Home

VMP Gas IOM

1. DI se Lei 13 VMP IOM Specifications Models VMP 130 150 Unit Horsepower 130 150 Boiler Connections Steam Outlet 15 PSI 150 Flanged IN 6 6 MM 152 152 Steam Outlet 150 PSI IN NPT 6 6 150 Flanged MM 152 152 Feedwater Inlet IN NPT 1 25 1 25 MM 32 32 Blowdown Outlet IN NPT 2 2 MM 51 51 Water Column Blowdown IN NPT 1 1 MM 25 25 Surface Blowdown IN NPT 15 15 MM 19 19 Safety Valve 150 PSI Inlet INNPT 1 5 1 5 MM 38 38 Safety Valve 150 PSIOutlet IN NPT 2 2 MM 51 51 Safety Valve 15 PSI Inlet 2 IN NPT 2 2 MM 51 51 Safety Valve 15 PSI Outlet 2 IN NPT 2 2 MM 51 51 Natural Gas Connection IN 2 5 2 5 MM 63 63 Burner Motor HP 10 10 KW TA TA Approximate Weights Shipping Weights approx LB 12800 12800 KG 5806 5806 Operating Weight approx LB 20585 20585 KG 9337 9337 Ratings Sea Level to 3000 FT 914 M Output 1000 BTU HR 4353 5022 1000 KCAL HR 1097 1266 Steam Output LBS HR 4485 5175 KG HR 2035 2348 Water Content GAL 810 810 LITERS 3066 3066 Approximate Fuel Consumption at Rated Capacity Natural Gas
2. 2 40 420 Fulton Pump Relay 120V 0 5 0 23 2 40 421 Fulton Burner Relay 120V 0 5 0 23 2 40 422 Base for Fulton Pump Relay 0 25 0 11 2 40 423 Base for Fulton Burner Relay 0 25 0 11 2 12 090 Spring Retainer for burner pump relay 0 001 0 2 40 131 General Purpose Relay Ice Cube AB 0 8 0 36 2 40 096 Base for Ice Cube Relay 0 1 0 05 2 45 091 On Off Switch 0 05 0 02 2 45 092 Manual Reset Switch 0 05 0 02 2 45 090 Night Switch for two 2 Pressuretrols 0 05 0 02 2 40 552 4 Alarm Bell 1 0 45 2 40 551 120V Transformer for Bell 1 0 45 2 45 412 AB Green Panel Light 120 V NEMA4 0 02 0 01 2 45 413 AB Amber Panel Light 120 V NEMA 4 0 02 0 01 2 45 4111 AB Red Panel Light 120 V NEMA 4 0 02 0 01 2 45 410 AB White Panel Light 120 V NEMA 4 0 02 0 01 2 40 567 Motor Contactor AB 100 3RT1015 1AK6 0 8 0 36 2 40 642 3 Phase Motor Contactor 3RT1017 1AK6 0 8 0 36 2 40 648 Overload AB BSB 16 3RB1015 2PBO 0 45 0 2 Overload AB BSB 15 0 45 0 2 Overload AB BSB 30 0 45 0 2 Overload AB BSC 10 0 45 0 2 Overload AB BSC 15 0 45 0 2 Overload AB BSC 24 0 45 0 2 Overload AB BSB 42 0 45 0 2 2 40 573 Overload 60 3RB1015 2SBO 0 45 0 2 Overload AB BSB 80 0 45 0 2 2 40 566 Overload 3RB1015 2NBO 0 45 0 2 2 40 651 Overload 3RB1025 20BO 4 40 050 Night Heating Pressuretrol Set Up 3 5 1 59 2 40 227 Pressuretrol L404A 2 15 PSI 1 7 0 77 2 40 228 Pressuretr
3. 3 Support ASN Necessary N Must Not Exceed 70 Of Total Rise _ Drail Reguiator Be i If Necessary I 60 45 Mi e Horizontal 45 Mg y Cleanoul Door Conventional Venting The stack should rise continuously to the connection with the chimney and should contain no more than two bends at 45 angles or less If required as the result of space limitations one 90 elbow can be fitted at the back of the boiler There should be two feet of straight horizontal flue before any bends or turns Any alternative stack arrangement must supply a negative 02 04 W C pressure 0 508 to 1 016 mm with the burner off The run in the total distance of stack ducting as measured in a straight line from the outlet of the boiler to the outlet of the stack should not exceed 70 of the rise With the exception of a duct run described in Item a horizontal sections of ducting must be avoided and should not exceed four feet of total run The stack and chimney must be constructed from material that is rated for 1000 F operating temperature Check all local codes for exact requirements This Distance ei __ Draft Regulalos ___ Installation Minimum 6 Above Any Structure Wathin 30 i Roof 7 i _ Expansion Joints As Required Stagger lt Entrances If Necessary Horizontal Run 2 Adequate provision must be made for the support of the weight of the chimney
4. Aquesial 14 VMP IOM The Gas Supply a Gas Piping should be installed in accordance with National Fuel Gas Code ANSI Z223 1 1984 or latest addenda and any other local codes which may apply In Canada gas installations must be in accordance with the current CAN CGA B149 1 and 2 and or local codes Install a dirt trap ahead of all of the gas valves The pipe and the fittings used must be new and free of dirt or other deposits The piping must be of the proper size to ensure adequate gas supply to the gas head assembly Consult your gas company for specific recommendations 7 11 wc gas pressure is required during run for 40 60 HP boilers with standard burners 9 11 wc gas pressure is required during run for 80 100 HP boilers with standard CSD 1 burners 11 13 wc gas pressure is required for 80 100 HP IRI boilers 40 W C is required for 130 150 HP For propane or butane gas see e above Propane not available for LONOx boilers g When making gas piping joints use a sealing compound resistant to the action of liquefied petroleum gases Do not use teflon tape on gas line threads h The main and the pilot gas pressure regulators must be vented to the atmosphere i After gas piping is completed carefully check all piping connections factory and field for gas leaks Use a soap and water solution CAUTION Some soaps used for leak testing are corrosive to certain types
5. 1 Modulation is available as an option on Fulton gas fired steam boilers for 40 150 HP units 2 Boilers equipped with modulation will have the linkage rod disconnected between the modulation motor and the gas butterfly valve for shipment NOTE If Seiman linkageless modulation is ordered no mechanical linkage rod is required thus none provided 3 Mount the gas train on the pipe nipple of the bumer plate with the gas train inlet directly facing over the panel box Reconnect the linkage from the butterfly valve to the modulation motor 4 The end of the linkage arm that attaches to the butterfly valve will have a notch on both sides of it where the swivel collar should be centered This setting was based on factory test fire conditions 5 Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics 6 The modulating burner will have a modulation lock switch to enable you to lock the firing sequence anywhere along the firing rate from low to high 7 Depending on the combustion characteristics it may be necessary to adjust both linkage arms To adjust the linkages unscrew the swivel collar and move the linkage rod in the appropriate direction 8 Standard modulating burners will have a proportioning pressure control in addition to the standard operating pressure control that will send a 0 135 ohm signal to the modulation motor to adjust the firing rate
6. 5 Clean water traps and strainers in fuel lines 6 Check operation of all steam traps on condensate return system 7 Remove brass pipe plug at the cross connection below water column and clean nipple into boiler Boiler must be cold and water level below pipe Recommended Semi Annual Maintenance Schedule 1 Cleaning the gas bumer assembly a Disconnect the gas head from the burner by disconnecting the union Remove the burner plate screws Withdraw the bumer assembly and clean the flame rod and ignition electrode b Check that the settings of the flame rod if applicable and ignition electrode correspond to those in the illustration below c Reassemble the burner assembly and check the flame rod setting or scanner setting d Check the combustion efficiency of the burner and adjust if necessary e Clean probe on top of boiler shell and probes in water column There must be no pressure on the boiler during the removal of the probes f Check refractories for soot or breakage and inspect the stainless steel ring 50 100 HP only g With the boiler under no more than 15 PSI pressure check that the steam safety valve is operating by lifting the lever 2 Drain condensate tank and clean tank by flushing with hose Check float valve operation 3 Check electrical controls and motors for correct operation 4 Check water pump for correct operation 5 Shut off the boiler completely and dra
7. 7 Boiler size Boiler may be undersized Boiler is Surging 1 Steam traps blowing through Check traps to see if they are clean or replace as necessary 2 High organic in boiler Drain and clean boiler with washing soda per instruction manual i e Perc or oil 3 High boiler TDS Drain boiler and flush system Refill and increase blow down rate frequency 4 Too much water akalinity Have water tested by water treatment company lower boiler alkalinity high PH to recommended level 5 High sudden steam load Check total equipment horsepower required against horsepower of boiler being used Decrease amount of equipment being used at one time or reduce the steam flow by partially closing the steam stop valve 6 High level of water Consult water treatment expert and adjust levels to boiler treatment chemicals recommended levels Boiler Rumbles and 1 Draft problem Check draft with a gauge Draft should be a 02 to 04 W C with Pulsates burner off or 04 to 06 when operating May need to install a barometric damper Boiler pushing water with the steam carryover Pump will not cut off Pump runs but does not put water into boiler 1 Steam Traps Check traps Clean or replace as necessary 2 High boiler TDS Drain boiler and flush system Refill and increase blow down rate frequency 3 High level of water Consult water treatment expert and adjust to boiler treatment chemicals recommended levels
8. The following lists cover the most common troubles that may occur on the Fulton gas fired boilers Refer to left hand column of the chart to locate the problem Determine which cause listed in the center column that represents the problem by performing the corrective action as listed in the right hand column titled REMEDY Maintenance Troubleshooting Gas Fired Boilers PROBLEM CAUSE REMEDY Ignition Failure 1 Power Supply Check fuse or circuit breaker Reset or replace as necessary 2 Ignition Electrodes 3 Transformer Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain If found replace Check voltage between transformer leads at terminal block to be sure transformer is being powered 4 Flame Safeguard Control Check voltage between ignition terminal and neutral Check must be made before control locks out on safety If no power replace control 5 Faulty Air Switch Check for bad air switch by jumpering the two air switch leads at the terminal block If the boiler starts and runs with these terminals jumpered the air switch should be replaced 6 Gas Valve Sticking Pilot Check for dirt in valve or orifice and clean if necessary Check for faulty actuator or valve and replace if necessary 7 Gas Supply Check for gas pressure and for intermittent supply problems Gas press
9. Power Supply Check fuse or circuit breaker Reset or replace as necessary 2 Gas Supply Check for gas pressure and for intermittent supply problems 3 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Primary Air Adjustment Check air adjustment Air may be blowing flame away from bumer head 5 Scanner Check for dirt on flame scanner and clean Check for proper location of detector 6 Flame Safeguard Control Check voltage at terminal leading to main gas valve If no power replace the control 7 Loose wire at fuel valve circuit Tighten wiring connections 8 Contact open on air safety switch Adjust to proper setting 9 Scanner wiring reversed Change to correct terminals at panel box Burner Cut Off 1 Power Supply Check fuse or circuit reset or replace as necessary 2 Gas Supply Check to be sure main gas cock is not closed Check coil in gas valve with OHM meter Replace if faulty Check gas regulator setting and readjust as necessary Check inlet gas pressure and increase or decrease as necessary 3 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Scanner Check for dirt on flame scanner and clean Check for proper location of d
10. add a small amount of water to the siphon to create a water seal to buffer the gauge element This must be done to prevent inaccurate pressure readings and or premature failure of the gauge Install the steam gauge into the siphon on the water column Installation Blow Down Valve There are four blow down valves on the boiler Two main bottom blow down valves the gauge glass blow down valve and the water column blow down valve All blow down connections must be piped to blow down seperator Feed Water Piping 1 Provisions must be made for adequate water supply and properly sized piping Piping must be done in compliance with all local codes The following chart may be used as a guideline for sizing BHP Minimum Water Supply Piping Size IN MM 40 1 25 50 1 25 60 1 25 80 1 25 100 1 25 31 7 130 1 25 31 7 150 1 25 31 7 When feeding the boiler using a return system the city water pressure should not exceed 40 PSI A pressure reducing valve should be installed a head of the return tank when above this pressure It is important that all piping be lined up and not forced into place It is recommended that you begin piping at the pump If the lines are ended at the pump particularly if the last piece is cut too short or long the pump will be forced to meet the pipe and strain or distortion will result Do not use the pump as a piping support It is critical that the pipe be indepen
11. center or outer fire chamber By moving the damper closed the air is forced to the outside of the fire chamber with less air going down the blast tube area By 28 VMP IOM Primary Air Adjustment is located at the fan housing face pulling the damper open more air is forced down the blast tube and less on the outside wall of the deflector face and fire chamber Itis important in the combustion process to maintain proper air mixtures between the outer surface and center of the blast tube area On most boilers the damper is locked in a wide open position However if it is necessary to close the damper care should be taken to close the damper slowly and no more than 1 4 of the distance of the swing of the damper assembly A visual examination down the blast tube should reveal that no heat flames or fumes are backing up through the burner plate area If they are the secondary damper must be opened up once again Failure to remove the flame or gases from the blast tube area can cause a backfire as well as cause premature failure of electrodes flame rods and other burner components A visual inspection down the burner view port should also show the fire completely covering the furnace walls If the fire is tunneling down or is not to the outside wall of the furnace the efficiency will drop off Close the secondary air damper until tunneling stops Burner Viewing Port Blast Tube Viewing Port Ope
12. condenses because the flue temperature is above the dew point of the combustion gas The combustion gas then dries out dehydrates the hydrochloric acid solution leaving behind dry chloride salt Gas Train Available with Optional High Low Off or Modulation Gas Regulator Modulation Motor Scroll Ignition Transformer _ Blower Air Gate Control circuit transformer Electric Control Panel VMP IOM Gas Valve When the next cold start up occurs the process repeats except that more and more chloride collects and concentrates along the flue As the quantity of chloride increases it does not dehydrate completely as the flue heats up and a corrosive poultice develops which attacks the steel and will also attack the boiler Concentration levels of ony a few ppm of chlorine containing compounds in combustion air can produce serious corrosion over long periods of time High chlorine containing compounds such as carbon tetrachloride or perchloroethylene would be prime suspects In addition normal combustion creates carbon dioxide which may condense in a cold flue to form carbonic acid Ignition Pressure Switch Electrode ES UV Scanner Lifting Lug Installation Check Points 1 Make sure all piping connections are complete and tight 2 Make sure the pressure controls are adjusted properly 3 Make sure all electrical connections in the control panel
