Serial Number Instruction, Operation

Model Number and Maintenance

Manual
CO Number

Sold To Fulton Electric Steam

Job Name Boilers
Date 12 kW to 1000 kW 1.2 to 100 HP
Introduction

This manual is provided as a guide The requirements and instructions Note

to the correct operation and mainte- contained in this section generally
nance of your Fulton Electric Steam relate to the standard Fulton Electric If it is necessary to store the boil-
Boiler, and should be permanently Steam Boiler. When installing a er for a prolonged period of time
available to the staff responsible for packaged unit, this entire section prior to installation, the boiler
the operation of the electric boiler. should be read to ensure that the should be stored at a minimum 40
These instructions must not be con- installation work is carried out correctly. degree F in an atmosphere in
sidered as a complete code of prac- which excessive moisture cannot
tice, nor should they replace exist- Prior to shipment the following tests damage the controls or the steel
ing codes or standards which may were made to assure the customer casing. If the storage is to be over
be applicable. the highest standards of sixty days, one element should be
manufacturing: removed. Place several bags of
The installation of the Fulton dry dessicant inside the boiler.
Electric Steam Boiler should be a) Material inspections. Bolt a blank flange over the
carried out by competent person- b) Manufacturing process inspections. element mounting plate to seal
nel in accordance with all relevant c) ASME welding inspections. the boiler. If handholes are provid-
safety regulations. A complete ed, these can be used to provide
list of all safety precautions may d) ASME hydrostatic test inspection. an opening versus an element to
be found in the safety summary at e) Electrical components inspection. place the dessicant.
the conclusion of Section 1. It is f) Operating test.
the responsibility of the installer
to ensure that the installation is in g) Crating inspection.
compliance with these regulations.
Contents
Section Page No.

1 Safety Warnings & Precautions 2

2 Description/Instructions
Locating the Boiler
Dimensions & Specifications 1.2-3.6 BHP
4

Dimensions & Specifications 5-20 BHP

Dimensions & Specifications 30-100 BHP
Boiler, Condensate Tank, and Blow off Separator Piping
Feed Water Piping
Blow off Valve
Main Steam Valve
Steam Safety Valve
Electrical Requirements
Boiler Controls
Water Control Relays
Water Gauge Glass & Gauge Glass Installation
Water Supply
Recommended Water Treatment
Glossary of Water Supply Corrosives & Inhibitors
Installation Check Points
Cleaning the Pressure Vessel

3 Operation
Introduction
Starting the Boiler
20

Boiler Controls
Thermostat
Sight Glass Isolation Valves

4 Maintenance
Introduction
Recommended Daily Maintenance
24

Daily blow off Sequence

Recommended Monthly Maintenance
Recommended Six Month Maintenance
Recommended Annual Maintenance
Troubleshooting

Parts 30
5 Spare Parts Ordering Instructions
Parts List

6 Warranty 36

7 Component Data Sheets 38

1-ES 4-00 Fulton Boiler Works, Inc.

Safety Warnings/Precautions

1
Fulton Boiler Works, Inc. 2-ES 4-00
Safety Warnings/Precautions

Safety Warnings Cautions & Caution versus an element to place the dessi-
cant.
Notes Unless otherwise specified, the steam
safety valve supplied with the boiler is Note
The following WARNINGS , CAU- pre-set. This valve is provided as a
TIONS, and NOTES appear in vari- safety device for the boiler and Where a condensate return tank is to
ous chapters of this manual. They should not be used as the sole pro- be fitted, this should:
tection for other equipment using a) Be vented and
are repeated on these safety sum- steam from the boiler. Do not tamper b) Have a capacity sufficient to satis-
mary pages as an example and for with the setting (It could accidentally fy boiler consumption as well as
emphasis. be set at a pressure higher than the maintain proper return tank tempera-
design pressure of the boiler and, ture
WARNINGS must be observed to therefore ,create a hazardous condi- and
tion. c) Vent pipe should not be down-
prevent serious injury, or death to sized (This may cause pressure build
personnel. Caution up in the condensate tank.)

CAUTIONS must be observed to Do not exceed pressure rating on Note

boiler.
prevent damage or destruction of Care should be taken to ensure that
equipment or loss of operating Caution the blow off receptacle used meets
effectiveness. the regulations covering such items.
In general, ensure that the boiler area If in doubt, consult a Fulton
NOTES must be observed for essen- is in conformance with established Representative for advice.
boiler room requirements. Review
tial and effective operating proce- national and local codes. Note
dures, conditions, and as a state-
ment to be highlighted. Caution Only properly trained personnel
should install and maintain water
Do not tamper with the safety features gauge glass and connections. Wear
lt is the responsibility and duty of all of the low water safety cut out. safety glasses during installation.
personnel involved in the operation Before installing, make sure all parts
and maintenance of this equipment Caution of free of chips and debris.
to fully understand the WARNINGS,
CAUTIONS, and NOTES by which Keep boiler area clear and free from Note
combustible materials, gasoline, and
hazards are to be reduced or other flammable vapors and liquids. Keep gauge glass in original packag-
eliminated. Personnel must become ing until ready to install.
thoroughly familiar with all aspects Caution
of safety and equipment prior to Note
Do not use harsh compounds that will
operation or maintenance of the injure the feed water pump or ele- After Installation is complete and
equipment. ments. prior to operation, the pressure vessel
Caution should be cleaned.
Warning
Do not clean the gauge or gauge Note
Improper installation or maintenance glass while pressurized or in opera-
of gauge glass and connections can tion. Check with local authorities where
cause immediate or delayed breakage approval for start-up is required. In
resulting in bodily injury and/or prop- Caution some localities, final inspection of
erty damage. services may be required.
Prior to performing the “try lever”
Warning test, be certain to take precautions as Note
a loud noise and high velocity steam
When stopping the boiler for any will discharge freely from discharge To ensure that your Fulton Steam
extensive repairs, shut off main power port and through drain hole provided Boiler is kept operating safely and
switch and pull main disconnect in the side of the valve body. efficiently follow the maintenance pro-
switches on both the boiler side as cedures set forth in this manual.
well as the feed water side. Note
Note
Warning If it is necessary to store the boiler for
a prolonged period of time prior to The policy of Fulton Boiler Works,
Prior to the commencement of any installation, the boiler should be Inc. is one of continuous improve-
work requiring the removal of cover stored at a minimum 40 degree F in ment, and therefore, we reserve the
plates and the opening of the control an atmosphere in which excessive right to change prices, specifications,
panel box, the electrical supply to the moisture cannot damage the controls and equipment without notice.
boiler must be disconnected. or the steel casing. If the storage is to
be over sixty days, one element
Caution should be removed. Place several
bags of dry dessicant inside the boil-
Do not downsize piping below safety er. Bolt a blank flange over the ele-
valve size. ment mounting plate to seal the boil-
er. If handholes are provided, these
can be used to provide an opening

3-ES 4-00 Fulton Boiler Works, Inc.

Boiler Description/Instructions

2
Fulton Boiler Works, Inc. 4-ES 4-00
Description/Instructions 12 - 36 kW / 1.2 - 3.6

Element(s) are horizontally mounted at the bottom

of the pressure vessel. All probes are located in
the top of the boiler.

Locating the Boiler

The boiler should be located in dry 1. Pressure Vessel Built to ASME 11. Steam Outlet
surroundings on a level base, as close Code - 5 Year Warranty 12. Safety Valve
as possible to the steam using 2. Electrical Control Panel Box 13. Steam Gauge Assembly
machinery. See right hand page for 3. Electric Heating Element(s) 14. Steam Pressure Gauge
minimum clearances to ensure that 4. Low Water Cut off Probe 15. High Temperature Insulation
there is sufficient room around the boiler 5. Second (Auxiliary) Low Water Surrounds the Pressure Vessel
to enable the operator and maintenance Cut off Probe 16. Large (3"x4") Easily Accessible
engineer to gain access to all parts of 6. Pump "On" Probe Handholes
the boiler. Check location for ease of 7. Pump "Off Probe 17. Feedwater Shut Off Valve
water supply and electrical connections. 8. Sight Glass Assembly 18. Blowdown Valve
9. Operating Pressure Control
10. High Limit Pressure Control with
Manual Reset

