Mini Compack IOM

Mini Compack IOM
Fulton Boiler Works (Great Britain) Ltd.
OPERATOR, SERVICE
& PARTS MANUAL
MINI-COMPACK
STEAM BOILER
MC 06 2006
For Your Safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
WARNINGS
Must be observed to prevent serious injury or
death to personnel.
CAUTIONS
Must be observed to prevent damage or
destruction of equipment or loss of operating
effectiveness.
NOTES
Must be observed for essential and effective
operating procedures, conditions and as a
statement to be highlighted.
It is the responsibility and duty of all personnel involved
in the operation and maintenance of this equipment to
fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.
WARNING
Steam Boilers are a potential hazard,
possibly fatal if not properly maintained.
CAUTION
It is vitally important that the instructions
given in this manual are strictly adhered
to. Failure to carry out the routine
maintenance checks could result in a
drastic reduction in the life expectancy
of the boiler.
MC 06 2006
LIST OF CONTENTS
TITLE
SECTION
INTRODUCTION
General
Technical Data
Special 6kW Model
1
1.1
1.2
1.2.1
INSTALLATION
General
Siting
Water Supply
Connections
Electrical Requirements
Steam Pressure Control
Commissioning
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
OPERATION
Starting the Boiler
Daily Blowdown
Control Panel Indicators and Switches
3
3.1
3.2
3.3
MAINTENANCE
Daily Maintenance
Weekly Maintenance
Three-Monthly Maintenance
Element Care and Protection
Fault Indication
Common Faults
4
4.1
4.2
4.3
4.4
4.5
4.6
GENERAL DATA
5
SPARE PARTS
6
MC 06 2006
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
It is the responsibility of the installer to ensure all parts
supplied with the boiler are fitted in a correct and safe
manner.
Only qualified persons should be allowed to
operate and maintain the boiler and its equipment.
Boilers should always be drained through an approved
Blowdown Vessel.
WARNING
Do not try to do repairs or any other maintenance
work you do not understand. Obtain a Service Manual
from Fulton or call a Fulton Service Engineer
WARNING
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection can cause injury and or damage.
WARNING
Non-approved modifications can cause injury and
damage. Contact your Fulton dealer before modifying
the boiler.
WARNING
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.
WARNING
A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing parts.
Make sure that all maintenance procedures are completed before using the boiler.
WARNING
The importance of correct boiler water and feed water
cannot be over emphasised, see the relevant section in
this manual.
WARNING
DANGER FROM HOT SURFACES
Steam Boilers have high temperature surfaces, that if
touched may cause serious burns. Only competant and
qualified personnel should work on or in the locality of a
steam boiler and ancillary equipment. Always ensure the
working area and floor are clear of potential hazards,
work slowly and methodically.
CAUTION
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is
normally only required by engineering surveyors /
inspectors.The material the boiler is manufactured from,
has not been impact tested, as it is not a requirement of
BS1894 (boiler construction standard). In order to
ensure the material / pressure vessel does not suffer
from brittle fracture, hydraulic testing should not be
carried out below 5 OC.
WARNING
Operating the boiler beyond its design limits can damage
the boiler, it can also be dangerous. Do not operate the
boiler outside its limits. Do not try to up grade the boiler
performance by unapproved modifications.
CAUTION
Low feed water temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary pre-heat the
feed water. If in doubt consult FBW.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners
and chemical treatment plants are NOT SUPPLIED by
Fulton.
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.
CAUTION
Obey all laws and local regulations which affect you and
your 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
(b)
Health and Safety Executive, local office.
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
(c)
Your Competent Person.