13. replace 3 Transformer Check voltage between transformer leads at terminal block to be sure transformer is being powered 4 Flame Safeguard Control Check voltage between ignition terminal and neutral Check must be made before control locks out on safety If no power replace control 5 Faulty Air Switch Check for bad air switch by jum pering the two air switch leads at the terminal block If the boiler starts and runs with these terminals jumpered the air switch should be replaced 6 Gas Valve Sticking Pilot Check for dirt in valve or orifice and clean if necessary Check for faulty actuator or valve and replace if necessary 7 Gas Supply Check for gas pressure and for intermittent supply problems See test fire sheet for last elbow 8 Loose wire connection Check connections to all components Main Flame Fails 1 Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report Adjust gas servo setting 2 Air Servo Motor not set properly Verify the over burner pressure matches the start up report Adjust the air servo motor Boiler Fails while 1 Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report Modulating adjust gas servo setting 2 Air Servo Motor not set properly Verify the over burner pressure matches the start up report Adjust air servo setting VMP IOM Maintenance PROBLEM CAUSE REMEDY Flame Failure 1
14. water gauge In addition to these procedures the advice of a water treatment supplier should be sought and followed An ASME Section VIII blow down receptacle must be provided for the appropriate pressure 1 Blow down the boiler each morning by starting the boiler and generating not more than 10 PSI 703 kg cm2 of steam Turn on tap water to blow down separator then open the boiler blow down valves for approximately 10 seconds then close the valve Shut off tap water to blow down separator Blow Down Boiler Daily Shown is the blow down Y valve NOTE If the boiler is being operated automatically on a time clock the blow down operation may be done once during the working day and once at the end of the day when at 10 PSIG or less 2 Blow down water column each moming when boiler is at 10 PSI 703 kg cm by opening the water column and the water gauge blow down valves for approximately 5 seconds then close the valves 3 If the feed water is being treated by compounds make sure that this treatment is carried out carefully and according to the manufacturer s instructions NOTE Fulton recommends that the feedwater treatment should be added between the pump and the boiler 4 When first starting the boiler each day make sure ignition and burner are working properly 5 Check water level in sight glass 6 Check to be sure feed water pump is working 7 For float type water level control blow
15. 1 Dirty Probes Clean or replace as necessary 2 Relay failed Make sure relay is plugged in tightly If so replace water level relay 3 Ground Connection Check for tightness and clean 4 Probes not sensitive enough Replace probes and relays with extra sensitive ones RO DI Water Vapor locking of pump Allow system to cool down check steam traps and check temp If it is to be sure retum lines are not insulated Check return tank above 180 F 82 C vapor locking of pump may occur Inspect check valves Clean and replace as needed Replace pump with multistage centrifugal good for 250 F 121 C 2 Impeller Adjustment Check for impeller wear and adjust per component information in instruction manual Burks only 3 Pump suction plugged Remove clean inlet strainer 4 Plugged feed water nipple Check and clean or replace as necessary 5 Pump undersized wom Replace with appropriate pump Water pump will not 1 Scale on probes Check and clean or replace as necessary come on at times 2 Bad Pump Contactor Check to see if contactor is being powered Check to see if contactor coil is pulling in Replace if necessary 3 Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power If power is present but motor does not run replace it Low Fuel pressure 1 Gas pressure regulator Check and replace Boiler Flooding 1 Pump does not shut off Dirty probes Clean or replace as necessa
16. 18 2 30 118 Air Switch 80 100 HP 0 72 0 33 5 20 018 Burner Plate Gas 30 60 HP 1 0 45 5 10 398 Burner Plate Gas 80 HP 1 0 45 5 10 399 Burner Plate Gas 100 HP 1 0 45 7 20 094 Air Deflector Gas 80 amp 100 HP 65 29 55 7 20 092 Air Deflector Gas 40 60 HP 45 20 45 2 40 533 Gas Pressure Switch High Low 3 25 1 48 2 30 298 1 2 Pilot Gas Valve 80 100 HP 1 5 0 68 2 30 312 1 1 2 Gas Valve V5055A 40 60 HP 10 7 4 86 2 30 313 2 Gas Valve V5055A 80 100 HP 9 85 4 48 2 30 3003 Modulating Butterfly Valve 40 60 HP 2 30 3020 Modulating Butterfly Valve 80 100 HP 2 30 303 1 1 2 Main Gas Valve V48A 4 5 2 05 2 40 253 Gas Valve Body P O C V5055C 40 60 HP 11 5 5 23 2 40 254 Gas Valve Body P O C V5055C 80 100 HP 10 5 4 77 2 40 High Low Off Gas Valve Body 80 HP 2 40 Hlgh Low Off Gas Valve Body 100 HP 2 40 214 Actuator Valve Body 13 70 6 23 2 40 220 Actuator Valve Body w Proof of Closure Switch 12 8 5 82 2 30 583 High Low Off Gas Valve Actuator 80 and 100 HP 2 30 402 1 1 4 Vent Valve 120V Normally Open 4 7 2 14 2 30 401 1 Vent Valve 120V Normally Open 4 3 1 95 2 30 198 1 8 Gas Cock Pet Cock 0 25 0 11 2 30 111 1 2 Pilot Gas Cock 0 6 0 27 2 30 115 1 1 2 Main Gas Cock 48 2 18 2 30 110 2 Main Gas Cock 16 8 7 64 2 30 102 1 2 Gas Pressure Regulator RV 48 0 7 0 32 2 30 107 1 1 2 Gas Pressure Regulator RV 81 4 8 2 18 2 30 108 2 Gas Pressure Regulator RV 91 8 5 3 86 7 20 298 Natural Gas Orifice 40 HP 4 1 81 7 20 299 N
17. 422 506 675 843 1097 1266 Steam Output LBS HR 1380 1708 1725 2070 2760 3450 4485 5175 KG HR 626 775 783 939 1252 1565 2035 2348 Water Content GAL 172 274 242 270 383 518 810 810 LITERS 651 1038 916 1022 1450 1960 3066 3066 Approximate Fuel Consumption at Rated Capacity Natural Gas FT 7 HR 1595 1972 1992 2392 3188 3985 5200 5978 M HR 45 56 56 68 90 113 147 169 LP Gas FT HR 638 788 797 957 1275 1594 2080 2391 M HR 18 22 23 27 36 45 59 68 Light Oil GPH 11 0 13 9 14 0 17 0 22 8 28 0 37 0 42 0 LPH 41 6 52 6 53 64 3 87 106 140 159 Gas Pressure Required Standard Burners Min IN W C 7 7 7 7 9 9 40 40 Gas Pressure Required Standard Gas Train Max IN W C 13 13 13 13 27 27 5 psig 5 psig Electrical Requirements Amps for Burner Motors 208V 50 60 CY 3 Phase Gas Oil 6 6 7 5 6 6 7 5 6 6 7 5 6 6 7 5 10 6 10 6 30 8 30 8 230V 50 60 CY 3 Phase Gas Oil 6 0 6 8 6 0 6 8 6 0 6 8 6 0 6 8 9 6 9 6 28 28 460V 50 60 CY 3 Phase Gas Oil 3 0 3 4 3 0 3 4 3 0 3 4 3 0 3 4 4 8 4 8 14 14 Steam separator or dual steam nozzle design required Ratings From 0 PSIG and at 212 Degrees F and KG HR From 0 KG CM and at 100 Degrees C Consumption based on natural gas 1000 BTU FT3 Propane 2500 and Light Oil 140 000 BTU GAL NOTE 7 11 wc gas pressure is required during run for 40 60 HP boilers with standard burners 9 11 wc gas pressure is required during run for 80 100 HP boilers with standard CSD 1 burners 40 W C is required
18. 6 6 MM 101 101 101 101 152 152 203 203 Steam Outlet 150 PSI IN NPT 3 3 3 3 3 3 4 4 MM 76 76 76 76 76 76 101 Feedwater Inlet IN NPT 1 1 1 1 1 1 25 1 25 1 25 MM 25 25 25 25 25 31 32 32 Blowdown Outlet 2 IN NPT 1 5 1 5 1 5 1 5 1 5 2 2 2 MM 38 38 38 38 38 51 51 51 Water Column Blowdown IN NPT 1 1 1 1 1 1 1 1 MM 25 25 25 25 25 25 25 25 Surface Blowdown IN NPT 75 75 15 15 15 75 75 75 MM 19 19 19 19 19 19 19 19 Safety Valve 150 PSI Inlet IN NPT 75 1 1 1 1 25 1 25 1 5 1 5 MM 19 25 25 25 31 31 38 38 Safety Valve 150 PSIOutlet IN NPT 1 1 25 1 25 1 25 1 5 1 5 2 2 MM 25 31 31 31 38 38 51 51 Safety Valve 15 PSI Inlet 2 IN NPT 1 25 1 25 1 25 1 25 1 5 1 5 2 2 MM 31 31 31 31 38 38 51 51 Safety Valve 15 PSI Outlet IN NPT 1 5 1 5 1 5 1 5 2 2 2 2 MM 38 38 38 38 51 51 51 51 Natural Gas Connection IN 1 5 1 5 1 5 2 2 2 2 2 MM 38 38 38 51 51 51 51 51 Light Oil Connection IN 25 25 25 25 25 25 375 375 MM 6 6 6 6 6 6 9 5 9 5 Burner Motor Gas HP 1 5 1 5 1 5 1 5 3 3 10 10 KW 1 1 1 1 1 4 1 1 2 2 2 2 7 5 7 5 Burner Motor Oil Combo HP 2 2 2 2 3 3 10 10 KW 1 5 1 5 1 5 1 5 2 2 2 2 7 5 7 5 Approximate Weights Shipping Weights approx LB 5775 6550 6575 7370 8000 9500 12350 12350 KG 2620 2972 2980 3340 3630 4310 5600 5600 Operating Weight approx LB 6720 8850 8209 9227 11760 14525 20135 20135 KG 3050 4015 3720 4190 5330 6590 9130 9130 Ratings Sea Level to 3000 FT 914 M Output 1000 BTU HR 1340 1656 1673 2009 2678 3347 4353 5022 1000 KCAL HR 338 417
19. Both operating pressure controls should have the same setting 9 NEMA 4 units will use a digital pressure controller with transducer as the operating pressure control which sends a Oma signal to the modulation motor to control firing rate Gas Burner Set Up For Boilers Equipped with High Low Off 1 A gas fired burner equipped for high low off firing is available as an option on Fulton gas fired steam boilers for 40 150 HP units 2 Boilers that have a high low off firing rate will have a linkage between the high low gas valve and the primary air gate This valve is equipped with a spring retum 3 The linkage will be disconnected from the gas valve for shipment 4 Mount the gas train on the pipe nipple of the burner plate with the gas train inlet directly facing over the panel box Reconnect the linkage from the primary air gate to the high low gas valve VMP IOM 27 Operation 5 The end of the linkage arm that goes to the gas valve will have a notch on both sides of where the swivel collar should be centered This setting was based on factory test fire conditions 6 Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics 7 To adjust the linkage unscrew the swivel collar and move the linkage rod in the appropriate direction The high low off configuration comes with two operating pressure controls 8 Set the low operating pressure co
20. Checklist to Fulton s Service department The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports must be produced for warranty consideration The warranty is valid for the original installation only in the U S A and Canada 08 20 10 The Fulton Companies 972 Centerville Road Pulaski New York USA 13142 Call 315 298 5121 Fax 315 298 6390 www fulton com No part of this Installation Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies Fulton Heating Solutions Inc Fulton Boiler Works Inc amp Fulton Thermal Corporation are part of the Fulton Group of Companies manufacturers of high grade industrial commercial heat transfer products 2010 0106 iom vmp
21. Fulton Installation Operation And Fulton VMP Maintenance Manual Vertical Multi Port nasse Gas Fired Steam Boilers 40 150 HP Serial Model Fulton Order Sold To Job Name Date Date January 22 2010 Subject Water Chemistry Requirements for Fulton Steam Products Products ICS ICX FB A FB F FB S VMP PVLP PHP Electric Steam Boilers and Unfired Steam Generators Please note that the water chemistry is different for carbon steel vs stainless steel pressure vessels and vertical vs horizontal orientation Effective immediately please use the limits below Should you have any questions please do not hesitate to contact Fulton at 315 298 5121 Water Chemistry Requirements for Fulton Steam Products to 300 psig MAWP Carbon Steel Stainless Steel Feedwater Vertical Horizontal Feedwater Vertical Horizontal Boiler Steam Boiler Steam Boiler Steam Boiler Steam Pac Water Pac Water Pac Water Pac Water 7 5 9 5 8 5 10 5 8 5 10 5 6 0 9 5 8 5 10 5 8 5 10 5 lt 2ppm lt 10 ppm lt 15 ppm lt 2 ppm lt 10 ppm lt 15 ppm lt 300 ppm lt 500 ppm lt 300 ppm lt 500 ppm Temperature D3vf gt a fOofo mio ERES E o 3 S VISOS 3 8 a Si gt 2 1035 lt Q lu o S 3 oO D vn o a na n D pon D O U g turbidity turbidity turbidity turbidity turbidity turbidity No foam No foam No foam No foam No foam No foam Colorless Colorless Colorless Colorless liqui
22. NOTE The pump will continue to operate until the water reaches the correct level in the boiler This level is approximately the center of the water gauge glass 7 Activate the boiler power on switch located on the side of the panel box 8 With the unit full of water the low water safety relay s will be in a lock out mode Press the low water safety relay manual reset button located on the side of the control panel box Gas Burner Set Up 1 Open the manual gas cocks on the pilot and main lines of the gas head 2 Switch on the main power to the bumer The water level relay is equipped with a manual reset Depress the button on the box 3 The flame programmer is the main control in the panel box The programmer in conjunction with a sensing device either a flame rod or a UV scanner supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lock out and the burner will shut down NOTE To reset the boiler burner after a Lock out signal push the reset button on the control Operation 4 When the pilot flame is established the flame rod or ultra violet scanner senses the voltage which is created in the flame between the flame rod and the gas nozzle ground This signal is transmitted back to the flame programmer
23. all parts are free of chips and debris Gauge glass valves must be fully open to prevent boiler water damage if a gauge glass breaks WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected WARNING DO NOT TAMPER WITH THE SAFETY FEATURES OF THE LOW WATER SAFETY CUT OFF WARNING When shutting down the boiler for any extensive repairs shut off main disconnect switches on both the boiler and the feed water pump WARNING Do not clean the gauge glass while pressurized Ensure gauge glass valves are fully shut prior to glass removal WARNING Do not allow anyone to operate service or repair this equipment unless they fully understand all applicable sections of this manual CAUTION To prevent corrosion fatigue at the feedwater nozzle or cold end corrosion boiler feed water must be at least 140 F prior to entry into the boiler CAUTION A temperature exceeding 100 F in the boiler room may cause premature failure of electrical components in the boiler control panel CAUTION The water chemistry in the boiler must be kept within limits outlined in this manual Failure to do so will likely cause premature boiler pressure vessel failure and poor steam quality O VMP IOM NOTE After installation is complete and prior to operation the pressure vessel should be cleaned or boiled out per instructions includ
