Fulton Electric Hot Water Boiler User Manual

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Page 1

INSTALLATION AND

OPERATION MANUAL

Electric Hot Water Boiler (FB-W)

12 to 700 kW

1.2 to 70 HP

Serial/National Board #

Model

Fulton Order

Sold To

Job Name

Date

FBW-IOM-2014-0312

Page 2

Page 3

FBW-IOM-2014-0311 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................ 1-2

Disclaimers and Local Codes ................................................................................ 1-2

Installation 2-1

Product Overview ................................................................................................. 2-2

Review Shipment Contents .................................................................................. 2-2

BOILER STORAGE PRIOR TO INSTALLATION ................................................................................22

Placement & Rigging ........................................................................................... 2-2

Clearances and Serviceability .............................................................................. 2-3

Boiler Trim ............................................................................................................ 2-3

Temperature Control ............................................................................................ 2-5

STEP CONTROLLERS .................................................................................................................... 25

Water Supply ........................................................................................................ 2-5

WATER QUALITY ..........................................................................................................................25

WATER SPECIFICATION ................................................................................................................25

Electrical Installation ............................................................................................ 2-7

MOTORS........................................................................................................................................ 27

ELECTRIC ELEMENTS....................................................................................................................28

Operation 3-1

Before Start Up ..................................................................................................... 3-2

Start-Up ............................................................................................................... 3-2

Boiler Controls ...................................................................................................... 3-2

CIRCULATING PUMP SWITCH IF SUPPLIED WITH THE BOILER ...............................................33

THERMOSTAT OPTIONAL .......................................................................................................... 33

Maintenance 4-1

General ................................................................................................................. 4-2

Daily Maintenance and Inspection Schedule ...................................................... 4-2

Monthly Maintenance and Inspection Schedule ................................................. 4-2

Annual Maintenance and Inspection Schedule ................................................... 4-2

HANDHOLE GASKET INSTALLATION ........................................................................................... 43

SCALE FORMATION ......................................................................................................................43

Troubleshooting ................................................................................................... 4-4

Warranty & Parts 5-1

Standard Warranty ............................................................................................... 5-2

Parts ..................................................................................................................... 5-3

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 4

TABLE OF CONTENTS FBW-IOM-2014-0311

0-2

Page 5

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

1-1

Page 6

INTRODUCTION FBW-IOM-2014-0311 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

 Material inspections

 Manufacturing process inspections

 American Society of Mechanical Engineers (ASME)

welding inspection

 ASME hydrostatic test inspection

 Electrical components inspection

 Operating test

 Final engineering inspection

 Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

 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 e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z2231 and National Fire Protection Association (NFPA) 54, latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

Since an external electrical source is utilized, the boiler must be electrically grounded in accordance with the National Electrical Code, ANSI/NFPA 70-latest edition.

When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV.

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INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-1

Page 8

INSTALLATION FBW-IOM-2014-0311 SECTION 2

! WARNING

4 CAUTION

This boiler is certi ed for indoor installation only.

Product Overview

Prior to the performance of installation, operation, or maintenance procedures, personnel should become familiar with the equipment (Table 1a and 1b, Figure

1) and its components.

The following speci cations, equipment and operating descriptions apply to typical Fulton Electric Hot Water Boilers. This section is provided for general reference purposes only, and may not re ect speci c details for your boiler.

The Fulton Electric Hot Water Boiler pressure vessel assembly consists of an annular jacket with a tangential inlet to provide rising spiraling  ow across the elements. It is ASME constructed and stamped.

Forced even circulation of water is achieved by a design that ensures the water spins upward in the water vessel. The spinning water is evenly mixed and heated, eliminating strati cation. This unique circulation method achieves an even  ow of water across the elements. It is heated uniformly while it washes each element. This results in low  ux temperatures and long element life.

Multiple vertically oriented stainless steel or Incolloy elements discourage buildup because element expansion and contraction causes mineral or lime deposits to  ake o and drop to the bottom of the boiler, thus assuring longer element life.

Low element heat  ux (watt density) promotes uniform heating and long element life. Symmetric element placement stabilizes water level.