5-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions 12 - 36 kW / 1.2 - 3.6
Dimensions
Model FB-L 012 015 018 024 030 036
Unit Size: kW 12 15 18 24 30 36
HP 1.2 1.5 1.8 2.4 3.0 3.6
Height
(A) Boiler Overall IN 24 24 24 24 24 24
MM 610 610 610 610 610 610
(B) Boiler w/Piping IN 30 30 30 30 30 30
MM 762 762 762 762 762 762
(C) Feedwater Inlet IN 8 8 8 8 8 8
MM 203 203 203 203 203 203
(D) Blowdown Outlet IN 4 4 4 4 4 4
MM 102 102 102 102 102 102
(E) Electric Control Box IN 20.5 20.5 20.5 20.5 20.5 20.5
MM 521 521 521 521 521 521
(F) Hand Hole IN 11 11 11 11 11 11
MM 279 279 279 279 279 279
Width & Depth
(G) Boiler Only IN 20 20 20 20 20 20
MM 508 508 508 508 508 508
(H) Overall Depth Electric IN 30 30 30 30 30 30
Panel to Blowdown MM 762 762 762 762 762 762
(I ) Electric Panel Width IN 14 14 14 14 14 14
MM 356 356 356 356 356 356
(J) Boiler Width Overall IN 33 33 33 33 33 33
MM 838 838 838 838 838 838
Boiler Connection Sizes
Steam Outlet 15 PSI IN .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19
Steam Outlet 16-300 PSI IN .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19
Feedwater Inlet IN .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19
Blowdown Outlet IN 1 1 1 1 1 1
MM 25 25 25 25 25 25
Sight Glass Blowdown Outlet IN .25 .25 .25 .25 .25 .25
MM 6 6 6 6 6 6
Safety Valve 15 PSI IN .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19
Safety Valve 16-300 PSI IN .50 .50 .50 .50 .50 .50
MM 13 13 13 13 13 13
Minimum Clearances
(K) Horizontal IN 14 14 14 14 14 14
to remove elements MM 356 356 356 356 356 356
(M) Front of Boiler IN 24 24 24 24 24 24
MM 610 610 610 610 610 610
(N) Sides & Rear of Boiler IN 12 12 12 12 12 12
MM 305 305 305 305 305 305

Specifications
Number of Elements 1 1 1 2 2 2
Output 1000 BTU/HR 41 51 61 82 102 123 Notes
1000 KCAL/HR 10 13 15 21 26 31
Steam Output** LB/HR 40 50 60 81 101 121 **Steam output ratings, at
KG/HR 18 23 27 37 46 55 180oF (82oC) feedwater
Approx. Shipping Weight LB 420 420 420 440 450 450 temperature, 0 PSIG.
KG 191 191 191 200 201 204 --Indicates not available.
Probe liquid level control,
Water Capacity GALLONS 7 7 7 7 7 7 standard on all units.
LITERS 26 26 26 26 26 26
Electrical Power Requirements (In Amps) Optional Water Level Controls
Watts 142-5
208V 3 Phase 34 42 50 67 84 100 McDonnell Miller 53-2
230V 1 Phase 52 65 78 -- -- -- McDonnell Miller 47-2
240V 3 Phase 29 36 43 58 73 87
480V 3Phase 15 18 21 29 36 44
575V 3 Phase 13 16 18 24 30 36
Dimensions are approximate. We reserve the right to change specifications. Fulton Boiler Works, Inc. 6-ES 4-00
Description/Instructions 50-200 kW / 5 - 20 BHP

Elements are vertically mounted.

All probes are mounted in the top
of the boiler.

Locating the Boiler

The boiler should be located in dry 1. Pressure Vessel Built to ASME 11. Steam Outlet
surroundings on a level base, as Code - 5 Year Warranty 12. Safety Valve
close as possible to the steam using 2. Electrical Control Panel Box 13. Steam Gauge Assembly
machinery. See right hand page for 3. Electric Heating Elements 14. Steam Pressure Gauge
minimum clearances to ensure that 4. Low Water Cut off Probe 15. High Temperature Insulation
there is sufficient room around the boiler 5. Second (Auxiliary) Low Water Surrounds the Pressure Vessel
to enable the operator and maintenance Cut off Probe 16. Large (3"x4") Easily Accessible
engineer to gain access to all parts of 6. Pump "On" Probe Handholes
the boiler. Check location for ease of 7. Pump "Off Probe 17. Feedwater Shut Off Valve
water supply and electrical connections. 8. Sight Glass Assembly 18. Blowdown Valve
9. Operating Pressure Control
10. High Limit Pressure Control with
Manual Reset

7-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions 50-200 kW / 5 - 20 BHP
Dimensions
Model FB-L 050 075 100 150 200
Unit Size: kW 50 75 100 150 200
HP 5 7.5 10 15 20
Height
(A) Boiler Overall IN 55 55 55 55 55
MM 1397 1397 1397 1397 1397
(B) Boiler w/Piping IN 65 65 65 65 71
MM 1651 1651 1651 1651 1803
(C) Feedwater Inlet IN 16 16 16 16 16
MM 406 406 406 406 406
(D) Blowdown Outlet IN 6 6 6 6 6
MM 152 152 152 152 152
(E) Electric Control Box IN 50 50 50 50 48
MM 1270 1270 1270 1270 1219
(F) Hand Hole IN 38 38 38 38 38
MM 965 965 965 965 965
Width & Depth
(G) Boiler Only IN 17 24 24 28 32
MM 432 610 610 711 813
(H) Overall Depth Electric IN 35 35 35 39 46
Panel to Blowdown MM 899 899 899 991 1168
(I ) Electric Panel Width IN 17 32 32 32 40
MM 432 813 813 813 1016
(J) Boiler Width Overall IN 35 42 42 46 52
MM 889 1067 1067 1168 1321
Boiler Connection Sizes
Steam Outlet 15 PSI IN 1 1.5 1.5 2 3
MM 25 38 38 51 76
Steam Outlet 16-300 PSI IN .75 1 1 1.25 1.5
MM 19 25 25 32 38
Feedwater Inlet IN .75 .75 1 1 1
MM 19 19 25 25 25
Blowdown Outlet IN 1 1 1 1 1.25
MM 25 25 25 25 32
Sight Glass Blowdown Outlet IN .25 .25 .25 .25 .25
MM 6 6 6 6 6
Safety Valve 15 PSI IN 1 1 1 1.25 1.50
MM 25 25 25 32 38
Safety Valve 16-300 PSI IN .75 .75 .75 .75 1
MM 19 19 19 19 25
Minimum Clearances
(L) Floor to Ceiling IN 92 92 92 92 130
to remove elements MM 2337 2337 2337 2337 3302
(M) Front of Boiler IN 24 32 32 32 34
MM 610 813 813 813 864
(N) Sides & Rear of Boiler IN 12 12 12 12 24
MM 305 305 305 305 610

Specifications
Number of Elements 2 3 4 6 4
Output 1000 BTU/HR 171 256 341 512 683
1000 KCAL/HR 43 64 86 129 172
Steam Output** LB/HR 169 252 336 505 674
KG/HR 77 115 153 230 306
Notes
Approx. Shipping Weight LB 580 850 970 1223 1425
KG 263 386 440 556 648 **Steam output ratings, at 180oF
Water Capacity GALLONS 13 39 39 50 79 (82oC) feedwater temperature, 0 PSIG.
LITERS 49 148 148 189 299
Electrical Power Requirements (In Amps) Probe liquid level control, standard.
208V 3 Phase 139 208 278 416 556 Optional Water Level Controls
240V 3 Phase 120 180 241 361 482 McDonnell Miller 157-157M McDonnell
Miller 53-2
480V 3Phase 60 90 120 180 241 McDonnell Miller 47-2
575V 3 Phase 50 76 101 150 201
Dimensions are approximate. We reserve the right to change specifications.

Fulton Boiler Works, Inc. 8-ES 4-00

Description/Instructions 300 -1000 kW / 30 -100

Elements are vertically mounted.

These boilers have an externally
mounted water bottle assembly
housing the low water cut-off probe,
pump on probe and pump off probe.
The second (auxiliary) low water
cut-off probe is mounted in the top of
the boiler.

Locating the Boiler

The boiler should be located in dry 1. Pressure Vessel Built to ASME 11. Steam Outlet - 30 HP
surroundings on a level base, as Code - 5 Year Warranty 11. Steam Outlet - 50, 75, 100 HP
close as possible to the steam using 2. Electrical Control Panel Box 12. Safety Valve
machinery. See right hand page for 3. Electric Heating Elements 13. Steam Gauge Assembly
minimum clearances to ensure that 4. Low Water Cut off Probe 14. Steam Pressure Gauge
there is sufficient room around the boiler 5. Second (Auxiliary) Low Water Cut off Probe 15. High Temperature Insulation
to enable the operator and maintenance 6. Pump "On" Probe Surrounds the Pressure Vessel
engineer to gain access to all parts of 7. Pump "Off Probe 16. Large (3"x4") Easily Accessible
the boiler. Check location for ease of 8. Sight Glass Assembly Handholes
water supply and electrical connections. 9. Operating Pressure Control 17. Feedwater Shut Off Valve
10. High Limit Pressure Control with 18. Blowdown Valve
Manual Reset 19. Water Bottle Assembly