24. box the water column and elsewhere are secure 4 Make sure the door in the boiler room is closed Combustion air contaminates can cause damage to the boiler jacket and stack NOTE After installation is complete and prior to operation the pressure vessel should be cleaned Primary steam outlet Valve not shown Exhaust stack Safety Valve s adapter Cleaning Boil out the Pressure Vessel After the boiler has been installed and before it is placed in service it is advisable to purge the pressure vessel of any oil film dirt or other impurities Clean the pressure vessel as follows 1 Isolate the boiler from the system by shutting off the main steam valve 2 Remove the steam safety valve 3 Mix washing soda with water in a one gallon container and pour it into the boiler through the steam safety valve opening 4 The mixture of washing soda to water is as follows Boiler Size Soda 40 50 60 4 Ib 1 814g 80 5 Ib 22709 100 7Ib 31789 130 9 lb 40809 150 10 5 Ib 47609 5 Replace the steam safety valve 6 Fill the boiler with water Water level is about center in the water gauge glass 7 Generate 15 PSI 1 054 kg cm of steam and shut off the boiler Allow this hot solution to remain in the boiler for 10 minutes 8 Drain and flush the boiler twice with fresh water 9 To remove all the oil and dirt from the main steam and the condensate return lines allow
25. from the Fulton factory It is not necessary to reinstall the shipping clips Install the stainless steel combustion ring burner assembly and clean out plug 10 Normal operation can be resumed immediately Gas Train Assembly Air Deflector Stainless Steel Combustion Chamber Ring Top Castable Refractory Turbulator Bottom Castable Refractory Handhole VMP IOM amp Pilot Adjustment for Fulton LoNOx Burner 1 Close downstream shut off valve 2 Start boiler and check flame signal on pilot lock programmer into pilot hold 3 Adjust air and gas regulator as needed to obtain a strong pilot signal 4 Slowly open downstream shut off valves and take the flame programmer off of hold Main Flame Adjustment For LE Models 1 Place a combustion analyzer in the exhaust of the boiler 2 Do not adjust main gas regulator To increase fuel to the burner the servos that control modulating gas valves require adjustment Burner Tile Replacement For LE Models 1 Remove scroll assembly 2 Break off top holding clips 3 Remove ceramic fiber burner tile 4 Replace bumer tile bottom holding clips if needed 5 Replace with new burner tile 6 Carefully replace scroll assembly so that the ceramic fiber burner tile is not damaged Servo Motor Replacement For LE Models If it is determined that a servo motor needs to be replaced the first step in this process is to verify the model numbe
26. of metals Rinse all piping thoroughly with clean water after leak check has been completed j The boiler must be disconnected at the boiler shut off valve from the gas supply piping system during any pressure testing of the system at pressure in excess of 1 2 PSIG 14 W C k The boiler must be isolated from the gas supply piping system by closing the shut off cock during any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 PSIG 14 W C Cold Waler Supply Check Valves Installation The Gas Supply For LE Models A minimum of 40 w c gas pressure is required at the inlet of the gas train while operating for the 40 100HP 60 w c for the 130 150HP boiler WARNING For units equipped with Flue Gas Recirculation FGR the ducting must be insulated CAUTION Do not exceed the rated pressure of the fuel train Shul OF Valve Basic Boiler Condensate Tank and Blow Down Separator NOTE Where a condensate return tank is to be fitted 1 This should be vented to a safe location 2 This should have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature o Vent pipe should not be down sized this may cause pressure build up in the condensate tank 4 Return pipes must not be insulated This can cause overheating the return system causing a vapor lock in the pump 5 See Return System Instructio
27. reach the bottom of the indication window The main gas pressure regulator is only used to comply with standard regulations and therefore uses a high outlet pressure spring that is set at the max The SKP70 fuel valves have a built in regulator function Glossary of Terms PRIMARY GAS The smaller gas line injects fuel at the burner head SECONDARY GAS The main gas line inject fuel prior to the burner head REVERSING ACTUATOR Used for positioning control inlet damper combustion air AIR GAS RATIO CONTROLLING ACTUATOR Regulates gas flow according to air pressure VMP IOM Section Maintenance VMP IOM amp Maintenance Gas Train Assembly Burner Plate Assembly Transformer Top Plate Assembly Secondary Air Damper Seral Burner Motor Flue Cover Plate Steam Gauge Assembly Lifting Hook s Gauge Glass Stainless Steel Ring Valve Gauge Glass and Protector Flue Outlet Gauge Glass Valve FERERREFRRIE Hi Water Column Top Refractory Turbulator Control Box Fiberglas Insulation Bottom Refractory Outside Jacket Feedwater Inlet Blowdown Outlet Handhole Blowdown Outlets Castable Refractory Insulation Clean Out Opening O P C Operating Pressure Control H P C High Pressure Control O VMP IOM Maintenance NOTE To ensure the continued safety and efficiency of the boiler the schedule of maintenance outlined in this section should be a
28. 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 vertically aligned with the bottom gauge fitting then inset glass into bottom fitting until glass bottoms out on the shoulder inside the bottom fitting 8 Carefully raise glass about 1 16 and slide lower glass packing down until the glass packing contacts the lower gauge fitting DO NOT allow the glass to remain in contact with any metal 9 Carefully slide upper glass packing up as far as possible VMP IOM 10 Hand tighten both glass packing nuts 11 then tighten 1 2 tum more by wrench Tighten only enough to prevent leakage DO NOT OVER TIGHTEN If any leakage should occur tighten slightly a quarter turn at a time checking for leakage after each turn Install the protective guard and utilize automatic ball checks where necessary to help prevent injury in case of glass breakage WARNING Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and or property damage Installation Water Supply Feed water cont
29. the returns to go into a floor drain or a safe discharge point for the first week of operation CAUTION Do not store halogenated hydrocarbons in or near the boiler room In general ensure that the boiler area is in conformance with established boiler room requirements Review national and local codes We cannot emphasize enough the importance of proper water treatment Water analysis should be made by a competent water treatment concern and their recommendations should be followed VMP IOM 23 24 VMP IOM Section Operation VMP IOM 25 Operation Starting the Gas Fired Boiler STOP Make sure you have read and followed all previous safety information Check with local authorities where approval for start up is required In some localities final inspection of services may be required In general ensure that the boiler area is in conformance with established boiler room requirements Review national and local codes Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down 1 Close the blow down valves 2 Close the water gauge drain valve 3 Open main steam stop valve at the top of the boiler 26 VMP IOM 4 Open the water feed valve on the boiler 5 Open valves on makeup water line to return if return system is used 6 Place feedwater pump fused switch in the on position
30. which opens the main gas valve giving a main flame All Fulton propane or butane boilers and Fulton natural gas boilers 50 HP and above are standardly furnished with UV Scanners a If the installation is new or the burner has been disassembled the burner may not fire at the first attempt due to air which must be purged from the gas lines This will result in the burner flame programmer going to lockout Repeat the procedure for starting the burner b The main gas valve will remain open as long as there is a demand for heat and the flame is carrying a sufficient signal to the flame programmer c If the flame is not established at the start the safety switch in the flame programmer control will open the contacts and shut off the burner d Push the reset button on the control to reset If trouble persists it may be necessary to check the flame rod setting or the UV scanner See Maintenance Section 4 for procedure to check flame rod setting or UV Scanner Gas Burner Set Up For LE Models WARNING For units equipped with Flue Gas Recirculation FGR the ducting must be insulated a Open the manual gas cocks on the pilot and main lines of the gas head Switch on the main power to the burner The water level relay is equipped with a manual reset Depress the button on the box c The flame programmer is the main control in the panel box The programmer in conjunction with a UV scanner supervises t
31. 0 45 4 23 014 Mica Paint Quart 2 0 91 4 23 044 Mica Paint Gallon 7 8 3 55 2 12 504 TIW Filler Insulation per sq ft 48 VMP IOM Parts and Warranty Part No Description Approx Net Weight Ibs kgs Burner Assembly Parts Common 2 40 613 1 5 HP 115 230 60 1 Burner Motor 3450 RPM 40 18 18 2 40 615 1 5 HP 230 460 60 3 Burner Motor 2850 3450 RPM 31 14 09 2 40 621 3 0 HP 230 460 50 60 3 Burner Motor 2850 3450 RPM 43 19 55 2 12 014 Pyrex Plate Glass 1 4 100 HP 0 1 0 05 2 45 025 Bakelite Terminal 90 for Electrode 0 05 0 02 2 45 026 Bakelite Terminal Straight for Electrode 0 05 0 02 2 45 017 Ignition Wire per foot 0 01 0 2 11 080 Burner Scroll Casting 80 amp 100 HP 65 29 55 5 20 061 Burner Scroll Casting 40 50 amp 60 HP 50 22 73 Burner Fans Size HP Applicable Fuel Hz 2 30 421 8 3 8 x 2 1 2 x 1 40 50 Propane or nat Gas 50 60 3 00 1 36 60 Propane or nat Gas 50 60 3 00 1 36 2 30 826 9 15 16 x 3 1 2 x LO75 80 2 30 559 9 15 16 x 3 x LO75 100 When ordering burner fans check for the correct part number on the back of the fan plate Burner Assembly Gas 2 40 082 Ignition Transformer Gas 115 60 9 5 4 32 2 45 026 Straight Bakelite Terminal 0 03 0 01 4 45 010 Ignition Cable with 90 Bakelite Terminal 0 5 0 23 2 20 033 Ignition Electrode 0 4 0
32. 1 1 2 Ball Valve 200 47 2 14 2 30 025 2 Ball Valve 200 6 35 2 89 2 30 208 3 Ball Valve 200 18 8 18 2 30 393 1 1 2 Y Type Blowdown Valve 200 8 4 3 82 2 30 394 2 Y Type Blowdown Valve 200 13 5 6 14 2 30 023 1 1 2 Quick Action Blowdown Valve 23 10 45 2 30 024 2 Quick Action Blowdown Valve 28 12 73 2 40 133 Timer for Automatic Blowdown System 0 8 0 36 2 30 403 1 1 2 Motorized Valve for Automatic Blowoff 12 6 5 73 2 30 389 2 Motorized Valve for Automatic Blowoff 13 7 6 23 2 30 1066 1 2 Steam Solenoid Valve 120V 2 3 1 05 2 30 122 3 4 Steam Solenoid Valve 120V 2 5 1 14 2 30 146 1 Steam Solenoid Valve 120V 4 5 2 05 2 30 147 1 1 4 Steam Solenoid Valve 120V 4 9 2 23 2 30 148 1 1 2 Steam Solenoid Valve 120V 6 3 2 86 2 30 016 1 1 2 15 Series 19 V Stamped Safety Valve 2 0 91 2 30 217 2 15 Series 19 V Stamped Safety Valve 2 5 1 14 2 30 085 1 1 4 150 Safety Valve 6 8 3 09 2 30 086 1 1 2 15 Safety Valve 2 0 91 2 30 087 1 1 2 100 Safety Valve 12 4 5 64 2 30 088 1 1 2 125 Safety Valve 10 9 4 95 2 30 089 1 1 2 150 Safety Valve 12 3 5 59 2 35 518 1 4 Steel Pigtail Syphon for Steam Gauge Assembly Long 0 6 0 27 2 30 326 0 30 PSI Steam Pressure Gauge 0 5 0 23 2 30 334 0 60 PSI Steam Pressure Gauge 0 5 0 23 2 30 333 0 200 PSI Steam Pressure Gauge 0 5 0 23 2 30 332 0 300 PSI Steam Pressure Gauge 0 5 0 23 2 30 327 0 600 PSI Steam Pressure Gauge 0 5 0 23 2 12 027 Teflon Disc for 1 1 2 Y Valve 0 2 0 09 2 11 017 Brass Sea
33. 31 31 Safety Valve 150 PSIOutlet INNPT 1 1 25 1 25 1 25 1 5 1 5 MM 25 31 31 31 38 38 Safety Valve 15 PSI Inlet 2 IN NPT 1 25 1 25 1 25 1 25 1 5 1 5 MM 31 31 31 31 38 38 Safety Valve 15 PSI Outlet 2 IN NPT 1 5 1 5 1 5 1 5 2 2 MM 38 38 38 38 51 51 Natural Gas Connection IN 1 5 1 5 1 5 2 2 2 MM 38 38 38 51 51 51 Burner Motor HP 5 5 5 5 5 7 5 KW 3 7 3 7 3 7 3 7 3 7 5 6 Approximate Weights Shipping Weights approx LB 6575 7375 7375 8170 8800 10300 KG 2982 3345 3345 3706 3992 4672 Operating Weight approx LB 8659 9684 9684 10671 12051 14700 KG 3928 4393 4393 4840 5466 6668 Ratings Sea Level to 3000 FT 914 M Output 1000 BTU HR 1340 1656 1673 2009 2678 3347 1000 KCAL HR 338 417 422 506 675 843 Steam Output LBS HR 1380 1708 1725 2070 2760 3450 KG HR 626 775 783 939 1252 1565 Water Content GAL 172 274 242 270 383 518 LITERS 651 1038 916 1022 1450 1960 Approximate Fuel Consumption at Rated Capacity Natural Gas FT 7 HR 1595 1972 1992 2392 3188 3985 M HR 45 56 56 68 90 112 Gas Pressure Required Min IN W C 30 30 30 40 40 40 Gas Pressure Required Max PSIG 5 5 5 5 5 5 Electrical Requirements Amps for Burner Motors 208V 60 CY 3 Phase 16 7 16 7 16 7 16 7 16 7 24 2 230V 60 CY 3 Phase 15 2 15 2 15 2 15 2 15 2 22 0 460V 60 CY 3 Phase 7 6 7 6 7 6 7 6 7 6 11 0 Steam separator or dual steam nozzle design required Consult factory for availability Steam Output LB HR From 0 PSIG and at 212 Degrees F and KG HR From O K
34. 5 141 MM 2718 2832 2832 2984 3150 3200 3429 3582 E Overall Boiler Width IN 56 62 62 62 68 74 84 5 84 5 MM 1422 1575 1575 1575 1727 1880 2146 2146 F Flue Outlet Diameter IN 12 12 12 12 14 14 14 16 MM 305 305 305 305 356 356 356 407 G To Center of Flue Outlet IN 79 86 86 92 95 95 107 107 MM 2006 2184 2184 2237 2413 2413 2718 2718 H Feedwater Inlet IN 35 35 35 35 35 35 39 39 MM 889 889 889 889 889 889 991 991 J Blowdown Outlet IN 17 18 18 18 18 18 22 22 MM 432 457 457 457 457 457 559 559 K Height to Steam Outlet IN 73 77 77 84 89 89 102 102 MM 1854 4956 4956 2134 2260 2260 2591 2591 L Min Clearance to Ceiling IN 110 115 115 125 130 132 145 145 MM 2794 2921 2921 3175 3302 3353 3683 3683 Specifications and Dimensions are approximate We reserve the right to change specifications and or dimensions NOTE Minimum clearance is 24 to the side and back and 36 in front of unit 1 The boiler may be fitted with a 90 elbow spool piece making the steam outlet connection higher Minimum Clearance For Burner Removal mne 2 5 9 3 To O T P L T D LI K B T q H II TE O E I i i L Top View Side View Front View 11 VMP IOM Specifications Models VMP 40 49 5 50 60 80 100 130 150 Unit Horsepower 40 49 5 50 60 80 100 130 150 Boiler Connections Steam Outlet 15 PSI 150 Flanged IN 4 4 4 4 6 6
35. 8 3734 3734 Specifications and Dimensions are approximate We reserve the right to change specifications and or dimensions NOTE Minimum clearance is 24 to the side and back and 36 in front of the unit 1 The boiler may be fitted with a 90 elbow spool piece making the steam outlet connection higher mn Bei 9 O Top View Side View Front View 12 VMP IOM Specifications Models VMP 40 49 5 50 60 80 100 Unit Horsepower 40 49 5 50 60 80 100 Boiler Connections Steam Outlet 15 PSI IN 4 4 4 4 6 6 150 Flanged MM 101 101 101 101 152 152 Steam Outlet 150 PSI INNPT 3 3 3 3 3 3 150 Flanged MM 76 76 76 76 76 76 Feedwater Inlet INNPT 1 1 1 1 1 1 25 MM 25 25 25 25 25 31 Blowdown Outlet IN NPT 1 5 1 5 1 5 1 5 1 5 2 MM 38 38 38 38 38 51 Water Column Blowdown IN NPT 1 1 1 1 1 1 MM 25 25 25 25 25 25 Surface Blowdown IN NPT 15 15 15 15 75 75 MM 19 19 19 19 19 19 Safety Valve 150 PSI Inlet INNPT 75 1 1 1 1 25 1 25 MM 19 25 25 25