Four (4) inches (2” for models FB-012-W through FB-070-W) of high temperature glass  ber insulation is wrapped around the boiler vessel. A neatly  nished steel jacket encloses the insulation. The top of the unit is encased in a screen material for venting.

Review Shipment Contents

Your boiler shipment should be fully reviewed upon receipt. The customer should also examine the equipment for any shipment damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are  tted in a correct and safe manner.

 Boiler Storage Prior To Installation

If it is necessary to store the boiler for a prolonged period of time prior to installation, the boiler should be stored at a minimum 40 F ambient temperature in an environment in which excessive moisture cannot damage the controls or jacket.

2-2

Placement & Rigging

Proper placement of your Fulton product is essential. Attention paid to the following points will save a great deal of di culty in the future. Correct placement is the  rst step to trouble-free installation, operation, and

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SECTION 2 FBW-IOM-2014-0311 INSTALLATION

maintenance.

Adhere to the following for placement and rigging:

1. Locate in dry surroundings on a solid level base. Take note of the dimensions given in Table 1.

2. Since an external electrical source is utilized, the boiler must be electrically grounded in accordance with the National Electrical Code, ANSI/NFPA 70-latest edition.

3. Ensure that there is su cient room around the boiler to enable the operator and the maintenance engineer to gain access to all parts of the boiler.

4. Check location for ease of water supply and electrical connections. UL requires at least 36” clear space be maintained in front of any electrical panel.

5. Unit is crated for forklift transport. Do not allow weight to bear on any equipment components.

Clearances and Serviceability

! WARNING

Competent personnel in accordance with all applicable local codes should carry out the installation of the Fulton equipment. All state and jurisdictional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classi cation, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.

Adhere to the following for clearances and serviceability:

1. All local and national codes (NFPA, ANSI, UL, ETL, ASME) must be followed for proper clearances and serviceability for your boiler or heater. Authorities having jurisdiction should be consulted before installations are made.

2. Appropriate front, back, side and top clearances must be maintained. This will allow access around the equipment to facilitate maintenance and a safe work environment. UL requires at least 36” clear space be maintained in front of any electrical panel.

3. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

Boiler Trim

Each boiler is supplied with the following (supplied standard or  tted to boiler). Additional trim may be provided as ordered.

 Temperature/Pressure Gauge

 Low Water Cut O (Probe Type)

The equipment must be installed on a non-combustible surface.

Failure to provide required and safe access to the equipment could impede commissioning and maintenance.

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

4 CAUTION

Do not allow weight to bear on equipment

components to prevent damage.

 Water Relief Safety Valve (ASME Rated)

 Operating Aquastat

 High Limit Aquastat

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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INSTALLATION FBW-IOM-2014-0311 SECTION 2

TABLE 1A BOILER DIMENSIONS

Mod el FB -W 012 015 018 02 4 0 30 036 05 0 0 70 105 140 175 210 28 0 35 0 420 49 0 56 0 630 700

Unit Size kW 12 15 18 24 30 36 50 70 105 140 175 210 280 350 420 490 560 630 700

HP 1.2 1.5 1.8 2.4 3 3.6 5 7 10.5 14 17.5 21 28 35 42 49 56 63 70

Height

(A) Heater Overall

(B) Hot Water Outlet

(D) Drain Outlet

(E) Electric Control Box

(F) Hand Hole

Width & Depth

(G) Heater Diame ter

(H) Overall Depth Electric Panel to Drain

(I) Elec tric Panel Width

(J) Heater Width O verall

Minimum Clearances

(K) Horizontal to remove Elements

(L) Floor to Ceiling to Remove Elements

(M) Front of Heater (min. to open door)