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
MC 06
052002
MC
2006
LIST OF ILLUSTRATIONS
TITLE
FIG
Mini Compack Boiler General Arrangement
Major Components
Boiler Connection Points
Recommended External Wiring
1
2
3
4
Steam Pressure Control
Commissioning the Boiler
Control Panel Indicator Lamps
Boiler Maintenance
Water Level Probe
5
6
7
8
9
Boiler Dimensions
Wiring Diagram - Standard
Wiring Diagram - for 6kW Special
10
11
12
MC 06 2006
1
1
Safety Valve
Steam Outlet
Feedwater
Tank
(optional)
Feedwater Pump
Boiler
Blowdown
Safety Valve
Steam Outlet
Pressure
Controller
Water Level
Probes
Pressure
Gauge
Operator
Control
Panel
Feed Water Tank
(optional - side or
rear mounted)
Electrical
Control
Panel
FIG. 1 MINI COMPACK BOILER GENERAL ARRANGEMENT
1
MC 06 2006
1
1
INTRODUCTION
SECTION 1
1.1
GENERAL (Fig. 1)
The Fulton Mini Compack Electric Steam Boiler is a compact and highly efficient unit designed
to meet the requirements of the lower demand steam user. Every care is taken to ensure that
quality and reliability standards are maintained. However, satisfactory performance can only be
ensured if the installation recommendations, operating routines and maintenance schedules
laid out in this manual are adhered to.
Particular attention should be paid to electrical installation and water treatment.
1.2
TECHNICAL DATA
BOILER MODEL
9kW
12kW
15kW
18kW
Amps/Phase 415V (3-ph)
13.35
17.5
21.7
25.85
Amps/Phase 380V (3-ph)
13.9
18.3
22.7
27.0
Number of elements
1
1
1
1
Output from & at 100O C - lb/h
30
40
50
60
Output from & at 100O C - kg/h
13.5
18
23.0
27.0
1.2.1 Special 6kW Model
6kW
(see fig. 11 special element wiring for 6kW boiler)
Amps/Phase 230V (1-ph)
29A
Number of elements
1 (see element wiring diagram, section 5)
Output F & A 100O C
9.6 kg/h
MC 06 2006
2
2
2
Feed Water Tank (Optional)
Boiler Blowdown Valve
Feed Water
Check Valve
Feed Water Tank
to Pump
Feed Water
Pump
FIG. 2 MAJOR COMPONENTS
3
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2
2
INSTALLATION
SECTION 2
2.1
GENERAL
The installation of the Fulton Mini Compack Electric Steam Boiler should be carried out by competent
personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to
ensure that these regulations are complied with.
WARNING
At all stages of operation the boiler will generate excessive heat 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.
2.2
SITING
The boiler should be sited in dry surroundings on a level base as close as possible to the steam using
machinery.
Take note of the dimensions given in Section 5 - General Data and ensure there is sufficient room at
the rear and to the right-hand side of the boiler to allow for the connection of all services. Also ensure
that there is room at the front of the boiler to enable the maintenance engineer to gain access to all
parts of the boiler.
2.3
WATER SUPPLY
Note: It is most important the values quoted in Section 5, Recommended Water Conditions, are strictly
observed.
The quality of the water used in the boiler will affect the life and performance of the boiler. It is strongly
recommended that a reputable water treatment concern is consulted prior to commissioning the boiler.
Note: 1.The boiler feedwater pump may contain an inhibitor and this should be flushed from the pump prior to fitting
the pump to the boiler. Failure to do so may result in water bounce or foaming due to the inhibitor forming a seal
in the boiler.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical
treatment plants are NOT SUPPLIED by Fulton.
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.
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4
2
2
D
C
E
B
A
FIG. 3 BOILER CONNECTION POINTS
Not Fulton Supply
MAINS SUPPLY
N L1 L2 L3
E
CONTACTOR
PUMP
MCB
ELEMENT
MCB
Fulton Control Panel
DOOR
MICROSWITCH
F00620
FIG. 4 RECOMMENDED EXTERNAL WIRING
5
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2
2.4
2
CONNECTIONS (Fig. 3)
All connections for services are mounted at the rear and on the right-hand side of the boiler.