36. Assembly DI Secondary Air Damper Sai Burner Motor Flue Cover Plate Steam Gauge Lifting Hook s Assembly 3 Gauge Glass Stainless Steel Ring Valve Gauge Glass and Protector Rods Flue Outlet Gauge Glass Valve pares EREBEREE ERHERRECH ERBEN FREE Sa pur PERI PEPEE Water Column Top Refractory Turbulator Control Box Fiberglas Insulation Bottom Refractory Outside Jacket Feedwater Inlet Blowdown Outlet Handhole Blowdown Outlet Castable Refractory Insulation Clean Out Opening O P C Operating Pressure Control H P C High Pressure Control VMP IOM Product Data Submittal Fulton Models VMP40 VMP49 5 VMP50 VMP60 VMP80 VMP100 VMP130 and Fulton Fulton Vertical MultiPort Steam Boilers VMP150 Standard Burners Dimensions Models VMP 40 49 5 50 60 80 100 130 150 Unit Size BHP 40 49 5 50 60 80 100 130 150 A Boiler Diameter IN 50 5 55 55 55 63 69 76 5 76 5 MM 1283 1397 1397 1397 1600 1753 1943 1943 B Boiler Height IN 84 91 91 97 100 100 115 115 MM 2133 2312 2312 2464 2540 2540 2921 2921 C Boiler Depth IN 90 100 100 100 114 119 128 130 MM 2286 2540 2540 2540 2896 3022 3251 3302 D Boiler Height w trim IN 107 112 112 118 124 126 13
37. FT HR 5182 5978 M HR 146 169 Gas Pressure Required Min INW C 21 21 Gas Pressure Required Max PSIG 5 5 Electrical Requirements Amps for Burner Motors 208V 60 CY 3 Phase 30 8 30 8 230V 60 CY 3 Phase 28 28 460V 60 CY 3 Phase 14 14 Steam separator or dual steam nozzle design required Consult factory for availability Steam Output LB HR From 0 PSIG and at 212 Degrees F and KG HR From 0 KG CM and at 100 Degrees C Consumption based on natural gas 1000 BTU FT and 20 ppm NO 3 O burner Fulton The Fulton Companies 972 Centerville Road Pulaski New York 13142 Call 315 298 5121 Fax 315 298 6390 www fulton com 13a VMP IOM vmp130 150le pds 2010 1008 Installation Locating the Boiler a The boiler should be located in dry surroundings on a level base making sure that there is sufficient room around the boiler to enable the operator and or the maintenance engineer to gain access to all parts of the boiler Check location for ease of water supply and electrical connections Place the boiler on a non combustible floor with clearances to unprotected combustible materials including plaster or combustible supports It is necessary to have the following vertical clearance from the floor to the ceiling for removal of the burner for servicing Minimum Vertical Clearances BHP IN MM 40 110 2794 50 115 2921 60 125 3175 80 130 3302 100 130 3302 130 145 3683 150 145 3683
38. G CM and at 100 Degrees C Consumption based on natural gas 1000 BTU FT and 20 ppm NO 3 CO burner Fulton The Fulton Companies 972 Centerville Road Pulaski New York 13142 Call 315 298 5121 Fax 315 298 6390 www fulton com 12a VMP IOM vmp40 100le pds 2010 1008 Product Data Submittal Fulton Models VMP130 and VMP150 Fulton Fulton Vertical MultiPort Steam Boilers Low Emissions Burners lt 30 PPM NOx Dimensions Models VMP 130 150 Unit Size BHP 130 150 A Boiler Diameter IN 76 5 76 5 MM 1943 1943 B Boiler Height IN 115 115 MM 2921 2921 C Boiler Depth IN 128 130 MM 3251 3302 D Boiler Height w trim IN 135 149 MM 3429 3785 E Overall Boiler Width IN 84 5 84 5 MM 2146 2146 F Flue Outlet Diameter IN 14 16 MM 356 407 G To Center of Flue Outlet IN 107 107 MM 2718 2718 H Feedwater Inlet IN 39 39 MM 991 991 J Blowdown Outlet IN 22 22 MM 559 559 K Height to Steam Outlet IN 102 102 MM 2591 2591 L Min Clearance to Ceiling IN 155 155 for Burner Removal MM 3937 3937 M Height to top of FGR Loop IN 121 121 MM 3073 3073 Specifications and Dimensions are approximate We reserve the right to change specifications and or dimensions NOTE Minimum clearance is 24 to the side and back and 36 in front of unit 1 The boiler may be fitted with a 90 elbow spool piece making the steam outlet connection higher
39. Mercury Switch 3 Wire 1 0 45 2 30 149 Water Gauge Glass Valves w Ball Checks 1 5 0 68 2 30 047 Try Cocks 0 4 0 18 2 12 065 8 5 8 Extra Heavy Gauge Glass 0 05 0 02 2 12 008 9 1 4 Water Gauge Glass standard 0 05 0 02 2 12 007 9 1 4 Extra Heavy Gauge Glass 0 1 0 05 2 12 017 9 1 4 Water Gauge Glass Corning 0 05 0 02 2 12 018 10 Water Gauge Glass MM 0 06 0 03 2 12 020 Brass Water Gauge Glass Gasket 0 0018 0 2 12 019 Rubber Water Gauge Glass Gasket 0 004 0 2 12 080 Teflon Water Gauge Gaskets 0 01 0 2 35 514 Brass Packing Nut for Gauge Glass Valve 0 1 0 05 2 30 330 Gauge Glass Protector Rods 0 04 0 02 2 12 022 Lucite Gauge Glass Guard for 9 1 4 Glass 0 4 0 18 50 VMP IOM Parts and Warranty Description Approx Net Weight kgs 2 12 024 Lucite Gauge Glass Guard for 10 Glass 0 5 0 23 4 21 010 Water Column Electrode Basket amp Cover 0 5 0 23 4 30 052 Set of four 4 Water Level Probes amp Plugs 80 100 HP 1 3 0 59 4 30 042 Set of 3 Water Column Probes 0 8 0 36 2 20 010 Pump Off Probe 7 1 4 0 2 0 09 2 20 0111 Pump On Probe 9 1 4 0 2 0 09 2 20 012 Low Water Probe in Water Column 11 1 4 0 3 0 14 2 20 017 Low Water Probe in Boiler 17 1 2 0 5 0 23 2 21 012 Probe Cover 2 1 0 45 2 21 013 Probe Cover 4 1 0 45 2 30 398 1 4 Male Female Ball Valve for Water Column 0 6 0 27 2 40 021 Probe Basket 0 05 0 02 Panel Box Parts
40. ains solids and dissolved gases These may promote formation of scale foaming priming surging and solids in steam corrosion and pitting or caustic embrittlement To prevent this feedwater must be studied individually and treated accordingly by reputable professionals specializing in this field It is strongly recommended that a competent water treatment company be consulted prior to the installation of the boiler The purpose of this treatment should be to provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized Dissolved oxygen high TDS levels and low pH can all be major causes of corrosion Untreated hardness is the major cause of scale deposits Poor quality feedwater will require increased blow down and increased chemical treatment costs to prevent boiler corrosion and scaling One way to lower the amount of dissolved oxygen in the boiler feed water is the feedwater preheating option This option injects live steam into the feedwater to increase the water temperature to at least 180 degrees F 82 degrees C which removes oxygen from the water TDS can be controlled by increasing the number and or duration of blow downs per day from one to four The Fulton Warranty does not cover damage or failure that can be attributed to corrosion scale or sludge accumulations Oxygen is corrosive See the Warranty Section of this manual for full details Recommended Water Treatme
41. and stack to avoid having too great a load imparted to the flue outlet connection of the boiler The proper flue size and draft control is most important for proper burner operation The flue must be as large or larger than the outlet on the boiler Avoid flue piping and elbows by placing the boiler as close as possible to the chimney A mechanical draft regulator should be installed in the flue outlet Do not install the draft regu lator prior to the first tum of the flue BHP Boiler Flue Size IN MM 40 50 60 12 305 80 100 130 14 356 150 16 406 The installer should check the draft with a meter at negative 02 04 W C pressure 0 508 to 1 016 mm with the burner off VMP IOM 21 Installation Corrosion of flue pipe In the case of a combustion flue pipe acid may develop over a long period of time per the following process Chlorine containing gases such as halocarbon refrigerants carbon tetrachloride trichloroethylene or perchloroethylene when drawn into combustion air are broken down into elemental chlorine gas which exits up the flue pipe If the flue pipe is cold as it would be if the combustion process had been off for some time the water vapor condenses in the flue pipe during the first few minutes of ignition and the chlorine in the combustion gas dissolves in the water forming hydrochloric acid As the combustion system flue line increases in temperature the water vapor no longer
42. atural Gas Orifice 50 HP 4 1 81 7 20 300 Natural Gas Orifice 60 HP 4 1 81 7 20 093 Natural Gas Orifice 80 HP 4 5 2 04 7 20 302 Natural Gas Orifice 100 HP 45 2 04 7 20 275 Propane Orifice 40 HP 4 1 81 Misc Propane Orifice 50 hP 4 1 81 VMP IOM 49 Parts and Warranty Part No Description Approx Net Weight Ibs kgs 7 20 322 Propane Orifice 60 HP 4 1 81 7 20 094 Propane Orifice 80 HP 4 5 2 04 7 20 095 Propane Orifice 100 HP 4 5 2 04 2 30 180 Propane Spring RV81 05 0 23 2 30 181 Propane Spring RV91 05 0 23 7 30 006 Top Plate Assembly 40 50 amp 60 HP Natural or Propane Gas 65 29 55 7 30 000079 Top Plate 80 HP NG LP 100 45 4 7 30 000081 Top Plate 80 HP Combo 100 45 4 7 30 000110 Top Plate 100 HP NG LP 100 45 4 7 30 000112 Top Plate 100 HP Combo 100 45 4 7 30 000031 Burner Plate Assembly 40 50 HP Natural Gas 12 5 45 7 30 000073 Burner Plate Assembly 80 HP Natural Gas 12 5 45 7 30 000075 Burner Plate Assembly 80 HP Combo 12 5 45 7 30 000173 Burner Plate Assembly 80 HP Propane 12 5 45 7 30 000174 Burner Plate Assembly 80 HP Town Gas 12 5 45 7 30 000175 Burner Plate Assembly 80 HP Butane 12 5 45 7 30 000115 Burner Plate 100 HP Gas 1 454 7 30 000117 Burner Plate 100 HP Combo 1 454 7 30 000176 Burne
43. chlorine OIL Oil is not a natural constituent of boiler water still it can frequently enter a system through leaks in a condenser or other heat exchanger Oil can also enter a system through the lubrication of steam driven reciprocating equipment Whatever the source the presence of oil in boiler water is undesirable Foaming is one indication of oil in boiler water Its presence can also be confirmed by first shaking a bottle containing boiler water If oil is present foam will result To ensure the foaming is being caused by oil add a small amount of powdered activated carbon to the bottle containing the boiler water and shake Little or no foam will appear if the foaming is caused by oil 20 VMP IOM Often oil in boiler water will originate in the condensate This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken Boiler and boiler system piping boil out procedure are designed to rid a system of oil contamination IRON OXIDES Iron in any of its oxide or complex forms is undesirable in boiler water It is very difficult to disperse so that it can be removed the bottom blow down lines Iron in its various forms can originate in the raw water makeup condensate retum water or form directly in the boiler as a result of corrosion Most iron oxide originates outside the boiler It concentrates in the boiler and it tends to collect in stagnant a
44. ctory d Measure input or monitor last elbow pressure Verify that these points are in general correspondence with the test fire sheet Repeat step b until the point position has a load value of 100 You are now at high fire Verify combustion is per test fire sheet 30 If operating on gas adjust the incoming gas pressure at the main gas regulator to match the test fire report Adjust the gas servo motor to change the last elbow pressure to match the test fire report Adjust the air servo motor to adjust the emissions as needed If operating on oil adjust the oil pump and air pressure regulator to match the pressures on the test fire sheet Adjust the oil servo until the oil flow rate matches the test fire sheet Adjust the air servo to match the test fire sheet 31 Repeat step 28 but start at the high fire point number Continually decrease the point number after combustion has been verified at each point 32 Once all the points have been verified press Escape until you are back to the main menu 33 You can observe the status of the burner by going to OperationalStat gt NormalOperation 34 Turn the main ON OFF switch to OFF The control will now postpurge 35 Follow steps 3 20 again to verify ignition with the new gas pressures 36 Turn the main burner switch to OFF The control will now post purge 37 Change the operation to Automatic under ManualOperation gt Auto Manual Off and press Enter and confirm Au
45. d liquid liquid liquid liquid liquid Oxygen Visual Oil ND ND lt 4477 lt 2985 lt 4477 NOTES This is a minimum temperature Feedwater temperatures below 200F will require an oxygen scavenger Solids Suspended Solids Total Organic Carbon Iron 20 DS X 5 E Ss S lt Suspended solids Take a water sample After the sample sits for 10 minutes no solids should be visible Total Organic Carbon Take a water sample Shake vigorously for 30 seconds No sheen or foam should be visible Iron Take a water sample Hold the sample against a white background The water should have no visible yellow red or orange tinge ND None Detected Fulton Product Bulletin 2010 001PB The Fulton Companies 972 Centerville Road Pulaski N Y 13142 Product Bulletin Section Contents Safety Warnings and Precautions PAGE 3 Installation PAGE 9 17 3 AT oOo Maintenance PAGE 31 Parts and Warranty PAGE 35 VMP IOM 0 VMP IOM Section Safety Warnings and Precautions VMP IOM VMP IOM Safety Warnings and Precautions This manual is provided as a guide to the correct operation and maintenance of your Fulton Gas Fired Steam Boiler and should be permanently available to the staff responsible for the operation of the gas fired boiler These instructions must not be considered as a complete code of practice nor should they replace existi
46. dently supported near the pump so no strain will be transmitted to the unit Connect the feed water stop valve to the feed water pipe at the rear of the boiler and pipe it to the return system Water Column Install the piping from the water column and water gauge glass to a safe blow down point Installation Water Gauge and 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 packaging 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 itis snug and the glass outlet is pointing directly upward Verify top and bottom fittings are threaded into the tappings the
47. dhered to WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected Procedure for Cleaning Water Probes Clean probe on top of boiler shell and probes in water column Make sure there is no pressure on the boiler during the removal of the probes Remove one probe clean with very fine emory 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 A 7 1 4 IN 184 mm B 9 1 4 IN 235 mm C 11 1 4 IN 286 mm D A IN 102 mm D is located in the boiler pressure vessel VMP IOM 35 Maintenance Gas Train Assembly Ignition Electrode Burner Viewing Port Blast Tube Flame Scanner Adjustments for Fulton Gas Fired Steam Boilers 1 Flame scanner adjustments are made with the detectors installed and the burner running It is essential to obtain optimum flame signal detection for safe and continual operation of the control relay 2 If a scanner is inoperable it may prove the detector is working and only an adjustment to the pilot flame is needed to improve the signal 3 If the scanner is found
48. down float chamber Recommended Weekly Maintenance Schedule Check that the low water cut off relay is operating correctly in the following manner 1 Make sure that the boiler is cool with little or no pressure showing on the steam pressure gauge 2 With the burner operating open the boiler blow down valves When the water drops below the required level note the level in the water gauge glass the burner should shut off this is when the water level falls below the low water electrode in the water column assembly and or the boiler shell Manual reset of the low water relay is required Recommended Monthly Maintenance Schedule WARNING Make sure main power switch is off before starting work 1 Cleaning the water gauge glass CAUTION Do not clean the gauge or gauge glass while pressurized or in operation a Clean the water gauge glass using a commercial non abrasive glass cleaner Use diluted acids such as hydrochloric muriatic acid when regular cleaners do not seem to work Do not use wire brushes or any other abrasive materials which could scratch the glass If any leakage is evident replace the gaskets b Always replace the high impact plastic gauge glass protector which is standard on all Fulton Boilers 2 Clean water pump strainers 3 Check scanner or flame rod and ignition electrodes 4 Check starter contacts Burned or pitted contacts should be replaced Do not use sand paper or file to clean