(N) Sides and Rear of Heater

IN 24 24 24 24 24 24 55 55 55 55 55 55 55 55 55 55 55 55 55

MM 6 10 610 610 6 10 610 6 10 139 7 139 7 13 97 1397 1397 1397 1397 1397 1397 1397 139 7 139 7 139 7

IN 18 18 18 18 18 18 45.5 45.5 45.5 45. 5 45.5 45.5 45. 5 45.5 45.5 45.5 45. 5 45.5 45.5

M M 4 57 4 5 7 4 57 4 5 7 4 57 4 5 7 11 56 11 5 6 115 6 115 6 115 6 115 6 11 5 6 115 6 115 6 115 6 115 6 11 56 115 6

IN 4.25 4.2 5 4.25 4.25 4.25 4.25 9.5 9.5 9.5 9. 5 9. 5 9. 5 9. 5 9. 5 9.5 9.5 9.5 9.5 9. 5

MM 108 108 108 10 8 10 8 10 8 241 241 241 241 241 241 241 241 241 241 241 241 241

IN 4.25 4.25 4.25 4.25 4.25 4.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25 6.25

MM 10 8 10 8 10 8 1 08 1 08 10 8 159 159 159 159 159 159 15 9 15 9 15 9 159 159 159 159

IN 20.5 20.5 20.5 20.5 20.5 20.5 47 47 47 47 47 47 48 48 52 49 49 54 60

M M 5 21 5 2 1 5 21 5 2 1 5 21 5 2 1 11 9 4 119 4 119 4 119 4 119 4 119 4 1 21 9 121 9 13 21 12 45 12 4 5 1 37 2 1 5 24

IN 9.5 9. 5 9. 5 9. 5 9. 5 9.5 9.5 9. 5 9. 5 9.5 9.5 9. 5 9. 5

MM 241 241 241 241 241 241 241 241 241 241 241 241 241

IN 20 20 20 20 20 20 17 17 24 24 28 28 36 40 40 44 44 50 50

M M 50 8 5 0 8 50 8 50 8 50 8 50 8 4 32 4 3 2 61 0 61 0 7 11 7 11 9 14 10 16 10 16 111 8 1118 12 70 127 0

IN 34 34 34 34 34 34 31 31 38 39 43 43 54 59 59 60 67 67 70

MM 864 864 864 864 864 864 787 787 965 991 1092 1092 1372 1499 1499 1524 1702 1702 1778

IN 22 22 22 22 22 22 22 22 32 32 32 40 40 40 44 44 44 44 60

M M 55 9 5 5 9 5 59 5 5 9 5 59 5 5 9 5 59 5 5 9 8 13 81 3 8 13 10 16 10 16 10 16 111 8 1118 111 8 1118 152 4

IN 30 30 30 30 30 30 23 23 32 32 37 40 41 53 53 53 58 64 64

MM 762 762 762 762 762 762 584 584 813 813 940 1016 1041 1346 1346 1346 1473 1626 1626

IN 15 15 15 15 15 15

MM 381 381 381 381 381 381

IN 95 95 95 95 95 95 95 95 95 95 95 95 95

MM 2413 2413 2413 2413 2413 2413 2413 2413 2413 2413 2413 2413 2413

IN 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36

MM 914 914 914 914 914 914 914 914 914 914 914 914 914 914 914 914 914 914 914

IN 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24

MM 610 610 610 610 610 610 61 0 610 61 0 610 61 0 610 61 0 610 61 0 610 610 610 610

All dimensions are approximate. Fulton reserves the right to change dimensions and/or speci cations without notice.

*For unspeci ed voltages, consult factory.

Models FB-W 012-036

FRONT

SIDE

A E

12 kW to 36 kW (1.2 to 3.6 BHP)

Models FB-W 050-700 50 kW to 700 kW (5 to 70 BHP)

TOP

2-4

FIGURE 1  BOILER DIMENSIONS

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SECTION 2 FBW-IOM-2014-0311 INSTALLATION

TABLE 1B  SPECIFICATIONS

Model FB -W 012 015 018 024 0 30 036 0 50 070 105 14 0 175 210 280 350 420 4 90 560 6 30 700

Number of Elements 11122222345645678910

Output

Approx. Shipping Weight

Water Capacity

Heater Connection Sizes

Hot Water Outlet

Hot Water Inlet

Drain Outlet

Safety Valve Inlet (160 PSIG)

