FULTON Electropack EP18 Installation, Operation And Maintenance Manual Download Page 1

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

EP18-72-IOMM-2015-7

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Electropack 18 kW - 72 kW

Electric Steam Boiler

Summary of Contents for Electropack EP18

Page 1: ...This manual must be available to the boiler operator at all times EP18 72 IOMM 2015 7 INSTALLATION OPERATION AND MAINTENANCE MANUAL Electropack 18 kW 72 kW Electric Steam Boiler...

Page 2: ...EP18 72 IOMM 2015 7 Fulton Ltd Page II...

Page 3: ...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 Fee...

Page 4: ...rved 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 th...

Page 5: ...ers 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...

Page 6: ...EP18 72 IOMM 2015 7 Fulton Ltd Page VI Figure 1 Electropack Electric Steam Boiler Pressure gauge Boiler control panel Boiler isolator switch Front access panel Top access panel...

Page 7: ...g 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 elec...

Page 8: ...EP18 72 IOMM 2015 7 Fulton Ltd Page 2...

Page 9: ...lations 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...

Page 10: ...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 t...

Page 11: ...connection points at rear of the boiler see Figure 3 Operator control panel Electrical control panel Pressure gauge Operating pressure controls Boiler elements Feedwater pump Boiler Pressure vessel F...

Page 12: ...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 co...

Page 13: ...alve Chemical dosing point Feedwater inlet Condensate return Steam outlet valve Boiler blowdown valve Feedwater tank vent Feedwater tank overflow Safety valve Water sample outlet Feedwater tank drain...

Page 14: ...s 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 The quality of the water used in the boiler will...

Page 15: ...ion point Figure 4 Electrical Supply Cable Location Fuse holders MCB s Electrical supply access hole Element contactors Door electrical isolator switch Circuit breakers LC relays Miniature relays Pump...

Page 16: ...High Limit Controller 1 Set the controller range scale to 5 psi below the safety valve setting 2 Set the differential scale to zero On Off Controller 1 Set the Range Scale A to the maximum pressure r...

Page 17: ...t to 85 C when heated tank fitted 6 Ensure all element switches are in the off position and connect to the mains electrical supply 7 Switch the supply main isolator and door isolator to the ON positio...

Page 18: ...will extinguish the feedwater pump will restart and fill the boiler to normal working level NWL 11 Fault indicators and switches checks see Figure 8 When the Boiler Low Water Level indicator extingui...

Page 19: ...er to its original setting Allow the steam pressure to fall below the set point of the high limit pressure controller The elements should not energise until the High Pressure Reset is pressed 16 Check...

Page 20: ...sate return pipe adjacent to the condensate return tank 2 Direct the returns to a floor drain or other safe discharge point and make safe 3 Leave in this position for one week to allow all impurities...

Page 21: ...al equipment service manuals are supplied they must be read and understood in conjunction with this manual All warnings and cautions must be observed SECTION 3 OPERATION 3 2 Controls and Indicators Th...

Page 22: ...Indicator This light will illuminate if there is an electrical fault with the feedwater pump 5 Boiler Low Water Indicator Indicates that a low water condition exists in the boiler and that the boiler...

Page 23: ...ch In the off position the feedwater pump control circuits are isolated 11 Audible Alarm 12 Feedwater Tank Low Water Indicator This light will illuminate if there is a low water condition in the feedw...

Page 24: ...Steam outlet valve b Main blowdown valve c Water level gauge blowdown valves where fitted 5 Switch the Pump Switch to the On position 6 Switch the Boiler Switch to the On position 7 Check a Boiler Low...

Page 25: ...ve 5 Open the boiler blowdown valve 6 Open all valves in the drain lines Boilers with automatic blowdown systems 1 The boiler should not be under pressure 2 The boiler should be cold 3 Close the blowd...

Page 26: ...ter level to the normal position and stop 6 Press the Low Water Level Reset button The light should extinguish and the audible alarm should cease The elements should re energise the Element Switches s...

Page 27: ...r and tank completely see Section 3 5 Draining the Boiler Remove all hand holes and boiler elements see Section 4 4 1 Element Removal 3 Same as 2 but also introduce a form of convection heating into t...

Page 28: ...EP18 72 IOMM 2015 7 Fulton Ltd Page 22...

Page 29: ...airs 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 Ensu...

Page 30: ...at the pump continues to run until the Pump Off level is reached and then switches off b If the boiler is heating and under load lower the water level by evaporation observing a pump cycle If the pump...

Page 31: ...re that the fault is rectified before the boiler is used 5 Switch on the pump using the Pump On Off switch 6 Verify that the pump runs and refills the boiler When the water level rises above the Low W...