9-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions 300 -1000 kW / 30 -100 BHP
Dimensions
Model FB-L 300 500 750 1000
Unit Size: kW 300 500 750 1000
HP 30 50 75 100
Height
(A) Boiler Overall IN 75 75 75 75
MM 1905 1905 1905 1905
(B) Boiler w/Piping IN 80 80 80 80
MM 2032 2032 2032 2032
(C) Feedwater Inlet IN 24 24 24 24
MM 610 610 610 610
(D) Blowdown Outlet IN 6.5 6.5 6.5 6.5
MM 165 165 165 165
(E) Electric Control Box IN 64 64 64 64
MM 1626 1626 1626 1626
(F) Hand Hole IN 55 55 55 55
MM 1397 1397 1397 1397
Width & Depth
(G) Boiler Only IN 36 44 50 63
MM 914 1118 1270 1600
(H) Overall Depth Electric IN 46 56 62 83
Panel to Blowdown MM 1168 1442 1575 2108
(I ) Electric Panel Width IN 52 64 64 64
MM 1321 1626 1626 1626
(J) Boiler Width Overall IN 56 64 72 91
MM 1422 1625 1829 2311
Boiler Connection Sizes
Steam Outlet 15 PSI IN 3 4 4 6
MM 76 100 100 150
Steam Outlet 16-300 PSI IN 2 3 3 3
MM 51 76 76 76
Feedwater Inlet IN 1 1 1 1.25
MM 25 25 25 32
Blowdown Outlet IN 1.25 1.5 1.5 2
MM 32 38 38 51
Water Col. Blowdown Outlet IN .75 .75 .75 .75
MM 19 19 19 19
Sight Glass Blowdown Outlet IN .25 .25 .25 .25
MM 6 6 6 6
Safety Valve 15 PSI IN 1.5 1.5 2 2.5
MM 38 38 51 64
Safety Valve 16-300 PSI IN 1 1.25 1.5 2
MM 25 32 38 51
Minimum Clearances
(L) Floor to Ceiling IN 139 139 139 139
to remove elements MM 3531 3531 3531 3531
(M) Front of Boiler IN 34 36 36 36
MM 864 914 914 914
(N) Sides & Rear of Boiler IN 24 24 24 24
MM 610 610 610 610

Specifications
Number of Elements 4 7 10 14
Output 1000 BTU/HR 1025 1708 2561 3416
1000 KCAL/HR 258 430 645 860 Notes
Steam Output* LB/HR 1011 1684 2526 3368
KG/HR 460 765 1148 1530 **Steam output ratings, at 180oF (82oC)
Approx. Shipping Weight LB 1440 1825 2150 2300 feedwater temperature, 0 PSIG.
KG 655 830 977 1043 * Indicates voltages available at special
Water Capacity GALLONS 115 195 270 360 request
LITERS 435 738 1022 1362 Probe liquid level control, standard.
Electrical Power Requirements (In Amps)
208V 3 Phase 832 * * * Optional Water Level Controls
MCDonnell Miller 157-157M
240V 3 Phase 724 * * * McDonnell Miller 53-2
480V 3Phase 363 607 906 1204 McDonnell Miller 47-2
575V 3 Phase 301 502 756 1004
Dimensions are approximate. We reserve the right to change specifications. Fulton Boiler Works, Inc. 10-ES 4-00
Description/Instructions

Basic Boiler,
Condensate Tank,
and Blow off
Separator
Piping Diagram

11-ES 4-00 Fulton Boiler Works, Inc.

 Note 2. Have a capacity sufficient to a) There are two blow off valves
Where a condensate return tank is to satisfy boiler consumption as well on the boiler; the main valve at the rear
be fitted, this should: as maintain proper return tank of the boiler and the water
temperature. gauge glass blow off valve. The
1. Be vented and boiler blow off valve supplied with
3. Vent pipe should not be the boiler should be screwed to the
down-sized (This may cause pres- blow off pipe at the rear of the boiler
sure build up in the condensate and connected to a blow off
receptacle of approved design
piping. All these procedures should be
done in accordance with state and/or
local codes. The water
gauge blow off valve should be
connected to the main blow off line.

Note

Care should be taken to ensure

that the blow off receptacle used
meets the regulations covering such
vessels. If in doubt consult
a Fulton Representative for advice.

Fulton Boiler Works, Inc. 12-ES 4-00

Description/Instructions
Feed Water Piping Steam Safety Valve
1) Before installing,be sure that all
steam pipes and connections have been
blown clean; pipe compound or dope is
used on external threads only; and inlet
of valve is free of any foreign material.
2) Do not use a pipe wrench! When
making installation, use proper type and
size wrench .
3) The valve should be installed in a
vertical upright position in the connec-
tion provided with no unnecessary
intervening pipe or lining. Under no
circumstances should there be a shut off
valve or restriction of any kind between
The water gauge blow off valve should the safety valve and the connection
be connected to the main blow off line. provided.
a) Connect the feed water stop valve to
the opening over the blow- off at the rear
4) Do not cap or plug drain hole in the
of the boiler and pipe it to the return sys-
side of valve body.
tem. If the city water pressure exceeds
40 lbs., a pressure reducing valve 5) Since the purpose of this safety valve
should be installed ahead of the return is to protect against an overpressure
tank. situation, it will loudly discharge hot
Note steam in doing so. Therefore, it is
recommended that a discharge pipe be
Where a condensate return tank is to
securely installed and run to a safe point
be fitted, this should:
of disposal.
1. Be vented and
6) When a discharge pipe is used, it
2. Have a capacity sufficient to satis-
must be of a pipe size equal to or
fy boiler consumption as well as
greater than that of the valve outlet.
maintain proper return tank tempera-
Use schedule 40 discharge pipe only.
ture.
Do not use schedule 80, extra strong or
3. Vent pipe should not be down- Note double extra strong discharge pipe or
sized (This may cause pressure build Care should be taken to ensure that connections. It must be as short and
up in the condensate tank. the blow off receptacle used meets straight as possible and so arranged as
the regulations covering such vessels. to avoid undue stress on the valve. It
Blow Off Valve If in doubt consult a Fulton must have an ample provision for
a) There are two blow off valves on the Representative for advice. draining condensate at or near the
boiler; the main valve at the rear of the valve outlet. It must terminate freely to
boiler and the water gauge glass blow Main Steam Valve atmosphere with no intervening valve of
off valve. The boiler blow off valve supplied a) Insert the main steam valve in the any description and it must be securely
with the boiler should be screwed to the steam supply line as close as possible anchored and supported.
blow off pipe at the rear of the boiler to the boiler and prior to any of the
and connected to a blow off receptacle steam using equipment, ensuring cor-
of approved design piping. All these rect steam traps are used. Caution
procedures should be done in accor- Do not downsize piping below safety
valve size.

Caution
Unless otherwise specified, the
steam 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
using steam from the boiler. Do not
tamper with the setting (It could
accidentally be set at a pressure
higher than the design pressure of
the boiler, and therefore create a
hazardous condition.
dance with state and/or local codes.

13-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions
Electrical Power Requirements (In Amps)

Model FB-L 012 015 018 024 030 036 050 075 100 150 200 300 500 750 -- Indicates
not available.
1000
208V 3 Phase 34 42 50 67 84 100 139 208 278 416 556 832 * * Indicates
* * voltages
available at
230V 1 Phase 52 65 78 -- -- -- -- -- -- -- -- --
special
-- -- -- request.

Electrical Requirements be adjusted to suit the boiler applica- equipped with one low water cut off relay
a) Connect wiring as shown in the tion. The control has two scales (main in the panel box connected to one
specific wiring diagram which is and differential) which can be adjusted probe in the top of the boiler and one
furnished inside the cover of the by means of screws on top of the con-
electrical control box. Be sure to install a trol. The main scale setting should be
separate fused disconnect for the adjusted to the desired operating steam
element contactors and a separate pressure.
fused disconnect for the feed water Caution
pump. All wiring must conform to NEC Do not adjust to exceed the pressure
Code. rating on the boiler.
b) A correctly sized fused disconnect b) A high limit pressure control is located
switch should be fitted as close to the next to the operating steam pressure
boiler as possible and connections control and should be set 5 to 10
made to the boiler control panel in pounds higher than the operating steam
compliance with NFPA (National Fire pressure control. This control serves as
Protection Association), NEC Code, and a secondary high pressure cut-off if for
local codes. The appropriate number of some reason the main operating steam
terminals are provided inside the control pressure control should become
panel box to take these connections, inoperative.
but the panel box must be drilled to water level control relay in the panel box
accept the type of conduit used. Water Control Relays
operating two probes in the top of the
Boiler Controls --Fulton packaged a) Boilers from 1.2 to 3.6 HP are boiler.
electric steam boilers are equipped with
both a steam pressure control and a
high limit pressure control mounted on
the outside of the electrical panel box.
a) The steam pressure control should

b) Boilers from
5 - 20 HP con-
tain two low
water cut off
relays in the
panel box con-
nected to two
independent
probes in the
top of the boiler.
c) Boilers from
30 - 100 HP
have an exter-
nal water col-
umn on the right
hand side of the
boiler. There are two low water cut off

Fulton Boiler Works, Inc.14-ES 4-00

Description/Instruction
Water Gauge & Gauge Glass
Installation Instructions

Note
Only properly trained personnel
should install and maintain water
gauge glass and connections. Wear
safety glasses during installation.
Before installing, make sure all parts
are free of chips and debris.