Safety Valve Outlet (160 PSIG)

Electrical Power Requirements (Amps) 208V 3 Phase 34 42 50 67 84 100 139 195 292 389 486 583 778 Consult Factory 230V 3 Phase 31 38 46 61 76 91 126 176 264 352 440 528 703 879 460V 3 Phase 16 19 23 31 38 46 63 88 132 176 220 264 352 440 528 616 703 791 879 575V 3 Phase 13 16 19 25 31 37 51 71 106 141 176 211 282 352 422 493 563 633 703

Speci cations are approximate.

result in higher amp draws. 160 PSIG design boilers operate up to 130 psi, 230 F.

1000 BTU/HR 41 51 62 82 103 124 172 241 3 62 4 83 6 03 724 966 1207 1449 1690 1932 2173 2415

1000 KCAL/HR 10 13 16 21 26 31 43 61 91 122 152 182 243 304 365 426 487 548 609

108 8

LB 420 420 420 450 450 45 0 580 58 0 950

KG 191 191 19 1 2 04 2 04 2 04 26 3 26 3 4 31 4 94 5 56 556 6 26 7 33 839 92 5 9 75 1052 1207

GALLONS131313131313212151516868132133133169169234234

LITER S 49 49 49 49 49 49 79 79 193 193 257 257 500 503 503 6 40 640 886 886

IN 1. 25 1.2 5 1.25 1. 25 1.2 5 1. 25 2 2 2 2 2 2 2 2 2 .5 3 3 3 3

MM 32 32 32 32 32 32 51 51 51 51 51 51 51 51 64 76 76 76 76

IN 1. 25 1.2 5 1.25 1. 25 1.2 5 1. 25 2 2 2 2 2 2 2 2 2 .5 3 3 3 3

MM 32 32 32 32 32 32 51 51 51 51 51 51 51 51 64 76 76 76 76

IN11111111111.251.251.251.251.51.51.51.51.5

MM 25 25 25 25 25 25 25 25 25 25 32 32 32 32 38 38 38 38 38

IN 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0. 75 0 .75 0.75 0.75 0. 75 0 .75 0 .75 0.75

MM 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19

IN1111111111111111111

MM 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25

122 5 12 25 138 0 1615

1850

2039 2150

1055

123 1 Consult Factory

2320 2660

Fulton reserves the right to change dimensions and/or speci cations without notice. Voltage applied higher than the above ratings will

 Drain Valve

 PID Type Temperature Controller

 Boilers 100kW and larger: staged element sequencer for

modulation of output

Temperature Control

Temperature control is achieved via an operating and high limit temperature controller. The high limit temperature controller is a temperature switch that is set to shut the boiler o if the water temperature exceeds the set point. For ASME Section IV hot water boiler, the high limit must be below 250 F.

The operating controller is a temperature sensor and PID Type controller that converts a temperature measurement into a 4-20 ma signal. The signal, which is proportional to the temperature of the water in the boiler, is used to energize/deenergize the contactors or step controller. The step controller (power modulation) will energize/de-energize each element based on a preset sequence to maintain the outlet water at a preset temperature.

stages added as demanded. When set point is reached, the  rst “on” stage is removed followed by the next stage “on”. Where control is a fraction of the total load, a sequence of onsteps will advance through the total number of stages, trailed by a sequence of “o ” steps. In this way all contactors and heaters tend to operate equally.

A back up operating temperature switch is supplied on each boiler and will act to energize/de-energize all elements simultaneous based on boiler water outlet temperature.

Water Supply

 Water Quality

The quality of the water used in the boiler will a ect the life of the elements and pressure vessel and it is strongly recommended that a competent water treatment concern be consulted prior to the operation of the boiler. Boiler internals damaged due to adverse water conditions cannot be replaced under warranty.

 Water Speciﬁ cation

 Step Controllers

At start up stage number one is  rst “on” with additional

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

All water supplies contain some amount of solids, dissolved gases and dissolved minerals. These materials may promote corrosion, deposition and/or fouling of equipment. To prevent

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Page 12

INSTALLATION FBW-IOM-2014-0311 SECTION 2

! WARNING

Do not downsize safety valve discharge piping below safety valve discharge

connection size. This is code violation.