Connections should be made as follows:
(a)
Overflow A from feedwater tank, DN25 (1in.BSP)
The overflow should be piped to a drainage point.
(b)
Cold water supply B connection, DN15 (1/2in.BSAP)
It is advisable to fit a stop valve as close as possible to this connection point.
(c)
Safety valve C, DN32 (1 1/4in.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
valve.
CAUTION
Unless otherwise specified, the steam safety valve supplied with the boiler is preset at 90 psi
(6.2 bar). 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.
(d)
Main steam valve D, DN15 (1/2in.BSP)
(e)
Boiler blowdown connection E, DN15 (1/2in.BSP)
The blowdown valve supplied with the boiler should be fitted as close as possible to the
boiler in a readily accessible position.
NOTE:
2.5
Local Water Authority bye-laws may require the fitting of a break (interpose)
tank between the mains water supply and the cold water inlet connection on the
boiler. Care should be taken to ensure that the blowdown receptacle used meets
the regulations covering these items.
ELECTRICAL REQUIREMENTS (Fig. 4)
A suitable 3-phase, neutral and earth isolated and fused supply is required external to the boiler.
It is essential that the electrical installation of the boiler is designed to protect both element
and pump circuits from excess current.
CAUTION
The boiler front access door is fitted with a safety microswitch. This switch automatically
isolates the boiler electrically when the front door is open, and must be connected to a
contactor fitted in the external mains supply distribution system.
A recommended layout for the external wiring is shown in Fig. 4.
Power requirements are shown in Section 1.2 Technical Data.
NOTE:- Any electrical work should be undertaken by a qualified installer, to current I.E.E. regulations.
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6
2
2
Main Scale
Differential Scale
FIG. 5 STEAM PRESSURE CONTROL
7
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2
2.6
2
STEAM PRESSURE CONTROL
1.
Remove the top cover and set the main scale pressure to the maximum pressure required.
2.
Set the differential scale to it's minimum pressure.
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8
2
2
E
F
K
VIEW ON REAR OF BOILER
F
G
A
L
H
G
K
B
C
J
FIG. 6 COMMISSIONING THE BOILER
9
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2
2
2.7
COMMISSIONING (Fig. 5)
2.7.1
General
These procedures must 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 carrying out the following tests.
2.7.2
2.7.3
Electrical
(1)
Remove the top panel A and open the front access door B.
(2)
Check that all electrical connections are tight.
(3)
Megger test the element C in accordance with the notes in Section 4.4 - Element Care and
Protection
(4)
Set the steam pressure control to 80psi maximum.
General
(1)
Open all valves in the water feed line E and pump supply line K, allow the water storage tank
F to fill.
Check for leaks.
(2)
Close the boiler blowdown valve G and the main steam valve H.
(3)
Close the front access door B and refit the top panel A.
(4)
Ensure that the boiler ON/OFF switch J mounted on the boiler control panel is switched to the
OFF position.
MC 06 2006
10
2
2
2.7.4
Boiler Start-up
WARNING
With the door open and the electrics overridden it is possible for the element to be LIVE.
Extreme caution must be observed when working under these conditions.
(1)
Switch on the electrical supply at the isolator.
The yellow POWER ON lamp should illuminate.
WARNING
The Power On indicator is derived from one phase. It is possible for the Power On indicator
supply phase to be down, leaving the other two phases live. Always isolate the supply before
working on the panel.
(2)
Open the main steam valve.
(3)
Depress the boiler ON/OFF switch to the ON position. The red LOW WATER alarm lamp should
illuminate (If it does not do so, refer to Section 4.5 - Fault Indication) and the feedwater pump
should start and an alarm should sound.
(4)
Check for correct rotation of the feedwater pump.
CAUTION
The pump impellor blades can be damaged by incorrect rotation. If the rotation is incorrect,
turn the On/Off 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.
The feedwater pump should run until the correct water level is attained.