Note
Keep gauge glass in original packag-
ing until ready to install.
1. Verify the proper gauge has
been supplied.
2. Examine the gauge glass and
packings carefully for damage before
installation. Do not use the glass if it
contains any scratches, chips, or any
other visible signs of damage.
3. Do not subject the gauge glass to
bending or torsional stresses.
4. Apply Teflon tape or pipe dope to
pipe threads. Install top gauge fitting
(fitting without a drain valve) into the
uppermost tapping. Wrench tighten the
fitting until it is snug and the glass outlet
is pointing at five o’clock (about 1/8 turn
from its final downward vertical position).
5. Install the bottom gauge fitting (the
fitting with a drain valve) until it is snug
and the glass outlet is pointing directly
upward. Verify top and bottom fittings
are threaded into the tappings the same
number of turns (distance A=distance
B).
6. Remove glass packing nut, friction
washer and glass packing from the
fittings, and place them, in the same
order, on to both ends of the gauge
glass. Push both packings about an
inch up the gauge glass.
7. Gently insert one end of the glass
into the top gauge fitting. Keeping the
glass inside the top fitting, gently rotate
the top gauge fitting clockwise until ver-
tically aligned with the bottom gauge fit- up as far as possible. utilize automatic ball checks where
ting, then inset glass into bottom fitting necessary to help prevent injury in case
until glass bottoms out on the shoulder of glass breakage.
inside the bottom fitting. 10. Hand tighten both glass
packing nuts, then tighten 1/2 turn Warning
8. Carefully raise glass about 1/16” and
more by wrench. Tighten only enough Improper installation or maintenance
slide lower glass packing down until the
to prevent leakage. Do not over of gauge glass and connections can
glass packing contacts the lower gauge
tighten! If any leakage should occur, cause immediate or delayed breakage
fitting. DO NOT allow the glass to
tighten slightly, a quarter turn at a time, resulting in bodily injury and/or
remain in contact with any metal!
checking for leakage after each turn. property damage.
9. Carefully slide upper glass packing
11. Install the protective guard, and

15-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions
Water Supply Feedwater: surprisingly rapid rate and can occur
not only in the boiler proper, but also in
Dissolved Oxygen.....less than 0.05
a) The quality of the water used in the pre-boiler equipment such as ecomomiz-
ppm
boiler will affect the life of the elements ers, feedwater heaters, and feedwater
pH Value...................9-11
and it is strongly recommended that a lines.
*Hardness..................less than 70 ppm
competent water treatment concern be in terms of calcium carbonate Sodium Sulfite Its purpose is to
consulted prior to the installation of the Oil.............................none chemically remove the dissolved oxy-
boiler. They should be advised that Suspended Solids.....none gen left in the feedwater after the feed-
treatment will be used on an electric Organic Matter..........less than 5.0 ppm water has been mechanically deareated.
boiler. Certain chemicals will attach to Chloride....................less than 50.0 ppm Sodium Sulfite reacts chemically with
boiler heating elements and shorten Total Dissolved Solids......less than dissolved oxygen, producing sodium
their life span. Elements damaged due 300ppm sulfate. Since it is desirable to remove
to adverse water conditions cannot be
Boiler Water: dissolved oxygen from the feedwater
replaced under warranty.
before it reaches a boiler. Sodium sulfite
Phosphate....................30 to 50 ppm is best introduced continuously at some
expressed as PO4 (Phosphate) suitable point in the feedwater system
b) Natural feedwater supplies contain
Alkalinity.......................less than 300 (the storage section of the feedwater
solids and dissolved gases. These
ppm as CACO3 (Calcium Carbonate) heater or deareator, six inches below
may promote incrustation or scale,
Chloride.......................less than 500 the water line). Chemical residual con-
foaming, solids in steam, corrosion,
ppm trol is based on the maintenance of a
and/or caustic embrittlement. To prevent
pH Value....................9 to 11 (measured specific excess of sodium sulfite in the
this, feedwater must be studied
at room temperature) boiler water. The essential requirement
individually and treated accordingly.
Total Dissolved Solids---less than 2,000 ppm being to maintain in the feedwater at all
The treatment should provide quality
Iron................................1 ppm maxi- times slightly more than enough sodium
feedwater to the boiler such that
mum sulfite to consume all of the dissolved
corrosion and deposition in the boiler
Silica........................180 ppm max. as oxygen that slips through the deareat-
will be minimized. Dissolved oxygen,
SIO2 ing
high chloride levels and low pH can all
Hardness..................less than 50.0 ppm equipment. When sodium sulfite is not
be major causes of corrosion. Untreated
Dissolved Oxygen....none fed continuously, protection of the boiler
hardness is the major cause of
deposits. Poor quality feedwater ppm = parts per million against oxygen attack must depend on
requires increased blowdown and * 1 Grain Hardness = 17.118 ppm the reserve of sodium sulfite that is
increased chemical treatment costs to Therefore: 70 ppm = 4.10 grains hard- present in the boiler water. In this case,
prevent boiler corrosion and scaling. ness it is important that the feedwater and
the boiler water are mixed thoroughly
b) It is critical that the boiler pH be and as quickly as possible so that boiler
c) One way to lower the amount of alkaline (9-11) whenever water is in the water sodium sulfite may consume
dissolved oxygen in the boiler feed boiler. This is traditionally maintained feedwater oxygen before the latter can
water is the sparge tube option. This through a combination of sodium cause damage to the boiler.
option injects live steam into the hydroxide and phosphate. The
feedwater to increase the water phosphate has the additional benefit of Sulfite as a treatment represents the
temperature to 180 degrees F removing any hardness that may lead second line of defense against oxygen
(degrees C) which removes oxygen past the softener. Solids that enter in corrosion. Primary protection against
from the water. with the feed water concentrate in this type of attack requires adequate
the boiler. facilities for mechanical deareation
of the feed-water plus a vigorous
d) Chlorides can be controlled by A regular schedule of boiler blowdown maintenance program to safe guard
increasing the number of blowdowns must be maintained to prevent high against oxygen leakage into the
per day from one to four. salt concentrations (chloride and pre-boiler system.
sulfate) from corroding the boiler or
forming deposits. Suspended Solids:Suspended solids
e) The Fulton Warranty does not are the undissolved matter in water,
cover damage or failure that can be Glossary of Water including dirt, silt vegetation, and any
attributed to corrosion, scale or dirt Supply Corrosives other insoluble organic matter. Normally
accumulations. Oxygen is a and Inhibitors suspended solids are expressed in
corrosive. terms of turbidity.
Dissolved Oxygen: Oxygen that is
dissolved in the feedwater will cause The presence of suspended solids in
Recommended Water Treatment the steel in the boiler and the feedwater cooling water can increase impingement
system to be attacked by the water in a type corrosion. Suspended solids may also
a) Following are recommendations manner described as “pitting”. The pits deposit in low velocity areas and create
for feed water and boiler water. that are produced y can vary from tiny differential aeration cells. Pitting can result.
Contact your local water treatment depressions to holes large enough to
professional for testing and treatment penetrate the boiler metal and are usual- The most common cause of high
recommendations. It is very important ly covered with tubercles of iron oxide. suspended solids is high hardness
that a strict water treatment program Once pitting starts, it may be extremely feedwater. Of the agents which cause
be followed. hard to arrest. Pitting can proceed at a foaming, suspended solids probably

