FULTON VMP Series Installation, Operation And Maintenance Manual Download Page 1

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

VMP-IOMM-2018-2

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

VMP (vertical multi-port)

Fuel Fired Steam Boiler

Summary of Contents for VMP Series

Page 1: ...This manual must be available to the boiler operator at all times VMP IOMM 2018 2 INSTALLATION OPERATION AND MAINTENANCE MANUAL VMP vertical multi port Fuel Fired Steam Boiler...

Page 2: ...fully modulating 28 3 3 Gas Monoblocs Non Modulating Burner 28 3 3 1 Multi Bloc Gas Valves 29 3 4 Cleaning Steam Lines and Pressure Vessels 32 SECTION 4 OPERATION 4 1 General 33 4 2 Controls 33 4 2 1...

Page 3: ...oting Oil boiler 63 6 3 Troubleshooting feedwater pump 68 6 4 Troubleshooting Siemens LMV 70 APPENDIX A TI SHEETS VMP Dimensions Specification 84 Water Level Probes 86 Auto TDS Blowdown Systems 88 Rec...

Page 4: ...n or maintenance of the equipment WARNING Steam boilers are a potential hazard possibly fatal if not properly maintained CAUTION It is vitally important that the instructions given in this manual are...

Page 5: ...er cannot be over emphasised see the relevant section in this manual WARNING DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustment to achieve low emissions safe clean and effic...

Page 6: ...t consult Fulton Ltd CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants CAN BE SUPPLIED by Fulton Ltd It is the responsib...

Page 7: ...uirements of the applicable European Directives and subject to proper maintenance should not give occasion to any hazardous conditions If such a condition should occur during commissioning or during s...

Page 8: ...VMP IOMM 2018 2 Fulton Ltd Page VIII...

Page 9: ...and maintenance of your Fulton equipment and should be read in its entirety and be made permanently available to the staff responsible for the operation of the boiler It should not however be conside...

Page 10: ...VMP IOMM 2018 2 Fulton Ltd Page 2 INTRODUCTION 1 Figure 1 General Arrangement 13 14 18 19 2 4 5 12 11 15 1 3 7 9 10 8 16 17 6 16...

Page 11: ...itch 8 Main boiler blowdown front 9 Air pressure switch 10 Boiler name plate 11 Main steam stop valve 12 Water level gauges sight glass 13 Water level gauges blowdown valves 14 Boiler control panel 15...

Page 12: ...in the design calculations K Design pressure The pressure used in the design calculations L Safety valve set pressure Pre set lift pressure of the fitted safety valve set to prevent boiler steam overl...

Page 13: ...Local regulations for discharge into existing drains G Suitable access for delivery and off loading H Safe access to the plant when installation is complete 2 1 General The installation of a VMP fuel...

Page 14: ...rdous conditions Particulate matter like lint combustible volatiles dust smog or chemicals example perchlorethlylene halogenated compounds in the combustion air supply to the equipment will cause dama...

Page 15: ...ve TYPICAL BOILER INSTALLATION Design and Layout will change with Boiler Specification Vent Cold Water Supply Sight Glass Vent Condensate Return Tank Discharge To Drain Blowdown Separator Shut Off Val...

Page 16: ...ere are six blowdown valves on the boiler two main boiler blowdown valves at the bottom of the boiler two water bottle blowdown valves and two water level gauge sight glass blowdown valves All of thes...

Page 17: ...s The water bottle blowdown cock should be connected to the auxiliary blowdown line 1st Low water probe blue Pump off grey Pump on black 2nd Low water probe brown 2 4 2 1 Main Boiler Blowdown Valve Th...

Page 18: ...e lift pressure is indicated on the safety valve do not adjust b The safety valve fitted to the boiler is designed to prevent the boiler exceeding its design pressure c Any system connected to the boi...

Page 19: ...e nipple provided on the assembly Test Point Steam Pressure Gauge Steam Cock Syphon Plugged Figure 8 Steam Pressure Gauge Distribution pipework should be run from the main steam valve on the boiler to...

Page 20: ...L P gas installations If the gas supply is in excess of 150 mbar for Natural gas a suitable regulator is required before the main gas valve Burners arranged for operation on L P gas are supplied with...

Page 21: ...s control valve on the Fulton burner An intermediate or Service Governor is therefore required to reduce the pressure further to below 80 mbar The siting of the LPG storage tank can be crucial particu...

Page 22: ...he oil storage tank will be dependent on site conditions and local regulations The burner fuel pump is of the bypass type requiring the installation of feed and return lines between the oil storage ta...

Page 23: ...nnect power to the terminal strip as supplied on the inside of the panel box Note Single skid systems are generally shipped completely pre wired Note The power ratings and requirements are given in Ap...

Page 24: ...to occur as required by monitoring the TDS in the boiler Valve supply Max rating 250V 3A resistive 250V 1A inductive Blowdown Alarm The blow down alarm is triggered if a high TDS value is measured or...

Page 25: ...VMP IOMM 2018 2 Fulton Ltd Page 17 INSTALLATION 2 Figure 10 Electrical Customer Terminal Connections...