When the water level is restored to normal working level (NWL) the low water light will extinguish.
(5)
Switch the element switch to the On position, the element energised indicator should illuminate.
(7)
Close the main steam valve.
(6)
Allow steam pressure to build up, check the reading on the steam pressure gauge L, until it
reaches the cut-off point as set on the STEAM PRESSURE control.
Readjust this control as necessary.
(7)
Depress the boiler ON/OFF switch to the OFF position and isolate the boiler at the main isolator.
Open the front door and remove the top cover A to check for steam or water leakage.
(8)
Close the front door and slowly open the steam valve to release the pressure in the boiler. Check
for steam leaks in all new pipework.
(9)
Replace the top cover A. Turn on the power at the main isolator and depress the boiler
ON/OFF switch to the ON position.
The boiler is now ready for placing into full operation.
11
MC 06 2006
3
3
OPERATION
SECTION 3
CAUTION
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 Boiler Works (Great
Britain) Ltd. if these instructions are ignored.
3.1
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 feedwater line.
(3)
Switch the isolator switch to the ON position.
(4)
Press the boiler ON/OFF switch to the ON position.
(a)
If the water is below the pump 'on' position, the pump will start. If the water is below the
pump 'on' and 'low water' positions, the pump will start and the alarm will sound. The
pump will restore the water level to the 'normal' position, the alarm will cancel, the LOW
WATER LEVEL lamp will extinguish and the ELEMENT ENERGISED lamp will
illuminate.
(b)
If the LOW WATER LEVEL lamp does not illuminate, the low water control should be
checked by opening the blowdown valve and allowing the water level to drop to the 'low
water' position.
If the boiler has not been used for some time it is possible that the boiler will be
either air-locked or under vacuum, it may be necessary to allow air into the boiler to
allow the water to drain. To do this, lift the safety valve lever.
(c)
When the LOW WATER LEVEL lamp is illuminated, the ELEMENT ENERGISED lamp
should extinguish. The boiler is now fully operational and will be controlled automatically
as follows:
The steam pressure control will control the on/off cycle of the element once the boiler is operating.
The low water relays automatically maintain the level of water in the boiler and will immediately
shut-off the power to the element should the water level fall to an unsafe level.
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12
3
3
3.2
DAILY BLOWDOWN
The following procedures should be carried out a minimum of once a day.
They are designed to prevent the build-up of scale, silt or sludge in the bottom of the boiler and
on the element.
More frequent blowdown may be required, the advice of the water treatment supplier should be
sought and followed.
A safe blowdown receptacle must be provided.
(1)
Carry out the procedures described in Section 3.1 - Starting the Boiler.
(2)
Allow the steam pressure to rise to approximately 10 psi.
(3)
Open the boiler blowdown valve for approximately 5 seconds.
Close the boiler blowdown valve.
(4)
Press the boiler ON/OFF switch to the ON position.
The boiler is now ready for service.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and
chemical treatment plants are NOT SUPPLIED by Fulton.
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.
3.3
CONTROL PANEL INDICATORS and SWITCHES
The control panel contains indicator lamps
to assist with the starting and testing
procedures described above.
A full description of the meaning of the fault
indicators is contained in Section 4 - Maintenance.
FIG. 7 CONTROL PANEL INDICATORS and SWITCHES
13
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4
4
MAINTENANCE
SECTION 4
CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out
the daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy
of the boiler.
WARNING
The electrical supply to the boiler must be isolated prior to the commencement of any work requiring
the opening of the access door or top panel.
4.1
4.2
4.3
DAILY MAINTENANCE
(1)
Check that the water level controls are working (see Section 3.1 - Starting the Boiler).
(2)
Blow down the boiler (see Section 3.2 - Daily Blowdown).
WEEKLY MAINTENANCE
(1)
Externally mounted storage tanks should be checked to ensure they are clean and not
obstructed.
