Fulton Electropack 100 kW User manual

Brand: Fulton

Model: Electropack 100 kW

Type: User manual

This manual must be available to the boiler operator at all times. EP100-IOMM-2017-11

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Electropack 100 kW

Electric Steam Boiler

(Step Controlled)

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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

2.7 Cleaning Steam Lines and Pressure Vessels 13

SECTION 3 - OPERATION

3.1 General 15

3.2 Controls 15

3.2.1 Boiler Control Panel 16

3.2.2 Steam Pressure Controls 18

3.2.2.1 Setting Steam Pressure Controls 19

3.2.2.2 Step Controller 20

3.2.2.3 Step Controller Indicator Lights 21

3.3 Filling The Boiler 22

3.4 Draining the Boiler 23

3.5 Boiler Start-Up (from cold)-all models 24

3.6.1 Boiler Start-Up Following short term Shut-Down 24

3.6 Boiler Shut-Down 25

3.6.1 Short Term Shut-Down (hours) 25

3.6.2 Long Term Shut-Down (weeks) 25

Electrical diagrams supplied separately

SECTION 4 - MAINTENANCE

4.1 Visual Checks 27

4.2 Water Level and Low Water Safety Controls 28

4.2.1 Feedwater Pump Test 28

4.2.2 Low Water Level Checks 29

4.2.3 Evaporation Check 29

4.3 Blowdown Procedures 30

4.3.1 Main Boiler Blowdown 30

4.3.2 Water Level Gauge (Sight Glass) Blowdown 30

4.4 Boiler Internal Inspection 31

4.5 Fitting New Gaskets To Boiler Inspection Holes 32

4.5.1 Important Information 32

4.5.2 Fitting Procedure 33

4.6 Element Care and Protection 34

4.6.1 Element Removal 35

4.7 Cleaning Water Level Probes 36

4.8 Schedule of Operator Tests and Checks 37

4.8.1 Daily 38

4.8.2 Weekly-in addition 38

4.8.3 Monthly-in addition 38

4.8.4 Three Monthly-in addition 39

4.9 Maintenance Record Keeping 40

4.10.1 Troubleshooting-boiler 41

4.10.2 Troubleshooting-feedwater pump 42

4.10.2 Troubleshooting-feedwater pump 43

APPENDIX A - TI SHEETS

 EP100Dimensions&Specication 46

EP Probe Lengths 48

Recommended Water Conditions 50

High Integrity Water Level Controls 51

Water Level Probes 52

Auto TDS Blowdown Systems 54

Auto TDS Blowdown System Install Guide 56

Auto Timed Blowdown System 58

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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



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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.



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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INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

1.2 TECHNICAL DATA

Forafullspecicationreferto

The Fulton Electropack 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

TheFultonElectropack100kWelectricsteamboilerisahighlyefcientunitdesignedtomeetthe

requirements of the lower demand steam user.

The Electropack 100 kW contains a pressure vessel, feedwater pump and system controls

including a step controller to automatically switch elements on and off with steam demand to

create a fully contained steam raising unit with easy access removable cabinet panels

The Electropack 100 kW is similar to the Electropack 18-72 kW range with differences such as a

larger pressure vessel and elements entering from the top of the boiler instead of the front. The

100 kW does not have a self contained feedwater tank like the 18-72 kW range due to the larger

pressure vessel. Feedwater and condensate return tanks can be supplied separately.

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INTRODUCTION - 1

Figure. 1 - General Arrangement

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INTRODUCTION - 1

1. Boiler control panel

2. Control panel lock

3. Boiler door isolator switch

4. Feedwater pump

5. Operating pressure control switch

6. High limit pressure control switch

7. Water level gauge (optional)

8. Water level gauge blowdown valve

9. Steam pressure gauge

10. Side access panel

11. Front access panel

12. Main steam stop valve

13. Boiler steam safety valve

14. Boiler water sample point

15. Feedwater check and isolating valves

16. Main boiler blowdown valve

17. Feedwater inlet

18. Water level probes

19. Boiler elements

20. Pressure vessel

Key

Figure. 2 - General Arrangement Inside

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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 Electropack 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 to

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

clearance for maintenance.

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 .

1. Feedwater Inlet

Anisolatingvalveanddisctypenon-returnvalvearesuppliedttedtotheboiler.Thisshouldbe

connected to the feedwater pump discharge which is mounted inside the cabinet.

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

Ifthewatersampleoutletisused,thevalveshouldbettedascloseaspossibletotheboiler.To

take a sample safely, a water sample cooler (not supplied as standard) should be installed.



The water level gauge blowdown cock should be connected to the auxiliary blowdown line from

the blowdown valve by 3/8 in. soft copper tubing.

CAUTION



be altered. 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 

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



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



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-130-EP100 Dimensions &

. The boiler contains all necessary electrical protection.

A suitable 3-phase, neutral and earth isolated and fused supply is required and must be

connected in accordance with local electrical regulations.

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

It is recommended that the electrical supply cable to the boiler is located through the rear of the

unit in the bottom left corner. Ensure the cable is not rubbing against areas capable of damaging

it.Thecableshouldberoutedfromthispointandsecuredinaglandnut(notsupplied)ttedthe

bulkhead at the base of the electrical panel.

Care should be taken to ensure the supply cable is the correct size and installed in accordance

with local regulations.

