Fulton Ltd

INSTALLATION, OPERATION & MAINTENANCE MANUAL

EFS Electric Flash Steam (Optional 9 Kw Heated Tank)

This Manual must be available to the boiler operator at all times.

EFS Optional heated tank Manual 05 2014 ISSUE 1 ! 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, whatever the cause, then the electrical supply to the boiler should be isolated immediately, until the fault has been investigated by a competent person and rectified.

For your Safety! The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.

! WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel injury or death to personnel. involved in the operation and maintenance of this equipment to fully understand the WARNINGS, ! CAUTIONS must be observed to prevent damage CAUTIONS and NOTES by which hazards are to be or destruction of equipment or loss of operating eliminated or reduced. effectiveness. Personnel must become familiar with all aspects of NOTES: must be observed for essential and safety and equipment prior to operation or effective operating procedures, conditions and as maintenance of the equipment. a statement to be highlighted.

! WARNING Steam 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 boiler.

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 SAFETY ASSESSMENT FEDERATION Limited. Nutmeg House, 60 Gainsford Street, Butlers Wharf, , SE1 2NY.

(b) Health and Safety Executive local office.

(c) Your Competent Person.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 LIST OF CONTENTS

INTRODUCTION 1 GENERAL DATA 5 General 1.1 Boiler Dimensions 5.1 Technical Data 1.2 Boiler Specification 5.2 Recommended Water Conditions 5.3 INSTALLATION 2 Gloassary of Terms 5.4 General 2.1 Siting 2.2 Electrical Diagrams (Supplied Separately) Water Supply (see also section 5.3) 2.3 Connections (no tank) 2.4.1 Connections (optional tank fitted) 2.4.2 Electrical Requirements 2.5 Steam Pressure Control 2.6 Commissioning 2.7 Electrical 2.7.1 General 2.7.2

OPERATION 3 Control Panel 3.1 Controls and Fault Indicators 3.1.1 Feedwater Tank Controls 3.1.2 Starting the Boiler 3.2

MAINTENANCE 4 Visual Checks 4.1 Water Level and Safety Controls 4.2 Pump Test 4.2.1 1st Low Water Level Check 4.2.2 2nd Low Water Level Check 4.2.3 Blowdown Procedure 4.3 Element Care and Protection 4.4 Internal Inspection 4.5 Removal 4.5.1 Replacement 4.5.2 Schedule of Operator Tests and Checks 4.6 Daily 4.6.1 Weekly 4.6.2 Three Monthly 4.6.3 Troubleshooting 4.7 Boiler Controls Test Log 4.8

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 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 boiler and serious personal injury.

! WARNING ! WARNING Do not try to do repairs or any other maintenance work you DANGER FROM HOT SURFACES do not understand. Obtain a Service Manual from Steam Boilers have high surfaces, that if touched Fulton Ltd. or call a Fulton Service Engineer. may cause serious burns. Only competent and qualified personnel should work on or in the locality of a steam boiler ! WARNING and ancillary equipment. Always ensure the working area It is the responsibility of the installer to ensure all parts and floor are clear of potential hazards, work slowly and supplied with the boiler are fitted in a correct and safe manner. methodically. Do NOT store inflammable materials near the boiler. ! WARNING Understand the electrical circuit before connecting or ! WARNING disconnecting an electrical component. A wrong connection The importance of correct boiler water and feedwater cannot can cause injury and or damage. be over emphasised, see the relevant section in this manual.

! WARNING ! CAUTION A defective boiler can injure you or others. Do not operate LOW FEEDWATER TEMPERATURE a boiler which is defective or has missing parts. Make sure Low feedwater temperature can result in thermal shock to the that all maintenance procedures are completed before using boiler pressure vessel. Return the maximum amount of the boiler. condensate and if necessary preheat the feedwater. If in doubt consult Fulton Ltd. ! CAUTION Obey all laws and local regulations which affect you and ! CAUTION your boiler. WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and ! WARNING chemical treatment plants CAN BE SUPPLIED by LIFTING EQUIPMENT Fulton Ltd. Make sure that lifting equipment complies with all local It is the responsibility of the operator to ensure adequate regulations and is suitable for the job. You can be injured supplies of chemical are available at all times (including if you use faulty lifting equipment. Make sure the lifting commissioning). equipment is in good condition. Costly repairs could be required should the plant operate without chemicals or the wrong dosage of chemicals. ! WARNING Operating the boiler beyond its design limits can damage the ! CAUTION boiler, it can also be dangerous. HYDRAULIC TEST - RISK OF BRITTLE FRACTURE Do not operate the boiler outside its limits. Hydraulic testing requires specialist equipment and is Do not try to upgrade the boiler performance by unapproved normally only required by engineering surveyors / inspectors. modifications. In order to ensure the material/ pressure vessel does not suffer from brittle fracture, hydraulic testing should not be ! WARNING carried out below 7°C. Non-approved modifications can cause injury and damage. Contact your Fulton dealer before modifying the boiler. WARNING Prior to the commencement of any work requiring the ! WARNING removal of cover plates and the opening of control panel Only qualified persons should be allowed to operate box, the electrical supply to the boiler must be isolated. and maintain the boiler and its equipment. Boilers should always be drained through an approved Blowdown Vessel.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 LIST OF ILLUSTRATIONS