(2)
Open the front door and check the controls for signs of leakage from the steam fittings and
the element.
(3)
Check the contactors by sliding up the contactors front cover and manually depressing the
contactor, ensuring they are free and operating correctly.
(4)
Check all fittings for signs of leakage.
THREE-MONTHLY MAINTENANCE
(1)
Close the water supply valve between the tank and boiler. Isolate and completely drain the boiler
by opening the boiler blowdown valve and allowing the boiler to drain through the blowdown
receptacle.
(2)
Remove the element and check for excessive scale build up or corrosion; clean as required.
Prior to refitting the element, examine the interior of the boiler for deposits of scale and sludge.
Clean the boiler as necessary then replace the element with a new gasket (see Section 4.4
- Element Care and Protection).
(3)
Check all electrical connections for tightness.
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14
4
4
Water Level Probe
Element and Pump
Contactors
Blowdown
Valve
Feed Water Valve
Heating Element
FIG.8 BOILER MAINTENANCE
15
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4
4.4
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 contained in Section 2.3 - Water Supply.
The dangers of scale to the life of the element cannot be overstressed. Scale possesses excellent
insulating 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 megohm), heating in an
oven at 300oC for three hours should restore the element.
4.5
FAULT INDICATION
The control panel contains a range of indicator lamps to assist with starting, testing and operating
procedures. These lamps have the following meaning.
(a)
POWER ON
Indicates that power is being supplied to the boiler control circuit and that the
control panel is live. This lamp should be illuminated immediately the boiler
isolator (not Fulton supply) is selected and should remain on until the isolator
is switched off.
CAUTION
It is essential that the electrical installation
(installation is the responsibility of the
installer) of the boiler is designed to protect
both the elements and the pump circuits
from excess current.
4.6
(b)
LOW WATER
Indicates that a low water condition exists in the boiler and that the heating
element(s) have been switched off. Operates in conjunction with an audible
alarm. The boiler will restart and the alarm cancel when the feed water pump
has restored the water level.
(c)
BOILER ON
The switch is illuminated when in the ON position and indicates that the boiler
is in a fully operational state. The switch should remain illuminated until
switched to the OFF position.
(d)
ELEMENT
ENERGISED
The lamp is illuminated when in the ON position and the element is
energised. The switch is extinguished when the element is de-energised
during the normal on/off cycle of operation, or low water condition.
COMMON FAULTS
POWER ON
indicator not
illuminated
(a)
Mains supply failure.
Door microswitch not made.
(b)
External circuit MCB requires resetting.
Fuses need replacing.
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16
4
4.6
4
COMMON FAULTS continued.
LOW WATER
lamp illuminated.
Audible alarm sounds.
Pump Off
(Black)
Insufficient water in the boiler.
(a)
No water in the feedwater tank.
Check that the feedwater supply line valves are open. Check that
the ball valve in the tank is operating correctly by removing the
inspection cover on the tank.
(b)
Obstruction in the feedwater line to the pump.
Check that the shut-off valve below the tank is open.
Remove and clean the filter in the strainer.
Check that the non-return valve is operating correctly.
(c)
Air lock in the pump.
Bleed the pump at the point provided.
(d)
Feedwater pump impellor worn.
(e)
Incorrect connections to water level probes.
(f)
Faulty water level relay.
Check that each relay is pressed firmly home on its base.
