) Vent pipe should not be down-sized (This may cause pressure buildup in the condensate tank.)

Note

Care should be taken to ensure thatthe blow off receptacle used meetsthe regulations covering such items.If in doubt, consult a FultonRepresentative for advice.

Note

Only properly trained personnelshould install and maintain watergauge glass and connections. Wearsafety glasses during installation.Before installing, make sure all partsof free of chips and debris.

Note

Keep gauge glass in original packag-ing until ready to install.

Note

After Installation is complete andprior to operation, the pressure vesselshould be cleaned.

Note

Check with local authorities whereapproval for start-up is required. Insome localities, final inspection ofservices may be required.

Note

To ensure that your Fulton SteamBoiler is kept operating safely andefficiently follow the maintenance pro-cedures set forth in this manual.

Note

The policy of Fulton Boiler Works,Inc. is one of continuous improve-ment, and therefore, we reserve theright to change prices, specifications,and equipment without notice.


Boiler Description/Instructions

2


Description/Instructions 12 - 36 kW / 1.2 - 3.6

Element(s) are horizontally mounted at the bottomof the pressure vessel. All probes are located inthe top of the boiler.


Locating the BoilerThe boiler should be located in dry surroundings on a level base, as closeas possible to the steam using machinery. See right hand page for minimum clearances to ensure thatthere is sufficient room around the boilerto enable the operator and maintenanceengineer to gain access to all parts ofthe boiler. Check location for ease ofwater supply and electrical connections.

1. Pressure Vessel Built to ASMECode - 5 Year Warranty

2. Electrical Control Panel Box3. Electric Heating Element(s)4. Low Water Cut off Probe5. Second (Auxiliary) Low Water

Cut off Probe6. Pump "On" Probe7. Pump "Off Probe8. Sight Glass Assembly9. Operating Pressure Control

10. High Limit Pressure Control withManual Reset

11. Steam Outlet12. Safety Valve13. Steam Gauge Assembly14. Steam Pressure Gauge15. High Temperature Insulation

Surrounds the Pressure Vessel16. Large (3"x4") Easily Accessible

Handholes17. Feedwater Shut Off Valve18. Blowdown Valve

Description/Instructions 12 - 36 kW / 1.2 - 3.6

DimensionsModel FB-L 012 015 018 024 030 036Unit Size: kW 12 15 18 24 30 36

HP 1.2 1.5 1.8 2.4 3.0 3.6Height(A) Boiler Overall IN 24 24 24 24 24 24

MM 610 610 610 610 610 610(B) Boiler w/Piping IN 30 30 30 30 30 30

MM 762 762 762 762 762 762(C) Feedwater Inlet IN 8 8 8 8 8 8

MM 203 203 203 203 203 203(D) Blowdown Outlet IN 4 4 4 4 4 4

MM 102 102 102 102 102 102(E) Electric Control Box IN 20.5 20.5 20.5 20.5 20.5 20.5

MM 521 521 521 521 521 521(F) Hand Hole IN 11 11 11 11 11 11

MM 279 279 279 279 279 279Width & Depth(G) Boiler Only IN 20 20 20 20 20 20

MM 508 508 508 508 508 508(H) Overall Depth Electric IN 30 30 30 30 30 30

Panel to Blowdown MM 762 762 762 762 762 762(I ) Electric Panel Width IN 14 14 14 14 14 14

MM 356 356 356 356 356 356(J) Boiler Width Overall IN 33 33 33 33 33 33

MM 838 838 838 838 838 838Boiler Connection SizesSteam Outlet 15 PSI IN .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19Steam Outlet 16-300 PSI IN .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19Feedwater Inlet IN .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19Blowdown Outlet IN 1 1 1 1 1 1

MM 25 25 25 25 25 25Sight Glass Blowdown Outlet IN .25 .25 .25 .25 .25 .25

MM 6 6 6 6 6 6Safety Valve 15 PSI IN .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19Safety Valve 16-300 PSI IN .50 .50 .50 .50 .50 .50

MM 13 13 13 13 13 13Minimum Clearances(K) Horizontal IN 14 14 14 14 14 14

to remove elements MM 356 356 356 356 356 356(M) Front of Boiler IN 24 24 24 24 24 24

MM 610 610 610 610 610 610(N) Sides & Rear of Boiler IN 12 12 12 12 12 12

MM 305 305 305 305 305 305

Specifications

Number of Elements 1 1 1 2 2 2Output 1000 BTU/HR 41 51 61 82 102 123

1000 KCAL/HR 10 13 15 21 26 31Steam Output** LB/HR 40 50 60 81 101 121

KG/HR 18 23 27 37 46 55Approx. Shipping Weight LB 420 420 420 440 450 450

KG 191 191 191 200 201 204Water Capacity GALLONS 7 7 7 7 7 7

LITERS 26 26 26 26 26 26Electrical Power Requirements (In Amps)208V 3 Phase 34 42 50 67 84 100230V 1 Phase 52 65 78 -- -- --240V 3 Phase 29 36 43 58 73 87480V 3Phase 15 18 21 29 36 44575V 3 Phase 13 16 18 24 30 36

Notes

**Steam output ratings, at180oF (82oC) feedwatertemperature, 0 PSIG.

--Indicates not available.Probe liquid level control,standard on all units.

Optional Water Level ControlsWatts 142-5McDonnell Miller 53-2McDonnell Miller 47-2

Dimensions are approximate. We reserve the right to change specifications. Fulton Boiler Works, Inc. 6-ES 4-00

Description/Instructions 50-200 kW / 5 - 20 BHP

The boiler should be located in dry surroundings on a level base, as close as possible to the steam usingmachinery. See right hand page for minimum clearances to ensure that there is sufficient room around the boilerto enable the operator and maintenanceengineer to gain access to all parts ofthe boiler. Check location for ease ofwater supply and electrical connections.

1. Pressure Vessel Built to ASMECode - 5 Year Warranty

2. Electrical Control Panel Box3. Electric Heating Elements4. Low Water Cut off Probe5. Second (Auxiliary) Low Water

Cut off Probe6. Pump "On" Probe7. Pump "Off Probe8. Sight Glass Assembly9. Operating Pressure Control


11. Steam Outlet12. Safety Valve13. Steam Gauge Assembly14. Steam Pressure Gauge15. High Temperature Insulation


Handholes17. Feedwater Shut Off Valve18. Blowdown Valve

Elements are vertically mounted.All probes are mounted in the topof the boiler.


Locating the Boiler

Description/Instructions 50-200 kW / 5 - 20 BHPDimensions

Model FB-L 050 075 100 150 200Unit Size: kW 50 75 100 150 200

HP 5 7.5 10 15 20Height(A) Boiler Overall IN 55 55 55 55 55

MM 1397 1397 1397 1397 1397(B) Boiler w/Piping IN 65 65 65 65 71

MM 1651 1651 1651 1651 1803(C) Feedwater Inlet IN 16 16 16 16 16

MM 406 406 406 406 406(D) Blowdown Outlet IN 6 6 6 6 6

MM 152 152 152 152 152(E) Electric Control Box IN 50 50 50 50 48

MM 1270 1270 1270 1270 1219(F) Hand Hole IN 38 38 38 38 38

MM 965 965 965 965 965Width & Depth(G) Boiler Only IN 17 24 24 28 32

MM 432 610 610 711 813(H) Overall Depth Electric IN 35 35 35 39 46

Panel to Blowdown MM 899 899 899 991 1168(I ) Electric Panel Width IN 17 32 32 32 40

MM 432 813 813 813 1016(J) Boiler Width Overall IN 35 42 42 46 52

MM 889 1067 1067 1168 1321Boiler Connection SizesSteam Outlet 15 PSI IN 1 1.5 1.5 2 3