4 CAUTION

Do not install this boiler on carpeting.

Boiler room temperatures greater than 100 F may cause premature failure of the control panel electrical components.

This boiler is equipped with a door safety switch, which will de-energize the boiler when the panel door is opened.

these contaminants from impacting on boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly. The following are installation recommendations for “closed-loop” recirculating hot water heating systems.

1. Automatic pressure activated water make up valve with back ow preventer providing water to the system, not fed directly to the boiler, set to maintain:

 Required NPSH for recirculating pump(s).

 A positive system pressure at the highest point of 5 to 10 psi.

 Make up water valve should be designed to add water to the system at

the outlet of the boiler and should not be fed directly into the boiler.

 Air removal equipment, including air separator and automatic air breather

valves.

 A functioning expansion tank designed to system speci cations.

 Filtration to remove particulates installed inline with the suction side of

the recirculating pump.

 Bypass chemical feeder for corrosion inhibitor maintenance.

 Optionally a water meter could be installed in series with the automatic

pressure activated water make up valve to monitor any make up water.

2. Ensure water quality meets the following:

 Oxygen - less than 250 ppb (operating condition)

 pH: 8 -10.5

 Total Iron & Copper - less than 25 ppm

 Corrosion Inhibitor - level capable of maintaining iron corrosion rates < 2

mpy. Due to changing environmental restrictions, a non-heavy metal, all organic inhibitor is recommended, which is designed for multi-metal systems including ferrous metals and yellow metals such as copper and brass.

 Chlorides - less than 250 ppm.

3. Maintenance: To prevent scale or corrosion in boiler and associated piping, make up water must be kept to a minimum. This is best achieved by ensuring immediate repair of all leaks and maintenance of system pressure.

NOTE:  There is a low water cut-o furnished as standard on all boilers.

 Water/Mechanical Installation

2-6

Adhere to the following for water supply installation:

1. Pipe the supply water and return lines to the openings on the boiler. Water stop valves should be in line between the boiler and the  rst piece of

Page 13

SECTION 2 FBW-IOM-2014-0311 INSTALLATION

equipment.

2. Install the water safety valve into the opening on the boiler, piping the outlet of the valve to a safe blow-o point.

NOTE:  Unless otherwise speci ed, the 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.

3. Install the water temperature / pressure gauge assembly.

4. The drain valve is connected to the lowest opening at the bottom rear of the boiler. Pipe from the outlet of the valve to a safe drain point. Provision should be made to allow easy access to the drain valve.

Electrical Installation

Adhere to the following for electrical installation:

1. Connect wiring as shown in wiring diagram which is furnished inside the electrical control panel. Be sure to install a fused switch for the contactors and a separate fused switch for the circulating pump(s).

! WARNING

Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

2. A correctly sized fused disconnect should be  tted as close to the boiler as possible and connections made to the boiler panel in compliance with NEC (National Electrical Code) and local codes.

3. Typical 120VAC controls allow for a +10% and a -15% voltage  uctuation.

 Motors

1. Motors are designed to operate within the following limits at the motor terminals:

 AC power supplied is within +/- 10 % of the motor rated voltage with the

rated frequency applied. OR

 AC power supplied is within +/- 5% of the rated frequency and with the

rated voltage OR

 A combined variation in voltage and frequency of +/- 10% (sum of

absolute values) of rated values provided the frequency variation does not exceed +/-5% of rated frequency.

2. For 3 phase motors, the line to line full load voltage must be balanced within 1% of the rated motor voltage. If the motor is rated 208-230V, the voltage deviations must be calculated from 230V. Operation outside of the above limits will degrade motor performance. 575V rated motors cannot be operated at voltages above 600V. Depending on the motor manufacturer, a 208V rated motor may not be able to run below the design voltage.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-7

Page 14

INSTALLATION FBW-IOM-2014-0311 SECTION 2

 Electric Elements

Electric elements will have an increase in watt density if the applied voltage is higher than the element design voltage. Therefore, electric elements have a 0% tolerance for operation over design voltage. Electric elements can tolerate a lower than design voltage but the kW must be derated accordingly.