49. e is located at the bottom of the boiler to the right hand side of the panel box The second one is 180 degrees on the opposite side of the boiler Break off the top holding clips that were used to keep the refractory in position during shipping The boiler has welded flat bars beneath the top refractory These bars will have to be cut to change the lower refractory Rewelding of the bars will be required prior to installation of the top refractory For the lower refractory you will also need to break off the top holding clips that were used to keep the refractory in position during shipment Break up the top and or bottom refractories and remove the pieces from the boiler through the clean out plugs NOTE If only the top refractory is to be changed the bottom refractory need not be broken 6 Round and bevel the outer edges of the new refractories The bottom refractory has the largest hole while the top refractory has the smallest Lower the bottom refractory down the furnace with wire fastened around the refractory in three positions When the refractory is close to position it can be tipped by maneuvering the wire to drop it flat on the holding clips If the refractory will not tip it may have to be removed and again rounded and beveled Install the top refractory in the same manner as the bottom refractory When installed the outer edges must be sealed with insulcrete a castable refractory mix available
50. e to get back to the main menu 10 Increase the setpoint on the temperature controller to create a heat demand 11 Turn the main burner switch to the Local or On position NOTE If the burner loses flame while driving to a point then e Turn the main ON OFF switch to OFF Reset the loss of flame fault Press Escape on the AZL once Press Enter on the AZL to reset the control The red light on the panel box door should go out e Adjust the air and gas servos for that point while the burner is off Follow steps 28 29 e Turn the main ON OFF switch to ON 23 Under Params amp Display gt RatioControl ProgramStop change the program stop to deactivated by using the arrow keys Confirm that deactivated is acknowledged in the current field 24 This change will allow the burner to modulate The burner will now drive to low fire Remember it is only important at this stage to set low fire to be stable and with clean combustion Exact setting is to be performed once high fire is confirmed 25 Press Escape 5 times to get back to the main menu Operation 26 You can observe the status of the burner by going to OperationalStat gt NormalOperation 27 Verify the flame signal on the display measure input if fuel meter is available If not match last elbow pressures and combustion from test fire sheet Adjust the burner as needed To adjust the servo position follow steps 28 29 SETTING LOW FIRE NOTE As s
51. ed in this manual NOTE a The fused disconnect switch that controls the feed water pump should be kept in the on position at all times during the boiler operation as well as during the non operating period of the boiler b This switch should be turned off only when repairs or adjustments should be made NOTE The feedwater pump will continue to operate until the water reaches the correct level in the boiler This level is approximately the center of the water gauge glass NOTE To ensure that your Fulton Steam Boiler is kept operating safely and efficiently follow the maintenance procedures set forth in Section 4 of this manual NOTE If only the top refractory is to be changed the bottom refractory need not be removed NOTE The boiler blow off operation should be done once during the day when the boiler is at 10 PSIG or less NOTE After a new Fulton Boiler has been in operation for several months pieces of burned metal will be found in the space at the bottom of the boiler These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation This is a normal condition and does not affect the efficiency or the life of the boiler in any way Safety Warnings and Precautions VMP IOM Q 0 VMP IOM Section Installation VMP IOM O Installation Gas Train Assembly aladas Burner Plate Assembly Transformer Top Plate
52. ee if they are plugged with soot or broken in pieces Replace as necessary 2 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks i nporcelain if found replace 3 UV Scanner Check for dirt on flame scanner and clean Check for proper location of detector 4 Draft Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper 5 Negative Room Pressure Make sure no exhaust fans are running in the boiler room 44 VMP IOM Maintenance PROBLEM CAUSE REMEDY Boiler will not 1 Gas Supply Check gas pressure coming into gas train If low contact gas company maintain pressure 2 Dirty Flue Check flue for carbon buildup or blockage Clean flue passages with brush 3 Pressuretrol Disconnect all power to the controller Disconnect the wires from the controller Put am OHM meter between the switch terminals Lower the set point and recheck with OHM meter Switch should break If the controller operates improperly replace it 4 Scale Built up in boiler Refer to Section 2 Pressure Vessel Cleaning 5 Refractories Check refractories to see if they are cracked or broken in pieces Replace as necessary 6 Steam traps blowing through Check traps to see if they are clean or replace as necessary
53. ent expert and adjust levels to boiler recommended levels Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper Boiler pushing water 1 Steam Traps Check traps Clean or replace as necessary with the steam carryover 2 High boiler TDS Drain boiler and flush system Refill and increase blow down rate frequency 3 High level of water treatment chemicals 42 VMP IOM Consult water treatment expert and adjust to boiler recommended levels Maintenance PROBLEM CAUSE REMEDY Pump will not cut off 1 Dirty Probes Clean or replace as necessary 2 Relay failed Make sure relay is plugged in tightly If so replace water level relay 3 Ground Connection Check for tightness and clean 4 Probes not sensitive enough Replace probes and relays with extra sensitive ones RO DI Water Pump runs but does 1 Vapor locking of pump Allow system to cool down check steam traps and check to be sure not put water into boiler return lines are not insulated Check return tank temp If it is above 180 F 82 C vapor locking of pump may occur Inspect check valves Clean and replace as needed Replace pump with multistage centrifugal good for 250 F 121 C 2 Impeller Adjustment Check for impeller wear and adjust per component information in instruction manual Burks only 3 Pump suctio
54. etector 5 Air Switch Check for bad air switch by jumpering the two air switch leads as the terminal block If the boiler starts and runs with these terminals jumpered the air switch should be replaced 6 Gas Valve Sticking Pilot Check for dirt in valve or orifice and clean if necessary Check for faulty actuator or valve and replace if necessary 7 Weak Amplifier Replace 8 Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator 9 Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight glass shows the proper water level If there is no power at this terminal the control is bad and must be replaced 10 Dirty or defective UV Scanner Clean or replace Poor Combustion 1 Refractories Check refractories to see if they are plugged with soot or broken in pieces Clean or replace as necessary 2 Air Adjustment Check CO and O levels Adjust Gas Air Ratio 3 Draft Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper 4 Dirty Flue Check flue for carbon buildup or blockage Clean flue passages with brush 5 Negative Room Pressure Make sure no exhaust fans are running in the boiler room 6 Gas Servo Malset Adjust gas servo setting 7 Air Servo Malset Adjust air servo setting Burner back fires 1 Refractories Check refractories to s
55. for 130 150 HP Specifications amp dimensions are approximate We reserve the right to change without notice Fulton The Fulton Companies 972 Centerville Road Pulaski New York 13142 vmpstd pds 2010 1008 Call 315 298 5121 Fax 315 298 6390 www fulton com 11a VMP IOM Product Data Submittal Fulton Models VMP40 VMP49 5 VMP50 VMP60 VMP80 and VMP100 Fulton Fulton Vertical MultiPort Steam Boilers Low Emissions Burners lt 20 PPM NOx Dimensions Models VMP 40 49 5 50 60 80 100 Unit Size BHP 40 49 5 50 60 80 100 A Boiler Diameter IN 49 55 55 55 63 69 MM 1245 1397 1397 1397 1600 1753 B Boiler Height IN 84 91 91 97 100 100 MM 2133 2312 2312 2464 2540 2540 C Boiler Depth IN 90 100 100 100 114 119 MM 2286 2540 2540 2540 2896 3022 D Boiler Height w trim IN 107 112 112 118 124 126 MM 2718 2832 2832 2984 3150 3200 E Overall Boiler Width IN 56 62 62 62 68 74 MM 1422 1575 1575 1575 1727 1880 F Flue Outlet Diameter IN 12 12 12 12 14 14 MM 305 305 305 305 356 356 G To Center of Flue Outlet IN 79 86 86 92 95 95 MM 2006 2184 2184 2237 2413 2413 H Feedwater Inlet IN 35 35 35 35 35 35 MM 889 89 889 889 889 889 J Blowdown Outlet IN 17 18 18 18 18 182 MM 432 457 457 457 457 457 K Height to Steam Outlet IN 73 77 77 84 89 89 MM 1854 4956 4956 2134 2260 2260 L Min Clearance to Ceiling IN 123 135 135 144 147 147 for Burner Removal MM 3124 3429 3429 365
56. g and readjust as necessary Check inlet gas pressure and increase or decrease as necessary 3 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Air Switch Check for bad air switch by jumpering the two air switch leads at the terminal block If the boiler starts and runs with these terminals jumpered the air switch should be replaced 5 Gas Valve Sticking Pilot Check for dirt in valve or orifice and clean if necessary Check for faulty actuator or valve and replace if necessary 6 Weak Amplifier Replace 7 Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator 8 Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight glass shows the proper water level If there is no power at this terminal the control is bad and must be replaced 9 Dirty or defective UV Scanner Clean or replace VMP IOM 41 Maintenance PROBLEM CAUSE REMEDY Poor Combustion 1 Refractories Check refractories to see if they are plugged with soot or broken in pieces Clean or replace as necessary 2 S S Ring Check to be sure ring is present and fits tight against the furnace wall 3 Primary Air Adjustment Check air adjustment Air fuel mixture may be off Open primary air so fire is to outside wal
57. ght Glass Isolation Valves The brass sight glass isolation valves are equipped with an internal ball check In the event that a sight glass should break the ball will seat preventing the discharge of steam and water The brass valve stem must be opened fully to enable this feature If the valve is in any other position than full open the ball will not seat For added safety all Fulton boilers are equipped with gauge glass protectors f High Limit Pressure Control Located in the control panel box and connected to the water column assembly by means of a copper tube The pressure is usually set 10 to 15 PSI 703 1 054 kg cm2 above the operating pressure but below the maximum pressure of the pressure relief valve If the pressure exceeds the high limit pressure control setting the boiler will automatically shut off The high limit pressure control must be manually reset by depressing the plunger located on top of the control g Air Pressure Switch Mounted on the burner scroll this switch is operated by the pressure of air entering the burner through the throat of the scroll Absence of air or insufficient pressure will prevent the switch completing the circuit thus preventing the burner from operating WARNING When stopping the boiler for any extensive repairs shut off main disconnect switches on both the boiler side as well as the feed water side NOTE To ensure that your Fulton Steam Boiler is kept opera
58. he ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lock out and the burner will shut down d When the pilot flame is established ultra violet scanner senses the flame This signal is transmitted back to the flame programmer which opens the main gas valve giving a main flame e If the installation is new or the bumer has been disassembled the burner may not fire at the first attempt due to air which must be purged from the gas lines This will result in the burner flame programmer going to lockout Repeat the procedure for starting the bumer f The main gas valve will remain open as long as there is a demand for heat and the flame is carrying a sufficient signal to the flame programmer g If the flame is not established at the start the safety switch in the flame programmer control will open the contacts and shut off the bumer h Push the reset button on the control to reset If trouble persists it may be necessary to check the UV scanner See Maintenance Section for procedure to check UV Scanner WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected Gas Burner Set Up For Boilers Equipped with Modulation
59. in 6 Remove the hand holes and inspect the interior of the vessel for scale or sludge deposits The amount of deposits will indicate the efficiency of the water treatment being used The frequency of the inspection will depend on the condition of the water side of the boiler 7 Replace hand hole gaskets using the following procedure a Remove the hand hole assembly using a 1 1 4 tee handle wrench or 1 1 4 drive socket wrench Maintenance b Remove the old gasket and thoroughly clean the surface on the boiler and the plate c Fit the hand hole assembly as follows i Placethegasketon the hand hole plate and ensure that it is seating correctly Do not use any grease lubricant or adhesive ii Position the plate in the boiler Set the yoke and tighten the securing nut sufficiently enough to provide a snug fit Verify the position of the plate in the boiler then make it hand tight and then snug with wrench about 1 4 turn Do not compress excessively Illustration shows correct pressure on gasket iii If the gasket leaks while pressure is being built up tighten only enough to stop leakage Never tighten more than necessary to prevent leakage Excessive tightening may shorten the life of the gasket Illustration shows over compressed gasket d Refill the boiler with fresh water NOTE After a new Fulton Boiler has been in operation for several months pieces of burned metal will be found