MM 25 38 38 51 76Steam Outlet 16-300 PSI IN .75 1 1 1.25 1.5

MM 19 25 25 32 38Feedwater Inlet IN .75 .75 1 1 1

MM 19 19 25 25 25Blowdown Outlet IN 1 1 1 1 1.25

MM 25 25 25 25 32Sight Glass Blowdown Outlet IN .25 .25 .25 .25 .25

MM 6 6 6 6 6Safety Valve 15 PSI IN 1 1 1 1.25 1.50

MM 25 25 25 32 38Safety Valve 16-300 PSI IN .75 .75 .75 .75 1

MM 19 19 19 19 25Minimum Clearances(L) Floor to Ceiling IN 92 92 92 92 130

to remove elements MM 2337 2337 2337 2337 3302(M) Front of Boiler IN 24 32 32 32 34

MM 610 813 813 813 864(N) Sides & Rear of Boiler IN 12 12 12 12 24

MM 305 305 305 305 610

Specifications

Number of Elements 2 3 4 6 4Output 1000 BTU/HR 171 256 341 512 683

1000 KCAL/HR 43 64 86 129 172Steam Output** LB/HR 169 252 336 505 674

KG/HR 77 115 153 230 306Approx. Shipping Weight LB 580 850 970 1223 1425

KG 263 386 440 556 648Water Capacity GALLONS 13 39 39 50 79

LITERS 49 148 148 189 299Electrical Power Requirements (In Amps)208V 3 Phase 139 208 278 416 556240V 3 Phase 120 180 241 361 482480V 3Phase 60 90 120 180 241575V 3 Phase 50 76 101 150 201

Notes

**Steam output ratings, at 180oF(82oC) feedwater temperature, 0 PSIG.

Probe liquid level control, standard.

Optional Water Level ControlsMcDonnell Miller 157-157M McDonnellMiller 53-2McDonnell Miller 47-2

Dimensions are approximate. We reserve the right to change specifications.


Description/Instructions 300 -1000 kW / 30 -100

Elements are vertically mounted.These boilers have an externallymounted water bottle assembly housing the low water cut-off probe,pump on probe and pump off probe.The second (auxiliary) low water cut-off probe is mounted in the top ofthe boiler.

Locating the BoilerThe boiler should be located in dry surroundings on a level base, as close as possible to the steam usingmachinery. See right hand page for minimum clearances to ensure that there is sufficient room around the boilerto enable the operator and maintenanceengineer to gain access to all parts ofthe boiler. Check location for ease ofwater supply and electrical connections.

1. Pressure Vessel Built to ASME Code - 5 Year Warranty

2. Electrical Control Panel Box3. Electric Heating Elements4. Low Water Cut off Probe5. Second (Auxiliary) Low Water Cut off Probe6. Pump "On" Probe7. Pump "Off Probe8. Sight Glass Assembly9. Operating Pressure Control


11. Steam Outlet - 30 HP11. Steam Outlet - 50, 75, 100 HP12. Safety Valve13. Steam Gauge Assembly14. Steam Pressure Gauge15. High Temperature Insulation


Handholes17. Feedwater Shut Off Valve18. Blowdown Valve19. Water Bottle Assembly


Description/Instructions 300 -1000 kW / 30 -100 BHP

DimensionsModel FB-L 300 500 750 1000Unit Size: kW 300 500 750 1000

HP 30 50 75 100Height(A) Boiler Overall IN 75 75 75 75

MM 1905 1905 1905 1905(B) Boiler w/Piping IN 80 80 80 80

MM 2032 2032 2032 2032(C) Feedwater Inlet IN 24 24 24 24

MM 610 610 610 610(D) Blowdown Outlet IN 6.5 6.5 6.5 6.5

MM 165 165 165 165(E) Electric Control Box IN 64 64 64 64

MM 1626 1626 1626 1626(F) Hand Hole IN 55 55 55 55

MM 1397 1397 1397 1397Width & Depth(G) Boiler Only IN 36 44 50 63

MM 914 1118 1270 1600(H) Overall Depth Electric IN 46 56 62 83

Panel to Blowdown MM 1168 1442 1575 2108 (I ) Electric Panel Width IN 52 64 64 64

MM 1321 1626 1626 1626(J) Boiler Width Overall IN 56 64 72 91

MM 1422 1625 1829 2311Boiler Connection SizesSteam Outlet 15 PSI IN 3 4 4 6

MM 76 100 100 150Steam Outlet 16-300 PSI IN 2 3 3 3

MM 51 76 76 76Feedwater Inlet IN 1 1 1 1.25

MM 25 25 25 32Blowdown Outlet IN 1.25 1.5 1.5 2

MM 32 38 38 51Water Col. Blowdown Outlet IN .75 .75 .75 .75

MM 19 19 19 19Sight Glass Blowdown Outlet IN .25 .25 .25 .25MM 6 6 6 6Safety Valve 15 PSI IN 1.5 1.5 2 2.5

MM 38 38 51 64Safety Valve 16-300 PSI IN 1 1.25 1.5 2

MM 25 32 38 51Minimum Clearances(L) Floor to Ceiling IN 139 139 139 139

to remove elements MM 3531 3531 3531 3531(M) Front of Boiler IN 34 36 36 36

MM 864 914 914 914 (N) Sides & Rear of Boiler IN 24 24 24 24

MM 610 610 610 610

Specifications

Number of Elements 4 7 10 14Output 1000 BTU/HR 1025 1708 2561 3416

1000 KCAL/HR 258 430 645 860Steam Output* LB/HR 1011 1684 2526 3368

KG/HR 460 765 1148 1530Approx. Shipping Weight LB 1440 1825 2150 2300

KG 655 830 977 1043Water Capacity GALLONS 115 195 270 360

LITERS 435 738 1022 1362Electrical Power Requirements (In Amps)208V 3 Phase 832 * * *240V 3 Phase 724 * * *480V 3Phase 363 607 906 1204575V 3 Phase 301 502 756 1004Dimensions are approximate. We reserve the right to change specifications. Fulton Boiler Works, Inc. 10-ES 4-00

Notes

**Steam output ratings, at 180oF (82oC)feedwater temperature, 0 PSIG.

* Indicates voltages available at specialrequest

Probe liquid level control, standard.

Optional Water Level ControlsMCDonnell Miller 157-157M McDonnell Miller 53-2McDonnell Miller 47-2

Description/Instructions

Basic Boiler,Condensate Tank,and Blow offSeparatorPiping Diagram


Note

Where a condensate return tank is tobe fitted, this should:

1. Be vented and

a) There are two blow off valves on the boiler; the main valve at the rearof the boiler and the water gauge glass blow off valve. The boiler blow off valve supplied with the boiler should be screwed to theblow off pipe at the rear of the boilerand connected to a blow off receptacle of approved design piping. All these procedures should bedone in accordance with state and/orlocal codes. The water gauge blow off valve should be connected to the main blow off line.

Note

Care should be taken to ensure that the blow off receptacle usedmeets the regulations covering suchvessels. If in doubt consult a Fulton Representative for advice.

2. Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature.

3. Vent pipe should not be down-sized (This may cause pres-sure build up in the condensate


Feed Water Piping

a) Connect the feed water stop valve tothe opening over the blow- off at the rearof the boiler and pipe it to the return sys-tem. If the city water pressure exceeds40 lbs., a pressure reducing valveshould be installed ahead of the returntank.

Note

Where a condensate return tank is tobe fitted, this should:

1. Be vented and

2. Have a capacity sufficient to satis-fy boiler consumption as well asmaintain proper return tank tempera-ture.

3. Vent pipe should not be down-sized (This may cause pressure buildup in the condensate tank.

Blow Off Valve

a) There are two blow off valves on theboiler; the main valve at the rear of theboiler and the water gauge glass blowoff valve. The boiler blow off valve suppliedwith the boiler should be screwed to theblow off pipe at the rear of the boilerand connected to a blow off receptacleof approved design piping. All theseprocedures should be done in accor-

dance with state and/or local codes.