2-8

Page 15

OPERATION

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE WARRANTY & PARTS

4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-1

Page 16

OPERATION FBW-IOM-2014-0311 SECTION 3

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations. Failure to follow instructions may result in a  re or explosion, causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other  ammable vapors and liquids in the vicinity of this or any other appliances.

Do not use this boiler if any part has been under water. Immediately call a quali ed service technician to inspect the boiler and to replace any impacted part of the control system.

Before turning on this boiler, ensure all electrical connections in the boiler control panel are tight and ensure all sections of this manual have been read and are understood.

Before Start Up

Before start up, ensure you have read and followed all previous safety information.

Start-Up

Perform the following to start boiler:

1. Close drain valve.

2. Open water stop valve at top of boiler. (Water Supply to System).

3. Open water feed valve on boiler. (Water Return to Boiler).

4. Open valves in makeup water line.

5. Fill the boiler and system with water. (While  lling the unit and system a bleed valve must be open at the highest point to allow air to escape). When the unit is full, close the bleed valve.

6. If the heating element is equipped with a thermostat, the dial should be set at number 11 at all times.

7. Activate the main power fused switch.

8. Activate the boiler power on switch, located on the top of the panel box (Figure 2).

When shutting the boiler down for any extensive repairs, shut o main power switch and main disconnect switches on both the boiler side as well as the supply water side.

Never tamper with the safety features of the low water safety cuto .

9. With the unit full of water (which activates the low water probe), the low water relay is enabled. Push manual reset button on panel box.

10. If, for any reason, the water leaves the low water cut-o probe, the unit will automatically shut down.

Boiler Controls

Once fully operational the boiler will be automatically controlled as follows:

 Pressure and Temperature Gauges – reads pressure and water temperature

of boiler.

 Low Water Cut-O – Probe Type – Shut down the unit when the water level

is too low. A low water cut-o condition will require pushing the manual reset button on the panel box.

 Water Relief Valve (ASME Approved) – releases extra pressure.

 Water Outlet Valve – allows water to circulate through system.

 Operating Aquastat – controls operating temperature.

 High Limit Aquastat – high temperature safety lock out.

3-2

 PID type temperature controller will control operating temperature set

point.

Page 17

SECTION 3 FBW-IOM-2014-0311 OPERATION

 The element sequencer will energize/de-energize elements in sequence to

maintain outlet temperature.

 Circulating Pump Switch (if supplied with the boiler)

The fused switch that controls the circulating pump should be kept in the “on” position at all times during the boiler operation as well as during the nonoperating period of the boiler. This should be turned “o ” only when repairs or adjustments should be made.

 Thermostat (optional)

An element thermostat may be supplied with your boiler. The thermostat is located on one of the heating elements and is preset from the factory. This should not be readjusted without consulting factory or your local Fulton representative.

! WARNING

Never attempt to operate a boiler that has failed to pass safety checks.

4 CAUTION

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

Legend:

A Runtime Meter (optional)

B. Alarm Horn

C. Temperature Controller

D. Various Lights/Alarms

E. Multimeter

FIGURE 2  PANEL BOX EXTERIOR

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-3

Page 18

OPERATION FBW-IOM-2014-0311 SECTION 3

! WARNING

FIGURE 3  PANEL BOX INTERIOR

Legend:

A Element Sequencer

B. Door Interlock Switch

C. Various Relays

D. Main Power Connections

E. Ground Fault Monitor (optional)

F. Element Contactors

CBDE

3-4

Page 19

MAINTENANCE

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE

WARRANTY & PARTS

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FBW-IOM-2014-0311 SECTION 4

! WARNING

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

General

Your boiler has been designed to provide years of trouble free performance. To ensure continued safety and e ciency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

Daily Maintenance and Inspection Schedule

Daily maintenance and inspection must include the following:

1. Check all valves for proper opening and closing.

2. Check supply water pump for proper operation.

3. Check make-up air water meter reading to verify no excessive leakage from hot water loop has occurred.

Monthly Maintenance and Inspection Schedule

Monthly maintenance and inspection must include the following:

1. Check safety valve for proper operation.

2. Check low-water cut-o relay for proper operation.

Do not use harsh cleaning compounds that could damage this equipment.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

Annual Maintenance and Inspection Schedule

Annual maintenance and inspection must include the following:

1. Inspect bottom of boiler for scale and lime by removing heating element. Clean/replace as needed. It is critical to perform this when boiler is cool and is vented to the atmosphere.

