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Summary of Contents for FULTON FB-L
- Page 1 INSTALLATION AND OPERATION MANUAL Fulton Electric Boilers (Steam Models) Serial/ National Board Number Model Fulton Order Owner Site Name Date FBL_ELEC-ST_IOM-2023-0124...
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Page 3: Table Of Contents
Troubleshooting ..................................... 4-7 Protetion from Corrosion of Boilers in Standby Mode ......................4-8 Section 5: Parts and Warranty ......................5-1 Spare Parts ......................................... 5-2 Section 6: Warranty ..........................6-1 Standard Warranty for Fulton Boilers ............................6-1 Limited Warranty for Fulton FB-L ..............................6-2... -
Page 5: Section 1: Safety & Warnings
Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty... -
Page 6: Safety And Warnings
Fulton reserves the right to change any part – NOTE: Where a condensate return tank is to be fitted, of this installation, operation and maintenance manual. - Page 7 The discharge from the safety relief valve shall be so maintenance work you do not understand. arranged that there will be no danger of scalding personnel or damage to equipment. Provisions Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
- Page 8 1 - SAFETY & WARNINGS should be made to properly drain safety relief valve To ensure that your Fulton equipment is operating safely and efficiently, follow the maintenance discharge piping. procedures set forth in this manual. Fluids under pressure may cause injury to personnel or Unless otherwise specified, the steam safety valve damage to equipment when released.
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Page 9: Steam Boiler Systems Warnings And Cautions
4) Return pipes must not be insulated as this can cause overheating in the feedwater tank and potential vapor lock in the pump. Return pipes should be shielded to prevent burn hazard. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... -
Page 10: Disclaimers And Local Codes
Bolt a blank flange over the element mounting plate to seal the boiler. If handholes are provided, these can be used to provide an opening versus an element to place the dessicant. © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124... -
Page 11: Installation
Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty... -
Page 12: Product Overview
Additionally, these instructions should be regarded as a any Fulton boiler. Use only lifting eyes or fork general guide and must not be considered as a complete holes for movement. - Page 13 • Therefore, electric elements have a 0% tolerance for operation over design voltage. Additionally, other components supplied may only be suitable for the design voltage. Electric elements can tolerate a lower than design voltage, but the kW must be derated accordingly. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
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Page 14: Component Locations
Water Bottle Assembly for 300 to 1000 kW only – NOTE: All Fulton Electric Steam Boilers have a second (auxiliary) low water cut-off probe. 12 TO 36 KW (1.2 TO 3.6 BHP) MODELS As shown below, element(s) are horizontally mounted at the bottom of the pressure vessel. - Page 15 (auxiliary) low water cut-off probe is mounted in the top of the boiler. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
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Page 16: Electrical Requirements
See additional notes at bottom of page 2-3. Boiler Controls Fulton packaged electric steam boilers are equipped with both a steam pressure control and a high limit pressure control mounted on the outside or inside of the electrical panel box. -
Page 17: Recommended Water Treatment
Osmosis is white background. The water should have no visible yellow, red or orange tinge. a process that uses a semipermeable membrane, under ND: None Detected ppm: parts per million Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 18 Normally suspended solids are expressed in terms The Fulton Warranty does not cover damage or failure of turbidity. Suspended solids may also deposit in that can be attributed to corrosion, scale or dirt low velocity areas and create fouling.
- Page 19 It can concentrate in the boiler and it tends to collect in stagnant areas. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
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Page 20: Piping Diagram And Specifications
Safety Outlet Valve Valve Water Bottle for Models 30-100 BHP Water Column or Water Bottle Electric Control Panel Blowdown Valve Shut-Off Check Check Valve Valve Valve Electric Steam Boiler Fast Opening Blowdown Valve Valve 2-10 © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124... - Page 21 Vent Cold Water Supply Sight Glass Vent Return Blowdown Condensation Separator Tank Temperature Outlet Control Valve Check Valve Thermometer Cold Water Inlet Union Drain Union Pump / Strainer 2-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
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Page 22: Feed Water Blowoff Piping
– NOTE: Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. If in doubt consult a Fulton – NOTE: Where a condensate return tank is to be fitted, Representative for advice. -
Page 23: Water Gauge And Gauge Glass
5. Install the bottom gauge fitting (the fitting with a Do not downsize piping below safety valve size. drain valve) until it is snug and the glass outlet is 2-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 24 Glass Packing 11. Install the protective guard, and utilize automatic ball checks where necessary to help prevent Bottom Gauge injury in case of glass breakage Fitting Drain Valve 2-14 © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
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Page 25: Removal Of Desiccant
If baking is not practical, consult our factory. – NOTE: No heater shall be operated with a resistance to ground reading of less than 10 megohms. A qualified electrician can check the megohm reading 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... -
Page 26: Installation Check Points
6. Generate 15 PSI (1 Kg/cm2) of steam and shut off the boiler. Allow this hot solution to remain in the boiler for ten minutes. 7. Drain and flush the boiler twice with fresh water. 2-16 © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124... - Page 27 8. To remove all the oil and dirt from the main steam and condensate return lines, allow the returns to go into a floor drain or a safe discharge point for a few hours of operation. 2-17 Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
- Page 28 2 - INSTALLATION 2-18 © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
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Page 29: Operation
Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty... -
Page 30: Introduction
Introduction 2. Close water gauge drain valve. The following instructions are given for the guidance of the operator in the use of Fulton Electric Steam Boilers. Before operating your Fulton Electric Steam Boiler: ! WARNING Make sure you have read and followed all previous safety information. -
Page 31: Boiler Controls
8. Turn the switch on the boiler to the “on” position. The white light will light indicating that the electrical circuit for the boiler has been energized and that all controls are working properly Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 32 3 - OPERATION ! CAUTION 2. Fulton Boilers are equipped with solid state plug- in relays. Manual reset is standard. It can easily be distinguished by the low water reset button Do not tamper with the safety features of the low located on the panel box.