The water gauge blow off valve shouldbe connected to the main blow off line.

NoteCare should be taken to ensure thatthe blow off receptacle used meetsthe regulations covering such vessels.If in doubt consult a FultonRepresentative for advice.

Main Steam Valve

a) Insert the main steam valve in thesteam supply line as close as possibleto the boiler and prior to any of thesteam using equipment, ensuring cor-rect steam traps are used.

Steam Safety Valve

1) Before installing,be sure that allsteam pipes and connections have beenblown clean; pipe compound or dope isused on external threads only; and inletof valve is free of any foreign material.

2) Do not use a pipe wrench! Whenmaking installation, use proper type andsize wrench .

3) The valve should be installed in a vertical upright position in the connec-tion provided with no unnecessary intervening pipe or lining. Under no circumstances should there be a shut offvalve or restriction of any kind betweenthe safety valve and the connection provided.

4) Do not cap or plug drain hole in theside of valve body.

5) Since the purpose of this safety valveis to protect against an overpressure situation, it will loudly discharge hotsteam in doing so. Therefore, it is recommended that a discharge pipe besecurely installed and run to a safe point of disposal.

6) When a discharge pipe is used, itmust be of a pipe size equal to orgreater than that of the valve outlet. Use schedule 40 discharge pipe only.Do not use schedule 80, extra strong ordouble extra strong discharge pipe orconnections. It must be as short andstraight as possible and so arranged asto avoid undue stress on the valve. Itmust have an ample provision for draining condensate at or near the valve outlet. It must terminate freely toatmosphere with no intervening valve ofany description and it must be securelyanchored and supported.

Caution

Do not downsize piping below safetyvalve size.

Caution

Unless otherwise specified, the steam safety valve supplied with the boiler is pre-set. This valve is provided as a safety device for theboiler and should not be used as thesole protection for other equipmentusing steam from the boiler. Do nottamper with the setting (It could accidentally be set at a pressure higher than the design pressure of the boiler, and therefore create a hazardous condition.



Electrical Power Requirements (In Amps)

Model FB-L 012 015 018 024 030 036 050 075 100 150 200 300 500 7501000

208V 3 Phase 34 42 50 67 84 100 139 208 278 416 556 832 *

* * 230V 1 Phase 52 65 78 -- -- -- -- -- -- -- -- ---- -- --

Electrical Requirements

a) Connect wiring as shown in the specific wiring diagram which is furnished inside the cover of the electrical control box. Be sure to install aseparate fused disconnect for the element contactors and a separatefused disconnect for the feed waterpump. All wiring must conform to NECCode.

b) A correctly sized fused disconnectswitch should be fitted as close to theboiler as possible and connectionsmade to the boiler control panel in compliance with NFPA (National FireProtection Association), NEC Code, andlocal codes. The appropriate number ofterminals are provided inside the controlpanel box to take these connections,but the panel box must be drilled toaccept the type of conduit used.

Boiler Controls --Fulton packaged electric steam boilers are equipped withboth a steam pressure control and ahigh limit pressure control mounted onthe outside of the electrical panel box.

a) The steam pressure control should

be adjusted to suit the boiler applica-tion. The control has two scales (mainand differential) which can be adjustedby means of screws on top of the con-trol. The main scale setting should beadjusted to the desired operating steampressure.

Caution

Do not adjust to exceed the pressurerating on the boiler.

b) A high limit pressure control is locatednext to the operating steam pressurecontrol and should be set 5 to 10pounds higher than the operating steampressure control. This control serves asa secondary high pressure cut-off if forsome reason the main operating steampressure control should become inoperative.

Water Control Relays

a) Boilers from 1.2 to 3.6 HP are

equipped with one low water cut off relayin the panel box connected to oneprobe in the top of the boiler and one

water level control relay in the panel boxoperating two probes in the top of theboiler.

b) Boilers from5 - 20 HP con-tain two lowwater cut offrelays in thepanel box con-nected to twoindependentprobes in thetop of the boiler.

c) Boilers from30 - 100 HPhave an exter-nal water col-umn on the righthand side of theboiler. There are two low water cut off


-- Indicatesnot available.

* Indicatesvoltages available atspecialrequest.

Fulton Boiler Works, Inc.14-ES 4-00

Description/Instruction

Water Gauge & Gauge GlassInstallation Instructions

Note

Only properly trained personnelshould install and maintain watergauge glass and connections. Wearsafety glasses during installation.Before installing, make sure all partsare free of chips and debris.

Note

Keep gauge glass in original packag-ing until ready to install.

1. Verify the proper gauge has been supplied.

2. Examine the gauge glass and packings carefully for damage beforeinstallation. Do not use the glass if itcontains any scratches, chips, or anyother visible signs of damage.

3. Do not subject the gauge glass tobending or torsional stresses.

4. Apply Teflon tape or pipe dope topipe threads. Install top gauge fitting(fitting without a drain valve) into theuppermost tapping. Wrench tighten thefitting until it is snug and the glass outletis pointing at five o’clock (about 1/8 turnfrom its final downward vertical position).

5. Install the bottom gauge fitting (the fitting with a drain valve) until it is snugand the glass outlet is pointing directlyupward. Verify top and bottom fittingsare threaded into the tappings the samenumber of turns (distance A=distanceB).

6. Remove glass packing nut, frictionwasher and glass packing from the fittings, and place them, in the sameorder, on to both ends of the gaugeglass. Push both packings about aninch up the gauge glass.

7. Gently insert one end of the glassinto the top gauge fitting. Keeping theglass inside the top fitting, gently rotatethe top gauge fitting clockwise until ver-tically aligned with the bottom gauge fit-ting, then inset glass into bottom fittinguntil glass bottoms out on the shoulderinside the bottom fitting.

8. Carefully raise glass about 1/16” andslide lower glass packing down until theglass packing contacts the lower gaugefitting. DO NOT allow the glass toremain in contact with any metal!

9. Carefully slide upper glass packing

up as far as possible.

10. Hand tighten both glass packing nuts, then tighten 1/2 turn more by wrench. Tighten only enough to prevent leakage. Do not over tighten! If any leakage should occur,tighten slightly, a quarter turn at a time,checking for leakage after each turn.

11. Install the protective guard, and

utilize automatic ball checks where necessary to help prevent injury in caseof glass breakage.

Warning

Improper installation or maintenanceof gauge glass and connections cancause immediate or delayed breakageresulting in bodily injury and/or property damage.



Water Supply

a) The quality of the water used in theboiler will affect the life of the elementsand it is strongly recommended that acompetent water treatment concern beconsulted prior to the installation of theboiler. They should be advised that treatment will be used on an electricboiler. Certain chemicals will attach toboiler heating elements and shortentheir life span. Elements damaged dueto adverse water conditions cannot bereplaced under warranty.

b) Natural feedwater supplies containsolids and dissolved gases. These may promote incrustation or scale,foaming, solids in steam, corrosion,and/or caustic embrittlement. To preventthis, feedwater must be studied individually and treated accordingly.The treatment should provide qualityfeedwater to the boiler such that corrosion and deposition in the boilerwill be minimized. Dissolved oxygen,high chloride levels and low pH can allbe major causes of corrosion. Untreatedhardness is the major cause ofdeposits. Poor quality feedwaterrequires increased blowdown andincreased chemical treatment costs toprevent boiler corrosion and scaling.

c) One way to lower the amount of dissolved oxygen in the boiler feedwater is the sparge tube option. Thisoption injects live steam into the feedwater to increase the water temperature to 180 degrees F (degrees C) which removes oxygenfrom the water.

d) Chlorides can be controlled byincreasing the number of blowdownsper day from one to four.

e) The Fulton Warranty does not cover damage or failure that can beattributed to corrosion, scale or dirtaccumulations. Oxygen is a corrosive.