2. When the water level drops, the low water relay will shut o the contactor. This shows that the relay is working properly.

3. Check for loose terminals and wiring connections.

4. Remove and clean the water electrode probe in the boiler.

5. Inspect boiler shell for possible mineral build-ups and clean if necessary.

6. Inspect elements on top of boiler for leaks, or loose  ange bolts and nuts.

7. Check elements for correct amp rating.

8. Provide annual inspection by quali ed ASME boiler inspector.

9. See Handhole Gasket Installation section for correct hand hole gasket installation.

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10. Check temperature/pressure gauge periodically to verify compatibility with the operating aquastat/controller.

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SECTION 4 FBW-IOM-2014-0311 MAINTENANCE

 Handhole Gasket Installation

1. Remove old gasket and thoroughly clean the surface on boiler and on plate.

2. Place neoprene gasket on handhole plate. Be sure the gasket is pushed down tight on the plate. Do not use any grease, lubricant or adhesive.

3. After plate is in boiler and gasket is in place, set yoke and tighten nut only enough to provide a snug  t. See Figure 4. Make it hand tight then snug with wrench about ¼ turn. Do not compress excessively as neoprene gaskets should never be compressed as much as the old asbestos type.

4. If gasket leaks while pressure is being built up, tighten only enough to stop leakage. Never tighten more than necessary to prevent leakage. Excessive tightening may shorten life of gasket.

OVERTIGHTENED INCORRECT

! WARNING

Never use open  ame or other sources of ignition to check for gas leaks.

A defective boiler can cause injury. Do not operate a boiler that is defective, or has any missing parts. Do not attempt repairs or any other maintenance work that you do not understand.

Never store or use gasoline or other  ammables in the vicinity of this appliance.

SNUG FIT CORRECT

FIGURE 4  GASKET INSTALLATION

 Scale Formation

The dangers of scale to the life of the element cannot be over stressed. Scale possesses excellent insulating qualities and its formation on the element prevents the heat generated by the element from being transferred to the water, causing the element to overheat and burn out. Loose powdery formations can be removed with a wire brush. Hard scale may be removed using a mild chemical cleaning agent followed by a neutralizing agent.

Do not use this boiler if any part has been under water. Immediately call a quali ed service technician.

4 CAUTION

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

Do not allow oil leaks, dust, or dirt to accumulate around the boiler.

To protect unit components and prolong equipment life, it is essential that regular inspections are carried out. The most common causes of failure are excessive scale build-up and corrosion.

Elements, if stored correctly, have an inde nite shelf life. However, problems will arise if they are stored in damp or humid conditions. Moisture can be absorbed by the insulation as the elements are  tted with a breathing seal.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FBW-IOM-2014-0311 SECTION 4

Troubleshooting

Use the following table as a guide to troubleshooting your boiler.

Problem Check

Check fuse or circuit breaker. Use a multimeter to check voltage across the fuse. If power is off, remove fuse from fuse holder and check with multimeter or continuity light to see if there is a break in the fuse.

Unit Does Not Run

Fuse is Blown

Control Circuit Failure

Control Switch Fails to Operate

Faulty Low Water Safety Relay

Reset or replace, as necessary. Ensure unit is on. Water Level too low. Check supply water. Outlet temperature over the setpoint. Check water ﬂ ow and setpoint controller.

1. If power is on use a multi meter to check voltage across the fuse.

2. If power is off remove fuse from fuse holder and check with a multi meter or continuity light to see if there is a break in the fuse.