60. in the space at the bottom of the boiler These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation This is a normal condition and does not affect the efficiency or the life of the boiler in any way 40 VMP IOM Recommended Annual Maintenance Schedule 1 Have combustion CO O CO and input checked by responsible personnel 2 Dirty flues can cause air flow restrictions resulting in poor combustion and loss of efficiency Clean flues as follows a Remove the outer flue cover plate c Remove clean out plugs at lowest part of unit and clean the bottom of combustion chamber d Remove all soot from the top and from the clean out plugs at the bottom with a vacuum cleaner e Replace clean out plugs carefully so as not to damage insulation and replace burner and flue cover plates 3 Flush boiler out if necessary See Section 2 for proper procedure for Cleaning the Pressure Vessel 4 Provide annual inspection by a qualified ASME Boiler inspector Troubleshooting The following trouble shooting guide will assist in the diagnosis and the correction of minor field problems It contains instructions and information necessary to locate and isolate possible troubles which occur during normal operation It should be used in conjunction with the unit wiring diagram and the component literature provided in Section 7 of this manual
61. l of fumace 4 Secondary Air Adjustment Check main air adjustment to see if it is loosened up Adjust as necessary and tighten plate in position Check CO and O levels 5 Draft Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper 6 Dirty Flue Check flue for carbon buildup or blockage Clean flue passages with brush 7 Negative Room Pressure Burner back fires 1 Refractories Make sure no exhaust fans are running in the boiler room Check refractories to see if they are plugged with soot or broken in pieces Replace as necessary 2 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 3 Draft Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper 4 Negative Room Pressure Make sure no exhaust fans are running in the boiler room Boiler will not 1 Gas Supply Check gas pressure coming into gas train If low contact gas company maintain pressure Check coil in gas valve with AMP meter Replace if bad Check gas regulator setting and readjust as necessary 2 Dirty Flue Check flue for carbon buildup or blockage Clean flue passages with brush 3 Pressuretrol Disconnect al
62. l power to the controller Disconnect the wires from the controller Put an OHM meter between the switch terminals Lower the set point of the controller Switch should make Raise the set point and recheck with OHM meter Switch should break If the controller operates improperly replace it 4 Scale Built up in boiler Refer to Section 2 Pressure Vessel Cleaning 5 Refractories Check refractories to see if they are cracked or broken in pieces Replace as necessary 6 Steam traps blowing through Check traps to see if they are clean or replace as necessary 7 Boiler size Boiler is Surging 1 Steam traps blowing through Boiler may be undersized Check traps to see if they are clean or replace as necessary 2 High organic in boiler i e Perc or oil Drain and clean boiler with washing soda per instruction manual 3 High boiler TDS Drain boiler and flush system Refill and increase blow down rate frequency 4 Too much water akalinity high PH Have water tested by water treatment company lower boiler alkalinity to recommended level 5 High sudden steam load Check total equipment horsepower required against horsepower of boiler being used Decrease amount of equipment being used at one time or reduce the steam flow by partially closing the steam stop valve 6 High level of water treatment chemicals Boiler Rumbles and 1 Draft problem Pulsates Consult water treatm
63. ll in no event be liable for any consequential or incidental damages arising in any way including but not limited to any loss of profits or business even if the Fulton Companies has been advised of the possibility of such damages Fulton s liability shall never exceed the amount paid for the original equipment found to be defective To activate the warranty for this product the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval 9 9 09 Parts and Warranty Extended Warranty for Fulton Boilers Warranty Valid for Models ICS ICX VMP FB A FB F FB L FB S Ten 10 Year Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of ten 10 years from the date of shipment from the factory Fulton will repair or replace at our option F O B factory any part of the equipment as defined above provided this equipment has been installed operated and maintained in accordance with the Installation Operation and Maintenance Manual The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklist to Fulton s Service Department This warranty covers any failure caused by defective material or workmanship however waterside corrosion or scaling is not covered Therefore it is imperative that the boiler water management and chemistry be maintained as o
64. lowly drive the servo s motor to high fire insuring that the combustion readings stay within the given parameters Adjust secondary servo as needed d If the last elbow pressure is above or below the stated requirement on the test fire sheet adjust the combustion air damper to bring the last elbow pressure inline The gas pressure is directly proportional to the air pressure and therefore increasing the air pressure to the burner will increase the gas input proportionally e Manually drive the unit back to low fire and check combustion f If the combustion is outside of the test fire parameters for the servo adjust the secondary g After the unit is brought back into range manually drive the unit back to high fire h Adjust secondary air gas ratio slightly if needed i Repeat this procedure 2 or 3 times until you obtain consistency in high and low fire combustion j In most cases the primary gas should only be adjusted if the unit is unstabe at low fire and or NOx are not acceptable at low fire VMP IOM 31 Operation CAUTION During startup insure that adequate gas pressure is supplied to the main valves The indicator on the actuator should never reach the bottom of the indicator window In the event that this happens adjustability will be lost See minimum incoming gas pressure requirement on the test fire sheet The SKP10 actuator functions only as on off When activated the indicator will
65. m are provided in the control panel and are clearly indicated on the diagram Fresh Air Supply for Boiler It is most important to provide free access of air to the boiler To bum fuel properly it requires one square inch opening of fresh air for every 3 000 BTU input of fuel 6 4cm2 for every 756 Kcal Proper ventilation of the boiler room is essential for good combustion Install two fresh air openings one at a low level 24 610 mm from floor and one at a higher level in the boiler room wall This will provide a flow of air to exhaust the hot air from the boiler room Boiler room temp not to exceed 100 F The following openings are recommended for each size boiler Make Up Air Openings BHP FT2 M2 40 5 46 50 5 46 60 7 5 69 80 12 5 1 11 100 16 1 49 130 21 1 95 150 24 2 23 Be sure total BHP proper make up air opening size These measurements are subject to state and local regulations The installation of exhaust fans in a boiler room is not recommended An exhaust fan or similar equipment can create down draft in the stack or restrict the burner s air supply which will result In poor combustion It is essential that only fresh air is allowed to enter the combustion air system Foreign substances such as combustible volatiles and lint in the combustion system can create hazardous conditions _ slal Po ee Appropriate ZA E Weather f Cap ES Ed ES
66. n Manual for detailed instructions NOTE Care should be taken to ensure that the blow down receptacle used meets the regulations covering such vessels If in doubt consult a Fulton Representative for advice Water Cosumn amd Sight Glass VMP IOM Installation a Make sure two check valves are installed between the boiler and pump one check valve is supplied with the unit b In a closed system an end of the line trap should be installed c There are four blow down valves on the boiler Two main bottom blow down valves the gauge glass blow down valve and the water column blow down valve All blow down connections must be piped to blow down seperator All these procedures should be done in accordance with state and or local codes The water column blow down valve and the gauge glass blow down valve should be connected to the main blow down line Steam Supply Pipe the steam supply line from the top right side of the boiler Steam Safety Valve 1 Before installing be sure that all pipes and connections have been blown clean Pipe compound or dope is used on external threads only Be sure 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 connection provided on the top left side of the boiler with no unnecessary intervening pipe Under
67. n plugged Remove clean inlet strainer 4 Plugged feed water nipple Check and clean or replace as necessary 5 Pump undersized worn Replace with appropriate pump 3 Back pressure on pump Need to install repair kit on pump Water pump will not 1 Scale on probes Check and clean or replace as necessary come on at times 2 Bad Pump Contactor Check to see if contactor is being powered Check to see if contactor coil is pulling in Replace if necessary 3 Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power If power is present but motor does not run replace it Low Fuel pressure 1 Gas pressure regulator Check and replace Boiler Flooding 1 Pump does not shut off Dirty Probes Clean or replace as necessary 2 Relay failed Make sure relay is plugged in tightly If so replace water level relay 3 Ground Connection Check for tightness and clean 4 Vacuum created with boiler off As the boiler cools off it pulls water from the system piping To prevent this add a 1 4 check valve on the steam gauge assembly piping which closes under pressure and opens under vacuum Troubleshooting Gas Fired Boilers LE Models PROBLEM CAUSE REMEDY Ignition Failure 1 Power Supply Check fuse or circuit breaker Reset or replace as necessary 2 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustments Readjust if necessary Check for cracks in porcelain If found
68. nd Operation Manual Parts Warranty Fulton will repair or replace F O B factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one 1 year of shipment from the factory provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton s Quality Assurance department General Fulton shall be notified in writing as soon as any defect becomes apparent This warranty does not include freight handling or labor charges of any kind These warranties are contingent upon the proper sizing installation operation and maintenance of the boiler and peripheral components and equipment Warranties valid only if installed operated and maintained as outlined in the Fulton Installation and Operation Manual No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority Fulton will not pay any charges unless they were pre approved in writing by the Fulton Quality Manager This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose Fulton sha
69. ng codes or standards which may be applicable The requirements and instructions contained in this section generally relate to the standard Fulton Gas Fired Steam Boiler When installing a packaged unit this entire section should be read to ensure that the installation work is carried out correctly Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing a Material inspections b Manufacturing process inspections c ASME welding inspections d ASME hydrostatic test inspection e Electrical components inspection f Operating test g Final Engineering Inspection h Crating inspection All units are crated for fork lift transport Once uncrated all units can be transported with a forklift Under no circumstances should weight be allowed to bear on the jacket control panel or fan housing of any Fulton Boiler Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy equipment The customer should examine the boiler for any damage especially the refractories It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner NOTE The installation of the Fulton Gas Fired Steam Boiler should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association National or Canadian Electrical Code All state and jurisdic
70. no circumstances should there be a shut off valve or restriction of any kind between the safety valve and the connection provided 4 Do not cap or plug drain hole in the side of valve body 16 VMP IOM Inspection Teli Value si Shown Oper _ Steam Siphon Loop Ta 5 Since the purpose of this safety valve is to protect against an overpressure situation it will loudly discharge hot steam in doing so Therefore it is recommended that a discharge pipe be securely installed and run to a safe point of disposal 6 When a discharge pipe is used it must be of a pipe size equal to or greater than that of the valve outlet Use schedule 40 discharge pipe only Do not use schedule 80 extra strong or double extra strong discharge pipe or connections It must be as short and straight as possible and so arranged as to avoid undue stress on the valve It must have an ample provision for draining condensate at or near the valve outlet It must terminate freely to atmosphere with no intervening valve of any description and it must be securely anchored and supported i To Operating TEGRITO Canina Steam Pressure Gauge Assembly The gauge should be facing front towards the panel box and or operator of the boiler Except as noted each assembly or any of its component parts may be oriented other than as shown to provide improved operating clearances and or view of gauge Before installing steam gauge on the siphon
71. nsion Gasket 14 80 100 HP 1 0 45 2 12 521 Top Plate Gasket 40 60 HP 1 0 45 2 12 522 Top Plate Gasket 80 100 HP 1 0 45 4 12 516 Gas Oil amp Comb Gasket Kit 15 6 82 4 12 520 80 100 HP Gas Oil amp Comb Gasket Kit 10 4 55 See the component assembly drawings to assist with parts identification VMP IOM Q Parts and Warranty Q VMP IOM Parts and Warranty CREDI DENTE Pers A RF DELE ih AAA TI u i pr ay HIER TITTIS io Standard Warranty for Fulton Boilers Warranty Valid for Models ICS ICX ICW ICXW VMP VMPW FB A FB F FB L FB S FB W Five 5 Year 60 Months Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of five 5 years from the date of shipment from the factory Fulton will repair or replace F O B factory any part of the equipment as defined above provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton s Quality Assurance department This warranty covers any failure caused defective material or workmanship however waterside corrosion or scaling is not covered Therefore it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation a