Page 26: ...charge to the check valve inlet with 25 mm bore pipe this may be reduced to 15 mm where the discharge pipework is shorter than 4 m in total The pump suction pipework must remain at 25 mm minimum diame...

Page 27: ...in the boiler Chlorides If chloride levels are high enough to cause severe corrosion they can be controlled by limiting the cycles of concentration and increasing boiler blowdowns Corrosion from chlor...

Page 28: ...and or damage as a result of expansion contraction vibration or other movements must be factored 2 Valves are used in piping systems to stop and start the flow of fluids to regulate flow to prevent b...

Page 29: ...for safety Adhere to the following 1 Return tanks surge tanks and deaerators should be insulated Insulation should be chosen with care such that the fluid in the tanks does not exceed the maximum oper...

Page 30: ...VMP IOMM 2018 2 Fulton Ltd Page 22...

Page 31: ...ection Check joints between all flue sections for quality of seals Where the flue passes through the structure of the building use your judgement as to the integrity of this section of the flue b Smok...

Page 32: ...k that the burner is the correct type for use with the gas being supplied 4 Replace the burner and reconnect the gas connection ensuring these connections are tight Reconnect the ignition leads and re...

Page 33: ...t gas line see Section 3 2 Setting the burner controls 13 After the burner has been firing for approximately five minutes adjust the gas and main air control gate located on the burner scroll to obtai...

Page 34: ...t all terminal screws are tight 7 A barometric type draught stabiliser if fitted in the flue should be set for a draught of 0 025 mbar to 0 05 mbar of water bottle pressure with the burner off 8 Open...

Page 35: ...ucing set 3 2 1 Low High Fire The correct setting for low fire high fire operation is made by making adjustments to the two stage solenoid valve and the low fire steam pressure switch 1 Isolate the ma...

Page 36: ...ng Setting the pressure regulator 1 Remove the regulator cover 2 Using a screwdriver set the regulator to the desired pressure Clockwise to increase pressure Anticlockwise to decrease pressure Gas pre...

Page 37: ...governor Gas actuator Figure 12 Gas Valve non modulating burner Figure 13 Gas Valve fully modulating burner 3 3 1 Multi Bloc Gas Valves Main gas valve assembly Main gas line isolating valve Pilot lin...

Page 38: ...onnection upstream of Valve 1 Gas input filter cover Test point connection downstream of Valve 1 Adjustable pressure switch Operating indicator Output pressure controller adjusting screw Output pressu...

Page 39: ...rnal leak test Test point 2 downstream Test point 1upstream Output pressure controller adjusting screw Operating pressure indicators Figure 15 Gas Valve non modulating burner Major Components Gas Actu...

Page 40: ...condensate return pipe adjacent to the condensate return tank 2 Direct the returns to a floor drain or other safe discharge point and make safe 3 Leave in this position for one week to allow all impur...

Page 41: ...steam boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health Where original equipment service manuals are supplied...

Page 42: ...rner Programmer This is the main control in the panel box The programmer in conjunction with a sensing device supervises the ignition sequence proves the flame is satisfactory and finally monitors the...

Page 43: ...iate Low Water Limiter 2 This light will energise when the boiler water is below low limiter 2 The light will illuminate a continuous alarm will sound and the burner will go to lockout Once the water...

Page 44: ...isual indication that the magnetic oil valve for operating oil supply has been energised TDS Alarm This light will illuminate when a high level of TDS is detected in the boiler A boiler blowdown may b...

Page 45: ...n Ltd Page 37 OPERATION 4 Remote Panel Disable inside boiler panel Pressing this button will disarm the remote alarm panel to avoid nuisance remote alarms whilst maintenance is undertaken Figure 17 Co...

Page 46: ...essure Switch Sends a signal to the load controller to control the operating pressure in the boiler by modulating the burner output and turning the burner off when max operating pressure is achieved H...

Page 47: ...re to rise until the high limit pressure switch trips On the steam pressure gauge check that the pressure is not less than 0 5 barg below the safety valve lift pressure If the pressure is incorrect re...

Page 48: ...air damper until tunnelling stops 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...

Page 49: ...ed pump seals are water cooled The pump must never be allowed to run whilst dry irreparable damage may result Ensure the pump is fully primed before energising the motor 6 Vent the pump 7 Turn the doo...

Page 50: ...d Units Plant Rooms have internal drainage systems which require the same procedures Boilers with automatic blowdown systems 1 The boiler should not be under pressure The boiler should be cold 2 Open...

Page 51: ...set button for two seconds maximum The alarms will stop and the alarm lights will extinguish Reset high pressure switch The burner start sequence will commence 7 After a maximum of two minutes the bur...

Page 52: ...ion heating to the gas oil and water side A very effective solution is to install a small heater If the boiler has been shut down short term see Section 4 8 1 Short Term Shut Down the large thermal ma...

Page 53: ...are designed to allow easy maintenance access to the components at the top of the boiler i e the water level probes main steam valve vent and safety valves It is the responsibility of the user to ensu...