TITLE FIG. NO. EFS Boiler 1 General Arrangment (Heated Tank) 2 Boiler Connection Points (No Tank) 3a Boiler Connection Points (Optional Tank Fitted) 3b Electrical Connections (Unheated/No Tank) 4a Electrical Connections (Heated Tank) 4b Pressure Controllers 5 Feedwater Pump 6 Control Panel 7 Heating Elements 8 Hand Hole Assembly 9 Boiler Dimensions 10

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Electrical Control Panel

Pressure Gauge

FIG. 1 EFS Boiler

Page 6 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

The Fulton EFS Electric Flash Steam Boiler is a compact, fully automatic, self-contained steam raising unit, specifically designed to meet the requirements of applications requiring a short period high demand steam supply.

A heated feedwater tank is available as an option, the purpose of which is to reduce the level of non-condensable gases (NCG’s) in the steam as required by HTM* 2010 and to limit the temperature and pressure drop within the boiler when feedwater is introduced.

1.2 TECHNICAL DATA

For a full specification refer toSection 5.

Note: *Glossary of Terms Section 5.4

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 1 Audible Alarm

Electrical Control Panel

Delay Timer Door Isolator Switch

Pump Contactor

Cooling Fan

Boiler Feedwater Pump Feedwater

Pressure Controllers

Heating Elements Feedwater Isolation Valve

Chemical Dosing Point

FIG. 2 GENERAL ARRANGMENT (Heated Tank)

Page 2 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 2

SECTION 2 - INSTALLATION

2.1 GENERAL The installation of the Fulton EFS Electric Flash 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.

! WARNING At all stages of operation the boiler will generate high , which will be transferred to the boiler and the boiler fittings. Great care must be taken to avoid any chance of receiving burns when working on or near the boiler.

The Fulton Electric Flash Steam Boilers are designed to provide short term peak steam loads up to three times the boiler steady state output. This is achieved by providing the boiler with a very large pressure vessel, which acts as a combined boiler and steam accumulator. As is the case with all accumulator applications the peak load must be followed by a dwell/low load period to allow the accumulator to recharge back up to full pressure.

When a peak load which exceeds the normal output occurs, the boiler pressure falls releasing energy in the form of flash steam to satisfy the peak load.

Note: To enable this to happen it is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of 10.34 barg. 2.2 siting The boiler should be sited in dry surroundings on a level base as close as possible to the steam using equipment. Take note of the dimensions given in Section 5 and ensure there is sufficient room around the boiler to allow for the connection of all services and to enable the maintenance engineer to gain access to all parts of the boiler.

2.3 WATER SUPPLY The quality of the water used in the boiler will affect the life of the elements and it is strongly recommended that a competent water treatment supplier be consulted prior to the installation of the boiler. Water should be treated to obtain the values quoted in Section 5.3 Recommended Water Conditions.

Note: Elements damaged due to adverse water conditions cannot be replaced under guarantee. In order to take a boiler water sample safely it is advisable to fit a Water Sample Cooler which is not supplied as standard.

! CAUTION 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.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 3 2

Safety valve

Steam stop valve

Water sample point (valve not fitted as standard)

Boiler blowdown Water feed

FIG. 3A BOILER CONNECTION POINTS (No Tank)

Page 4 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 2

2.4.1 CONNECTIONS (NO tank)

All connections for services are located at the rear of the boiler, and should be made as follows:

a) Feedwater Inlet, DN20 (3/4 in. BSP) It is advisable to fit a stop valve as close as possible to this connection point. Local Water Authority bylaws may require the fitting of a break (interpose) tank between the mains water supply and the cold water inlet connection on the boiler. The feedwater tank is not suitable for condensate return.

b) Safety Valve DN25 (1 in. BSP) The outlet from this valve should be piped to a safe discharge point and the piping should be so arranged that condensate trapped in the discharge pipe is drained away from the safety valve and contains a weep/tell-tale leakage pipe.