Page 32: ...itching Pump and Element switches ON Note Where high levels of suspended solids are produced longer and or more frequent blowdown may be required Feedwater non return valve Boiler blowdown valve Boile...

Page 33: ...3 seconds the bottom gauge valve C 5 Open valve C 6 Close valve A Repeat for gauge set 2 On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are...

Page 34: ...s 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 usin...

Page 35: ...oiler heating elements Remove the four element securing nuts from the element mounting flange Element is now loose for removal from the boiler The elements will need removing to carry out internal ins...

Page 36: ...regular basis until satisfactory conditions are observed Thereafter inspections should be carried out at three monthly intervals Figure 15 Boiler Inspection Hole Boiler heating element Boiler heating...

Page 37: ...mp off black cable Feedwater Tank Isolate the boiler electrics at the isolator on the front access panel and remove the boiler top access panel Remove and clean the feedwater tank level probes taking...

Page 38: ...ult is found during these procedures shut down the boiler immediately and consult Fulton Ltd 4 7 Schedule of Operator Tests and Checks The following schedule is the advice of Fulton Ltd The frequency...

Page 39: ...ipework b Valves and fittings c Elements 4 7 1 Daily 4 7 2 Weekly in addition WARNING Ensure the main electrical supply is isolated before starting work WARNING Ensure the fittings around the steam sa...

Page 40: ...element and check for excessive scale build up or corrosion Clean as required and replace always use a new gasket see Section 4 4 Element Care and Protection 13 Check and clean the feedwater strainer...

Page 41: ...icated 1 Low Water Check that water supply line valves are open Check the feedwater solenoid valve is opening 2 Faulty water level relay Check that the feedwater relay is pressed firmly home on its ba...

Page 42: ...overload trips out occasionally 1 Overload setting is too low Set the overload correctly 2 Low voltage at peak times Check the electricity supply Motor contactor has not tripped out but the pump does...

Page 43: ...re it is seating and not allowing water passed Water pump will not come on at times 1 Scale on probes Check and clean probes replace as necessary 2 Faulty pump contactor Check the contactor has power...

Page 44: ...ater treatment values must be within known tolerances of the datum 5 Boiler Water datum value TDS reading datum value PH reading 6 Oxygen Scavenger Concentration datum value reading 7 Brine level corr...

Page 45: ...EP18 72 IOMM 2015 7 Fulton Ltd Page 39 MAINTENANCE 4 MAINTENANCE LOG Date Time Operation Performed Remarks Operators Initials...

Page 46: ...EP18 72 IOMM 2015 7 Fulton Ltd Page 40...

Page 47: ...on TI sheets These TI sheets can be found in this Appendix Note The TI sheets in this appendix can be updated replaced without revising the manuals issue number To check you have the most up to date T...

Page 48: ...id installation MODEL ELECTROPACK 18 24 36 48 54 72 A Minimum Clearance 2230 B Overall Width 760 C Overall Depth 1100 D Overall Height 1931 E Boiler Depth 965 F Safety Valve Discharge Height 1085 G St...

Page 49: ...ight Shipping Weight kg 390 390 390 390 390 390 Operational Weight kg 560 560 560 560 560 560 Boiler working water volume L 38 38 61 61 84 84 Feed Tank Volume L 77 77 77 77 77 77 Electrical Requiremen...

Page 50: ...PROBE LENGTHS EP 18 72 1 3 BRANCH Low Water 400 mm Solenoid Valve Open 215 mm Solenoid Valve Close 185 mm PV PROBE LENGTHS 2 BRANCH Pump OFF 185 mm Pump ON 215 mm Low Water Limiter 1 275 mm Low Water...

Page 51: ...n co uk Website www fulton co uk Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England FM 28400 003 FM 28400 500 Element Dead Section 350 Model 350 Sight Glass 264 Viewable in Sight Glass 405...

Page 52: ...pm Organic Matter Less than 5 ppm Oil None Minimum Temperature 85 C BOILER WATER water inside boiler pH Value 10 0 to 12 0 tested at room temperature Hardness Not detectable Suspended Solids Less than...

Page 53: ...Figure 2 N B The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture meaning the probe is ready to be installed without any adjustment The ONLY instance a spanner should be us...

Page 54: ...ed in two parts the head and the tip The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head Locate the pin provided into the slo...

Page 55: ...by you In all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to be incurred by us in respect of gauge or sight glasses packing glands or ele...

Page 56: ...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 sales fulton co uk FM 28400 003 EP18 72 IOMM 2015 7...

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