Fulton Boiler Works, Inc. 16-ES 4-00

Description/Instructions

Reasons for the increased hardness controlled in open recirculating systems Iron (oxides): Iron in any of its oxide or
or other suspended solids should be by limiting the cycles of concentration. complex forms is undesirable in boiler
determined. Corrosion from chlorides can also be water. It is very difficult to disperse so
controlled by increasing the amount of that it can be removed the bottom
In line filters, or various types of blowoff lines.
corrosion inhibitor or changing to a more
pretreatment can be used to lower the
effective inhibitor. Reverse osmosis is
suspended solids level. Various Iron in its various forms can originate in
another method of pretreatment to
polymers assist in holding solids in the raw water makeup, condensate
reduce chlorides.
suspension . return water, or form directly in the boiler
Osmosis is a process that uses a as a result of corrosion. Most iron oxide
Alkalinity: Alkalinity is the capacity of a originates outside the boiler. It does not
semi-permeable membrane, under
water to neutralize acids. Common water concentrate in the boiler and it tends to
pressure, to reject dissolved salts and
alkalinities consist of bicarbonate, collect in stagnant areas. If a boiler is
allow water to pass through. When a
carbonates, hydroxide, phosphate, and using raw water makeup, iron is almost
solution of salt and water is separated
silicate. These alkalinities, especially certain to be a major component of
by a membrane, the osmotic pressure
bicarbonates and carbonates, break developing scale.
forces the water through the membrane,
down to form carbon dioxide in steam,
diluting the salt solution. When pressure
which is a major factor in the corrosion Water Hardness: Water hardness is
greater than osmotic pressure is applied
on condensate lines. High alkalinity also the measure of calcium and magnesium
to the salt solution, the membrane allows
causes foaming and carry over in boilers. content as calcium carbonate
the water from the salt solution to pass
equivalents. Water hardness is a
Both foaming and carry over cause errat- into the water solution and rejects the
primary source of scale in boiler equipment.
ic boiler operation. When foaming occurs dissolved salts. The osmotic process is
an antifoam should be added or reversed, hence, reverse osmosis. Feedwater: Feedwater is the
increased. The reason for the high combination of fresh makeup and
Oil: Oil is not a natural constituent of
alkalinity should be determined. It may returning condensate that is pumped to
boiler water; still it can frequently enter a
result from lack of sufficient blow off. the boiler.
system through leaks in a condenser or
Pretreated makeup water and condensate
other heat exchanger. Oil can also enter Condensate: Condensate is
should also be checked. Quite often the
a system through the lubrication of condensed steam that is normally low in
source of alkalinity is an overdose of
steam driven reciprocating equipment. dissolved solids. Hence, it does not
alkaline internal water treatment chemical.
Whatever the source, the presence of oil contribute to the dissolved solid content
pH: pH is a measure of the degree of in boiler water is undesirable. Oil can act of the feedwater. In addition, condensate
acid or base of solution. Normal pH as a binder to form scale. In high is very expensive to waste. It's been
ranges of 6.5-9.0 will have little influence heat-transfer areas oil can carbonize and chemically treated, heated, pumped,
on the corrosion rate of cooling waters. If further contribute to the formation converted to steam, and condensed.
for some reason— pollution, etc.—the of scale. This costs money and when condensate
pH is lowered into the acid range, is returned to the boiler, money is saved.
Foaming is one indication of oil in
increased corrosion can be expected.
boiler water. Its presence can also be
The solution lies in determining the
confirmed by first shaking a bottle
cause of the low pH and correcting that
containing boiler water. If oil is present
condition. A low pH can result in
foam will result. To ensure the foaming is
corrosion of metals, while a high pH can
being caused by oil, add a small amount
result in scale formation. In order to
of powdered activated carbon
control boilers and equipment used for
to the bottle containing the boiler water
the external treatment of make up
and shake. Little or no foam will appear
water, it is essential that reliable pH mea-
if the foaming is caused by oil. Often oil
surements be made.
in boiler water will originate in the
Phosphates: Ground or surface waters condensate. This contaminated
seldom contain large amounts of condensate should be directed to the
phosphates. If present, it generally sewer until the source of the oil is
indicates fertilizer runoff or pollution. determined and corrective steps taken.
Phosphate from raw water can be the
Silica: Silica in boiler deposits is usually
cause of scale problems in open
combined with other constitutents.
recirculating cooling water systems after
Silicates form a number of different scale
the water is concentrated.
complexes with calcium, magnesium,
Chlorides: Chlorides are involved in aluminum, sodium, and iron. Since there
most cooling water corrosion cells. Other is at present no effective dispersant for
factors being equal, it can be assumed silicate deposits, the scale problem can
the higher the chloride content, the more be alleviated by maintaining close
corrosive the water. When pits or cracks control of calcium, aluminum, and iron as
occur on stainless steel or other metals, well as silica. The usual control
chlorides are always suspect. procedure is to maintain the silica
level in open recirculating water at
If chloride levels are high enough to 180 PPM max.
cause severe corrosion, they can be

17-ES 4-00 Fulton Boiler Works, Inc.

Description/Instructions

Installation Check Points 3. Mix washing soda with water in a 5. Fill the boiler with water. Water level
one-gallon container and pour it into the is about center in the water gauge
1. Make sure all piping connectors are boiler through the steam safety valve glass.
complete and tight opening.
2. Make sure the pressure controls are
adjusted properly.
3. Make sure all electrical connections
in the control panel box, the water
column, and elsewhere are secure.
Note
After installation is complete and
prior to operation, the pressure vessel
should be cleaned.

Cleaning The Pressure Vessel

a) After the boiler has been installed
and before it is placed in service, it is
The mixture of washing soda is
advisable to clean the pressure vessel
as follows:
to eliminate any oil film, dirt, or other
impurities. Clean the pressure vessel
as follows: Boiler Size Soda
1. Isolate the boiler from the system by
shutting off the main steam valve. 12 Kw to 36 Kw 1/2 lb. (227g)

50 Kw to 75 Kw 1 lb.
(454g)

100 Kw to 150 Kw 2 lbs. (908g)

200 Kw to 300 Kw 3 lbs. (1362g)

500 Kw 3-1/2 lbs.

(1589g)

750 Kw 4 lbs.
(1816g)

1000 Kw 5 lbs.
(2270g)

2. Remove the steam safety valve. 4. Replace the steam safety valve.

Fulton Boiler Works, Inc. 18-ES 4-00

Operation

3
Fulton Boiler Works, Inc. 20-ES 4-00
Operation

Introduction c) Open main steam stop valve at the feed water pump should be kept in the
The following instructions are given for the top of the boiler. “on” position at all times during the
guidance of the operator in the use of boiler operation as well as during the
Fulton Electric Steam Boilers. Before non-operating period of the boiler. This
operating your Fulton Electric Steam Boiler: should be turned off only when repairs
or adjustments are to be accomplished.
Stop! Make sure you have read and
followed all previous safety information.
Note
Check with local authorities where
approval for start-up is required. In
some localities, final inspection of
services may be required.
Caution
In general, ensure that the boiler area
is in conformance with established
boiler room requirements. Review
national and local codes.
Starting the Boiler d) Open water feed valve on boiler.
Do not attempt to start the boiler until all
of this section has been read. Carry out
the following procedure on the initial
start up of the boiler and on every sub-
sequent occasion when restarting the h) Turn the switch on the boiler to the
boiler after a shut down. “on” position. The white light will light
a) Close blow-off valve. indicating that the electrical circuit for
the boiler has been energized and that
all controls are working properly.

e) Open valves on makeup water line to

return if return system is used.

f) Place feedwater pump fused switch

in the “on” position. The water pump
will continue to operate until the water
has reached the proper level in the boil-
er. This level is at about the center of
b) Close water gauge drain valve. the water gauge glass.

g) To check proper boiler control

operation and pressure control settings,
you may choose to close the steam
supply valve on initial start up. This will
enable you to observe the complete
boiler operation without heating the
complete system.

The fused switch that controls the

21-ES 4-00 Fulton Boiler Works, Inc.

Operation

Boiler Controls re-energize the elements when the water button located on the panel box. For
The boiler is now fully operational and in the boiler has regained a safe level. Models FB-012-L through FB-036-L
will be automatically controlled as follows: Proper water level control is maintained there is a pump control relay and one
automatically by two water level probes low water cut off control relay located in
located in the boiler shell (1.2-20 HP) or the panel box. For Models FB-050-L
in the water column (30-100 HP). These through FB-1000-L there is a pump
control relay and two low water cut off
control relays located in the panel box.
The pump control relay is located on the
left and the water level control relay(s)
on the right.
Caution
Do not tamper with the safety features
of the low water safety cut off.
c) The boiler has a manual reset control
should a low water condition arise. It
will be necessary to reset the low water
control after the water again reaches a
safe level in the boiler. In the event of
power failure this control must also be
a) The steam operating pressure control reset. Place the main switch to the “on”
will control the on/off cycle of the ele- two probes turn the water pump on or position and press the low water reset
ments once the boiler is operating. The off. button and the contactor will start.
low water cut-off probes will signal the
low water relays and shut off power to b) Fulton Boilers are equipped with d) On Models FB-012-L through
the elements should the water in the solid state plug-in relays. Manual FB-075L after starting the boiler and the
boiler drop to an unsafe level and will reset is standard. It can easily be steam pressure reaches the set pres-
only distinguished by the low water reset sure on the operating pressure control,
the heating element will then shut off
automatically, and the amber light will
go out. After the steam pressure drops
according to the differential setting on
the operating pressure control, the
heating element will then restart
automatically and the amber light will
come back on. The differential can be

changed on the steam operating

pressure control by adjusting the screws
found on the top of the control.
e) Models FB-100-L through FB-1000-L
do not have an amber light, but
instead, are standardly supplied with a
step sequencer which is located inside
the panel box. The step sequencer

Fulton Boiler Works, Inc. 22-ES 4-00

Operation

Warning
When stopping the boiler for any
extensive repairs, shut off main
power switch and pull main
disconnect switches on both the
boiler side as well as the feed
water side.

