FULTON Electropack Series Installation, Operation And Maintenance Manual
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FULTON Electropack Series Installation, Operation And Maintenance Manual

Electric steam boiler 18 kw-72 kw
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Electropack 18 kW - 72 kW
Electric Steam Boiler
This manual must be available to the boiler operator at all times.
EP18-72-IOMM-2015-7

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  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Electropack 18 kW - 72 kW Electric Steam Boiler This manual must be available to the boiler operator at all times. EP18-72-IOMM-2015-7...
  • Page 2 Fulton Ltd Page II EP18-72-IOMM-2015-7...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Fulton Ltd SECTION 1 - INTRODUCTION SECTION 4 - MAINTENANCE General Visual Checks Product Overview Water Level and Low Water Safety Controls Technical Data 4.2.1 Feedwater Pump Test 4.2.2 Low Water Level Checks SECTION 2 - INSTALLATION 4.2.3...
  • Page 4 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.
  • Page 5 Obey all laws and local regulations which affect you and you do not understand. Obtain a service manual from your boiler. Fulton Ltd or call a Fulton service engineer. LOW FEEDWATER TEMPERATURE It is the responsibility of the installer to ensure all parts...
  • Page 6 Fulton Ltd Top access panel Boiler control panel Boiler isolator switch Pressure gauge Front access panel Figure. 1 - Electropack Electric Steam Boiler Page VI EP18-72-IOMM-2015-7...

  • Page 7: Section 1 - Introduction

    SECTION 1 - INTRODUCTION GENERAL 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.
  • Page 8 Fulton Ltd Page 2 EP18-72-IOMM-2015-7...

  • Page 9: Section 2 - Installation

    SECTION 2 - INSTALLATION GENERAL 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.

  • Page 10: Major Components

    INSTALLATION - 2 Fulton Ltd MAjOR COMPONENTS Boiler/Pressure vessel. Mounted inside the cabinet in the lower half. Feedwater and condensate return tank. Mounted inside the cabinet in the upper half. Operator control panel. Mounted inside the cabinet behind the front access panel and accessible with the access panel attached..
  • Page 11 INSTALLATION - 2 Fulton Ltd Operator control panel Feedwater tank Data plate (at rear) Electrical control panel Pressure gauge Boiler/Pressure vessel Operating pressure controls Boiler elements Feedwater pump Note: For connection points at rear of the boiler, see Figure. 3.

  • Page 12: Boiler Connections

    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. Water Sample Outlet If the water sample outlet is used, the valve should be fitted as close as possible to the boiler.
  • Page 13 INSTALLATION - 2 Fulton Ltd Feedwater inlet Feedwater tank vent Condensate return Feedwater tank overflow Steam outlet valve Safety valve Water sample outlet Boiler blowdown valve Feedwater tank drain Recommended entry area for mains electrical cable Pump inlet isolating valve Chemical dosing point Strainer Figure.

  • Page 14: Water Supply

    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).
  • Page 15 INSTALLATION - 2 Fulton Ltd Door electrical isolator (supply cable connection point) Supply cable access hole (fit with a gland nut suitable for the electrical supply cable used) Figure. 4 - Electrical Supply Cable Location N.B. Control Panel frame is unbolted on right hand side to...

  • Page 16: Steam Pressure Control

    INSTALLATION - 2 Fulton Ltd STEAM PRESSURE CONTROL Adjust the steam pressure controls to suit the boiler application. It should be noted that boilers are designed to operate most efficiently at their maximum operating pressure. Where steam is required below a pressure of 60 psi (4 bar), consideration should be given to the fitting of a pressure reducing set. Setting the pressure controllers High Limit Controller 1.

  • Page 17: Commissioning The Boiler

    INSTALLATION - 2 Fulton Ltd 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.
  • Page 18 INSTALLATION - 2 Fulton Ltd Removable cover to check pump rotation Feedwater pump bleed nipple Figure. 7 - Feedwater Pump Switch the pump MCB ON. Check the rotation of the feedwater pump. Correct rotation is anti-clockwise when viewed from the top of the pump.
  • Page 19 INSTALLATION - 2 Fulton Ltd 13. Pump on/off check When the pump switches OFF, the boiler is at NWL, OPEN the blowdown valve until the pump switches ON, CLOSE the blowdown valve the pump will start to replace the blowdown losses and then stop, SHUT the steam valve.

  • Page 20: Cleaning Steam Lines And Pressure Vessels

    Fulton Ltd CLEANING STEAM LINES AND PRESSURE vESSELS During the first 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 floor drain or other safe discharge point and make safe. 3. Leave in this position for one week to allow all impurities to flush through. 4. Drain the boiler completely each day. 5. After the week is completed, drain and flush the condensate return tank, removing all installation sediment. Reconnect the condensate return pipe to the condensate return tank.

