FULTON Electropack Series User manual

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

EP18-72-IOMM-2015-7
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TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Product Overview 1
1.3 Technical Data 1
SECTION 2 - INSTALLATION
2.1 General 3
2.2 Pre-Installation 3
2.2.1 Siting 3
2.3 Major Components 4
2.3.1 Steam Safety Valves 4
2.4 Boiler Connections 6
2.5 Water Supply 8
2.6 Electrical Requirements 8
2.7 Steam Pressure Control 10
2.8 Commissioning the Boiler 11
2.9 Cleaning Steam Lines and Pressure Vessels 14
SECTION 3 - OPERATION
3.1 General 15
3.2 Controls and Indicators 15
3.3 Filling The Feedwater Tank 17
3.4 Filling The Boiler 18
3.5 Draining the Boiler 19
3.6 Draining the Feedwater Tank 20
3.7 Boiler Start-Up 20
3.7.1 Boiler Start-Up Following short term Shut-Down 20
3.8 Boiler Shut-Down 21
3.8.1 Short Term Shut-Down (hours) 21
3.8.2 Long Term Shut-Down (weeks) 21 Electrical diagrams supplied separately
SECTION 4 - MAINTENANCE
4.1 Visual Checks 23
4.2 Water Level and Low Water Safety Controls 24
4.2.1 Feedwater Pump Test 24
4.2.2 Low Water Level Checks 25
4.2.3 Evaporation Check 25
4.3 Blowdown Procedures 26
4.3.1 Main Boiler Blowdown 26
4.3.2 Water Level Gauge (Sight Glass) Blowdown 27
4.4 Element Care and Protection 28
4.4.1 Element Removal 29
4.5 Boiler Internal Inspection 30
4.5.1 Feedwater Tank Internal Inspection 30
4.6 Cleaning Water Level Probes 31
4.7 Schedule of Operator Tests and Checks 32
4.7.1 Daily 33
4.7.2 Weekly in addition 33
4.7.3 Monthly in addition 33
4.7.4 Three Monthly in addition 34
4.8.1 Troubleshooting boiler 35
4.8.2 Troubleshooting feedwater pump 36
4.8.2 Troubleshooting feedwater pump 37
APPENDIX A - TI SHEETS
 EP18-72Dimensions&Specication 42
EP Probe Lengths 44
Recommended Water Conditions 46
Water Level Probes 47

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WARNINGS
The Pressure System Safety Regulations 2000
Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.
For further information contact:
(a) SAFed
SAFETYASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) HealthandSafetyExecutivelocalofce.
(c) Your Competent Person.
For your safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
• WARNINGS must be observed to prevent serious
injury or death to personnel.
• CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
effectiveness.
• Notes: must be observed for essential and
effective operating procedures, conditions and as
a statement to be highlighted.
It is the responsibility and duty of all personnel involved
in the operation and maintenance of this equipment
to fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.
CAUTION
In case of emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.
If such a condition should occur during commissioning or during subsequent operation of this product,
regardless of the cause, then the electrical supply to the boiler should be isolated immediately, until the fault
hasbeeninvestigatedbyacompetentpersonandrectied.
!
WARNING
Steam boilers are a potential hazard, possibly fatal if not properly maintained.
CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry
out the routine maintenance checks could result in a drastic reduction in the life expectancy of the
systemandincreasethepossibilityofre,explosion,propertydamage,personalinjuryorlossoflife.
!
!

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WARNINGS
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the heater and serious personal injury.
WARNING
Do not try to do repairs or any other maintenance work
you do not understand. Obtain a service manual from
Fulton Ltd or call a Fulton service engineer.
It is the responsibility of the installer to ensure all parts
suppliedwiththeboilerarettedinacorrectandsafe
manner.
Understand the electrical circuit before connecting
or disconnecting an electrical component. A wrong
connection can cause injury and or damage.
A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing
parts. Make sure that all maintenance procedures are
completed before using the boiler.
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local
regulations and is suitable for the job. You can be injured
if you use faulty lifting equipment. Make sure the lifting
equipment is in good condition.
Operating the boiler beyond its design limits can damage
the boiler, it can also be dangerous. Do not operate the
boiler outside its limits. Do not try to upgrade the boiler
performancebyunapprovedmodications.
Non-approvedmodicationscancauseinjuryand
damage. Contact your Fulton dealer before modifying
the boiler.
Onlyqualiedpersonsshouldbeallowedto
operate and maintain the boiler and its equipment.
Boilers should always be drained through an approved
blowdown vessel.
Prior to the commencement of any work requiring the
removal of cover plates and the opening of control panel
box, the electrical supply to the boiler must be isolated.
Steam boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent and
qualiedpersonnelshouldworkonorinthelocalityof
a steam boiler and ancillary equipment. Always ensure
theworkingareaandoorareclearofpotentialhazards,
work slowly and methodically.
DoNOTstoreinammablematerialsneartheboiler.
The importance of correct boiler water and feedwater
cannot be over emphasised, see the relevant section in
this manual.
!
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary preheat the
feedwater. If in doubt consult Fulton Ltd.
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners
and chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
It is the responsibility of the operator to ensure adequate
supplies of chemical are available at all times
(including commissioning). Costly repairs could be
required should the plant operate without chemicals or
the wrong dosage of chemicals.
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and
is normally only required by engineering surveyors /
inspectors. In order to ensure the material/ pressure
vessel does not suffer from brittle fracture, hydraulic
testing should not be carried out below 7 °C.
!