! CAUTION Unless otherwise specified the steam safety valve supplied with the boiler is preset and must not be adjusted. This valve is provided as a safety device for the boiler and should not be used as the sole protection for other equipment using steam from the boiler.

c) Main Steam Valve DN40 (1 1/2 in. BSP) It is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of 10.34 barg.

d) Boiler Blowdown Connection DN20 (3/4 in. BSP) Connection must be made from the blowdown valve to a blowdown receptacle of approved design. Regulations exist covering such items and care must be taken to ensure compliance with these regulations. If in any doubt regarding blowdown arrangements consult Fulton After Sales Department.

e) Water Sample Outlet DN15 (1/2 in. BSP) If the water sample point is used the valve should be fitted as close as possible to the boiler.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 5 2

Condensate Return DN15 (1/2in. BSP) Feed Tank Overflow and Vent DN25 (1in.BSP)

Feedwater Inlet DN20 (3/4in.BSP)

Safety Valve DN25 (1in.BSP) Steam Stop Valve DN40 (1 1/2in.BSP)

Boiler Water Sample Point DN15 (1/2in.BSP)

Feed Water Tank Drain Check Valve DN15 (1/2in.BSP)

Boiler Blowdown DN20 (3/4in.BSP) Feedwater Isolation Valve

Boiler layout may vary from the photograph.

FIG. 3b BOILER CONNECTION POINTS (Optional Tank Fitted) Page 6 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 2

2.4.2 CONNECTIONS (optional tank fitted)

All connections for services are located at the rear of the boiler, and should be made as follows:

a) Combined Overflow and Vent pipe DN25 (1 in. BSP) The overflow should be piped to a suitable drainage point. The vent should be piped to a safe discharge point, avoiding any possibility of condensation problems.

b) Feedwater Inlet (Solenoid Valve) DN20 (3/4 in. BSP) It is advisable to fit a stop valve as close as possible to this connection point. Local Water Authority bylaws may require the fitting of a break (interpose) tank between the mains water supply and the cold water inlet connection on the boiler.

c) Connection for Condensate Return Line DN15 (1/2 in. BSP)

d) Safety Valve Outlet DN32 (1 1/4 in. BSP) The outlet from this valve should be piped to a safe discharge point and the piping should be so arranged that condensate trapped in the discharge pipe is drained away from the safety valve and contains a weep/tell-tale leakage pipe.

! CAUTION Unless otherwise specified the steam safety valve supplied with the boiler is preset and must not be adjusted. This valve is provided as a safety device for the boiler and should not be used as the sole protection for other equipment using steam from the boiler.

e) Main Steam Valve DN40 (1 1/2 in. BSP) It is essential that a steam pressure reducing valve is installed in the system, and that the boiler steam pressure control is set at the boiler maximum operating pressure of 10.34 barg.

f) Boiler Blowdown Connection DN20 (3/4 in. BSP) Connection must be made from the blowdown valve to a blowdown receptacle of approved design. Regulations exist covering such items and care must be taken to ensure compliance with these regulations. if in any doubt regarding blowdown arrangements consult Fulton Ltd.

g) Water Sample Outlet DN15 (1/2 in. BSP) If the water sample point is used the valve should be fitted as close as possible to the boiler.

h) Chemical Dosage Point (If required) is provided in the feedwater pump pipework. (See Fig 2)

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 7 2

Pump overload protection

Element MCBs

Pump Door contactor isolation switch

Element Controls contactors MCB

FIG. 4a ELECTRICAL CONNECTIONS (Unheated/No Tank)

Pump overload protection

Tank Element Element MCBs Tank Element Contactor Door Controls isolation MCB switch

Pump contactor Element contactors

FIG. 4b ELECTRICAL CONNECTIONS (Heated Tank)

Note: Water level relays are behind the facial panel.

Page 8 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 2

2.5 ELECTRICAL REQUIREMENTS

Power ratings are given in Section 5.2, EFS Specification.

The boiler contains all necessary electrical protection.

An electrical isolator should be fitted on the wall as close as possible to the boiler, and connections made to the terminals on the Residual Current Device mounted on the electrical panel inside the boiler.

A Three Phase and Neutral supply is required and care should be taken to ensure that the wire used is the size given in Section 5.2, EFS Specification.

! WARNING The control circuit live light is derived from a single phase. It is possible that with the control phase down or a defective bulb, the other phase could be live. Always isolate the supply before investigating any fault.

! WARNING Isolate the electrical supply before removing the feedwater tank heating element cover.

2.6 steam pressure control

Adjust the steam pressure controls to 10.34 barg. (see Section 2.1).

Setting the pressure controllers

High Limit Controller

1. Set the controller range scale to 5 psi below the safety valve setting. Set the differential scale to zero.

Operating (On/Off) Controller

1. Set the Range Scale A to the maximum pressure required.

2. Set the Differential Scale B to give the required pressure differential between the boiler heating elements being de-energised (switched off) and energised (switched on).

A valve is fitted in the pressure supply line to allow the testing of the boiler pressures and the controllers.