  • Page 21: Section 3 - Operation

    Fulton Ltd SECTION 3 - OPERATION 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. GENERAL...
  • Page 22 OPERATION - 3 Fulton Ltd Figure. 9 - Controls and Indicators 1. High Pressure Reset Button The high pressure reset button will illuminate when the steam high limit controller is tripped. Reset the control by depressing the push button, having first ascertained and corrected the reason for the high pressure condition. 2. Low Water Reset Button Indicates that a low water condition exists and the boiler has shut down.

  • Page 23: Filling The Feedwater Tank

    OPERATION - 3 Fulton Ltd 9. Boiler On/Off Switch 10. Pump On/Off Switch In the off position the feedwater pump control circuits are isolated. 11. Audible Alarm 12. Feedwater Tank Low Water Indicator This light will illuminate if there is a low water condition in the feedwater tank.

  • Page 24: Filling The Boiler

    OPERATION - 3 Fulton Ltd FILLING THE BOILER 1. Ensure the feedwater tank has been filled (see Section 3.3 - Filling the Feedwater Tank) 2. Ensure Boiler and Pump switches are both in the OFF position 3. Ensure the following valves are OPEN: a) All valves in the feedwater line to the boiler b) Water level gauge (sight glass) isolating valves (where fitted) 4.

  • Page 25: Draining The Boiler

    OPERATION - 3 Fulton Ltd DRAINING THE BOILER CAUTION Your local regulations could state boiler water above 43 °C must not be discharged into the drain. ALWAYS check your local regulations. Boilers with manual blowdown valves 1. Ensure the boiler is cold.

  • Page 26: Draining The Feedwater Tank

    OPERATION - 3 Fulton Ltd 3.6 DRAINING THE FEEDWATER TANk 1. Ensure the tank is cold (heated tanks only). 2. Isolate the boiler electrics at the isolator on the front access panel. 3. Turn off the water supply to the tank.

  • Page 27: Boiler Shut-Down

    OPERATION - 3 Fulton Ltd BOILER SHUT-DOWN 3.8.1 SHORT TERM SHUT-DOWN (HOURS) 1. Select Boiler OFF on the operators control panel switch. The elements will de-energise. 2. Close the steam outlet vale 3.8.2 LONG TERM SHUT-DOWN (WEEkS) To store the boiler in a corrosion-free situation there are three practical solutions: 1.
  • Page 28 Fulton Ltd Page 22 EP18-72-IOMM-2015-7...

  • Page 29: Section 4 - Maintenance

    MAINTENANCE - 4 Fulton Ltd SECTION 4 - MAINTENANCE CAUTION It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy of the boiler.

  • Page 30: Water Level And Low Water Safety Controls

    MAINTENANCE - 4 Fulton Ltd WATER LEvEL AND LOW WATER SAFETY CONTROLS The following procedures ensure the correct functioning of the water level controls and the low water safety controls. 4.2.1 FEEDWATER PUMP TEST a) If the boiler is not heating and not under steam pressure, lower the water level using the main...

  • Page 31: Low Water Level Checks

    MAINTENANCE - 4 Fulton Ltd 4.2.2 LOW WATER LEvEL CHECkS 1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off. 2. Switch OFF the pump using the Pump On/Off switch. 3. Allow the water level to lower by natural evaporation below the Low Water level.

  • Page 32: Blowdown Procedures

    Keep the boiler, elements, water level gauge (sight glass) and interconnecting pipework free from sludge and scale build-up by following these blowdown procedures. Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.

  • Page 33: Water Level Gauge (Sight Glass) Blowdown

    On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are CLOSED. Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure.

  • Page 34: Element Care And Protection

    MAINTENANCE - 4 Fulton Ltd ELEMENT CARE AND PROTECTION To protect the element and prolong its life, it is essential that regular inspections are carried out. The most common causes of element failure are excessive build up of scale and corrosive attack.

  • Page 35: Element Removal

    MAINTENANCE - 4 Fulton Ltd 4.4.1 ELEMENT REMOvAL Isolate and completely drain the boiler (see Section 3.5 - Draining the Boiler) before removing the boiler heating elements. Remove the four element securing nuts from the element mounting flange. Element is now loose for removal from the boiler. The elements will need removing to carry out internal inspections of the boiler and to complete element checks mentioned in Section 4.4 - Element Care and Protection.

  • Page 36: Boiler Internal Inspection

    MAINTENANCE - 4 Fulton Ltd BOILER INTERNAL INSPECTION The boiler elements should be removed (see Section 4.4.1 Element Removal) after one month of operation and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, it should be removed and the water treatment supplier advised.

  • Page 37: Cleaning Water Level Probes

    MAINTENANCE - 4 Fulton Ltd 4.6 CLEANING WATER LEvEL PROBES Feedwater Tank Isolate the boiler electrics at the isolator on the front access panel and remove the boiler top access panel. Remove and clean the feedwater tank level probes taking note of probe lead positions.

  • Page 38: Schedule Of Operator Tests And Checks

    Fulton Ltd SCHEDULE OF OPERATOR TESTS AND CHECkS The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler is installed in. Failure to maintain the boiler adequately may void the Fulton guarantee.

