Fulton Dragon User manual

Brand: Fulton

Model: Dragon

Type: User manual

This manual must be available to the boiler operator at all times. DRAGON-IOMM-2016-5

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Dragon

Electric Steam Boiler

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TABLE OF CONTENTS

SECTION 1 - INTRODUCTION

1.1 General 1

1.2 Technical Data 1

1.3 Product Overview 1

SECTION 2 - INSTALLATION

2.1 General 5

2.2 Pre-Installation 5

2.2.1 Siting 6

2.3 Boiler Connections 6

2.3.1 Steam Safety Valves 7

2.4 Water Supply 8

2.5 Electrical Requirements 8

2.6 Commissioning the Boiler 10

SECTION 3 - OPERATION

3.1 General 13

3.2 Controls 13

3.2.1 Boiler Control Panel 14

3.2.2 Steam Pressure Controls 16

3.2.2.1 Setting Steam Pressure Controls 16

3.3 Filling The Boiler 17

3.4 Draining the Boiler 18

3.5 Boiler Start-Up (from cold)-all models 19

3.5.1 Boiler Start-Up Following short term Shut-Down 19

3.6 Boiler Shut-Down 20

3.6.1 Short Term Shut-Down (hours) 20

3.6.2 Long Term Shut-Down (weeks) 20

Electrical diagrams supplied separately

SECTION 4 - MAINTENANCE

4.1 Visual Checks 21

4.2 Water Level and Low Water Safety Controls 22

4.2.1 Feedwater Pump Test 22

4.2.2 Low Water Level Checks 23

4.2.3 Evaporation Check 23

4.3 Blowdown Procedures 24

4.3.1 Main Boiler Blowdown 24

4.3.2 Water Level Gauge (Sight Glass) Blowdown 24

4.4 Element Care and Protection 25

4.4.1 Element Removal 26

4.5 Boiler Internal Inspection 26

4.5.1 Feedwater Tank Internal Inspection 27

4.6 Cleaning Water Level Probes 27

4.7 Schedule of Operator Tests and Checks 28

4.7.1 Daily 29

4.7.2 Weekly-in addition 29

4.7.3 Monthly-in addition 29

4.7.4 Three Monthly-in addition 30

4.8 Maintenance Record Keeping 31

4.9.1 Troubleshooting-boiler 32

4.9.2 Troubleshooting-feedwater pump 33

APPENDIX A - TI SHEETS

 DragonDimensions&Specication 36

Dragon Probe Lengths 38

Recommended Water Conditions 39

Water Level Probes 40

Auto TDS Blowdown Systems 42

Auto TDS Blowdown System Install Guide 44

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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

SAFETY ASSESSMENT FEDERATION Limited.

Nutmeg House,

60 Gainsford Street,

Butlers Wharf,

London, SE1 2NY.

(b) HealthandSafetyExecutivelocalofce.

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,

regardless of the cause, then the electrical 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.

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.

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.

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.

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Page 1

INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

1.2 TECHNICAL DATA

ForafullspecicationrefertoAppendixA-TI-113-DRAGONDimensions&Specication.

The Fulton Dragon electric steam boiler service manual is a generic publication, providing

information on standard boiler operation and maintenance.

Every care has been taken in the manufacture of the boiler to ensure that quality and reliability

standards are maintained. Satisfactory performance can only be ensured if the installation

recommendations, operating routines and maintenance schedules laid out in this manual are

adhered to.

Particular attention should be paid to electrical installation and water treatment.

1.3 PRODUCT OVERVIEW

CONTINUED ON NEXT PAGE

TheFultonDragonelectricsteamboilerisacompactandhighlyefcientunitdesignedtomeet

the requirements of the lower demand steam user.

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INTRODUCTION - 1

Figure. 1 - General Arrangement

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INTRODUCTION - 1

Figure. 2 - General Arrangement Top

1. Boiler control panel

2. Steam pressure gauge

3. Front access door

4. Access door lock

5. Top access panel

6. Electrical control panel

7. Operating pressure controller

8. Boiler steam safety valve

9. Main steam stop valve

10. Boiler blowdown valve

11. Water sample point

12. Feedwater pump

13. Boiler feedwater check valve

14. Boiler feedwater stop valve

15. Feedwater tank mounted (optional)

16. Feedwatertankoverow

17. Feedwater tank water inlet

18. Feedwater pump feed

19. Feedwater tank drain

20. Pressure vessel

21. Boiler water level probes

Key

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INSTALLATION - 2

2.1 GENERAL

SECTION 2 - INSTALLATION

2.2 PRE-INSTALLATION

Prior to delivery of the boiler, consideration should be given to the following:

(Planning regulations may call for more consents than those listed below, always check with your

Local Planning Authority).