Recommended Water Treatment

a) Following are recommendations for feed water and boiler water. Contact your local water treatment professional for testing and treatmentrecommendations. It is very importantthat a strict water treatment program be followed.

Feedwater:

Dissolved Oxygen.....less than 0.05ppmpH Value...................9-11*Hardness..................less than 70 ppmin terms of calcium carbonate Oil.............................noneSuspended Solids.....noneOrganic Matter..........less than 5.0 ppmChloride....................less than 50.0 ppmTotal Dissolved Solids......less than300ppm

Boiler Water:

Phosphate....................30 to 50 ppmexpressed as PO4 (Phosphate)Alkalinity.......................less than 300ppm as CACO3 (Calcium Carbonate)Chloride.......................less than 500ppmpH Value....................9 to 11 (measuredat room temperature)Total Dissolved Solids---less than 2,000 ppmIron................................1 ppm maxi-mumSilica........................180 ppm max. asSIO2Hardness..................less than 50.0 ppmDissolved Oxygen....none

ppm = parts per million* 1 Grain Hardness = 17.118 ppmTherefore: 70 ppm = 4.10 grains hard-ness

b) It is critical that the boiler pH be alkaline (9-11) whenever water is in theboiler. This is traditionally maintainedthrough a combination of sodiumhydroxide and phosphate. The phosphate has the additional benefit ofremoving any hardness that may leadpast the softener. Solids that enter inwith the feed water concentrate in the boiler.

A regular schedule of boiler blowdownmust be maintained to prevent high salt concentrations (chloride and sulfate) from corroding the boiler orforming deposits.

Glossary of WaterSupply Corrosivesand Inhibitors

Dissolved Oxygen: Oxygen that is dissolved in the feedwater will causethe steel in the boiler and the feedwater system to be attacked by the water in amanner described as “pitting”. The pitsthat are produced y can vary from tinydepressions to holes large enough topenetrate the boiler metal and are usual-ly covered with tubercles of iron oxide.Once pitting starts, it may be extremelyhard to arrest. Pitting can proceed at a

surprisingly rapid rate and can occurnot only in the boiler proper, but also in pre-boiler equipment such as ecomomiz-ers, feedwater heaters, and feedwaterlines.

Sodium Sulfite Its purpose is to chemically remove the dissolved oxy-gen left in the feedwater after the feed-water has been mechanically deareated.Sodium Sulfite reacts chemically withdissolved oxygen, producing sodiumsulfate. Since it is desirable to removedissolved oxygen from the feedwaterbefore it reaches a boiler. Sodium sulfiteis best introduced continuously at somesuitable point in the feedwater system(the storage section of the feedwaterheater or deareator, six inches belowthe water line). Chemical residual con-trol is based on the maintenance of aspecific excess of sodium sulfite in theboiler water. The essential requirementbeing to maintain in the feedwater at alltimes slightly more than enough sodiumsulfite to consume all of the dissolvedoxygen that slips through the deareat-ing equipment. When sodium sulfite is notfed continuously, protection of the boileragainst oxygen attack must depend onthe reserve of sodium sulfite that is present in the boiler water. In this case,it is important that the feedwater andthe boiler water are mixed thoroughlyand as quickly as possible so that boilerwater sodium sulfite may consumefeedwater oxygen before the latter cancause damage to the boiler.

Sulfite as a treatment represents the second line of defense against oxygencorrosion. Primary protection againstthis type of attack requires adequate facilities for mechanical deareation of the feed-water plus a vigorous maintenance program to safe guardagainst oxygen leakage into the pre-boiler system.

Suspended Solids:Suspended solidsare the undissolved matter in water,including dirt, silt vegetation, and anyother insoluble organic matter. Normallysuspended solids are expressed interms of turbidity.

The presence of suspended solids incooling water can increase impingementtype corrosion. Suspended solids may alsodeposit in low velocity areas and createdifferential aeration cells. Pitting can result.

The most common cause of high suspended solids is high hardnessfeedwater. Of the agents which causefoaming, suspended solids probably




Reasons for the increased hardness or other suspended solids should bedetermined.

In line filters, or various types of pretreatment can be used to lower thesuspended solids level. Various polymers assist in holding solids in suspension .

Alkalinity: Alkalinity is the capacity of awater to neutralize acids. Common wateralkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, andsilicate. These alkalinities, especiallybicarbonates and carbonates, breakdown to form carbon dioxide in steam,which is a major factor in the corrosionon condensate lines. High alkalinity alsocauses foaming and carry over in boilers.

Both foaming and carry over cause errat-ic boiler operation. When foaming occursan antifoam should be added orincreased. The reason for the high alkalinity should be determined. It mayresult from lack of sufficient blow off.Pretreated makeup water and condensateshould also be checked. Quite often thesource of alkalinity is an overdose ofalkaline internal water treatment chemical.

pH: pH is a measure of the degree ofacid or base of solution. Normal pHranges of 6.5-9.0 will have little influenceon the corrosion rate of cooling waters. Iffor some reason— pollution, etc.—thepH is lowered into the acid range,increased corrosion can be expected.The solution lies in determining thecause of the low pH and correcting thatcondition. A low pH can result in corrosion of metals, while a high pH canresult in scale formation. In order to control boilers and equipment used forthe external treatment of make up water, it is essential that reliable pH mea-surements be made.

Phosphates: Ground or surface watersseldom contain large amounts of phosphates. If present, it generally indicates fertilizer runoff or pollution.Phosphate from raw water can be thecause of scale problems in open recirculating cooling water systems afterthe water is concentrated.

Chlorides: Chlorides are involved inmost cooling water corrosion cells. Otherfactors being equal, it can be assumedthe higher the chloride content, the morecorrosive the water. When pits or cracksoccur on stainless steel or other metals,chlorides are always suspect.

If chloride levels are high enough tocause severe corrosion, they can be

controlled in open recirculating systemsby limiting the cycles of concentration.Corrosion from chlorides can also becontrolled by increasing the amount ofcorrosion inhibitor or changing to a moreeffective inhibitor. Reverse osmosis isanother method of pretreatment toreduce chlorides.

Osmosis is a process that uses a semi-permeable membrane, under pressure, to reject dissolved salts andallow water to pass through. When asolution of salt and water is separated by a membrane, the osmotic pressureforces the water through the membrane,diluting the salt solution. When pressuregreater than osmotic pressure is appliedto the salt solution, the membrane allowsthe water from the salt solution to passinto the water solution and rejects thedissolved salts. The osmotic process isreversed, hence, reverse osmosis.

Oil: Oil is not a natural constituent ofboiler water; still it can frequently enter asystem through leaks in a condenser orother heat exchanger. Oil can also entera system through the lubrication ofsteam driven reciprocating equipment.Whatever the source, the presence of oilin boiler water is undesirable. Oil can actas a binder to form scale. In high heat-transfer areas oil can carbonize andfurther contribute to the formation of scale.

Foaming is one indication of oil in boiler water. Its presence can also be confirmed by first shaking a bottle containing boiler water. If oil is presentfoam will result. To ensure the foaming isbeing caused by oil, add a small amountof powdered activated carbon to the bottle containing the boiler waterand shake. Little or no foam will appear if the foaming is caused by oil. Often oilin boiler water will originate in the condensate. This contaminated condensate should be directed to thesewer until the source of the oil is determined and corrective steps taken.

Silica: Silica in boiler deposits is usuallycombined with other constitutents.Silicates form a number of different scalecomplexes with calcium, magnesium,aluminum, sodium, and iron. Since thereis at present no effective dispersant forsilicate deposits, the scale problem canbe alleviated by maintaining close control of calcium, aluminum, and iron aswell as silica. The usual control procedure is to maintain the silica level in open recirculating water at 180 PPM max.