A B

FIG. 5 PRESSURE CONTROLLERS

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 9 2

2.7 COMMISSIONING

These procedures should be carried out by a competent person. Although every care is taken to ensure that the boiler has been despatched from the factory fully tested, it is possible that during transportation and installation, pipework and electrical connections may be loosened or broken. On completion of the installation and prior to switching on the boiler it is advisable to carry out the following checks.

! WARNING The boiler electrical circuit must be isolated prior to doing the following tests.

2.7.1 ELECTRICAL

1. Remove the front and right hand access panels.

2. Check that all electrical connections are tight.

3. Megger* test the elements in accordance with the notes in Section 4.3 - Element Care and Protection. (Including heated tank element if fitted)

4. Set the High Limit and Operating (On/Off) steam pressure controllers to the pressures required.

5. Set the tank thermostat to 85°C. (Heated tank only)

2.7.2 general in addition

6. Ensure that the element switches are in the off position, and that the Pump On/Off switch is in the pump off position. Turn the Boiler On/Off switch to the on position.

7. Open all the valves in the water feed line and allow the water storage tank to fill. Check for leaks. The water level controls will close the solenoid when the water level reaches the normal working level.

8. Open the feedwater pump inlet isolating valve, prime/bleed the pump by releasing air from the bleed nipple.

9. Close the boiler blowdown valve and the main steam valve.

10. Ensure that the Boiler On/Off switch mounted on the boiler control panel is switched to the OFF position.

Feedwater Pump Bleed Nipple

FIG. 6 Feedwater PUMP

Note: *Glossary of Terms Section 5.4 Page 10 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 2

! WARNING Use extreme caution. Live element terminals.

11. Switch on the electrical supply at the isolator. Manually override the front panel interlock microswitch.

12. Turn the Boiler On/Off switch on. The boiler Low Water alarm light should light up. If it does not do so, refer to the list of fault indications. Turn the feedwater Pump On/Off switch to on.

! WARNING Do not make contact or place anything in touch with the moving parts of the pump drive. The cover is removed only for the visual checking of the pump rotation.

13. Check for correct rotation of the feedwater pump by removing the cover to expose the pump drive shaft coupling. Correct rotation is anti-clockwise when viewed from the top of the pump. Switch the pump off and wait until the drive shaft stops rotating before replacing the cover.

Note: The pump impeller blades can be damaged by incorrect rotation. If the rotation is incorrect turn the selector switch to the off position. Isolate the boiler and alter the phase connections between the pump contactor overload and the pump. Check that the pump rotation is now correct.

14. Turn the Boiler and Pump selector switches to the off position. Release the front panel interlock microswitch.

15. Replace the front panel.

! WARNING The front panel must be replaced when the elements are live.

16. Switch the element switches to the on position.

17. Turn the Boiler and Pump switches to the on position.

18. Allow steam pressure to build up, check the reading on the steam pressure gauge, until it reaches the high limit cut-off point as set on the on/off steam pressure control. Re-adjust this control as necessary.

19. Allow the steam pressure to fall until the lower limit on the On/Off pressure controller is reached, the boiler should restart. Re-adjust this control as necessary.

20. Test the high limit contoller by changing the high limit on the On/Off contoller to a value above the value set on the high limit contoller, allow the boiler to build-up steam pressure until the high limit controller value is reached, the boiler should cutout. Reset the On/Off controller to its original setting.

21. Turn the Boiler and Pump switches to the off position. Isolate the boiler at the main isolator and remove the front and right hand panels to check for steam or water leakage.

22. Replace the panels and slowly open the steam valve to release the pressure in the boiler. Check for steam leaks in all new pipework. Reset the High Pressure Reset button.

23. The boiler is now ready for placing into full operation.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 11 Low Water Pump Element Boiler On/Off Tank Low Water Reset Fault Fault If Fitted

High Low Circuit Element Pump Audible Pressure Water Live switches On/Off alarm Reset

FIG. 7 CONTROL PANEL

Page 12 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 3

SECTION 3 - OPERATION

! WARNING The following instructions are given for the guidance of the operator in the use of the Fulton electric steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.

3.1 control panel

The control panel contains a range of indicator lights to assist with the starting and testing procedures described in Sections 3.2 and 4.2, in addition the panel contains warning and fault indicators. Should a warning or fault be indicated the boiler must be isolated and the cause investigated by a competent person.

3.1.1 CONTROLS AND FAULT INDICATORS

! CAUTION The control circuit live light is derived from a single phase. It is possible that with the control phase down or a defective bulb the other phase could be live. Always isolate the supply before investigating any fault.

Circuit Live Indicates that power is being supplied to the boiler control circuit and that the control panel is live. This light should be illuminated immediately the main isolator is switched on and should remain on until the main isolator is switched off.

Low Water Indicates that a low water condition exists in the boiler and that the boiler has shut down Operates in conjunction with an audible alarm. The alarm will cancel and the boiler will restart when the normal working water level is restored.