A. Local Planning consents where appropriate.

B. Consideration given to access for delivery and positioning of the boiler.

C. Preparation of a suitable base, which must be able to support the total weight of the system

under operating conditions.

The locations of services to the site required for the system, under operating conditions.

D. Electricity supply, check the loading required/available.

E. Drainage system, check the suitability of the drainage system.

F. Local regulations for discharge into existing drains.

G. Suitable access for delivery and off-loading.

H. Safe access to the plant when installation is complete.

The installation of the Fulton Dragon electric 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.

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INSTALLATION - 2

2.2.1 SITING

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-113-DRAGONDimensions&Specication

to ascertain the relevant dimensions and weights, special note should be taken of the required

clearanceformaintenance.Allowsufcientroomattherearoftheboilertoallowforthe

connection of all services.

Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto

support the boiler.

All connections for services are mounted at the rear of the boiler.

For connection sizes, refer to AppendixA-TI-113-DRAGONDimensions&Specication.

1. Feedwater Inlet

Itisadvisabletotastopvalveascloseaspossibletothisconnectionpoint.

2. Steam Safety Valve Discharge

The outlet from this valve should be piped to a safe discharge point and the piping should be

so arranged that condensate trapped in the discharge pipe is drained away from the valve.

3. Steam Outlet Valve

4. Boiler Blowdown Valve

Connection must be made from the Blowdown valve 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 any doubt regarding blowdown arrangements consult Fulton Ltd.

5. Water Sample Outlet

This is to be connected to a sample cooler to take safe boiler water samples.

NON STANDARD FITTING CONNECTIONS

6. Water Level Gauge (sight glass) Blowdown

It is recommended the blowdown connection is made with a short (6 in.) length of soft copper

tube connected to steel tube running to the blowdown receiver. The copper tube will relieve any

stresses on the water level gauge set caused by the steel blowdown line.

7.Feedwatertankoverow

Theoverowshouldbepipedtoadrainagepoint.

8. Feedwater pump feed

9. Feedwater tank drain

10. Feedwater tank water inlet

CAUTION

Unlessotherwisespeciedthesteamsafetyvalvesuppliedwiththeboilerispre-set.Thisvalveis

provided as a safety device for the boiler and should not be used as the sole protection for other

equipment using steam from the boiler.

2.3 BOILER CONNECTIONS

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INSTALLATION - 2

Figure. 3 - Boiler Connection Points

2.3.1 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.

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INSTALLATION - 2

2.5 ELECTRICAL REQUIREMENTS

The quality of the water used in the boiler will affect the life and performance of the boiler and

elements.

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.

Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. Should chemical

dosage of the boiler feedwater be required a connection point and a water sampling point are provided at the rear

of the boiler.

2.4 WATER SUPPLY

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.

An individual wiring diagram for the boiler is located with the control panel. When referring to the

electricalspecicationoftheboiler,thewiringdiagramnumbershouldbequoted.

The power ratings and requirements are given in Appendix A - TI-113-Dragon Dimensions &

Specication.

A suitable 3-phase, neutral and earth isolated and fused supply is required external to the boiler

and must be connected in accordance with local electrical regulations.

CAUTION

Theboilerfrontaccessdooristtedwithasafetymicroswitch.Thisswitchautomaticallyisolates

theboilerelectricallywhenthefrontdoorisopen,andmustbeconnectedtoacontactorttedinthe

external mains supply distribution system.

It is essential that the electrical installation of the boiler is designed to protect both element and

pump circuits from excess current. See Figure. 4 for recommended external wiring.

Anelectricalisolatorshouldbesecurelyttedascloseaspossibletotheboiler.

Note: Any electrical work should be undertaken by a qualied installer, to current I.E.E regulations.