Thermostat (Optional) Sight Glass Isolation Valves

a) An optional thermostat may a) The brass sight glass isolation valves

be supplied with your boiler. This ther- are equipped with an internal ball
mostat is located on one of the heating check. In the event that a sight glass
elements and is factory preset at num- should break, the ball will seat, prevent-
ber 11. This should not be readjusted ing the discharge of steam and water.
without consulting the factory or your The brass valve stem must be opened
f) The high limit pressuretrol is located local Fulton Representative. fully to arm this capability. If the valve is
on the side of the control box and con- in any other position than full open, the
nected to a steam pressure fitting in ball will not seat. For added safety all
the boiler by means of a copper tube. Fulton boilers are equipped with gauge
The high limit pressuretrol will shut the glass protectors.
boiler off when the maximum pressure
is reached. This pressure is usually set
10 to 15 PSI above the operating pres-
sure -- but below--the maximum pres- Note
sure of the relief valve.
To ensure that your Fulton
steam boiler is kept operating safely
and efficiently, follow the
maintenance procedures set forth in
this manual.

23-ES 4-00 Fulton Boiler Works, Inc.

Maintenance

4
Fulton Boiler Works, Inc. 24-ES 4-00
Maintenance
Introduction
Your Fulton Electric Steam Boiler has Caution plates and the opening of the control
been designed for years of trouble-free panel box, the electrical supply to be
Keep boiler area clear and free from
performance. To ensure the continued boiler must be disconnected.
combustible materials, gasoline, and
safety and efficiency of the boiler, the
other flammable vapors and liquids.
schedule of maintenance outlined in this Caution
section should be adhered to. The Warning
boiler should be inspected annually. All Do not use harsh compounds which
service should be performed by a Prior to the commencement of any will injure the feed water pump
certified contractor. work requiring the removal of cover or elements.

Recommended Daily 3. When the steam pressure has Recommended Monthly

Maintenance reached 20 PSIG, turn on the tap water Maintenance
to the blow down separator, then open
a) The following procedures should be blow down valve(s) for approximately
a) Feed water pump and motor should
carried out daily. They are designed to 10-20 seconds. Close the valve(s).
be lubricated according to the manufac-
prevent the build up of scale, silt, or 4. Shut off tap water to blow off turer’s instructions.
sludge in the bottom of the boiler and in separator.
the pipes leading to the water gauge. In
addition to these procedures the advice of 5. For 30 - 100 HP Electric Boilers you b) Heating Element - Inspect heating
a water treatment supplier should be must also blow down water level control element. To protect the element and
sought and followed. An ASME Section each morning by opening the water prolong its life, it is essential that regular
VIII blow off receptacle must be provided column and water gauge blow off inspections are carried out. The most
for the appropriate pressure. valves for approximately 10 seconds. common causes of element failure are
Close valves. excessive build up of scale and corro-
b) Make a daily inspection of the boiler sive attack. Both causes are due to
and system for leaks or any unusual adverse water treatment.
condition in the operation of the controls
and feed pump. 1. The dangers of scale to the life of the
element cannot be overstressed. Scale
c) Check water level in sight glass.
possesses excellent insulative qualities
(It should be halfway in the sight glass and its formation on the
to prevent a dry fire condition which can element prevents the heat generated by
permanently damage the elements and the element from being transferred to the
pressure vessel.) water, causing the element to overheat
and burn out.
d) Check all valves to see that they are
opening and closing properly. 2. Loose powdery formations can be
removed with a wire brush.
e) Daily Blow Off Sequence:
1. Close main steam supply valve. 3. Hard scale may be removed using a
mild chemical cleaning agent
2. Start the boiler. followed by a neutralizing agent.
Blow down water column each morning by
opening the water column and water gauge c) Low water cut-off relay — Check
blow-off valves.
that the low water cut-off relay is operat-
ing correctly in the following manner:
6. Allow the boiler feed water pump to
restore the water level in the boiler. 1. With the boiler operating, open the
boiler blow down valve.
7. Reopen main steam supply valve for
plant operation. If surging occurs, clos-
ing the main steam valve partially will 2. When the water drops below the
often stop this. required level, the relay will shut off the
contactor. This shows that the relay is
f) Water gauge glass — inspect daily working properly. Reset low water cut-off
until the need for replacement becomes by pushing the reset button on the side
apparent. This will assist in establishing of the panel (5 to 100 BHP only).
routine replacement schedules. Examine
the surface of the glass for scratches, 3. Close blow-off valve lines and allow
corrosion, chips, cracks, surface flaws, boiler to fill to proper level.
Blow Down Boiler Daily. Shown is the blow or nicks. To do this, shine a very bright
down “Y” valve.
concentrated light at an angle of about d) Blow down the boiler and sight glass
45 degrees. A defective glass will glis- completely as described under daily
ten as the light strikes imperfections. maintenance.

25-ES 4-00 Fulton Boiler Works, Inc.

Maintenance

e) Clean the Water Gauge Glass Recommended Quarterly

Caution: Maintenance
Do not clean the gauge or gauge a) Shut off the boiler completely
glass while pressurized or in and drain.
operation.
b) Remove the handholes and inspect
1. Clean the water gauge glass using a the interior of the vessel for scale or
commercial non-abrasive glass cleaner. sludge deposits. The amount of
Use diluted acids such as hydrochloric deposits will indicate the efficiency of
(muriatic) acid when regular cleaners do the water treatment being used. The fre-
not seem to work. Do not use wire quency of this inspection will be depen-
brushes or any other abrasive materials dent on the condition of the water side
which could scratch the glass. If any of the boiler.
leakage is evident, replace the gaskets.

illustration shows correct pressure on gas-

ket

Inspect handholes for scale or sludge buildup

Clean Glass; Replace Gaskets If Leaking

c) Replace handhole gaskets using
the following procedure.
2. Always replace the high impact
plastic gauge glass protector which is Illustration shows over compressed gasket
1) Remove old gasket and thoroughly
standard on all Fulton Boilers. clean the surface on the boiler and the
f) Clean water pump strainers. plate. every six months. Testing should be
g) Check operation of all steam traps 2) Place gasket on handhole plate. Be performed more often under severe
on condensate return system. sure the gasket is pushed down tight on service conditions or if corrosion or
the plate. Do not use any grease, deposits are noticed within the valve
h) Remove pipe cap at the cross body. A “try lever” test should also be
connection below water column and lubricant or adhesive.
performed at the end of any extended
clean nipple into boiler. Boiler must be non-service period. Check that the
3) After the plate is in the boiler and
cold and water level below pipe, steam safety valve is operating properly
the gasket is in place, set yoke and
(30 - 100 BHP only). by conducting a “try lever” test.
tighten nut only enough to provide a
snug fit. Make it hand tight and then
snug with wrench about 1/4 turn. Do not Caution
compress excessively.
Prior to performing the “try lever” test,
4) If the gasket leaks while pressure is be certain to take precautions as a
being built up, tighten only enough to loud noise and high velocity steam
stop leakage. Never tighten more than will discharge freely from discharge
necessary to prevent leakage. port and through drain hole provided
Excessive tightening may shorten life of in the side of the valve body.
the gasket.
1. The test lever is designed to be
c) Refill the boiler with fresh water. activated only when 75% or more of the
relief pressure is reached, otherwise
distortion could result. The valve should
Recommended Six Month be tested at or near maximum operating
Maintenance pressure by holding the test lever fully
a) Steam Safety Valve -- Under normal open for approximately 5 seconds to
operating conditions a “try lever” test flush the valve seat free of any debris
Remove cap at cross section; clean nipple should be performed approximately or sediment.
to boiler

Fulton Boiler Works, Inc. 26-ES 4-00

Maintenance

a) Steam Safety Valve (cont.)

2. Permit the valve check to snap shut.
3. If lift lever does not activate and there
is no evidence of valve
discharge, shut down equipment
immediately and replace valve.
b) Cleaning Probes: Clean probe on top
of boiler shell and probes in water col-
umn (30 - 100 BHP). Make sure there is
no pressure on boiler during the removal of
the probes. Remove one probe, clean
with very fine emery cloth and replace it
before removing another to assure no
probe mix ups that would change the
control functions.

For replacement purposes, installed

probe lengths are indicated in the chart
below. For a universally adaptable
plug and probe which can be cut to
length in the field to fit all boilers, order
Part No. 2-20-017.

1.2 to 3.6 HP 5-20 HP 30-100 HP

A = 9-1/2” A =11-1/2” A = 7-1/4”
B = 10-1/2” B = 13” B = 9-1/4”
C = 11-1/2” C = 15” C = 11-1/4”
D = 11-1/2 D = 15” D = 16”

c) Drain the condensate tank and clean

by flushing with hose. Check float valve
operation.
d) Make sure pump is functioning.
e) Clean boiler out if necessary. See
Installation Check Points: cleaning the A
pressure vessel.

Recommended Annual
Maintenance B
a) Repeat six month maintenance.
b) Check elements for correct amp draw.
c) Provide annual inspection by quali-
fied ASME Boiler Inspector (if applicable C D
in your state).

27-ES 4-00 Fulton Boiler Works, Inc.

Maintenance
Troubleshooting
This troubleshooting guide will assist in the diagnosis and correction of minor field problems. It should be used in conjunction
with the unit wiring diagram. In any case requiring additional assistance, contact your local authorized Fulton Representative.