72. nt a Following are recommendations for feed water and boiler water Contact your local water treatment professional for testing and treatment recommendations It is very important that a strict water treatment program be followed Feedwater Dissolved Oxygen less than 0 05 ppm PH Value 9 11 tested at room temperature Hardness less than 25 ppm in the form of CACO3 AAA indaco none Suspended Solids none Organic Matter less than 5 0 ppm Total Dissolved Solids less than 300ppm Boiler Water Alkalinity less than 300 ppm in the form of CACO3 Chioride less than 500 ppm pH Value 9 to 11 tested at room temperature Total Dissolved Solids 2 000 ppm maximum Hardness less than 50 0 ppm Dissolved Oxygen none Suspended Solids 40 ppm ppm parts per million CACO3 Calcium Carbonate PO4 Phosphate SiO silicon dioxide 1 Grain Hardness 17 118 ppm Therefore 70 ppm 4 10 grains hardness b It is critical that the boiler pH be alkaline 9 11 whenever water is in the boiler Solids that enter in with the feed water concentrate in the boiler Daily boiler blow down is recommended to prevent corrosion and or deposits from forming Glossary of Water Supply Corrosives and Inhibitors DISSOLVED OXYGEN Oxygen
73. ntrol to approximately 60 of your desired set point and the main operating pressure control to your desired set point WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected Primary Air Adjustment for Fulton Gas Fired Steam Boilers 1 The primary air adjustment or main air control is located at the fan housing face This control is used to supply the burner with excess air needed to facilitate good combustion Too much or too little air will result in poor combustion It is important to make sure the lowest level of excess oxygen is present while still maintaining a high level of carbon dioxide and negligible carbon monoxide Using a CO or O tester it is possible to determine the percent of excess air in the combustion mixture 2 It is a good policy on a gas fired unit to have between 3 5 and 4 oxygen present in the combustion This will give you 10 5 to 9 5 carbon dioxide The carbon monoxide level should always be less than 400 PPM Secondary Air Adjustment Procedure for Fulton Gas Fired Steam Boilers 1 The secondary air control adjustment is located on the top right hand side of the bumer assembly This damper type air controller is used to introduce air to and through the blast tube of the bumer The purpose of the secondary air adjustment is to proportionately divide the air to the
74. ol L404A 5 50 PSI 2 0 91 2 40 229 Pressuretrol L404A 10 150 PSI 2 0 91 2 40 230 Pressuretrol L404A 20 300PSI 2 7 1 23 2 40 231 Pressuretrol L404C 2 15 PSI 2 0 91 2 40 232 Pressuretrol L404C 5 50 PSI 2 0 91 2 40 233 Pressuretrol L404C 10 150 PSI 2 0 91 2 40 234 Pressuretrol L404C 20 300 PSI 2 7 1 23 2 40 161 Flame Scanner Mini Peeper 0 5 0 23 2 40 262 RM7800M Programmer 40 100 HP 120 V 2 5 1 14 2 40 265 7 Second Prepurge Timer 0 1 0 05 2 40 266 30 Second Prepurge Timer 0 1 0 05 2 40 267 60 Second Prepurge Timer 0 1 0 05 2 40 269 RM7800 Amplifier For UV Amp 0 2 0 09 2 40 161 Mini Peeper For All 7800 0 5 0 23 VMP IOM 51 Parts and Warranty Part No Description Approx Net Weight Ibs kgs 2 40 270 Base For All 7800 0 5 0 23 2 40 272 Display Module for 7800 Controls English Also Available in Spanish 0 5 0 23 2 40 247 Remote Mounting Bracket for 7800 0 65 0 3 2 40 248 Extension Cable Boiler Trim 2 30 396 1 Spring Loaded Check Valve 200 2 55 1 16 2 30 397 1 1 4 Spring Loaded Check Valve 200 3 8 1 73 2 30 019 1 4 Ball Valve 200 0 6 0 27 2 30 008 1 2 BallValve 200 0 7 0 32 2 30 027 3 4 BallValve 200 1 4 0 64 2 30 026 1 Ball Valve 200 1 75 0 8 2 30 001 1 MxF Ball Valve 200 2 0 91 2 30 017 1 1 4 Ball Valve 200 3 1 1 41 2 30 018
75. on point 13 Verify the jumper on the motor is located on the same pins as the motor that was replaced 14 Turn power to the boiler on 15 The screen will display system test The fault Fault Feedback Air Actuator will be displayed DO NOT RESET THIS FAULT YET Press Escape twice to clear the fault from the screen 16 Press Escape to get to the main menu Under Params amp Display gt Actuators gt Addressing select either the gas actuator or air actuator depending upon which was replaced The control will run an actuator check then display Start Address Assignment with ENTER Press Enter The display will then have you press the addressing button on the actuator This is the red button on the actuator The screen will then display Actuator Address Assignment Successful 17 Press Escape until the main menu is reached Under OperationalStat gt Status Reset reset the fault CAUTION The boiler emissions may not be correct after changing the servo motor Verify the emissions throughout the range of modulation If emissions are off the servo motor can be adjusted by following the procedure in the Commissioning the Boiler section of this manual 18 Attach cover to servo motor Recommended Daily Maintenance Schedule The following procedures should be carried out daily They are designed to prevent the build up of scale silt or sludge in the bottom of the boiler and in the pipes leading to the
76. oon as a servo position is altered the servo will move to that position Only change servo settings by a maximum of 0 5 at a time before verifying combustion 28 Go to Params amp Display gt RatioControl gt GasSettings or Oil Settings depending on the current fuel gt CurveParams 29 Wait for the spinning line on the left to disappear Press Enter The number 1 should appear to the right of the cursor this is the Point Number Press Enter once Select ChangePoint by pressing the arrow keys to highlight and then press Enter to select This will cause the servo motors to move to this low fire point Check combustion and adjust the servo motors as required To adjust a servo motor arrow to it and press Enter Then adjust the setting as required and press Enter You can now adjust another servo motor if needed When combustion is properly set for that point press Escape once more If it asks you to store the point press Enter Note the AZL will only ask to save if either servo value has been altered Low fire is now set and stored SETTING THE COMPLETE RANGE a Remember it is only necessary to approximate the setting through the modulation range until high fire conditions are established b Press Enter once more to have access to the point number field Increase the point number by one and press Enter Select ChangePoint and press Enter The servos will now move to that point c Verify combustion is satisfa
77. phosphate and silicate These alkalinities especially bicarbonates and carbonates break down to form carbon dioxide in steam which is a major factor in the corrosion on condensate lines High alkalinity also causes foaming and carry over in boilers Both foaming and carry over cause erratic boiler operation When foaming occurs an anti foam should be added or increased The reason for the high alkalinity should be determined It may result from lack of sufficient blow down Pretreated makeup water and condensate should also be checked quite often the source of alkalinity is an overdose of alkaline internal water treatment chemical pH pH is a measure of the degree of acid or base of solution Neutral pH ranges of 6 5 7 5 will have negative influence on the corrosion rate of carbon steel Alow pH can result in corrosion of metals while a high pH can result in scale formation Optimal boiler pH is 9 11 slightly alkaline In order to control boilers and equipment used for the external treatment of make up water it is essential that frequent reliable pH measurements be made VMP IOM Installation CHLORIDES CHLORINE Chlorides are generally considered detrimental in stainless steel systems only Stress corrosion cracking can occur from high chlorides High chlorine levels can cause severe corrosion Corrosion from chlorine can be controlled by removal via carbon filtration City water can contain high levels of
78. r Plate 100 HP Propane 1 454 7 30 000177 Burner Plate 100 HP Town Gas 1 454 7 30 000178 Burner Plate 100 HP Butane 1 454 7 54 1006 Gas Train Assembly 40 50 HP Natural Gas 70 31 82 7 54 5158 Gas Train Assembly 80 HP Natural Gas On Off 100 45 45 7 54 5159 Gas Train Assembly 100 HP Natural Gas On Off 100 45 45 7 54 6158 Gas Train Assembly 80 HP Propane Gas On Off 100 45 45 7 54 6159 Gas Train Assembly 100 HP Propane Gas On Off 100 45 45 7 54 8488 Gas Train Assembly 80 HP Natural Gas High Low Off 100 45 45 7 54 8489 Gas Train Assembly 100 HP Natural Gas High Low Off 100 45 45 7 54 7758 Gas Train Assembly 80 HP Natural Gas Modulation 100 45 45 7 54 7759 Gas Train Assembly 100 HP Natural Gas Modulation 100 45 45 7 54 8498 Gas Train Assembly 80 HP Propane Gas High Low Off 100 45 45 7 54 8499 Gas Train Assembly 100 HP Propane Gas High Low Off 100 45 45 7 54 8409 Gas Train Assembly 80 HP Propane Gas Modulation 100 45 45 7 54 8410 Gas Train Assembly 100 HP Propane Gas Modulation 100 45 45 Water Column 5 20 022 Fulton Water Column Bottle Casting 4 100 HP 20 9 09 2 30 151 MM 150 Pump Control 25 11 36 2 30 193 MM 150 M R Control 25 11 36 2 30 152 MM 150 HD Assembly 25 11 36 2 30 192 MM 150 M HD M R Head 25 11 36 2 12 125 MM 150 14 Gasket 0 05 0 02 2 30 136 MM 157 Pump Control and Low Water Cutoff 39 7 18 05 2 30 137 MM 53 2 Boiler Feeder and Low Water Cutoff 38 5 17 5 2 45 144 MM Mercury Switch 2 Wire 1 0 45 2 45 143 MM
79. r of the new servo motor is the same as the old servo motor The model number starts with the letters SQM and is displayed on a label on the side of the motor Once the new motor has been verified to be correct tum power to the boiler off 1 Turn off all electricity to the boiler 2 Remove the cover on the servo motor to be changed 3 Remove the green wiring plugs and the conduit termination point from the motor by pulling them towards you A black grounding wire runs from the motor to the conduit termination point Pull it off from the conduit termination point 38 VMP IOM gt Also note the location of the jumper on the left side of the motor 5 Loosen the allen screws on the motor end of the motor to valve coupling 6 Unbolt the motor from the mounting bracket and remove the motor 7 Tum the valve so it is in the closed position and can rotate clockwise to open 8 Mark the coupling or valve shaft if needed so the position of the valve can be determined when the servo motor is installed 9 Bolt the new servo motor on to the mounting bracket with the motor shaft inserted into the coupling 10 Rotate the valve shaft coupling assembly closed as stated above 11 While holding the valve closed tighten the allen screws on the coupling 12 Install the wired green wiring plugs and the conduit termination point on the new motor Connect the black grounding wire from the motor to the conduit terminati
80. ration Boiler Controls a Flame safeguard burner control This is the main control in the panel box The programmer in conjunction with a sensing device either a flame rod or an ultra violet scanner supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lock out and the burner will shut down b Low Water Cut Off Probe Type Cuts off the unit when water level is too low after a 3 second time delay to avoid nuisance shut downs As a standard feature Fulton boilers are equipped with ASME CSD 1 Code controls which include a manual reset feature on the bumer low water cut off relay and ASME CSD 1 Code controls also feature an independent second low water cut off relay Press the low water reset button and the boiler will start CAUTION Do not tamper with the safety features of the low water safety cut out c Pressure Relief Valve Limits the maximum operating pressure of the boiler d Operating Steam Pressure Control Located in the control panel box and connected to the steam pressure gauge assembly by means of a copper tube The pressure control regulates the on off cycle of the burner shutting the bumer off when maximum pressure is reached and switching on when the steam pressure falls below a predetermined level e Si
81. reas If a boiler is using raw water makeup iron is almost certain to be a major component of developing scale or sludge deposits WATER HARDNESS Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents Water hardness is a primary source of scale in boiler equipment Hardness is removed by water softeners or RO DI systems It can also be treated with various chemical treatments i e Phosphates FEEDWATER Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler Hot gt 180 F feedwater free of hardness solids and oxygen will yield the most protection to a boiler CONDENSATE Condensate is condensed steam that is normally low in dissolved solids Hence it does not contribute to the dissolved solid content of the feedwater In addition condensate is very expensive to waste It s been chemically treated heated pumped converted to steam and condensed This costs money and when condensate is returned to the boiler money is saved Electrical Requirements 1 Connect wiring as shown in the wiring diagram which is furnished inside the electrical control panel box 2 Be sure to install a separate disconnect for each piece of equipment The disconnects should be installed in compliance with the NEC National Electric Code and all local codes 3 Connections for an optional audible alar
82. ry 2 Relay failed Make sure relay is plugged in tightly If so replace water level relay 3 Ground Connection Check for tightness and clean 4 Vacuum created with boiler off As the boiler cools off it pulls water from the system piping To prevent this add a 1 4 check valve on the steam gauge assembly piping which closes under pressure and opens under vacuum VMP IOM B 46 VMP IOM Section Parts and Warranty VMP IOM Parts and Warranty It is important that the correct replacement part is fitted to your Fulton Gas Fired Steam Boiler weer Fulton Fuel Fired make sure that the full information given in a the Parts List is supplied together with the following details as shown on your boiler eam OI er identification plate Boiler No 1 Boiler Number 3 Electrical Specifications National Board No NOTE The policy of Fulton Boiler Works Inc is one of continuous improvement and therefore we reserve the right to change prices specifications and equipment MD Lbs Steam Hr SH zZ u N E E BEE Fulton Fulton Boiler Works Inc Pulaski NY 13142 Part No Description Approx Net Weight Ibs CH 5 60 100 Instruction Manual Fuel Fired 2 0 91 5 60 165 Certification Papers Boiler Shell Parts 5 12 017 Furnace Refractory 30 OD x 91 2 ID 80 HP Top 225 102 27 5 12 018 Furnace Refracto
83. ry 30 OD x 10 ID 100 HP Top 225 102 27 5 12 019 Furnace Refractory 30 OD x 13 D 80 amp 100 HP Bottom 225 102 27 5 12 015 Furnace Refractory 24 OD x 8 ID 40 60 HP Top 125 56 82 5 12 016 Furnace Refractory 24 OD X 10 ID 40 60 HP Bottom 125 56 82 2 12 000 Furnace Cement 2 Ib can 2 0 91 2 12 001 Furnace Cement 8 Ib can 8 3 64 2 12 002 Furnace Cement 15 Ib can 15 6 82 Misc Flue Cover 40 60 HP 10 5 10 11034 Flue Cover Plate 80 HP 10 64 29 09 5 10 11024 Flue Cover Ring 100 HP 10 75 34 09 5 12 003 Square Cleanout Plug 15 6 82 2 12 064 Flexitalic HHG Extra Heavy High Pressure 0 5 0 23 2 12 088 Blue Max HHG 0 05 0 02 5 10 804 Handhole Welding Patch 60 100 HP 1 1 0 5 2 12 004 Handhole Gasket 60 100 HP 0 05 0 02 2 11 TIL105 HandholeYoke 1 5 0 68 2 11 TIL104 3 x 4 Handhole Cover 40 100 HP Blue 2 0 91 4 11 028 40 100 HP Handhole Assembly Blue 7 3 18 2 12 504 Blanket Insulation Sq ft 0 5 0 23 5 21 306 Steel Jacket 40 60 HP No Holes Cut 125 56 82 5 21 308 Steel Jacket 80 HP No Holes Cut 180 81 82 5 21 309 Steel Jacket 100 HP No Holes Cut 205 93 18 5 21 375 Exhaust Transition 40 60 HP 5 21 374 Exhaust Transition 80 HP 8 5 3 86 5 21 373 Exhaust Transition 100 HP 2 12 502 Kast Set per Ib 10 lbs minimum Use for making refractories 2 21 015 Buckeye Stamping for Bottom Handhole 60 100 HP 1 0 45 2 21 093 Buckeye Stamping for Upper Handhole 60 100 HP 1 0 45 2 23 171 Touch Up Paint MICA Spray 10 oz 1