Low Water Reset Indicates that a 2nd low water condition exists and the boiler has shut down. An audible alarm will continue to sound and the elements will remain de-energised until the normal working water level is restored and the Reset button is depresseed.

Pump Fault This light will illuminate if there is an electrical fault with the feedwater pump.

Boiler Indicator/ Boiler On/Off Switch Indicates that the selector switch has been switched to the on position and that the boiler is in a fully operational position. This light should remain on until the selector switch is turned to the off position.

Element Switches and Element Indicators The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised during normal on/off cycle of operation.Each element has its own M.C.B.* which will activate the indicator and shut down the electrical supply to the element. It is safe to operate the boiler with the faulty element switched off providing the faulty element is not allowing steam or water to escape.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 13 3

High Pressure Reset The High Pressure Reset button will illuminate when the steam high limit controller is tripped. Reset the control by depressing the push button, having first ascertained the reason for the high pressure condition.

Pump On/Off In the off position the feedwater pump control circuits are isolated. In the on position the On/Off switch will illuminate and the feedwater pump will be controlled by the boiler water level controls.

3.1.2 feedwater tank controls

WARNING Isolate the electrical supply before removing the feedwater tank heating element cover.

Tank Low Water This light will illuminate if there is a low water condition in the feedwater tank. The boiler feed pump will be inhibited until the water level in the tank is restored.

Element On/Off If fitted. The switches are illuminated in the on position and the elements are energised. The switches are not illuminated when elements are de-energised.

Element Fault If fitted. The feedwater tank element has its own M.C.B.* which will activate the indicator and shut down the electrical supply to the element. It is safe to operate the boiler with the faulty element switched off providing the faulty element is not allowing water to escape.

Tank Thermostat The tank thermostat will allow the tank heating element to heat the water in the tank to the set temperature, normally 85°C, and maintain that temperature. Should the Element On/Off indicator not illuminate on start up from cold it may indicate a fault in the thermostat.

Page 14 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 3

3.2 starting the boiler

Do not attempt to start the boiler until this section has been read and fully understood. Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shutdown.

1. Open the steam valve.

2. Open all the valves in the water feed line. Ensure the feedwater pump is primed.

3. Switch the isolator switch to the on position.

4. With the Boiler selector switch on. Turn the feedwater Pump On/Off switch to the off position. Open the boiler blowdown valve and lower the water level in the boiler until the low water alarm reset button is illuminated and the alarm sounds.

Note: When the low water level alarm sounds elements that are energised should de-energise and the element selector switches should extinguish.

5. Close the blowdown valve.

6. Turn the feedwater Pump On/Off switch to the on position. The feedwater pump should start and restore the water level to the normal position and stop.

7. Press the low water level reset button. The light should extinguish and the audible alarm should cease. The elements should re-energise, the element selector switches should illuminate.

The boiler is now ready for use.

a) The on/off steam pressure controller will control the on/off cycle of the elements once the boiler is operating.

b) The low water relays automatically maintain the level of water in the boiler and will immediately shut off the power to the elements should the water level fall to an unsafe level.

c) The element switches situated on the control panel enable elements to be switched on or off independently to meet steam requirements.

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SECTION 4 - MAINTENANCE

Fulton recommends that these tests and checks are carried out on a regular basis to ensure that the boiler is operating safely.

Tests should be carried out by a competent person trained to perform such tests. If any test shows that the equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used.

The Boiler Controls Test Log supplied in Section 4.8 should be copied and used to maintain a record of the daily and weekly procedures carried out. Any rectification or repairs should be carried out by trained, competent service personnel.

! WARNING The electrical supply to the boiler must be isolated prior to the opening of the casing doors.

4.1 VISUAL Checks

Inspect the steam and feedwater pipework, valves and fittings for signs of leakage. If leaks are suspected, shut the system down and evacuate the system to atmospheric pressure before attempting any repairs.

Note: Ensure that the water level is maintained during the pressure build up. If any part of the equipment is not operating correctly, the fault should be investigated before the boiler is used. Ensure that all blowdown pipework is safe and discharged to a blowdown receptacle.

4.2 water level and safety controls

The following procedures ensure the correct functioning of the water level controls and the low water safety controls and should be carried out with the boiler turned on.

4.2.1 pUMP TEST

a) If the boiler is not heating and not under steam pressure, lower the water level using the main blowdown valve:

If the pump is running:

1. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. Lower the water level by opening the main boiler blowdown valve.

2. Verify that the pump starts to run when the water level reaches the Pump On level.

3. Close the main boiler blowdown valve.

4. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 17 4

b) If the boiler is heating and under load, lower the water level by evaporation, observing a pump cycle:

If the pump is running:

1. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. The water level will lower through natural evaporation.