Problem Cause Check

Control Circuit Failure A. Fuse If a break is detected, shut off power and
remove fuse. Replace with a new fuse of same voltage and
amps. Turn power on.

B. Voltage Trace wiring diagram through each component

to verify power in each stage. If voltage is not
detected at any point, replace component and
continue test until circuits test clear.

C. Control Switch Check all wires from switch terminals for looseness
or corrosion. Replace if either is evident. Next check for proper make and break of
switch.

D. Low Water Safety Relay Verify that boiler has water. Check to verify
power on terminal #1. If power is present, check to verify
power on terminal #10. If power is not present, press the low water reset button
to reset relay. If relay does not reset, inspect terminals for loose
connections. Inspect probe connection.

E. Corrosion of Probes Check all wires to verify proper wiring to each

probe. If a wire is suspected to be in the wrong place, shut
off power and check wire with a con tinuity light. Check probes. If probes
are dirty, clean with very fine emory paper and replace.

F. Staging Controller Verify timing and stage selection on DIP switches.

Pump Circuit Failure A. Fuse If a break is detected, shut off power and remove
fuse. Replace with a new fuse of same voltage and amps. Turn
power on.

B. Corrosion of Probes To verify proper wiring to each probe. If a wire is

suspected to be in the wrong place, shut off power and check wire with a con-
tinuity light. Check probes. If probes are dirty,clean with veryfine emory paper and
replace.

C. Wiring Connections With power off, check continuity of circuit through

each point in the circuit. If a break in the circuit is found, repair. After
repair, recheck with continuity light with power off. Turn power on and check
with an amp meter.

D. Motor Starter Relay Check power supply to coil on motor starter.coil

is being powered, check if contactors are being engaged completely.
If coil and contactors are engaging, check power in and out on the con-
trol circuits. If contactor is chattering, clean contacts.
If motor starter relay is weak or bad, replace.

Primary Voltage Circuit A. Fuse If a break is detected, shut off power and
remove fuse. Replace with a new fuse of the same volt-
age and amps. Turn power on.

B. Voltage Trace wiring diagram through each component

to verify power in each stage. If voltage is not detected at any
point, replace component and continue test until circuits test clear.

Fulton Boiler Works, Inc. 28-ES 4-00

Maintenance

Troubleshooting
Problem Cause Check
Primary Voltage Circuit C. Wiring Connections With power off, check continuity of circuit
through each point in the circuit. If a break in
the circuit is found, repair. After repair, recheck with continuity light
with power off. Turn power on and check with an amp meter.

D. Burned or Broken Wiring With power off, check continuity of circuit

through each point in the circuit. If a break in
the circuit is found, repair. After repair, recheck with continuity light
with power off. Turn power on and check with an amp meter.
Verify wire size is sufficient for amp draw.

E. Contactor Contact Points If burned or dirty, clean with fine emory paper.
If burned through, replace. If not engaging com pletely,coil may be weak. Replace.

F. Elements Shorting or Open Circuit With power using a continuity tester, check to
see if an element is burned out between each point. If power is on, a volt meter may
be used. If an element is bad, replace.

Low Water Condition A. Circulating Pump Clean or replace all filters or screens to
assure proper water flow through them.

B. Water Makeup Supply Check to see that your supply water has not
been shut off or that there are no restrictions in the line leading to the boil-
er.

C. Leaks in the System Check piping for any leaks.

29-ES 4-00 Fulton Boiler Works, Inc.

Parts

5
Fulton Boiler Works, Inc. 30-ES 4-00
Parts

Spare Parts
a) It is important that the correct supplied, together with the following Note:
replacement part is fitted to your details as shown on your boiler
Fulton Electric Steam Boiler. identification plate: The policy of Fulton Boiler Works,
Inc. is one of continuous improve
b) When ordering replacement or 1. Boiler Number ment, and therefore, we reserve the
spare parts, make sure that the full 2. Boiler Type right to change prices, specifications,
information given in the Parts List is 3. Electrical Specifications and equipment without notice.

Fulton Boiler Identification Plate

Fulton Electric Steam Boiler

Underwriters
Laboratories Inc.® LISTED ELECTRIC BOILER CONTROL NO. 87CO
Boiler No./National Board Number Model

Month Year

MD Lbs. Steam/Hr. SH HD HS MWP

Volts Phase kw Amps Freq.

Use Supply Cable Rated 75°C

Control Circuit Pump Motor

Volts Amps Freq. Phase HP

Maximum Time Delay Fuse Amps Maximum Supply Circuit Ampacity

For Connections Use Wire Suitable For At Least 167°F (75°C) Minimum

CRN No.

Fulton Boiler Works, Inc.

Pulaski, NY 13142

31-ES 4-00 Fulton Boiler Works, Inc.

Parts

Replacement Parts Listing (available from authorized Fulton Representatives)

Part Number Item Description
5-60-110 Instruction Manual - Electric
5-10-800 Weld Patch 1.2-100 HP
4-11-010 Handhole Assembly 1.2 - 5 HP (White)
4-11-012 Handhole Assembly 7.5 -15 HP (Red)
4-11-014 Handhole Assembly 20 HP (Green)
4-11-016 Handhole Assembly 30 - 45 HP (Yellow)
4-11-018 Handhole Assembly 50 -100 HP (Blue)
2-11-100 Handhole Plate 1.2 - 5 HP (White)
2-11-101 Handhole Plate 7.5 -15 HP (Red)
2-11-102 Handhole Plate 20 HP (Green)
2-11-103 Handhole Plate 30 - 45 HP (Yellow)
2-11-104 Handhole Plate 50 -100 HP (Blue)
2-11-105 Handhole Yoke
2-12-004 Handhole Gasket
2-23-237 Touch-Up Paint (Spray Can 16 oz.)
4-23-010 Touch-Up Paint (Quart)
4-23-040 Touch-Up Paint (Gallon)
5-10-397 T-Handle Wrench
2-20-017 Water Level Plug & Long Brass Rod Suitable for Cutting
2-30-137 McDonnell Miller 53-2 Boiler Feeder
2-30-149 Water Gauge Valves Only w/Ball Checks
2-12-017 9-1/4“ Water Gauge Glass
2-12-019 Rubber Water Gauge Glass Gasket
2-12-020 Brass Water Gauge Glass Gasket
2-35-514 Brass Packing Nut for Water Gauge Valve
2-12-022 Lucite Gauge Glass Guard
2-30-399 142S Watts Water Feeder
2-40-403 IDIDO Relay 115 Volt
2-40-402 IGIDO Relay 115 Volt
2-40-401 ID2DO Relay 230 Volt
4-45-050 Set of (3) Coils for IDIDO
2-45-092 Manual Reset Switch
2-40-420 Fulton Pump Relay - 120V
2-40-421 Fulton Burner Relay-120V
2-40-422 Base for Fulton Pump Relay
2-40-423 Base for Fulton Burner Relay
2-40-405 Fulton Pump Relay 220v
2-40-406 Fulton Burner Relay 220v
2-45-090 Night Switch for (2) Pressuretrols
4-40-050 Night Heating Pressuretrol Set-Up
2-45-107 White Panel Box Indicating Lights 120 V
2-45-108 Amber Panel Box Indicating Lights 120 V
2-45-110 Red Panel Box Indicating Lights 120 V

Fulton Boiler Works, Inc. 32-ES 4-00

Parts

Replacement Parts Listing (continued)

Part Number Item Description

2-45-115 White Panel Box Indicating Lights 240 V

2-45-116 Amber Panel Box Indicating Lights 240 V
2-45-114 Red Panel Box Indicating Lights 240 V

2-40-904 240V 10 Step Solitech Sequencer

2-40-227 Pressuretrol L404A 1354 2-15 PSI

2-40-228 Pressuretrol L404A 1370 5-50 PSI
2-40-229 Pressuretrol L404A 1396 10-150 PSI
2-40-230 Pressuretrol L404A 1404 20-300 PSI
2-40-231 Pressuretrol L404C 1147 2-15 PSI
2-40-232 Pressuretrol L404C 1150 5-50 PSI
2-40-233 Pressuretrol L404C 1162 10-150 PSI
2-40-234 Pressuretrol L404C 1139 20-300 PSI
2-40-225 Pressuretrol L91B 1035 0-15 PSI
2-40-226 Pressuretrol L91A 1050 5-150 PSI

2-45-000 Terminal Block 1492-1 OOX A-B

2-40-023 60 Amp Contactor 120 volt
2-40-295 60 Amp Contactor 240 volt
2-40-296 60 AmpContactor 220 volt with 300 volt fuse clip

2-40-024 60 Amp Contactor 120 volt with 300 Volt Fuse Clip
2-40-025 60 Amp Contactor 120 volt with 600 Volt Fuse Clip
2-40-022 60 Amp Contactor 220V with 600 Volt Fuse Clip -
2-40-027 240 Volt Coil for 60 Amp Contactor
2-45-006 SC-40 Fuse
2-45-007 SC-50 Fuse
2-45-008 SC-60 Fuse
2-45-010 JKS-35 Fuse
2-45-011 JKS-40 Fuse
2-45-012 JKS-50 Fuse
2-45-013 JKS-60 Fuse

2-30-100 Flange Gasket 12-35 KW Element

2-30-101 Flange Gasket 50-75 KW Element
2-45-015 Thermostatfor 12-35 KW Element
2-45-016 Thermostat for 50-75 KW Element

33-ES 4-00 Fulton Boiler Works, Inc.