Iron (oxides): Iron in any of its oxide orcomplex forms is undesirable in boilerwater. It is very difficult to disperse sothat it can be removed the bottomblowoff lines.

Iron in its various forms can originate inthe raw water makeup, condensatereturn water, or form directly in the boileras a result of corrosion. Most iron oxideoriginates outside the boiler. It does notconcentrate in the boiler and it tends tocollect in stagnant areas. If a boiler isusing raw water makeup, iron is almostcertain to be a major component ofdeveloping scale.

Water Hardness: Water hardness is the measure of calcium and magnesiumcontent as calcium carbonate equivalents. Water hardness is a primary source of scale in boiler equipment.

Feedwater: Feedwater is the combination of fresh makeup and returning condensate that is pumped tothe boiler.

Condensate: Condensate is condensed steam that is normally low indissolved solids. Hence, it does notcontribute to the dissolved solid contentof the feedwater. In addition, condensateis very expensive to waste. It's beenchemically treated, heated, pumped,converted to steam, and condensed.This costs money and when condensateis returned to the boiler, money is saved.


Installation Check Points

1. Make sure all piping connectors arecomplete and tight

2. Make sure the pressure controls areadjusted properly.

3. Make sure all electrical connectionsin the control panel box, the water column, and elsewhere are secure.

Note

After installation is complete andprior to operation, the pressure vessel

should be cleaned.

Cleaning The Pressure Vessel

a) After the boiler has been installedand before it is placed in service, it isadvisable to clean the pressure vessel to eliminate any oil film, dirt, or other impurities. Clean the pressure vessel as follows:

1. Isolate the boiler from the system byshutting off the main steam valve.

2. Remove the steam safety valve.

3. Mix washing soda with water in aone-gallon container and pour it into theboiler through the steam safety valveopening.

The mixture of washing soda is as follows:

Boiler Size Soda

12 Kw to 36 Kw 1/2 lb. (227g)

50 Kw to 75 Kw 1 lb.(454g)

100 Kw to 150 Kw 2 lbs. (908g)

200 Kw to 300 Kw 3 lbs. (1362g)

500 Kw 3-1/2 lbs.(1589g)

750 Kw 4 lbs.(1816g)

1000 Kw 5 lbs.(2270g)

4. Replace the steam safety valve.

5. Fill the boiler with water. Water level is about center in the water gaugeglass.


Operation

3


Operation

Introduction

The following instructions are given for theguidance of the operator in the use ofFulton Electric Steam Boilers. Beforeoperating your Fulton Electric Steam Boiler:

Stop! Make sure you have read andfollowed all previous safety information.

Note

Check with local authorities whereapproval for start-up is required. Insome localities, final inspection ofservices may be required.

Caution

In general, ensure that the boiler areais in conformance with establishedboiler room requirements. Reviewnational and local codes.

Starting the Boiler

Do not attempt to start the boiler until allof this section has been read. Carry outthe following procedure on the initialstart up of the boiler and on every sub-sequent occasion when restarting theboiler after a shut down.

a) Close blow-off valve.

b) Close water gauge drain valve.

c) Open main steam stop valve at thetop of the boiler.

d) Open water feed valve on boiler.

e) Open valves on makeup water line toreturn if return system is used.

f) Place feedwater pump fused switchin the “on” position. The water pumpwill continue to operate until the waterhas reached the proper level in the boil-er. This level is at about the center ofthe water gauge glass.

g) To check proper boiler control operation and pressure control settings,you may choose to close the steam supply valve on initial start up. This willenable you to observe the complete boiler operation without heating the complete system.

The fused switch that controls the

feed water pump should be kept in the“on” position at all times during the boiler operation as well as during thenon-operating period of the boiler. Thisshould be turned off only when repairsor adjustments are to be accomplished.

h) Turn the switch on the boiler to the“on” position. The white light will lightindicating that the electrical circuit forthe boiler has been energized and thatall controls are working properly.


Operation

Boiler Controls

The boiler is now fully operational andwill be automatically controlled as follows:

a) The steam operating pressure controlwill control the on/off cycle of the ele-ments once the boiler is operating. Thelow water cut-off probes will signal thelow water relays and shut off power tothe elements should the water in theboiler drop to an unsafe level and willonly

re-energize the elements when the waterin the boiler has regained a safe level.Proper water level control is maintainedautomatically by two water level probeslocated in the boiler shell (1.2-20 HP) orin the water column (30-100 HP). These

two probes turn the water pump on oroff.

b) Fulton Boilers are equipped withsolid state plug-in relays. Manual reset is standard. It can easily be distinguished by the low water reset

button located on the panel box. ForModels FB-012-L through FB-036-Lthere is a pump control relay and onelow water cut off control relay located inthe panel box. For Models FB-050-Lthrough FB-1000-L there is a pump control relay and two low water cut offcontrol relays located in the panel box.The pump control relay is located on theleft and the water level control relay(s)on the right.

Caution

Do not tamper with the safety featuresof the low water safety cut off.

c) The boiler has a manual reset controlshould a low water condition arise. Itwill be necessary to reset the low water control after the water again reaches asafe level in the boiler. In the event ofpower failure this control must also bereset. Place the main switch to the “on”position and press the low water resetbutton and the contactor will start.

d) On Models FB-012-L through FB-075L after starting the boiler and thesteam pressure reaches the set pres-sure on the operating pressure control,the heating element will then shut off automatically, and the amber light will go out. After the steam pressure dropsaccording to the differential setting onthe operating pressure control, the heating element will then restart automatically and the amber light willcome back on. The differential can be

changed on the steam operating pressure control by adjusting the screwsfound on the top of the control.

e) Models FB-100-L through FB-1000-Ldo not have an amber light, but instead, are standardly supplied with astep sequencer which is located insidethe panel box. The step sequencer


Operation

Warning

When stopping the boiler for anyextensive repairs, shut off mainpower switch and pull main disconnect switches on both theboiler side as well as the feed water side.

f) The high limit pressuretrol is locatedon the side of the control box and con-nected to a steam pressure fitting inthe boiler by means of a copper tube.The high limit pressuretrol will shut theboiler off when the maximum pressureis reached. This pressure is usually set10 to 15 PSI above the operating pres-sure -- but below--the maximum pres-sure of the relief valve.

Thermostat (Optional)

a) An optional thermostat may be supplied with your boiler. This ther-mostat is located on one of the heatingelements and is factory preset at num-ber 11. This should not be readjustedwithout consulting the factory or your local Fulton Representative.

Sight Glass Isolation Valves

a) The brass sight glass isolation valvesare equipped with an internal ballcheck. In the event that a sight glassshould break, the ball will seat, prevent-ing the discharge of steam and water.The brass valve stem must be openedfully to arm this capability. If the valve isin any other position than full open, theball will not seat. For added safety allFulton boilers are equipped with gaugeglass protectors.

Note

To ensure that your Fulton steam boiler is kept operating safelyand efficiently, follow the maintenance procedures set forth inthis manual.


Maintenance

4


Maintenance

Your Fulton Electric Steam Boiler hasbeen designed for years of trouble-freeperformance. To ensure the continuedsafety and efficiency of the boiler, theschedule of maintenance outlined in thissection should be adhered to. The boiler should be inspected annually. Allservice should be performed by a certified contractor.

Caution

Keep boiler area clear and free fromcombustible materials, gasoline, andother flammable vapors and liquids.

Warning

Prior to the commencement of anywork requiring the removal of cover

plates and the opening of the controlpanel box, the electrical supply to beboiler must be disconnected.

Caution

Do not use harsh compounds whichwill injure the feed water pump or elements.