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Page 33: Thermostat (Optional)
2 to 3 turns and opening the fast opening ball / knife valve for a few seconds. The strategy should discharge a small water volume quickly. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 34 The brass valve stem must be opened fully to arm this capability. If the valve is in any other position than full open, the ball will not seat. For added safety all Fulton boilers are equipped with gauge glass protectors. –...
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Page 35: Maintenance & Troubleshooting
Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty... -
Page 36: Maintenance And Troubleshooting
4 - MAINTENANCE & TROUBLESHOOTING Introduction be considered. Your Fulton Electric Steam Boiler has been designed Keep boiler area clear and free from combustible for years of trouble-free performance. To ensure the materials, gasoline, and other flammable vapors and continued safety and efficiency of the boiler, the liquids. -
Page 37: Recommended Monthly Maintenance Schedule
The following steps should be carried out monthly: 1. Feed water pump and motor should be lubricated according to themanufacturer’s instructions. 2. Heating Element - Inspect heating element. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 38 (muriatic) connections for tightness. Replace any wires that show acid when regular cleaners do not seem to signs of damage. work. Do not use wire brushes or any other abrasive materials which could scratch the © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
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Page 39: Recommended Quarterly Maintenance Schedule
1/4 turn. Donot compress excessively. » If the gasket leaks while pressure is being built up, tighten only enough to stop leakage. Never tighten more than necessary Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... -
Page 40: Recommended Annual Maintenance Schedule
Part No. 2-20-017. 3. Drain the condensate tank and clean by flushing with hose. Check float valve operation. Figure 21 - Inspect hand holes for scale or sludge buildup © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124... -
Page 41: Troubleshooting
If coil and contactors are engaging, check Motor Starter Relay power in and out on the control circuits. If contactor is chattering, clean contacts. If motor starter relay is weak or bad, replace. Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 42 Elements High dissolved solids Blowdown schedule High alkalinity in boiler water Poor Steam High organics in boiler water Adequate blowdown schedule or over feeding of Quality water treatment chemicals. High total dissolved solids in boiler water © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
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Page 43: Protetion From Corrosion Of Boilers In Standby Mode
Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124... - Page 44 30 – protection as well as acting as a level control indicator. 50 ppm as a minimum. 4-10 © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
- Page 45 (180 degrees F – 200 degrees F). 4-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
- Page 46 Fulton heating elements are manufactured with high quality magnesium oxide. As added protection, each Fulton element terminal end has a high temperature silicone sealant moisture barrier just under the terminal insulator. All heater manufactured and shipped by Fulton are electrically tested in accordance with UL specifica- tions.
- Page 47 Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty...
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Page 48: Spare Parts
» Boiler Type » Electrical Specifications – NOTE: The policy of Fulton Steam Solutions is one of continuous improve ment, and therefore, we reserve the right to change prices, specifications, and equipment without notice. Fulton Steam Solutions Pulaski, NY 13142 Control Circuit / Pump Motor ©... - Page 49 Plug in Steps for Sequencer (White) Athena 2-40-912 Plug in Step Delay (Yellow) Athena 2-40-913 Plug in Signal Conditioner (Green) Athena 2-40-914 Plug in Starter for Sequencer (Black) Athena 2-40-107 10 Step Sequencer (Honeywell) Questions? Call (315) 298-5121, or visit us online at www.fulton.com FBL_ELEC-ST_IOM-2023-0124...
- Page 50 2-40-3040 Pressuretrol KP36MR 15-150 PSI (Danfoss) 2-40-3047 Pressuretrol KP37MR 58-300 PSI (Danfoss) 2-40-3042 Pressuretrol KP34 2-15 PSI (Danfoss) 2-40-3041 Pressuretrol KP35 6-50 PSI (Danfoss) 2-40-3043 Pressuretrol KP36 15-150 PSI (Danfoss) 2-40-3044 Pressuretrol KP37 58-300 PSI (Danfoss) © Fulton 2023 FBL_ELEC-ST_IOM-2023-0124...
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Page 51: Warranty
Section Safety & Warnings Installation Operation Maintenance & Troubleshooting Parts Warranty... -
Page 52: Standard Warranty For Fulton Boilers
Installation and Operation Checklists to Fulton’s Quality Assurance department. General Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. -
Page 53: Parts Warranty
PARTS WARRANTY Fulton will repair or replace F.C.A. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within eighteen (18) months of shipment from the factory or one (1) year from startup provided this equipment has been installed, operated, and maintained by the buyer in accordance with requirements in the manuals of Fulton and the component’s manufacturer. - Page 54 No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from Fulton. The Fulton Group of companies are global manufacturers of steam, hot water and thermal fluid heat transfer systems. © Fulton 2023 www.fulton.com...
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