Pump On
(Yellow)
FIG. 9 WATER LEVEL PROBES
17
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Low Water
(Red)
5
5
GENERAL DATA
SECTION 5
A
F
H
G
O
I
E
BOILER POWER
OFF ON
L
ON
ELEMENT
ENERGISED
LOW
WATER
MINI
COMPACK
M
K
B
J
D
C
FIG. 10 BOILER DIMENSIONS
A
B
C
D
E
F
G
H
J
K
L
M
(dimensions in mm)
DIMENSIONS
CP9
CP12
CP15
CP18
Total Height
Total Width (with pump)
Total Depth (with tank)
Total Depth (without tank)
Steam Valve (outlet)
Safety Valve (oulet)
Electrical Supply (inlet)
Water Supply (inlet)
Blowdown (outlet)
Tank Drain (outlet)
Tank Overflow (outlet)
Pump Feed (inlet)
640
610
910
770
455
530
450
465
25
90
410
160
640
610
910
770
455
530
450
465
25
90
410
160
640
610
910
770
455
530
450
465
25
90
410
160
640
610
910
770
455
530
450
465
25
90
410
160
13.5
9
13.4
13.9
18
12
17.5
18.3
23
15
21.7
22.7
27
17.5
25.9
27
Pipe Size
DN15 (1/2in.BSP)
DN20 (3/4in.BSP)
DN15 (1/2in.BSP)
DN15 (1/2in.BSP)
DN15 (1/2in.BSP)
DN25 (1in.BSP)
-
SPECIFICATION
Output kg/h (F&A 100OC)
Output kW
Amps/ph (415V)
Amps/ph (380V)
Electrical supply: 380/415V, 3ph, 50Hz, 4 wire supply required,
isolator, mains contactor and fusing not included.
Note: Not suitable for condensate return - cold water make-up only.
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18
5
5
FIG. 11 WIRING DIAGRAM
19
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DOOR
SWITCH
ELEMENT
E
E
L
N
EC
PUMP
L
N
SUPPLY CABLES BY OTHERS
FROM A SUITABLY FUSED
SUPPLY
OVERLOAD
PC
6.A MCB
DOOR
SWITCH
POWER
ON
BOILER
ON/OFF
A2
PL1
MC 06 2006
PUMP ON
PUMP OFF
2
OVERLOAD
PC
A1
3
4
1
5
6
PL1
1
~~ ~
~
~ ~
8
PL1
7
8
LW1
7
A2
EC
A1
6
5
1st LOW WATER
2
ELEMENT
ON/OFF
PRESSURE
SWITCH
LW1
3
4
EC06 0010
LOW
WATER
LW1
AUDIBLE
ALARM
5
5
FIG. 12 WIRING DIAGRAM FOR 6kW SPECIAL BOILER
20
5
5
IMPORTANT
Recommended Water Conditions
It is very important that a strict water management program is followed
to ensure trouble free boiler operation.
The following are recommended for feedwater and boiler water.
FEEDWATER (water entering boiler)
pH Value
Hardness
Suspended Solids
Chloride
Organic Matter
Oil
3.5 to 9.5 tested at room temperature,
less than 2.0mg/kg in the form of CACO3,
None
less than 50mg/kg
less than 5mg/kg
None
BOILER WATER (water inside boiler)
pH Value
Hardness
Suspended Solids
Chloride
Oxygen Scavenger,
Sodium Sulphite or Tannin
Phosphate
Total Alkalinity
Caustic Alkalinity
Total Dissolved Solids (TDS)
Iron
Silica
Dissolved Oxygen
9.5 - 11.5, tested at room temperature
Not detectable
Less than 100mg/kg
Less than 500mg/kg
20 to 50mg/kg
Less than 50mg/kg, in the form of PO4
Less than 1000mg/kg
Less than 300mg/kg as CACO3
Less than 2000ppm
Less than 1mg/kg
Less than 150mg/kg, in the form of SiO2
None
mg/kg
CACO3
PO4
SiO2
1 Grain hardness
therefore 70ppm
For practical purposes mg/kg
=
=
=
=
=
=
=
Milligrams per Kilogram
Calcium Carbonate
Phosphate
Silica
17.118ppm
4.10 grains hardness.
ppm
It is critical that the boiler water pH be alkaline (9.5 - 11.5) whenever water is in the boiler.
Daily boiler blowdown is essential to help prevent formation of deposits and reduce
Total Dissolved Solids (TDS).
Refer to the Maintenance Manual for blowdown procedures.
