FULTON FBW-IOM-2014-0311 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

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FBW-IOM-2014-0311 TABLE OF CONTENTS
0-1
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 PRIORTO 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 SUPPLIEDWITH 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

© The Fulton Companies 2014
TABLE OF CONTENTS FBW-IOM-2014-0311
0-2

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

© The Fulton Companies 2014
1-2
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
1
INSTALLATION
2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2014
INSTALLATION FBW-IOM-2014-0311 SECTION 2
2-2
! 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 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 build-
up 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.
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
2-3
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
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)
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 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.
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.

© The Fulton Companies 2014
INSTALLATION FBW-IOM-2014-0311 SECTION 2
2-4
TABLE 1A BOILER 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 115 6 1156 1156 1156 1156 1156 1156 1156 1156 115 6 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 521 521 521 521 521 521 119 4 119 4 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 50 8 508 50 8 508 50 8 50 8 432 432 610 610 711 711 914 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 specications without notice.
*For unspecied voltages, consult factory.
A E
J
G
I
FRONT
CF
B
D
H
SIDE
L
N
N
M
TOP
M
N
N
TOP
B
DC
H
E
F
SIDE
A
J
G
I
FRONT
K
Models FB-W 012-036
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)
FIGURE 1  BOILER DIMENSIONS

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SECTION 2 FBW-IOM-2014-0311 INSTALLATION
2-5
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/de-
energize 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.
Step Controllers
At start up stage number one is rst “on”with additional
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 on-
steps 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 Specification
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
TABLE 1B  SPECIFICATIONS
Model FB-W 012 015 018 024 030 036 050 070 105 140 175 210 280 350 420 490 560 630 700
NumberofElements 11122222345645678910
Output 1000 BTU/HR 41 51 62 82 103 124 172 241 362 483 603 724 966 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
Approx. Shipping Weight LB 420 420 420 450 450 450 580 580 950
1088 1225 1225 1380 1615 1850 2039 2150 2320 2660
KG 191 191 191 204 204 204 263 263 431 494 556 556 626 733 839 925 975 1052 1207
Water Capacity GALLONS131313131313212151516868132133133169169234234
LITERS 49 49 49 49 49 49 79 79 193 193 257 257 500 503 503 640 640 886 886
Heater Connection Sizes
Hot Water Outlet IN 1.25 1.25 1.25 1.25 1.25 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
Hot Water Inlet IN 1.25 1.25 1.25 1.25 1.25 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
Drain Outlet 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
Safety Valve Inlet (160 PSIG) 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
Safety Valve Outlet (160 PSIG) IN1111111111111111111
MM 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
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 1055 1231 Consult Factory
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. Fulton reserves the right to change dimensions and/or specications without notice. Voltage applied higher than the above ratings will
result in higher amp draws. 160 PSIG design boilers operate up to 130 psi, 230 F.

© The Fulton Companies 2014
INSTALLATION FBW-IOM-2014-0311 SECTION 2
2-6
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
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
! 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.
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.

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SECTION 2 FBW-IOM-2014-0311 INSTALLATION
2-7
! 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.
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).
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.

© The Fulton Companies 2014
INSTALLATION FBW-IOM-2014-0311 SECTION 2
2-8
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.

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

© The Fulton Companies 2014
OPERATION FBW-IOM-2014-0311 SECTION 3
3-2
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).
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.
PID type temperature controller will control operating temperature set
point.
! 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.
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.

Questions? Call [phone], or visit us online at www.fulton.com
SECTION 3 FBW-IOM-2014-0311 OPERATION
3-3
! 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.
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 non-
operating 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.
A
B
CD
E
FIGURE 2  PANEL BOX EXTERIOR
Legend:
A Runtime Meter (optional)
B. Alarm Horn
C. Temperature Controller
D. Various Lights/Alarms
E. Multimeter

© The Fulton Companies 2014
OPERATION FBW-IOM-2014-0311 SECTION 3
3-4
! 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.
A
CBDE
F
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

Questions? Call [phone], or visit us online at www.fulton.com 4-1
MAINTENANCE
INTRODUCTION
1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2014
MAINTENANCE FBW-IOM-2014-0311 SECTION 4
4-2
! 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.
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.
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 [phone] or your
local Fulton Thermal Representative.
In order to meet warranty conditions,
ensure all appropriate maintenance
activities are performed.
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.
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.
10. Check temperature/pressure gauge periodically to verify compatibility
with the operating aquastat/controller.