Recommended DailyMaintenancea) The following procedures should becarried out daily. They are designed toprevent the build up of scale, silt, orsludge in the bottom of the boiler and inthe pipes leading to the water gauge. Inaddition to these procedures the advice ofa water treatment supplier should besought and followed. An ASME SectionVIII blow off receptacle must be providedfor the appropriate pressure.

b) Make a daily inspection of the boilerand system for leaks or any unusual condition in the operation of the controlsand feed pump.

c) Check water level in sight glass.

(It should be halfway in the sight glassto prevent a dry fire condition which canpermanently damage the elements andpressure vessel.)

d) Check all valves to see that they areopening and closing properly.

e) Daily Blow Off Sequence:

1. Close main steam supply valve.

2. Start the boiler.

3. When the steam pressure hasreached 20 PSIG, turn on the tap waterto the blow down separator, then openblow down valve(s) for approximately 10-20 seconds. Close the valve(s).

4. Shut off tap water to blow off separator.

5. For 30 - 100 HP Electric Boilers youmust also blow down water level control each morning by opening the water column and water gauge blow off valves for approximately 10 seconds.Close valves.

6. Allow the boiler feed water pump torestore the water level in the boiler.

7. Reopen main steam supply valve forplant operation. If surging occurs, clos-ing the main steam valve partially willoften stop this.

f) Water gauge glass — inspect dailyuntil the need for replacement becomesapparent. This will assist in establishingroutine replacement schedules. Examinethe surface of the glass for scratches,corrosion, chips, cracks, surface flaws,or nicks. To do this, shine a very brightconcentrated light at an angle of about45 degrees. A defective glass will glis-ten as the light strikes imperfections.

Recommended MonthlyMaintenance

a) Feed water pump and motor shouldbe lubricated according to the manufac-turer’s instructions.

b) Heating Element - Inspect heatingelement. To protect the element andprolong its life, it is essential that regularinspections are carried out. The mostcommon causes of element failure areexcessive build up of scale and corro-sive attack. Both causes are due toadverse water treatment.

1. The dangers of scale to the life of theelement cannot be overstressed. Scalepossesses excellent insulative qualitiesand its formation on the element prevents the heat generated bythe element from being transferred to thewater, causing the element to overheatand burn out.

2. Loose powdery formations can beremoved with a wire brush.

3. Hard scale may be removed using amild chemical cleaning agent followed by a neutralizing agent.

c) Low water cut-off relay — Checkthat the low water cut-off relay is operat-ing correctly in the following manner:

1. With the boiler operating, open theboiler blow down valve.

2. When the water drops below therequired level, the relay will shut off thecontactor. This shows that the relay isworking properly. Reset low water cut-offby pushing the reset button on the sideof the panel (5 to 100 BHP only).

3. Close blow-off valve lines and allowboiler to fill to proper level.

d) Blow down the boiler and sight glasscompletely as described under dailymaintenance.


Introduction

Blow Down Boiler Daily. Shown is the blowdown “Y” valve.

Blow down water column each morning byopening the water column and water gaugeblow-off valves.

Maintenance

e) Clean the Water Gauge Glass

Caution:

Do not clean the gauge or gaugeglass while pressurized or in operation.

1. Clean the water gauge glass using acommercial non-abrasive glass cleaner.Use diluted acids such as hydrochloric(muriatic) acid when regular cleaners donot seem to work. Do not use wirebrushes or any other abrasive materialswhich could scratch the glass. If any leakage is evident, replace the gaskets.

2. Always replace the high impact plastic gauge glass protector which isstandard on all Fulton Boilers.

f) Clean water pump strainers.

g) Check operation of all steam trapson condensate return system.

h) Remove pipe cap at the cross connection below water column andclean nipple into boiler. Boiler must becold and water level below pipe,(30 - 100 BHP only).

Recommended QuarterlyMaintenancea) Shut off the boiler completely and drain.

b) Remove the handholes and inspectthe interior of the vessel for scale orsludge deposits. The amount ofdeposits will indicate the efficiency ofthe water treatment being used. The fre-quency of this inspection will be depen-dent on the condition of the water sideof the boiler.

c) Replace handhole gaskets usingthe following procedure.

1) Remove old gasket and thoroughlyclean the surface on the boiler and theplate.

2) Place gasket on handhole plate. Besure the gasket is pushed down tight onthe plate. Do not use any grease, lubricant or adhesive.

3) After the plate is in the boiler and the gasket is in place, set yoke and tighten nut only enough to provide asnug fit. Make it hand tight and thensnug with wrench about 1/4 turn. Do notcompress excessively.

4) If the gasket leaks while pressure isbeing built up, tighten only enough tostop leakage. Never tighten more thannecessary to prevent leakage.Excessive tightening may shorten life ofthe gasket.

c) Refill the boiler with fresh water.

Recommended Six MonthMaintenancea) Steam Safety Valve -- Under normaloperating conditions a “try lever” testshould be performed approximately

every six months. Testing should beperformed more often under severe service conditions or if corrosion ordeposits are noticed within the valvebody. A “try lever” test should also beperformed at the end of any extended non-service period. Check that thesteam safety valve is operating properlyby conducting a “try lever” test.

Caution

Prior to performing the “try lever” test,be certain to take precautions as aloud noise and high velocity steamwill discharge freely from dischargeport and through drain hole providedin the side of the valve body.

1. The test lever is designed to be activated only when 75% or more of therelief pressure is reached, otherwise distortion could result. The valve shouldbe tested at or near maximum operatingpressure by holding the test lever fullyopen for approximately 5 seconds toflush the valve seat free of any debris or sediment.

Inspect handholes for scale or sludge buildup

illustration shows correct pressure on gas-ket

Illustration shows over compressed gasket


Clean Glass; Replace Gaskets If Leaking

Remove cap at cross section; clean nippleto boiler

a) Steam Safety Valve (cont.)

2. Permit the valve check to snap shut.3. If lift lever does not activate and thereis no evidence of valve discharge, shut down equipment immediately and replace valve.

b) Cleaning Probes: Clean probe on topof boiler shell and probes in water col-umn (30 - 100 BHP). Make sure there isno pressure on boiler during the removal ofthe probes. Remove one probe, cleanwith very fine emery cloth and replace itbefore removing another to assure noprobe mix ups that would change thecontrol functions.

For replacement purposes, installedprobe lengths are indicated in the chartbelow. For a universally adaptable plug and probe which can be cut tolength in the field to fit all boilers, orderPart No. 2-20-017.

1.2 to 3.6 HP 5-20 HP 30-100 HP

A = 9-1/2” A =11-1/2” A = 7-1/4”

B = 10-1/2” B = 13” B = 9-1/4”

C = 11-1/2” C = 15” C = 11-1/4”

D = 11-1/2 D = 15” D = 16”

c) Drain the condensate tank and cleanby flushing with hose. Check float valveoperation.d) Make sure pump is functioning.e) Clean boiler out if necessary. SeeInstallation Check Points: cleaning thepressure vessel.

Recommended AnnualMaintenancea) Repeat six month maintenance.b) Check elements for correct amp draw.c) Provide annual inspection by quali-fied ASME Boiler Inspector (if applicablein your state).

Maintenance


A

DC

B

MaintenanceTroubleshootingThis troubleshooting guide will assist in the diagnosis and correction of minor field problems. It should be used in conjunctionwith the unit wiring diagram. In any case requiring additional assistance, contact your local authorized Fulton Representative.

Problem Cause CheckControl Circuit Failure A. Fuse If a break is detected, shut off power and

remove fuse. Replace with a new fuse of same voltage andamps. Turn power on.

B. Voltage Trace wiring diagram through each component to verify power in each stage. If voltage is not detected at any point, replace component and continue test until circuits test clear.