2. Verify that the pump starts to run when the water level reaches the Pump On level.

3. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

4.2.2 1st low water level check

1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch off the pump using the Pump Interrupt/Pump Run switch.

3. Allow the water level to lower by natural evaporation below the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burner stops firing.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Switch on the pump using the Pump Interrupt/Pump Run switch.

6. Verify that the pump runs and refills the boiler. When the water level rises above the 1st Low Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silences and the burner fire sequence starts.

7. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

Page 18 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 4

4.2.3 2nd low water level check

1. Ensure that the boiler is heating, the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch off the pump.

3. Allow the water level to lower by natural evaporation to the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the boiler stops heating.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Allow the water level to lower further by natural evaporation below the 2nd Low Water level.

6. Verify that the Low Water Reset switch illuminates.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

7. Switch on the pump using the Pump Interrupt/Pump Run switch.

8. Verify that the pump runs and refills the boiler. When the water level rises above the1st Low Water level, verify that the 1st Low Water lamp extinguishes but the elements do not energise.

9. Press the Low Water Reset switch- Verify that the 2nd Low Water lamp and audible alarm extinguishes and the elements energise.

10. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

4.3 blowdown procedure

Keep the boiler free from sludge and scale buildup by blowing down in the following manner:

Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.

1. Start the boiler and generate not more than 1 barg of steam.

2. Shut off both the elements and the pump.

Boiler Blowdown

1. Fully OPEN the boiler main blowdown valve for not more than 5 seconds, or as recommended by the water treatment specialist.

2. CLOSE the valve.

Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required.

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4.4 element care and protection

To protect the element and prolong its life, it is essential that regular inspections are carried out.

The most common causes of element failure are excessive build up of scale and corrosive attack. Both causes are due to adverse water conditions and reference should be made to the notes on water treatment.

The dangers of scale to the life of the element cannot be over stressed. Scale possesses excellent insulative qualities and its formation on the element prevents the heat generated by the element 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 chemical cleaning agent.

Elements, if stored correctly, have an indefinite 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 fitted with a breathing seal. It is, therefore, a useful precaution to megger test* elements prior to fitting or starting up, following prolonged shut down. If the reading is low (below 1 megaohm), heating in an oven at 300°C for three hours should restore the element.

1

2

3

FIG 8. HEATING ELEMENTS

Page 20 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 4

4.5 INTERNAL INSPECTION

The lower hand hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined. If scale or sludge build up is observed, it should be removed and the water treatment supplier advised.

New gaskets must be fitted every time a hand hole door is removed. Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are observed. Thereafter, inspections should be carried out at three monthly intervals.

Switch off the boiler and allow to cool before removing the hand hole cover.

4.5.1 removal

1. Using the special tee handle wrench provided remove the hand hole plate retaining nut.

2. Remove the complete assembly.

3. Remove the old gasket and thoroughly clean the mating surfaces of the hand hole plate and the boiler.

4.5.2 replacement

4. Locate the new gasket on the hand hole access plate, ensure it is seated correctly. DO NOT use any grease, lubricant or adhesive.

5. Position the plate inside the boiler and lightly secure in position with the crab, check the plate is located correctly in the boiler and tighten the retaining nut, (do not over tighten).

6. Using the tee wrench tighten the retaining nut a further quarter turn. DO NOT over tighten.

7. Check for leaks as the boiler pressure increases, Should a leak occur, tighten the retaining nut only sufficiently to stop the leak.

Hand hole

Hand Hole Cover Plate

Gasket

Crab

FIG. 9 HAND HOLE ASSEMBLY

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 21 4

4.6 schedule of operator tests and checks

The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler is installed in. Failure to maintain the boiler adequately may void the Fulton warranty. The Controls Test Log supplied in Section 4.7 should be copied and used to maintain a record of the daily and weekly procedures carried out.,

Maintenance must be carried out by competent, trained personnel. If any fault is found during these operations, contact your Fulton representative.

! WARNING 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.

! WARNING Ensure any residual pressure within the boiler is completely vented before working on the pressure vessel

! CAUTION It is essential that regular checks are made to ensure that scale buildup is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler feedwater is effective.

! CAUTION 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.

! IMPORTANT If any fault is found during these procedures, shut down the boiler immediately and consult Fulton Ltd.

The following procedures are designed to prevent the buildup of scale, silt or sludge in the bottom of the boiler, personnel involved in doing this work must have received the appropriate training in all aspects of maintenance and safety procedures.

In addition to these procedures, the advice of a water treatment specialist should be sought and followed.

4.6.1 DAILY

WARNING The electrical supply to the boiler must be isolated prior to the opening of the casing doors.

1. Check that the water level controls are working correctly. Perform the Water Level Test and Pump Test (See Section 4.2).