3. If a break is detected – shut off power and remove fuse with a fuse puller. Replace with a new fuse of the same voltage and amps. Turn power on.

1. If control circuit failure is suspected, trace the wiring diagram through each component with a multi meter to verify power in each stage or that component is supplied.

2. If part of the voltage is stopped at any point, replace that component and continue the test until all circuits test clear.

1. Turn off power.

2. Remove all wires from switch terminals.

3. Check all terminals for looseness or corrosion.

4. To test for proper make or break of circuit, use a multimeter or continuity light. If bad, replace using adjustable wrench and screwdriver.

1. With a multi meter check power on #1 terminal to see if power is coming to the relay. If it is, continue through the relay verifying circuit power to each part of the control.

2. If it is faulty, replace.

Faulty Probe

Faulty Element Thermostat

4-4

1. Check wire to probe. If the wire is suspected to be bad, shut off the power and check the wire with a continuity light.

2. If probe is dirty, clean with very ﬁ ne sandpaper or emery paper and replace into boiler.

1. If power is on, check across thermostat with a volt meter to verify power going through the switch on all points.

2. If power is off, read across contactors on switch with a continuity light to verify switch is not breaking down.

3. If the thermostat is bad replace it by using a ﬂ at-head or Phillips head screwdriver.

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SECTION 4 FBW-IOM-2014-0311 MAINTENANCE

1. With power off, check continuity of circuit through each point in the circuit.

2. If a break in the circuit is found, the connection should be repaired use the following tools: wire cutters, wire strippers, ﬂ at-head screwdriver, Phillips head screwdriver, crimping pliers,

Faulty Wiring Connections

Faulty Contactor Contact Points

needle nose pliers, tape, connectors, or wire splice connectors.

3. After the break has been corrected recheck it with a continuity light with the power off. Then turn off power on and check with multi-meter.

1. If a contactor has burned or dirty contacts, they should be brushed clean with a ﬁ ne sandpa- per or emery paper.

2. If they are burned through, the contactor should be replaced.

3. If they do not engage completely, the contactor coil may be weak and the contactor should be replaced.

4. An amp meter may be used to check amp draw through each leg of the contactor.

5. With power off an ohm meter can be used to check the contactor points between the contactor supply and contactor feed to verify the contactor is pulling in. A visual inspection on the side of the contactor can be made to see if the contactor is engaging.

6. All power coming into the contactor should be checked with a volt meter to verify proper feeding of contactor to eliminate possible overload.

7. If a contactor is in need of replacement, mark each wire and remove with a ﬂ at-head screw- driver; remove the base screws and replace with new contactor.

Faulty Elements

1. With the power off, a continuity tester can be used to see if an element is burned out between each point.

2. If the power is on, a volt meter can be used to check power between each point on the elements.

3. If an element is bad, it will require a ﬂ at-head screwdriver to remove wires. Two crescent or adjustable wrenches to remove bolts from element face. A new gasket and gasket seal should be used when replacing the element.

4. Be sure to check incoming voltage and amperage to each element to avoid overloading the element.

5. If the elements are dirty and not burned out, they may be cleaned by using caustic soda or soda ash in a combined solution.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FBW-IOM-2014-0311 SECTION 4

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WARRANTY & PARTS

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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WARRANTY & PARTS FBW-IOM-2014-0311 SECTION 5

Standard Warranty for ICS/FB-A, ICW, ICX/FB-F, VMP, VMPW, FB-S, FB-L, FB-W, ICT

E ective Date: 2010-09-01

Five (5) Year (60 Months) Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of  ve (5) years from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the equipment, as de ned above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused by defective material or workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation and Operation Manual.

Parts Warranty

Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department.

General

Fulton shall be noti ed 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. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or other representative of Fulton other than the Quality Manager or an o cer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and  tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of pro ts or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. Excessive cycling will reduce the life of any boiler. Veri cation that the system is properly designed and has been properly maintained to prevent excessive cycling may be required. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

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SECTION 5 FBW-IOM-2014-0311 PARTS & WARRANTY

! WARNING

Parts

Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherence with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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