C. Control Switch Check all wires from switch terminals for loosenessor corrosion. Replace if either is evident. Next check for proper make and break ofswitch.

D. Low Water Safety Relay Verify that boiler has water. Check to verify power on terminal #1. If power is present, check to verify

power on terminal #10. If power is not present, press the low water reset button to reset relay. If relay does not reset, inspect terminals for loose

connections. Inspect probe connection.

E. Corrosion of Probes Check all wires to verify proper wiring to each probe. If a wire is suspected to be in the wrong place, shut

off power and check wire with a con tinuity light. Check probes. If probesare dirty, clean with very fine emory paper and replace.

F. Staging Controller Verify timing and stage selection on DIP switches.

Pump Circuit Failure A. Fuse If a break is detected, shut off power and remove fuse. Replace with a new fuse of same voltage and amps. Turn

power on.

B. Corrosion of Probes To verify proper wiring to each probe. If a wire is suspected to be in the wrong place, shut off power and check wire with a con-

tinuity light. Check probes. If probes are dirty,clean with veryfine emory paper and replace.

C. Wiring Connections With power off, check continuity of circuit through each point in the circuit. If a break in the circuit is found, repair. After

repair, recheck with continuity light with power off. Turn power on and check with an amp meter.

D. Motor Starter Relay Check power supply to coil on motor starter.coil is being powered, check if contactors are being engaged completely.

If coil and contactors are engaging, check power in and out on the con-trol circuits. If contactor is chattering, clean contacts.

If motor starter relay is weak or bad, replace.

Primary Voltage Circuit A. Fuse If a break is detected, shut off power and remove fuse. Replace with a new fuse of the same volt-

age and amps. Turn power on.

B. Voltage Trace wiring diagram through each component to verify power in each stage. If voltage is not detected at any

point, replace component and continue test until circuits test clear.


Maintenance

TroubleshootingProblem Cause CheckPrimary Voltage Circuit C. Wiring Connections With power off, check continuity of circuit

through each point in the circuit. If a break in the circuit is found, repair. After repair, recheck with continuity light

with power off. Turn power on and check with an amp meter.

D. Burned or Broken Wiring With power off, check continuity of circuit through each point in the circuit. If a break in

the circuit is found, repair. After repair, recheck with continuity lightwith power off. Turn power on and check with an amp meter.

Verify wire size is sufficient for amp draw.

E. Contactor Contact Points If burned or dirty, clean with fine emory paper. If burned through, replace. If not engaging com pletely,coil may be weak. Replace.

F. Elements Shorting or Open Circuit With power using a continuity tester, check to see if an element is burned out between each point. If power is on, a volt meter maybe used. If an element is bad, replace.

Low Water Condition A. Circulating Pump Clean or replace all filters or screens to assure proper water flow through them.

B. Water Makeup Supply Check to see that your supply water has not been shut off or that there are no restrictions in the line leading to the boil-

er.

C. Leaks in the System Check piping for any leaks.


Parts

5


Parts

a) It is important that the correctreplacement part is fitted to yourFulton Electric Steam Boiler.

b) When ordering replacement orspare parts, make sure that the fullinformation given in the Parts List is

supplied, together with the followingdetails as shown on your boiler identification plate:

1. Boiler Number2. Boiler Type3. Electrical Specifications

Note:

The policy of Fulton Boiler Works,Inc. is one of continuous improvement, and therefore, we reserve theright to change prices, specifications,and equipment without notice.

Fulton Electric Steam BoilerUnderwritersLaboratories Inc.® LISTED ELECTRIC BOILER CONTROL NO. 87CO

Boiler No./National Board Number Model

Month

HDSHMD Lbs. Steam/Hr.

Year

Freq.AmpskwPhaseVolts

MWPHS

Use Supply Cable Rated 75°C

Control Circuit Pump Motor

HPPhaseFreq.AmpsVolts

Maximum Time Delay Fuse

CRN No.

Amps Maximum Supply Circuit Ampacity

For Connections Use Wire Suitable For At Least 167°F (75°C) Minimum

Fulton Boiler Works, Inc.Pulaski, NY 13142

Fulton Boiler Identification Plate


Spare Parts

Parts


Replacement Parts Listing (available from authorized Fulton Representatives)

Part Number Item Description

5-60-110 Instruction Manual - Electric

5-10-800 Weld Patch 1.2-100 HP

4-11-010 Handhole Assembly 1.2 - 5 HP (White) 4-11-012 Handhole Assembly 7.5 -15 HP (Red) 4-11-014 Handhole Assembly 20 HP (Green) 4-11-016 Handhole Assembly 30 - 45 HP (Yellow) 4-11-018 Handhole Assembly 50 -100 HP (Blue)

2-11-100 Handhole Plate 1.2 - 5 HP (White) 2-11-101 Handhole Plate 7.5 -15 HP (Red) 2-11-102 Handhole Plate 20 HP (Green) 2-11-103 Handhole Plate 30 - 45 HP (Yellow) 2-11-104 Handhole Plate 50 -100 HP (Blue)

2-11-105 Handhole Yoke 2-12-004 Handhole Gasket

2-23-237 Touch-Up Paint (Spray Can 16 oz.) 4-23-010 Touch-Up Paint (Quart) 4-23-040 Touch-Up Paint (Gallon) 5-10-397 T-Handle Wrench 2-20-017 Water Level Plug & Long Brass Rod Suitable for Cutting

2-30-137 McDonnell Miller 53-2 Boiler Feeder 2-30-149 Water Gauge Valves Only w/Ball Checks 2-12-017 9-1/4“ Water Gauge Glass 2-12-019 Rubber Water Gauge Glass Gasket 2-12-020 Brass Water Gauge Glass Gasket 2-35-514 Brass Packing Nut for Water Gauge Valve 2-12-022 Lucite Gauge Glass Guard 2-30-399 142S Watts Water Feeder

2-40-403 IDIDO Relay 115 Volt 2-40-402 IGIDO Relay 115 Volt 2-40-401 ID2DO Relay 230 Volt 4-45-050 Set of (3) Coils for IDIDO 2-45-092 Manual Reset Switch 2-40-420 Fulton Pump Relay - 120V 2-40-421 Fulton Burner Relay-120V 2-40-422 Base for Fulton Pump Relay 2-40-423 Base for Fulton Burner Relay

2-40-405 Fulton Pump Relay 220v 2-40-406 Fulton Burner Relay 220v

2-45-090 Night Switch for (2) Pressuretrols 4-40-050 Night Heating Pressuretrol Set-Up2-45-107 White Panel Box Indicating Lights 120 V 2-45-108 Amber Panel Box Indicating Lights 120 V 2-45-110 Red Panel Box Indicating Lights 120 V

Parts


Replacement Parts Listing (continued)


2-45-115 White Panel Box Indicating Lights 240 V

2-45-116 Amber Panel Box Indicating Lights 240 V

2-45-114 Red Panel Box Indicating Lights 240 V

2-40-904 240V 10 Step Solitech Sequencer

2-40-227 Pressuretrol L404A 1354 2-15 PSI




2-40-231 Pressuretrol L404C 1147 2-15 PSI




2-40-225 Pressuretrol L91B 1035 0-15 PSI


2-45-000 Terminal Block 1492-1 OOX A-B

2-40-023 60 Amp Contactor 120 volt

2-40-295 60 Amp Contactor 240 volt

2-40-296 60 AmpContactor 220 volt with 300 volt fuse clip

2-40-024 60 Amp Contactor 120 volt with 300 Volt Fuse Clip

2-40-025 60 Amp Contactor 120 volt with 600 Volt Fuse Clip

2-40-022 60 Amp Contactor 220V with 600 Volt Fuse Clip -

2-40-027 240 Volt Coil for 60 Amp Contactor

2-45-006 SC-40 Fuse

2-45-007 SC-50 Fuse

2-45-008 SC-60 Fuse

2-45-010 JKS-35 Fuse

2-45-011 JKS-40 Fuse

2-45-012 JKS-50 Fuse

2-45-013 JKS-60 Fuse

2-30-100 Flange Gasket 12-35 KW Element

2-30-101 Flange Gasket 50-75 KW Element

2-45-015 Thermostatfor 12-35 KW Element

2-45-016 Thermostat for 50-75 KW Element

Parts


Replacement Parts Listing (continued)