Parts

Replacement Parts Listing (continued)

Part Number Item Description
2-40-028 ABF 12-208 Volt 3 ph. Heating Element with Thermostat
2-40-029 XBF 12-208 Volt 3 ph. Heating Element
2-40-030 ABF 12-230 Volt 3 ph. Heating Element with Thermostat
2-40-031 XBF 12-230 Volt 3 ph. Heating Element
2-40-032 ABF 12-460 Volt 3 ph. Heating Element with Thermostat
2-40-033 XBF 12-460 Volt 3 ph. Heating Element
2-40-034 ABF 12-575 Volt 3 ph. Heating Element with Thermostat
2-40-035 XBF 12-575 Volt 3 ph. Heating Element
2-40-036 ABF 15-208 Volt 3 ph. Heating Element with Thermostat
2-40-037 XBF 15-208 Volt 3 ph. Heating Element
2-40-038 ABF 15-230 Volt 3 ph. Heating Element with Thermostat
2-40-039 XBF 15-230 Volt 3 ph. Heating Element
2-40-040 ABF 15-460 Volt 3 ph. Heating Element with Thermostat
2-40-041 XBF 15-460 Volt 3 ph. Heating Element
2-40-042 ABF 15-575 Volt 3 ph. Heating Element with Thermostat
2-40-043 XBF 15-575 Volt 3 ph. Heating Element
2-40-044 ABF 18-208 Volt 3 ph. Heating Element with Thermostat
2-40-045 XBF 18-208 Volt 3 ph. Heating Element
2-40-046 ABF 18-230 Volt 3 ph. Heating Element with Thermostat
2-40-047 XBF 18-230 Volt 3 ph. Heating Element
2-40-048 ABF 18-460 Volt 3 ph. Heating Element with Thermostat
2-40-049 XBF 18-460 Volt 3 ph. Heating Element
2-40-050 ABF 18-575 Volt 3 ph. Heating Element with Thermostat
2-40-051 XBF 18-575 Volt 3 ph. Heating Element
2-40-052 ABF 25-208 Volt 3 ph. Heating Element with Thermostat
2-40-053 XBF 25-208 Volt 3 ph. Heating Element
2-40-054 ABF 25-230 Volt 3 ph. Heating Element with Thermostat
2-40-055 XBF 25-230 Volt 3 ph. Heating Element
2-40-056 ABF 25-380 Volt 3 ph. Heating Element with Thermostat
2-40-057 XBF 25-380 3 ph. Heating Element
2-40-058 ABF 25-415 Volt 3 ph. Heating Element with Thermostat
2-40-059 XBF 25-415 3 ph. Heating Element
2-40-060 ABF 25-460 Volt 3 ph. Heating Element with Thermostat
2-40-061 XBF 25-460 3 ph. Heating Element
2-40-062 ABF 25-575 Volt 3 ph. Heating Element with Thermostat
2-40-063 XBF 25-575 3 ph. Heating Element
2-40-064 BWF 50-230 Volt 3 ph. Heating Element with Thermostat
2-40-065 XWF 50-230 Volt 3 ph. Heating Element
2-40-066 BWF 50-460 Volt 3 ph. Heating Element with Thermostat
2-40-067 XWF 50-460 Volt 3 ph. Heating Element
2-40-068 BWF 75-230 Volt 3 ph. Heating Element with Thermostat
2-40-069 XWF 75-230 Volt 3 ph. Heating Element
2-40-070 BWF 75-460 Volt 3 ph. Heating Element with Thermostat
2-40-071 XWF 75-460 Volt 3 ph. Heating Element

Fulton Boiler Works, Inc. 34-ES 4-00

35-ES 4-00 Fulton Boiler Works, Inc.
Warranty

6
Fulton Boiler Works, Inc. 36-ES 4-00
Warranty
ghhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhhi
n
j 5 Year (60 Month) Conditional Warranty*
n On the Fulton Boiler Pressure Vessel
j
n *Fulton Boiler Works, Inc. will repair or replace F.O.B. factory any Fulton pressure vessel which, within FIVE (5) years of the date
j of shipment from factory, is found to be defective in workmanship or material, provided this equipment is installed, operated and
maintained by the buyer in accordance with the Fulton instruction manual and approved practices, and that the +water quality
n used in the system has been regularly checked to meet the standards for ideal and proper boiler feedwater during the warranty
j period. ++This warranty does not cover damage or failure that can be attributed to corrosion, (including oxygen pitting) scale or
dirt accumulations, or to low water conditions. Follow feedwater specifications and recommended treatment specifications as
n detailed in Section 1 of the instruction manual shipped with your boiler as well as maintenance procedures as listed in Section
j 5. This 5 year warranty applies only in the continental U.S.A. and Canada. The Warranty does not include labor charges of any
n kind. In the event a failure is reported, Fulton will require an analysis of the boiler feedwater to determine that acceptable water
conditions are present at the installation site as well as documentation on the feedwater treatment employed since the installa-
j tion of the boiler. The boiler will be required to be shipped freight prepaid to the Fulton factory for inspection after a failure is
n reported. The customer may witness the inspection and verification at the factory.
j +Consult Fulton Boiler Works, Inc. for analysis of acceptable water conditions.
n of
++Feedwater treatment and proper daily blowdown procedures are very important in keeping your boiler heating surfaces free
scale formation, pitting, oxygen corrosion and foaming or bouncing water. Professional feedwater treatment consultants
j should be contacted when the boiler is installed. They will recommend the proper treatment required for prolonging boiler life. A
n thorough boiler inspection should take place during the first six months of operation to assess the effectiveness of boiler water
j treatment techniques, including analysis of potential oxygen pitting.
n that
It is the owner's responsibility to assure safe operation of the boiler. To avoid corrosion, scale or dirt accumulations, it is recommended
a daily blow down procedure be instituted. The boiler power should be left on during daily blow down so that correct opera-
j tion in the low water relay may be checked. While blowing down the boiler, the pressure will drop significantly. Detailed blow down
n procedures are in the boiler instruction manual shipped with your boiler.
j Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler. It is the owner's responsibility
to have the boiler room periodically tested to assure these damaging chemicals are not present.
n
j
n
j
n

1 Year (12 Month) Standard Warranty

A the implied warranties of merchantability and repair of their products. Therefore,
and fitness for a particular purpose. we request that our distributors and own-
Fulton Boiler Works, Inc. will repair or Fulton Boiler Works, Inc. shall in no ers of our Fulton Boilers utilize the nearest
replace F.O.B. factory any other part of event be liable for an consequential offices of the individual manufacturers,
this equipment of our manufacture or incidental damages arising in any for the exchange, service, and/or repair
which within twelve months of the date way, including but not limited to any of these defective items. We will be glad
of shipment from factory is found to be loss of profits or loss of business, to furnish the address of the manufacturer’s
defective in workmanship or material, even if Fulton Boiler Works, Inc. has nearest office. If it is more convenient
provided the equipment has been been advised of the possibility of for our distributors or owners of our
installed, commissioned, operated and such damages. Fulton Boilers, the effective item may be
maintained by the buyer in accordance returned to our factory. The manufacturer’s
with the operating instruction manual B sole judgement shall determine the
provided with the equipment and general- extent of allowance for or replacement
ly accepted approved practices, and Controls, motors, feed water pumps, of such parts claimed defective.
on the provision that the buyer gives auxiliaries, accessories, and parts
proper notification in writing as soon as manufactured by others may be
the defect becomes apparent, and that warrantied by them, but Fulton Boiler C
he has properly filled out and returned Works, Inc. does not provide any Please do not request the replacement
his warranty card. This warranty does warranty for parts manufactured by of parts on a no-charge basis that are
not include labor charges of any kind. others. We endeavor to use nationally not within the warranty period. No person-
Follow maintenance instructions as known controls of the highest quality nel of Fulton Boiler Works, Inc. has the
listed in the “Instruction Book.” and most of the manufacturers of these authorization to grant such a request.
controls maintain exchange or repair
This warranty is exclusive and in lieu offices in the principal cities in the We will not honor labor charges of any
of all other warranties, express or United States and foreign countries, kind unless authorized in writing by our
implied, including but not limited to expressly for the exchange, service, company.

37-ES 4-00 Fulton Boiler Works, Inc.

Component Data Sheets

7
Fulton Boiler Works, Inc. 38-ES 4-00