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INSTALLATION - 2

Figure. 4 - Electrical Panel

1. Miniature relays

2. MCB

3. Door electrical isolator (supply cable connection point)

4. LC relays

5. Element circuit breakers

6. Cooling fan

7. Fuse terminal

8. Step controller

9. Pump circuit breakers

10. Element contactors

11. Pump contactor

12. Pump overload

13. Supplycableaccesshole(twithglandnutsuitablefortheelectricalsupplycableused)

14. LOGO! PLC. (pressure controls)

Key

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INSTALLATION - 2

2.6 COMMISSIONING THE BOILER

1. Isolate boiler (door isolator and mains supply)

2. Remove front access panel

Remove right side access panel

3. Check all electrical connections for tightness

4. Insulation test the elements

5. Set the steam pressure controls (see Section 3.2.2.1 - Setting Steam Pressure Controls)

6. Ensure Boiler 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

Check for leaks

9. Ensure Boiler switch is in the OFF position

Ensure Pump switch is in the OFF position

10. Ensure master step controller Block one - Switch 3 is in the ON position

11. Replace front access panel

Replace right side access panel

12. Switch main isolator ON

Turn boiler door isolator ON

13. Fill the feedwater pump

Close the isolating valve on the discharge side of the feedwater pump (at rear of boiler).

Removetheprimingplugfromthepumpheadandslowlyllthepumpwithwater.Replacethe

priming plug and tighten securely.

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.

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INSTALLATION - 2

14. Feedwater pump checks

Bleed the feedwater pump (see Figure. 5)

Remove the feedwater pump cover to expose the pump drive shaft coupling (see Figure. 5)

Turn Pump switch ON

Check the rotation of the feedwater pump. Correct rotation is anti-clockwise when viewed from

the top of the pump.

Turn Pump switch OFF and wait until the drive shaft stops rotating before replacing the cover.

Note: The pump impeller blades can be damaged by incorrect rotation. If the rotation is incorrect turn the selector

switch to the OFF position. Isolate the boiler and alter the phase connections between the pump contactor

overload and the pump. Re-check the pump rotation.

WARNING

Do not make contact or place anything in touch with the moving parts of the pump drive. The cover is

removed for a visual inspection of the pump rotation. Stop the pump to replace the cover.

15. Fill the boiler

Open the isolating valve on the discharge side of the feedwater pump (at rear of boiler)

Turn Pump switch ON

Low water light and low water reset button will illuminate

Audible alarm sounds

Allowfeedwaterpumptolltheboiler

Check feedwater pump stops when correct water level is reached

Press low water reset button to cancel alarm and Low water warning lights

16. Elements automatic on/off check with Low water

Put the step controller into Commissioning mode (master unit, block 1, DIP switch 3 OFF)

Turn Boiler switch ON

Turn Pump switch OFF

Ensure Element Switches are in the ON position

Elements should energise indicated by the Element Switch lights

Figure. 5 - Feedwater Pump

Feedwater pump bleed nipple

Removable cover to check

pump rotation

CONTINUED ON NEXT PAGE

EP100-IOMM-2017-11

Fulton Ltd

Page 12

INSTALLATION - 2

WARNING

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

Turn Boiler switch OFF

Turn Pump switch OFF

Turn boiler door isolator OFF

Remove access panels

Check for steam/water leaks

Put step controller into Operation Mode (master unit, block 1, DIP switch 3 ON)

Replace access panels

Slowly open the steam valve to release pressure from the boiler to below high pressure set

point

Check for steam leaks in connecting pipework

Turn boiler door isolator ON

Turn Boiler switch ON

Turn Pump switch ON

Press High Pressure Reset button to cancel alarm and energise the elements

The boiler is now ready for placing into full operation.

Open Boiler Blowdown valve and drain water from the boiler until:

a) Low water light illuminates

b) Low water reset button illuminates

c) Audible alarm sounds

Close Boiler Blowdown valve

Check that the elements de-energise and Element lights switch off in Low water condition

Turn Pump switch ON

Checkfeedwaterpumpstartsandllstheboilertothecorrectwaterlevel

Press low water reset button to cancel alarm and Low water warning lights

Check that the elements energise and element lights illuminate when correct water level is

restored

17. Elements automatic on/off check with High pressure

Set the Steam Pressure Control to its maximum

Set the High Limit Pressure Control to 0.5 barg below the safety valve setting

With the Boiler switch ON, the boiler will slowly raise steam pressure

Check that the elements de-energise when the set high limit pressure is reached.

The High Pressure Reset button will illuminate and an audible alarm will sound

Check that the pressure reading on the pressure gauge at boiler cut-out corresponds with the

High Pressure Controller setting

Reset the Steam Pressure Control to the required working pressure

EP100-IOMM-2017-11

Fulton Ltd

Page 13

INSTALLATION - 2

2.7 CLEANING STEAM LINES AND PRESSURE VESSELS

Duringtherstweekofboileroperation,cleanalloilanddirtfromtheboiler,thesteamlineand

condensate return line.

1. Disconnect the condensate return pipe adjacent to the condensate return tank.

2. Directthereturnstoaoordrainorothersafedischargepointandmakesafe.

3. Leaveinthispositionforoneweektoallowallimpuritiestoushthrough.

4. Drain the boiler completely each day.

5. Aftertheweekiscompleted,drainandushthecondensatereturntank,removingall

installation sediment. Reconnect the condensate return pipe to the condensate return tank.

EP100-IOMM-2017-11

Fulton Ltd

Page 14

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Fulton Electropack 100 kW User manual

Fulton Electropack 100 kW User manual

Fulton Electropack 100 kW User manual

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