2. Blowdown the boiler (See Section 4.3 - Blowdown Procedure).

Page 22 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 4

4.6.2 weekly in addition

1. Check that the water storage tank is clean and free from obstructions.

2. Remove the front access panels and check for signs of leakage from the steam fittings and elements (See Section 4.1 - Visual Checks).

3. Check the element and pump contactors are free and operating correctly by manually depressing them.

4. Check all fittings for signs of leakage (See Section 4.1 - Visual Checks).

WARNING The safety valve may be very hot, take precautions to avoid burns.

4.6.3 three monthly in addition

Note: Isolate the electrical supply to the boiler and set the selector switch to off.

1. With the main steam valve open, close the boiler feedwater supply valve, located at the side of the boiler. Isolate and completely drain the boiler by opening the boiler blowdown valve and allowing the boiler to drain.

2. Remove each element and check for excessive scale build up or corrosion. Clean as required and replace, always use a new gasket (see Section 4.3 - Element Care and Protection).

3. Prior to refitting the elements, examine the interior of the boiler for deposits of scale and sludge. Clean the boiler if necessary.

4. Check and clean the feedwater strainer.

5. Check all electrical connections for tightness.

6. Note the probe lead positions, remove and clean both the boiler and feedwater tank probes.

Note: Ensure caps are reconnected to the correct probes.

7. Return all valves to the normal working position. Restore the boiler water level and reconnect the electrical supply.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 23 4

4.7 troubleshooting

Problem Cause Remedy CIRCUIT LIVE 1. Mains supply failure. Check fuse, replace as required. indicator not 2. Lower door interlock Check transformer. illuminated. microswitch not made Check control circuit. 3. Earth Leak Detector (RCD*) This fault can only be traced by a qualified has tripped, indicating an person with correct earth leakage in the electrical test equipment. boiler’s electrical circuit. Low Water Indicated 1. No water in the feedwater Check that water supply line valves are open. Insufficient water in tank. Check that the ball valve in the tank is operating the boiler correctly. 2. Obstruction in the water Check that the pump isolation valve below the tank feed line to the pump is open. Remove and clean the filter in the strainer. Check that the non-return valve is operating correctly. 3. Air lock in the pump Bleed the pump at the point provided. 4. Feed water pump impeller worn. 5. Incorrect connections to Check connections to water level probes. water level probes. 6. Faulty water level relay. Check that each relay is pressed firmly home on its base. PUMP FAULT 1. Electrical fault in the M.C.B.* requires re-setting. indicated. feedwater pump circuit Thermal overload fitted to the pump motor contactor requires re-setting. Check that the unit has been set to the correct amperage and adjust if necessary. If the fault continues after the controls have been reset, a major fault exists which can only be corrected by a qualified person with correct electrical test equipment. ELEMENT FAULT. Check M.C.B. setting. If the fault persists the element and the circuit must be fully checked by a qualified person.

Note: Unless a faulty element is allowing steam or water to cape, it is safe to operate the boiler with the faulty element fitted, provided that the element selector switch has been switched off.

Page 24 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 4

4.8 controls test log T est W eekly Date Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Date: T est Y - N Y - N Y - N Y - N Y - N D aily Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Y - N Boiler Number: pH TDS Date Model: Electric Boiler Controls Test Log Electric Boiler Controls Test and alarm sounded duration/seconds Softened water Brine level correct Boiler low water indicator Low water reset indicator Feed pump, start/stop Water treatment Water Pressure gauge reading The following tests are to be performed in accordance with the maintenance schedule Fulton Service Manual. Water Level Control Test by lowering Level Control Test Water water level Main Boiler Blowdown test carried out Time Boiler water test Operator Signature: Log examined by:

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 25 Page 26 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 5

SECTION 5 - GENERAL DATA

5.1 boiler dimensions

C B E

A

D

F

FIG. 10 BOILER dimensions

Model: eFS 18-48 60, 72 A Minimum Clearance * 2230 2230 B Overall Width 760 760 C Overall Depth 1100 1100 D Overall Height 1950 1950 E Boiler Depth 965 965 F Safety Valve Discharge Height 1355 1355 G Steam Outlet Height 1400 1400 H Feedwater Inlet Height 1810 1810 K Feedwater Tank Drain 210 210 L Feedwater Tank Overflow 1770 1770 M Condensate Return Height 1805 1805 N Main Boiler Blowdown 230 230 P Water Sample Point Height 590 590

Note: * Required for maintenance and element removal.

Dimensions mm Dimensions are approximate and only intended as a guide to aid installation.

Information from TI 114 Issue 4

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 27 5

5.2 boiler specification

Model: E.F.S. Unit 18 24 48 60 72 Designed and manufactured to BS EN 13445:2009 and PED 97/23/EC.