2-40-028 ABF 12-208 Volt 3 ph. Heating Element with Thermostat 2-40-029 XBF 12-208 Volt 3 ph. Heating Element 2-40-030 ABF 12-230 Volt 3 ph. Heating Element with Thermostat 2-40-031 XBF 12-230 Volt 3 ph. Heating Element 2-40-032 ABF 12-460 Volt 3 ph. Heating Element with Thermostat

2-40-033 XBF 12-460 Volt 3 ph. Heating Element 2-40-034 ABF 12-575 Volt 3 ph. Heating Element with Thermostat 2-40-035 XBF 12-575 Volt 3 ph. Heating Element 2-40-036 ABF 15-208 Volt 3 ph. Heating Element with Thermostat 2-40-037 XBF 15-208 Volt 3 ph. Heating Element


2-40-043 XBF 15-575 Volt 3 ph. Heating Element 2-40-044 ABF 18-208 Volt 3 ph. Heating Element with Thermostat 2-40-045 XBF 18-208 Volt 3 ph. Heating Element 2-40-046 ABF 18-230 Volt 3 ph. Heating Element with Thermostat 2-40-047 XBF 18-230 Volt 3 ph. Heating Element


2-40-053 XBF 25-208 Volt 3 ph. Heating Element 2-40-054 ABF 25-230 Volt 3 ph. Heating Element with Thermostat 2-40-055 XBF 25-230 Volt 3 ph. Heating Element 2-40-056 ABF 25-380 Volt 3 ph. Heating Element with Thermostat2-40-057 XBF 25-380 3 ph. Heating Element

2-40-058 ABF 25-415 Volt 3 ph. Heating Element with Thermostat2-40-059 XBF 25-415 3 ph. Heating Element2-40-060 ABF 25-460 Volt 3 ph. Heating Element with Thermostat2-40-061 XBF 25-460 3 ph. Heating Element2-40-062 ABF 25-575 Volt 3 ph. Heating Element with Thermostat

2-40-063 XBF 25-575 3 ph. Heating Element2-40-064 BWF 50-230 Volt 3 ph. Heating Element with Thermostat2-40-065 XWF 50-230 Volt 3 ph. Heating Element2-40-066 BWF 50-460 Volt 3 ph. Heating Element with Thermostat2-40-067 XWF 50-460 Volt 3 ph. Heating Element

2-40-068 BWF 75-230 Volt 3 ph. Heating Element with Thermostat2-40-069 XWF 75-230 Volt 3 ph. Heating Element2-40-070 BWF 75-460 Volt 3 ph. Heating Element with Thermostat2-40-071 XWF 75-460 Volt 3 ph. Heating Element


Warranty

6


Warranty

1 Year (12 Month) Standard Warranty


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5 Year (60 Month) Conditional Warranty*On the Fulton Boiler Pressure Vessel

*Fulton Boiler Works, Inc. will repair or replace F.O.B. factory any Fulton pressure vessel which, within FIVE (5) years of the dateof shipment from factory, is found to be defective in workmanship or material, provided this equipment is installed, operated and maintained by the buyer in accordance with the Fulton instruction manual and approved practices, and that the +water qualityused in the system has been regularly checked to meet the standards for ideal and proper boiler feedwater during the warrantyperiod. ++This warranty does not cover damage or failure that can be attributed to corrosion, (including oxygen pitting) scale ordirt accumulations, or to low water conditions. Follow feedwater specifications and recommended treatment specifications asdetailed in Section 1 of the instruction manual shipped with your boiler as well as maintenance procedures as listed in Section5. This 5 year warranty applies only in the continental U.S.A. and Canada. The Warranty does not include labor charges of anykind. In the event a failure is reported, Fulton will require an analysis of the boiler feedwater to determine that acceptable waterconditions are present at the installation site as well as documentation on the feedwater treatment employed since the installa-tion of the boiler. The boiler will be required to be shipped freight prepaid to the Fulton factory for inspection after a failure isreported. The customer may witness the inspection and verification at the factory. +Consult Fulton Boiler Works, Inc. for analysis of acceptable water conditions.++Feedwater treatment and proper daily blowdown procedures are very important in keeping your boiler heating surfaces freeof scale formation, pitting, oxygen corrosion and foaming or bouncing water. Professional feedwater treatment consultantsshould be contacted when the boiler is installed. They will recommend the proper treatment required for prolonging boiler life. Athorough boiler inspection should take place during the first six months of operation to assess the effectiveness of boiler watertreatment techniques, including analysis of potential oxygen pitting.

It is the owner's responsibility to assure safe operation of the boiler. To avoid corrosion, scale or dirt accumulations, it is recommendedthat a daily blow down procedure be instituted. The boiler power should be left on during daily blow down so that correct opera-tion in the low water relay may be checked. While blowing down the boiler, the pressure will drop significantly. Detailed blow down procedures are in the boiler instruction manual shipped with your boiler.

Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler. It is the owner's responsibilityto have the boiler room periodically tested to assure these damaging chemicals are not present.

AFulton Boiler Works, Inc. will repair orreplace F.O.B. factory any other part ofthis equipment of our manufacturewhich within twelve months of the dateof shipment from factory is found to bedefective in workmanship or material,provided the equipment has beeninstalled, commissioned, operated andmaintained by the buyer in accordancewith the operating instruction manualprovided with the equipment and general-ly accepted approved practices, andon the provision that the buyer givesproper notification in writing as soon asthe defect becomes apparent, and thathe has properly filled out and returnedhis warranty card. This warranty doesnot include labor charges of any kind.Follow maintenance instructions as listed in the “Instruction Book.”

This warranty is exclusive and in lieuof all other warranties, express orimplied, including but not limited to

the implied warranties of merchantabilityand fitness for a particular purpose.Fulton Boiler Works, Inc. shall in noevent be liable for an consequentialor incidental damages arising in anyway, including but not limited to anyloss of profits or loss of business,even if Fulton Boiler Works, Inc. hasbeen advised of the possibility ofsuch damages.

BControls, motors, feed water pumps,auxiliaries, accessories, and parts manufactured by others may be warrantied by them, but Fulton BoilerWorks, Inc. does not provide any warranty for parts manufactured by others. We endeavor to use nationallyknown controls of the highest qualityand most of the manufacturers of thesecontrols maintain exchange or repairoffices in the principal cities in theUnited States and foreign countries,expressly for the exchange, service,

and repair of their products. Therefore,we request that our distributors and own-ers of our Fulton Boilers utilize the nearestoffices of the individual manufacturers,for the exchange, service, and/or repairof these defective items. We will be gladto furnish the address of the manufacturer’snearest office. If it is more convenientfor our distributors or owners of ourFulton Boilers, the effective item may bereturned to our factory. The manufacturer’ssole judgement shall determine theextent of allowance for or replacementof such parts claimed defective.

CPlease do not request the replacementof parts on a no-charge basis that arenot within the warranty period. No person-nel of Fulton Boiler Works, Inc. has theauthorization to grant such a request.

We will not honor labor charges of anykind unless authorized in writing by ourcompany.

Component Data Sheets

7


Documents

Instruction, Operation Model Number and Maintenance Manual ... · Introduction This manual is provided as a guide to the correct operation and mainte-nance of your Fulton Electric