84. t for 1 1 2 Y Valve 0 1 0 05 2 12 028 Teflon Disc for 2 Y Valve 0 2 0 09 2 11 018 Brass Seat for 2 Y Valve 0 1 0 05 Test Equipment Tools 2 40 090 Test Leads 0 6 0 27 2 40 215 Microampmeter W136 2 0 91 2 60 100 Jr Amprobe Y25 1 0 45 2 60 102 Pocket Draft Meter 1 0 45 2 60 103 All Purpose Draft Meter 3 1 36 2 60 104 CO Tester Gas 15 6 82 2 60 105 CO Tubes 0 25 0 11 2 60 106 StackThermometer 4 1 82 2 60 108 SmokeTester Oil 2 0 91 2 60 110 Fisher Gauge 50 PZ 1 0 45 2 60 247 Flue Brush Pipe Type 2 1 2 100 HP 1 0 45 VMP IOM Parts and Warranty Part No Description Approx Net Weight Ibs kgs 2 60 248 Flue Brush Pipe Type 2 40 and 80 HP 1 0 45 5 10 397 Tee Handle Wrench 2 7 1 23 2 20 110 Fan Puller 5 8 Hub 2 0 91 Barometric Controls 2 30 099 14 M amp MG2 80 100 HP Oil Gas Comb 16 7 27 2 30 0415 16 M amp MG2 25 11 36 Spare Parts Kits 2 12 517 Burner Plate Gasket 40 80 and 100 HP Gas 0 06 0 03 2 12 023 Screws 11 0 001 0 00 5 12 046 Bottom Cleanout Gasket Only 0 5 0 23 2 12 550 Combination Gasket 0 05 0 02 4 12 114 Flue Cover Plate Gasket Strip amp Stick Box of 3 3 1 36 1 4 Braided Rope Gasket 80 100 HP price per foot 0 25 0 11 2 12 077 Handhole Funnel Gasket 80 100 HP Top 0 05 0 02 2 12 079 Handhole Funnel Gasket 80 100 HP Bottom 0 05 0 02 2 12 531 Scroll Gasket 40 60 HP 1 0 45 Scroll Gasket 80 100 HP 1 0 45 Stack Exte
85. that is dissolved in the feedwater will cause the steel in the boiler and the feedwater system to be attacked by the water in a manner described as pitting The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide Once pitting starts it may be extremely hard to arrest Pitting can proceed at a surprisingly rapid rate and can occur not only in the boiler proper but also in pre boiler equipment such as economizers feedwater heaters and feedwater lines SUSPENDED SOLIDS Suspended solids are the undissolved matter in water including dirt silt rust and any other insoluble matter Normally suspended solids are expressed in terms of turbidity The presence of suspended solids in cooling water can increase impingement type corrosion Suspended solids may also deposit in low velocity areas and create differential aeration cells Pitting can result The most common cause of high suspended solids is high hardness feedwater piping corrosion and inadequate blow down rate In line filters or various types of pretreatment can be used to lower the suspended solids level Various polymers assist in holding solids in suspension Boiler blow down is the best way to control suspended solids ALKALINITY Alkalinity is the capacity of a water to neutralize acids Common water alkalinities consist of bicarbonate carbonates hydroxide
86. ting safely and efficiently follow the maintenance procedures set forth in Section 4 of this manual VMP IOM 29 Operation Air and Gas Adjustment for LE Models The low emission burner can be best described as a fuel staged multi radial injection type Two air gas ratio electro servo actuators control the fuel supplied to this burner A radial blade type fan supplies the air A direct coupled reversing actuator modulates the air which in turn regulates the fuel input No mechanical linkage is utilized with this system As a safety device a thermocouple is placed in the small partial premix area of the burner to monitor temperature It is used in conjunction with a temperature limit that should be set between 600 and 700 F Commissioning Start Up for LE Models WARNING Commissioning Start Up by a non Fulton authorized person will void the product warranty Before commissioning the boiler verify with authorized personnel that the gas lines have been purged SIEMENS LMV LINKAGELESS BURNER MANAGEMENT SYSTEM If Equipped The Siemens LMV system is a fully packaged burner management system linkageless control and first out annunciator When operating the Siemens LMV systems all changes are made through the Siemens AZL display The left and right arrow keys are used for scrolling through the menu and changing controller parameters Enter accepts the menu and parameter changes It is possible to return
87. tional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes for its corresponding classification should be followed in all cases Jurisdictional authorities must be consulted prior to installation WARNING Operating the boiler beyond its design limits can damage the boiler and can also be dangerous Do not operate the boiler outside its limits Do not try to upgrade the boiler performance by unapproved modifications Unapproved modifications can cause injury and damage Contact your Fulton dealer before modifying the boiler 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 Do not attempt repairs or any other maintenance work you do not understand Obtain a Service Manual from Fulton or call a Fulton Service Engineer WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach yo
88. tive of Fulton other than the Quality Manager or an officer of the company has warranty authority Fulton will not pay any charges unless they were pre approved in writing by the Fulton Quality Manager This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose Fulton shall in no event by liable for any consequential or incidental damages arising in any way including but not limited to any loss of profits or business even if Fulton has been advised of the possibility of such damages Fulton s liability shall never exceed the amount paid for the original equipment found to be defective Conditions of Warranty Warranties are only valid if the boiler is installed operated and maintained as outlined in the Installation Operation and Maintenance Manual Fulton shall accept no responsibility if the equipment has been improperly installed operated or maintained or if the buyer has permitted any unauthorized modification adjustment and or repairs to the equipment The use of replacement parts not manufactured or authorized by Fulton will void any warranty express or implied Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a factory certified technician The commissioning agency must successfully complete and return the equipment Installation and Operation
89. to be defective replace NOTE The scanner is located on the outside edge of the burner top plate for 40 80 and 100 HP 4 For the RM7800 Series use a keyboard display module or volt meter The flame safeguard will require a 1 25 VDC signal to pull in the main flame Then a maximum signal should be obtained on main flame 5 0 VDC 36 VMP IOM Blast Tube Viewing Port Burner Plate Scanner Location Gas Orifice Assembly Top Plate Deflector 5 Adjustments to establish a good signal may include the following items a Primary and secondary air adjustments b Increasing the pilot gas through the pilot gas regulator Checking the Stainless Steel Combustion Ring on Fulton Gas Fired Steam Boilers 1 The stainless steel combustion ring in Fulton gas fired boilers are designed to bring quick and effective flame transfer to the fire wall The ring should fit securely and tight against the furnace wall for best results 2 The ring should be inspected for distortion in the event of poor combustion which could result in flame failures Stainless Steel Combustion Ring 40 100 Maintenance Furnace Refractory Replacement Procedure 1 Remove the burner plate and top plate assembly up and out of the air to air heat exchanger Remove the stainless steel combustion ring from the furnace Remove the clean out plugs from the bottom sides of the boiler The boiler has two clean out plugs on
90. to get a After you have pressed Enter on the last character of the password press Enter once more to accept the password If you do not have the password contact your Fulton Authorized Representative to perform the changes 4 Select Params amp Display Press Enter Select RatioControl Press Enter Select ProgramStop Press Enter Change the Program Stop to 44 Interv1 by using the arrow keys Confirm the change by pressing Enter This will set the burner management system to a pilot hold setting Verify that the current value curr changes to 44 Interv 1 The full list of program stops are 24 Air damper in the prepurge position 32 Traveling to the FGR position if the unit is equipped with FGR 36 lgnition position before pilot ignition 44 Ignition position after pilot ignition 52 Ignition position after main burner ignition 72 Air damper in the postpurge position 76 Traveling to the FGR position if the unit is equipped with FGR 5 Press Escape 4 times to get back to the main menu 6 Under ManualOperation gt Setload change the load to 0 by using the arrow keys Press enter and verify the 0 has been acknowledged in the curr field 7 Press Escape once to get back to the ManualOperation menu 8 Under Auto Manual Off change the operation to Burner On by using the arrow keys Press enter and verify that Burner On is acknowledged in the current field 9 Press Escape twic
91. to the main menu at any time by repeatedly pressing Escape When running the boiler the status of the burner is to be monitored with the Siemens AZL display 30 VMP IOM If at any time the burner control locks out on a fault condition and the red flame failure light illuminates Read the diagnostic feedback on the AZL display address the fault if possible Press escape on the AZL once Press enter on the AZL to reset the control The red light should go out If the fault persists contact Fulton If the boiler has a dual fuel burner the burner setup procedures on the following pages must be performed for each fuel LMV Control for LE Models NOTE The following procedure must be repeated for each fuel the boiler is equipped to operate on PRE IGNITION STEPS 1 Verify the main burner switch is in the OFF position If the boiler has dual fuels verify the fuel selector switch is turned to the correct fuel 2 Supply power to the boiler The AZL will display system test and then move to the main menu 3 Select PWLogin press Enter Select AccessServ Press Enter This type of step will be shown as PWLogin gt AccessServ for the remainder of this section Enter the service passwords using the arrow key The password is case sensitive The case of a letter can be changed by pressing the other arrow key For example if you used the right arrow key to get to the letter A press the left arrow key
92. tomatic is entered in the current field 38 Press Escape twice to get back to the main menu 39 Under Updating gt ParamBackup select LMV51 AZL This will store all of the adjustments that have been made in the LMV base module to the display If the base module were to fail the display can be used to download all of the parameters into a new base module 40 Press Escape 4 times Select PW Logout the password is now logged out 41 Press Escape twice Select OperationalStat gt NormalOperation The control is now on the normal operational display screen 42 The boiler is now ready to run Adjust your setpoint on the temperature control to the desired temperature and tum the main ON OFF switch to ON for the bumer to operate BEFORE LEAVING THE INSTALLATION Check all controls to insure they are operating properly Cycle the boiler several times Make sure the installation complies with all applicable codes NOTE Decreasing the primary will typically decrease the NOx levels If the primary is decreased too much stability may be compromised a Start the boiler and check for stable combustion at low fire Refer to the test fire sheet for acceptable parameters b Adjust secondary servo air gas if needed to bring combustion into an acceptable range Adjust carefully as this is the main fuel adjustment c After a stable flame is achieved and the combustion is within the test fire sheet parameters manually and s
93. ur gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier VMP IOM O Safety Warnings and Precautions For Your Safety The following WARNINGS CAUTIONS and NOTES appear in various sections of this manual They are repeated on these safety summary pages as an example and for emphasis 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 operating 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 Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels A means to cool boiler blowdown water to lt 140 F prior to discharging to floor drains is required for personnel and equipment protection WARNING Only properly trained personnel should install and maintain water gauge glass and connections Wear safety glasses during installation Before installing make sure
94. ure for natural gas should be 3 1 2 W C plus fan pressure at the elbow to the burner and 7 to 11 W C at the head of the train 8 Loose wire connection Check connections to all components Flame Failure 1 Power Supply Check fuse or circuit breaker Reset or replace as necessary 2 Gas Supply Check for gas pressure and for intermittent supply problems Gas pressure for natural gas should be 3 1 2 W C plus fan pressure at the elbow to the burner and 7 to 11 W C at the head of the train 3 Ignition Electrodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Primary Air Adjustment Check air adjustment 5 UV Scanner Adjustment Check for dirt on flame scanner and clean Check for proper location of detector 6 Flame Safeguard Control Check voltage at terminal leading to main gas valve If no power replace the control 7 Loose wire at fuel valve circuit Tighten wiring connections 8 Contact open on air safety switch Adjust to proper setting 9 Scanner wiring reversed Change to correct terminals at panel box Burner Cut Off 1 Power Supply Check fuse or circuit reset or replace as necessary 2 Gas Supply Check to be sure main gas cock is not closed Check coil in gas valve with OHM meter Replace if faulty Check gas regulator settin
95. utlined in the Installation Operation and Maintenance Manual The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system Generally this system MUST include ALL of the following equipment in order for the warranty to apply Fulton boiler with model number as listed above Fulton DA or condensate return system with preheat kit Fulton blowdown tank separator Water softener Chemical feed system Automatic surface or bottom blowdown which must operate to maintain TDS levels as specified in the Installation Operation and Maintenance Manual Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation Operation and Maintenance Manual There is a 1 000 labor allowance for any failed pressure vessel that is covered under the above warranty Parts Warranty Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve 12 months of shipment from the factory provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers General Fulton shall be notified in writing as soon as any defect becomes apparent This warranty does not include freight handling or labor charges of any kind No Sales Manager or other representa

VMP Gas IOM

Contents

Download Pdf Manuals

Related Search

Related Contents