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Figure. 1 - Electropack Electric Steam Boiler
Pressure gauge
Boiler control
panel
Boiler isolator
switch
Front access
panel
Top access
panel

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INTRODUCTION - 1
SECTION 1 - INTRODUCTION
1.1 GENERAL
1.3 TECHNICAL DATA
ForafullspecicationrefertoAppendixA-TI-115-EP-18-72Dimensions&Specication.
The Fulton Electropack electric steam boiler service manual is a generic publication, providing
information on standard boiler operation and maintenance.
Every care has been taken in the manufacture of the boiler to ensure that quality and reliability
standards are maintained. Satisfactory performance can only be ensured if the installation
recommendations, operating routines and maintenance schedules laid out in this manual are
adhered to.
Particular attention should be paid to electrical installation and water treatment.
1.2 PRODUCT OVERVIEW
TheElectropackelectricsteamboilerisacompactandhighlyefcientunitdesignedtomeetthe
requirements of the lower demand steam user.
The Electropack 18-72 contains a feedwater tank, pressure vessel, feedwater pump and system
controls to create a fully contained steam raising unit with easy access removable cabinet panels
There is the option to heat the feedwater tank with the purpose of reducing the level of
Non-Condensable Gases (NCG’s) in the steam as required by HTM2010 and to limit the
temperature and pressure drop within the boiler when feedwater is introduced.

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INSTALLATION - 2
2.1 GENERAL
2.2.1 SITING
Theboilerhouseshouldbesufcientlysizedtoalloweasyandsafeaccesstoallpartsofthe
boiler for operational and maintenance purposes.
Reference should be made to AppendixA-TI-115-EP-18-72Dimensions&Specication
to ascertain the relevant dimensions and weights, special note should be taken of the required
vertical clearance required for maintenance.
Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto
support the boiler.
SECTION 2 - INSTALLATION
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.
2.2 PRE-INSTALLATION
Prior to delivery of the boiler, consideration should be given to the following:
(Planning regulations may call for more consents than those listed below, always check with your
Local Planning Authority).
A. Local Planning consents where appropriate.
B. Consideration given to access for delivery and positioning of the boiler.
C. Preparation of a suitable base, which must be able to support the total weight of the system
under operating conditions.
The locations of services to the site required for the system, under operating conditions.
D. Electricity supply, check the loading required/available.
E. Drainage system, check the suitability of the drainage system.
F. Local regulations for discharge into existing drains.
G. Suitable access for delivery and off-loading.
H. Safe access to the plant when installation is complete.

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INSTALLATION - 2
2.3 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..
Electrical control panel. Mounted inside the cabinet in the upper half behind the front access
panel. Panel must be removed for access.
Operating pressure controls
Boiler feedwater pump (Grundfos). 1 x Grundfos feedwater pump is provided for the boiler
feedwater mounted to the base of the cabinet.
For more information on the feedwater pump, please refer to the Grundfos OEM literature.
Steam pressure gauge. Fitted to the cabinet frame and visible from the front with the access
panel attached.
Steam outlet valve.Steamoutletstopvalvettedcentrallytotherearofthecabinet.
Safety valve. Fitted to the rear of the cabinet.
Main boiler blowdown valve. Fitted centrally to the rear of the cabinet at the bottom.
Water level gauge set (sight glasses) (optional). Fitted to the side of the cabinet.
2.3.1 STEAM SAFETY VALVES
Safetyvalvesarefactoryttedandpre-set,theyMUSTNOTbeadjusted.Thedischargeoutlet
should be piped to a safe discharge point and the piping so arranged that any condensate
trapped in the pipework will drain away from the valve.
Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806
clause 4.9.7. / BSEN 134801-1:2002
a) The lift pressure is indicated on the safety valve (donotadjust).
b) Thesafetyvalvettedtotheboilerisdesignedtopreventtheboilerexceedingitsdesign
pressure.
c) Any system connected to the boiler not capable of accepting boiler pressure must be protected
by a separate safety valve set to the required pressure.
WARNING
Factoryttedsafetyvalvesarepre-settoprotecttheboileronlyandmustnotbeusedtoprotectany
other items not capable of accepting boiler pressure.
!