Fulton Electric Hot Water Boiler User Manual

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

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
BoilerTrim ............................................................................................................	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
StandardWarranty...............................................................................................	5-2
Parts .....................................................................................................................	5-3

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TABLE OF CONTENTS

FBW-IOM-2014-0311

0-2

© The Fulton Companies 2014

INTRODUCTION

INTRODUCTION	1
INSTALLATION	2
OPERATION	3
MAINTENANCE	4
WARRANTY & PARTS	5

1-1

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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 staff 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, qualified 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 qualified and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training specific 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 effectiveness.

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 specific 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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© The Fulton Companies 2014

INSTALLATION

INTRODUCTION	1
INSTALLATION	2
OPERATION	3
MAINTENANCE	4
WARRANTY & PARTS	5

2-1

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INSTALLATION

FBW-IOM-2014-0311

SECTION 2

! 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.

4 CAUTION

This boiler is certified 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 specifications, equipment and operating descriptions apply to typical Fulton Electric Hot Water Boilers. This section is provided for general reference purposes only, and may not reflect specific 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 flow 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 stratification. This unique circulation method achieves an even

flow of water across the elements. It is heated uniformly while it washes each element. This results in low flux 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 flake off and drop to the bottom of the boiler, thus assuring longer element life.

Low element heat flux (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 fiber insulation is wrapped around the boiler vessel. A neatly finished 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 fitted 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.

Placement & Rigging

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

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© The Fulton Companies 2014

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 sufficient 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

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 fitted to boiler). Additional trim may be provided as ordered.

Temperature/Pressure Gauge

Low Water Cut Off (Probe Type)

Water Relief Safety Valve (ASME Rated)

Operating Aquastat

High Limit Aquastat

! 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.

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 classification, 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.

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 fire.

4 CAUTION

Do not allow weight to bear on equipment

components to prevent damage.

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INSTALLATION

FBW-IOM-2014-0311

SECTION 2

TABLE 1ABOILER DIMENSIONS

	Model FB-W			012	015	018	024	030	036	050	070	105	140	175	210	280	350	420	490	560	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	IN	24	24	24	24	24	24	55	55	55	55	55	55	55	55	55	55	55	55	55
			MM	610	610	610	610	610	610	1397	1397	1397	1397	1397	1397	1397	1397	1397	1397	1397	1397	1397
	(B)	Hot Water Outlet	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
			MM	457	457	457	457	457	457	1156	1156	1156	1156	1156	1156	1156	1156	1156	1156	1156	1156	1156
	(C)	Return Water Inlet	IN	4.25	4.25	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	108	108	108	241	241	241	241	241	241	241	241	241	241	241	241	241
	(D)	Drain Outlet	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	108	108	108	108	108	108	159	159	159	159	159	159	159	159	159	159	159	159	159
	(E)	Electric Control Box	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
			MM	521	521	521	521	521	521	1194	1194	1194	1194	1194	1194	1219	1219	1321	1245	1245	1372	1524
	(F)	Hand Hole	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
	Width & Depth
	(G)	Heater Diameter	IN	20	20	20	20	20	20	17	17	24	24	28	28	36	40	40	44	44	50	50
			MM	508	508	508	508	508	508	432	432	610	610	711	711	914	1016	1016	1118	1118	1270	1270
	(H)	Overall Depth Electric Panel to Drain	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
	(I)	Electric Panel Width	IN	22	22	22	22	22	22	22	22	32	32	32	40	40	40	44	44	44	44	60
			MM	559	559	559	559	559	559	559	559	813	813	813	1016	1016	1016	1118	1118	1118	1118	1524
	(J)	Heater Width Overall	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
	Minimum Clearances
	(K)	Horizontal to remove Elements	IN	15	15	15	15	15	15
			MM	381	381	381	381	381	381
	(L)	Floor to Ceiling to Remove Elements	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
	(M)	Front of Heater (min. to open door)	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
	(N)	Sides and Rear of Heater	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	610	610	610	610	610	610	610	610	610	610	610	610	610

All dimensions are approximate. Fulton reserves the right to change dimensions and/or specifications without notice. *For unspecified voltages, consult factory.

Models FB-W 012-036

12 kW to 36 kW (1.2 to 3.6 BHP)

J	H	N

G

FRONT			B	TOP
A	SIDE	D	C	N
E
I
F
K
				M

Models FB-W 050-700

50 kW to 700 kW (5 to 70 BHP)

J

H

G

N

SIDE

FRONT

L

B

TOP

I

A

E

N

M

F

D C

FIGURE 1 - BOILER DIMENSIONS

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© The Fulton Companies 2014