General Steam Output F & A 100°C kg/h 29 38 77 96 115 kW Rating kW 18 24 48 60 72 Operating Pressure barg 10.34 10.34 10.34 10.34 10.34 Number of Elements 2 2 2 3 3 Weight Shipping Weight kg 390 390 390 390 390 Operational Weight kg 560 560 560 560 560 Water Content L 133 133 133 133 133 Feed Tank Volume L 77 77 77 77 77 Electrical Requirements FLC 400 V 3 ph 50 Hz A/ph 30 39 74 91 108 FLC 230 V 1 ph 50 Hz A 83 109 214 265 318 Connection Sizes All threads BSP F= Female, M=Male Steam Outlet DN 40 40 40 40 40 Safety Valve Discharge DN 25 25 25 25 25 Feedwater Inlet DN 20 20 20 20 20 Blowdown, Boiler DN 20 20 20 20 20 Tank Drain DN 15 15 15 15 15 Tank Overflow DN 25 25 25 25 25 Water Sample Outlet DN 15 15 15 15 15

Note: Instantaneous outputs are up to 300 kg/h.

Information from TI 114 Issue 4

Page 28 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 5

5.3 recommended water conditions

! IMPORTANT

It is very important that a strict water management program is followed to ensure trouble free boiler operation.

The following are recommended for feed water and for boiler water

FEEDWATER (water entering boiler) pH Value 8.5 to 9.5 tested at room temperature.

Hardness less than 2.0 mg/kg in the form of CaCO3. Suspended Solids None. Chloride Less than 50 mg/kg. Organic Matter Less than 5 mg/kg. Oil None. BOILER WATER (water inside boiler) pH Value 9.5 - 11.5, tested at room temperature. Hardness Not detectable. Suspended Solids Less than 100 mg/kg. Chloride Less than 500 mg/kg. Oxygen Scavenger, Sodium Sulphite or Tannin 20 to 50mg/kg.

Phosphate Less than 50 mg/kg, in the form of PO4. Total Alkalinity Less than 1000 mg/kg.

Caustic Alkalinity Less than 300 mg/kg as CaCO3. Total Dissolved Solids (TDS) Less than 2000 ppm. Iron Less than 1 mg/kg.

Silica Less than 150 mg/kg, in the form of SiO2. Dissolved Oxygen None.

mg/kg = Milligrams per Kilogram

CaCO3= Calcium Carbonate

PO4 = Phosphate

SiO2 = Silicon Dioxide

1 Grain hardness = 17.118 ppm therefore 70 ppm = 4.10 grains hardness.

For practical purposes mg/kg = ppm

It is critical that the boiler water pH be alkaline in the range 9.5 -11.5.

Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids (TDS).

Consult your Water Treatment specialist to establish the frequency and duration of blowdown required to achieve the required conditions.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Page 29 5

5.4 Glossary of terms

WORD MEANING (Electrical Engineering) an instrument that generates a high voltage Megger Test in order to test the resistance of insulation. (Electronics) Miniature Circuit Breaker; a small trip switch operated M.C.B by an overload and used to protect an electric circuit Non Condensible Gases - incapable of being liquified at normal NCG temperatures HTM Health Technical Memorandum BSP British Standard Pipe

Residual Current Device, is a life-saving device which is designed to RCD prevent you from getting a fatal electric shock if you touch something live, such as a bare wire.

Page 30 EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 Material & Workmanship Warranty

5 Year

On theWarranty Fulton Boiler Pressure Vessel

Fulton Ltd will repair or replace EXW factory any Fulton pressure vessel which within five (5) years of the date of delivery is found to be defective in workmanship, or material, provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the Manufacturer’s Handbook. This Warranty does not cover damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions. This Warranty is good only in the of Great Britain and Northern Ireland. This Warranty does not include labour or delivery charges of any kind.

Fulton Ltd

General Warranty

The Fulton general Guarantee is given in lieu of Defective goods or parts must be returned to and in exclusion of any warranty expressed or us as soon as possible after discovery of the implied, statutory or otherwise, as to the state, defect, Costs of carriage and of detaching and condition, performance, quality or fitness of the incorporating parts will be borne by you..ln all goods. Save thereunder we shall be under no cases at the termination of such 12 months all obligation or liability of any kind to you in liability on our part will cease. regard to the goods. In the case of new goods No liability whatsoever is to be incurred by us in manufactured and supplied by us we will make respect of gauge or sight-glasses, packing glands good any defect developing therein under proper or electric motors orany goods or accessories not use within 12 months of delivery, provided that of our manufacture. But so far as we are able, we after investigation in our sole discretion we are shall let you have the benefit of any guarantee or satisfied that the defect arose from faulty design, warranty given to us in respect thereof. materials or workmanship and from no other cause whatsoever.

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1 www.fulton.co.uk

Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 Email: [email protected]

EFS OPTIONAL heated tank Manual 05 2014 ISSUE 1