  • Page 39: Daily

    MAINTENANCE - 4 Fulton Ltd 4.7.1 DAILY 1. Visually inspect boiler casing exterior for signs of leakage (see Section 4.1 - visual Checks): a) Steam and feedwater pipework b) V alves and fittings 2. Low water level check (see Section 4.2.2 - Low Water Level Check).

  • Page 40: Three Monthly In Addition

    MAINTENANCE - 4 Fulton Ltd 4.7.4 THREE MONTHLY IN ADDITION 9. Drain the boiler (see Section 3.5 - Draining The Boiler). 10. Remove boiler elements (see Section 4.4.1 - Element Removal). 11. Visually inspect the internal water space of the pressure vessel (see Section 4.5 - Boiler Internal Inspection).

  • Page 41: Troubleshooting Boiler

    MAINTENANCE - 4 Fulton Ltd 4.8.1 TROUBLESHOOTING BOILER Problem Cause Remedy Mains supply failure. External circuit MCB requires resetting. Circuit Live indicator Fuses need replacing. not illuminated Door interlock microswitch Indicator lamp needs replacing. not made. 1. Insufficient water in the Check that the feedwater supply line valves are Boiler Low Water boiler.

  • Page 42: Troubleshooting Feedwater Pump

    MAINTENANCE - 4 Fulton Ltd 4.8.2 TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 1. Supply failure. Connect the electricity supply. FEEDWATER PUMP Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers. 3. Motor contactor overload has Reactivate the motor protection.

  • Page 43: Troubleshooting Feedwater Pump

    MAINTENANCE - 4 Fulton Ltd 4.8.2 TROUBLESHOOTING FEEDWATER PUMP Problem Cause Remedy 1. Leakage in suction pipe. Repair the suction pipe. Pump runs backwards when 2. Foot or non-return valve is Repair the foot or non-return valve. switched off. defective.
  • Page 44 MAINTENANCE - 4 Fulton Ltd Page 38 EP18-72-IOMM-2015-7...
  • Page 45 MAINTENANCE - 4 Fulton Ltd Page 39 EP18-72-IOMM-2015-7...
  • Page 46 Fulton Ltd Page 40 EP18-72-IOMM-2015-7...

  • Page 47: Appendix A - Ti Sheets

    Fulton Ltd APPENDIX A - TI SHEETS The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in this Appendix. Note: The TI sheets in this appendix can be updated/replaced without revising the manuals issue number. To check you have the most up to date TI sheet, please check the downloads section on the Fulton website (www.fulton.co.uk/support/downloads) or consult Fulton Ltd.

  • Page 48: Ep 18 - 72 Dimensions & Specification

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 115 Issue 9 Electropack 18 kW - 72 kW Dimensions & Specification Dimensions MODEL: ELECTROPACK 18, 24, 36, 48, 54, 72 Minimum Clearance* 2230 Overall Width Overall Depth 1100 Overall Height...
  • Page 49 APPENDIX - A Fulton Ltd Specification TI-115-EP18-72-DS-2017-9 MODEL: ELECTROPACK UNIT EP18 EP24 EP36 EP48 EP54 EP72 Designed and manufactured to BS EN 13445:2009 and PED 2014/68/EU. General Steam Output F & A 100°C kg/h kW Rating Operating Pressure barg 10.34 10.34...

  • Page 50: Ep Probe Lengths

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 62 Issue 6 EP, EU & Dragon Probe Lengths 1, 2 & 3 Branch Electropack and Dragon 1 Branch 1 Branch 1 Branch PV PROBE LENGTHS 1 BRANCH Pump OFF 185 mm...
  • Page 51 APPENDIX - A Fulton Ltd Europacks and 100 kW TI-62-EP-EU-DR-ProbeLengths-2017-6 PV PROBE LENGTHS - EU & EP100 IN BOTTLE Pump OFF 300 mm 204 mm Pump ON 330 mm 234 mm 1st. Low Water 405 mm 2nd. Low Water 405 mm E.F.S...

  • Page 52: Recommended Water Conditions

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 139 Issue 3 J Series & Electric Steam Boilers Recommended Water Conditions IMPORTANT It is very important that a strict water management program is followed to ensure trouble free boiler operation.

  • Page 53: Water Level Probes

    APPENDIX - A Fulton Ltd Technical Information Sheet No. 103 Issue 3 Water Level Probes Replacement Standard Probes (brass) Probes are supplied in a standard length and should be cut to the length required, (the length of the probe being replaced) ensuring measurements are taken from the underside of the probe hexagonal nut, remove any burrs caused by cutting.
  • Page 54 APPENDIX - A Fulton Ltd TI-103-WaterLevelProbes-2015-3 High Integrity Probes (stainless steel) The probe is supplied in two parts, the head and the tip. The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head.
  • Page 55 G U A R A N T E E On the Fulton Boiler Pressure Vessel Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within five (5) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the manufacturer’s handbook.
  • Page 56 EP18-72-IOMM-2015-7 Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 Email: sales@fulton.co.uk FM 28400...

This manual is also suitable for:

Electropack ep24Electropack ep18Electropack ep36Electropack ep48Electropack ep54Electropack ep72

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