Consult your Water Treatment specialist to establish the frequency and duration
of blowdown required to achieve the required water conditions.
MC 06 2006
6
6
SPARE PARTS
SECTION 6
WARNING
The use of incorrect parts could be a risk to safety
and seriously damage your boiler.
Replacement Safety Valves
To comply fully with safety regulations it is essential that the correct safety
valves are used. If in any doubt contact Fulton Boiler Works (Great Britain) Ltd.
Sales and Service Department for assistance.
When ordering replacement or spare parts ensure you provide
all the details given in the parts lists together
with the following:
Boiler number :
Boiler type :
Wiring Diagram No.:
Commissioning Date:
WARNING
The type, size and lift pressure safety valve fitted to a boiler is specific to that boiler. When ordering
spare safety valves it is important that, as well as the information requested above, the following
additional information is given:
Boiler design pressure (given on the boiler data plate)
Make and type (eg fig. no.) of safety valve fitted
MC 06 2006
21
6
6
MINI-COMPACK BOILER AND FITTINGS
Item Part Number
1
2
3
4
5
6
7
8
9
10
11
12
10016
10351
10570
11639
11760
11823
11824
11825
12215
12217
10418
14339
Description
Remarks
Gasket, element
Element
Gauge, pressure
Valve, ball
Pump, water
Valve, check
Gasket
Flange
Facia
Hose, pump inlet
Probe, water level
Valve, safety
3mm thick
wired as 6kW
2 1/2in. 0 - 300psi
1/2in.
TP78E
DN15
15mm PN16
1/2in. PN16 screwed
mini compack
1/2in. x 16in.
supplied at 17in. cut to required size
FG500, DN15, 6.2 bar
MC 06 2006
6
6
MINI-COMPACK CONTROL BOX AND PANEL
Item Part Number
1
2
3
4
5
6
7
8
9
10
11
11850
11869
11904
11947
12759
13381
13448
14215
14330
14335
14368
Description
Remarks
Contactor
Relay
Base, LC relay
Microswitch, miniture
Contactor
Alarm, audible
relay, thermal over/load
Control, pressure
Holder, fuse
Cover, pressure control top
Fuse
MC 06 2006
LC1-D09U7 240V
LC3 LED 240V
LC1-D25U7 240V
pulsating
LRD-06
4 - 12 bar
1 amp cartridge
Material & Workmanship Warranty
5 Year
Warranty
On the Fulton Boiler Pressure Vessel
Fulton Boiler Works (Great Britain) Ltd. will repair or replace FoB 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 dir t accumulation or to low water conditions. This Warranty
is good only in the United Kingdom of Great Britain and Northern Ireland. This Warranty does not include
labour or delivery charges of any kind.
Fulton Boiler Works, (Great Britain) Ltd.
General Warranty
The Fulton general Guarantee is given in lieu
of
and in exclusion of any warranty expressed or
implied, statutory or otherwise, as to the state,
condition, performance, quality or fitness of the
goods. Save thereunder we shall be under no
obligation or liability of any kind to you in regard
to the goods. In the case of new goods
manufactured and supplied by us we will make
good any defect developing therein under
proper use within 12 months of delivery,
provided that after investigation in our sole
discretion we are satisfied that the defect arose
from faulty design, materials or workmanship
and from no other cause whatsoever.
Defective goods or parts must be returned to
us as soon as possible after discovery of the
defect, Costs of carriage and of detaching and
incorporating parts will be borne by you. ln 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 electric motors or any goods or
accessories not of our manufacture. But so far
as we are able, we shall let you have the benefit
of any guarantee or warranty given to us in
respect thereof.
Fulton Boiler Works (Great Britain) Ltd.
Broomhill Road
Bristol BS4 4TU
England
Telephone 0117 972 3322
Fax: 0117 972 3358
'e'-mail: uk-info@fulton.com
web site: www.fulton.com
FM 28400
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