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INSTALLATION - 2

Figure. 4 - Recommended External Wiring

Figure. 5 - Electrical Panel

LC relays

Element and

pump overload

Audible alarm

Element and

pump contactors

MCB

MAIN

ISOLATOR

3 PHASE FUSED AND ISOLATED SUPPLY

L3 L2

NOT FULTON SUPPLY

MCB MCB MCB

External Wiring Box

CONTACTOR

ELEMENT 1

CONTACTOR

ELEMENT 2

CONTACTOR

ELEMENT 3

CONTACTOR

FEED PUMP

External

Supply

Wiring

Panel

Wiring

Main Terminal Rail

Connections

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INSTALLATION - 2

WARNING

The Power On indicator is derived from one phase. It is possible for the Power On indicator supply

phase to be down, leaving the other two phases live. Always isolate the supply before working on the

panel.

CONTINUED ON NEXT PAGE

2.6 COMMISSIONING THE BOILER

These procedures should be carried out by a competent person.

Although every care is taken to ensure that the boiler has been despatched from the factory

fully tested, it is possible that during transportation and installation, pipework and electrical

connections may be loosened or broken. On completion of the installation and prior to switching

on the boiler it is advisable to carry out the following checks:

WARNING

The boiler electrical circuit must be isolated prior to doing the following tests.

1. Isolate boiler (mains supply)

2. Open front access door

Remove access cover on the top of the boiler

3. Check all electrical connections for tightness

4. Insulation test (IR) the elements

5. Set the steam operating pressure control to maximum pressure required

6. Ensure Mains switch Circuit live switch is in the OFF position

Connect to the mains electrical supply

7. Close boiler blowdown valve

Close main steam valve

8. Open all valves in the feedwater line and pump supply line

Allowfeedwatertanktoll

Check for leaks

9. Loosen the air release valve on the pump until water emerges from the plug and then re-

tighten

10. Close front access door

Retaccesscoveronthetopoftheboiler

WARNING

With the door open and the electrics overridden it is possible for the elements to be LIVE.

Extreme caution must be observed when working under these conditions.

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INSTALLATION - 2

11. Switch main isolator ON

Check the Circuit Live light illuminates

12. Open the main steam valve

13. Switch the Mains On/Off switch to the ON position

Check:

a) Low Water lights illuminate

b) Feedwater pump starts

c) Alarm sounds

CAUTION

The feedwater pump impeller blades can be damaged by incorrect rotation.

14. Check rotation of the feedwater pump (correct rotation shown by arrow on the pump)

Note: If the rotation is incorrect, switch the Mains On/Off switch to the OFF position, isolate the boiler and alter

the phase connections between the pump contactor overload and the pump. Check that the pump rotation is now

correct.

15. Check the feedwater pump runs until correct water level is achieved.

When water level is at normal working level (NWL) the Low Water lights will extinguish

16. Switch the element switches to the ON position

The element switches should illuminate

17. Close the main steam stop valve

18. Observing the steam pressure gauge, allow the boiler to build-up steam pressure until it

reaches the set limit on the operating pressure control switch and de-energises the elements.

Adjust the control switch as necessary

19. Check for leaks:

Turn Mains switch OFF

Turn element switches OFF

Turn main electrical isolator OFF

Open access cover on the top of boiler and front access door

Check for steam/water leaks

Close access cover on the top of boiler and close front access door

Check for steam leaks in connecting pipework

Turn main electrical isolator ON

Turn Mains switch ON

Turn element switches ON

Slowly open the steam valve to release pressure from the boiler until it reaches the set limit on

the operating pressure control switch and re-energises the elements

The boiler is now ready for placing into full operation.

WARNING

The boiler electrical circuit must be isolated prior to doing the following tests.

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OPERATION - 3

CAUTION

The following instructions are given for the guidance of the operator in the use of the Fulton steam

boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.

3.1 GENERAL

The following instructions are given for the guidance of the operator in the use of the Dragon

electric steam boiler and to provide adequate information to ensure that when the boiler is put into

use it will be done safely and without risk to health. Where original equipment service manuals

are supplied, they must be read and understood in conjunction with this manual.

All warnings and cautions must be observed.

SECTION 3 - OPERATION

3.2 CONTROLS

The following brief description of the controls used on the Dragon steam boiler is intended to

provide the operator with a basic understanding of the operating principles, which is essential for

thecontinuedefcientoperationoftheboiler.

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OPERATION - 3

Figure. 6 - Controls and Indicators

The control panel contains a range of rocker switch lights to assist with the starting and testing

procedures, in addition the panel contains warning and fault indicators. Should a warning or fault

be indicated, the boiler must be isolated and the cause investigated by a competent person.

3.2.1 BOILER CONTROL PANEL

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Fulton Dragon User manual

Fulton Dragon User manual

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