Page 54: ...o exclude all light 4 The burner control should go to a lockout flame failure condition 2 3 sec gas 34 sec oil and will require manual resetting Note The fan will run on for a short time but the flame...

Page 55: ...rts to run when the water level reaches the Pump On level 4 Close the main boiler blowdown valve 5 Continue to observe the water level in the water level gauge and verify that the pump continues to ru...

Page 56: ...t allow the water level to drop below the bottom of the water level gauge sight glass 4 Check a Low Water limiter lights illuminate b Low Water audible alarm sounds c Burner stops firing d Feedwater p...

Page 57: ...le and interconnecting pipework free from sludge and scale build up by blowing down in the following manner Note Where a boiler is operating continuously at steam pressure advice should be sought from...

Page 58: ...he appropriate blowdown procedure WORKING POSITION STEAM BLOWDOWN WATER BLOWDOWN A A A B B B C C C Operating Positions Figure 26 Water Level Gauge Operating Positions 5 6 Boiler Internal Inspection Th...

Page 59: ...alignment As such gaskets are very flexible it is possible to cure the leak by excessive tightening but such an action will seriously reduce the life of the gasket and cause problems later Undue stre...

Page 60: ...Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack If the gasket is misaligned over tightening to seal a leak will not prevent subseq...

Page 61: ...ediately and consult Fulton Ltd 5 8 Schedule of Operator Tests and Checks The following schedule is the advice of Fulton Ltd The frequency of tests and checks may vary according to site risk assessmen...

Page 62: ...ater Level Check see Section 5 4 2 Note Where high integrity level controls are fitted please refer to Appendix D Spirax High Integrity Level Controls 3 Blowdown the Boiler see Section 5 5 1 Note If t...

Page 63: ...inspect feedwater pipe into the boiler Ensure the pipe is not blocked clean as required 2 Clean the ignition electrode 3 Clean out the flue passes 4 Apply a small quantity of oil to the bearings of th...

Page 64: ...ng connections for conditions and tightness 5 Refill boiler with water checking for leaks 6 Test for gas safety 7 Check oil pressure or gas flow rate and combustion parameters Re commissioning 8 Refil...

Page 65: ...er Concentration datum value reading 9 Brine level correct Y N Y N Y N Y N Y N Y N Y N WEEKLY TESTS 7 10 Flame Sensor Test Y N 11 Feedwater Pump Test Feedwater pump start stop Y N 12 Safety valve outl...

Page 66: ...VMP IOMM 2018 2 Fulton Ltd Page 58...

Page 67: ...faulty air switch 9 Gas Valve Check filters in the valve block Clean as required 10 Loose wire connections Check connections to all components 2 Flame Failure During Start up 1 Gas supply Check for ga...

Page 68: ...Ignition Electrodes Check for cracks in porcelain if found replace the electrode Check electrodes for carbon build up Clean as required Check settings adjust if required 4 UV Detector Check the detect...

Page 69: ...heck fan for obstructions clean as required 7 Burner Back Fires 1 Refractory Bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Ignition Electrodes...

Page 70: ...eplace as required 2 Contamination in boiler Empty boiler and feed tank Flush out and refill if system operates but progressively deteriorates there is probably a leak somewhere in the system 3 Scale...

Page 71: ...k must be made before control locks out on safety If no power replace control 8 Oil nozzle clogging Check oil nozzle s clean or replace as necessary 9 Faulty Oil Pump Check to see if oil is being pump...

Page 72: ...etector clean as required Check for proper location of detector 5 Faulty Air Switch Check for faulty air switch by jumpering the two air switch leads at the terminal block If the boiler starts and run...

Page 73: ...Burner back fires 1 Refractory bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Ignition electrodes Check electrodes for carbon build up clean i...

Page 74: ...or the application Consult Fulton 8 Boiler is surging 1 Steam traps blowing through Check traps clean or replace as required 2 Scale build up or lime deposits Call water treatment company and consult...

Page 75: ...opening and closing 15 Oil fumes coming out around the oil pump housing 1 Bad draft condition Check the draft with a gauge should read neutral May need to install a barometric damper 2 Venting of room...

Page 76: ...tant 1 Pump inlet pressure is too low cavitation Check the suction conditions 2 Suction pipe pump partly blocked Clean the pump or suction pipe 3 Pump draws in air Check the suction conditions 5 Pump...

Page 77: ...1 Scale on probes Check and clean probes replace as necessary 2 Faulty pump contactor Check the contactor has power Check the contactor is pulling in Replace if necessary 3 Faulty pump motor Check the...

Page 78: ...xtraneous light during startup 1 Extraneous light during shutdown 2 Extraneous light during startup prevention of startup 6 Extraneous light during startup air pressure start prevention 18 Extraneous...

Page 79: ...e is leaking Check to see if the pressure switch for the leakage test is closed when gas pressure is present Check wiring for short circuit 14 POC 0 POC open Check to see if the valve s closing contac...

Page 80: ...n circuit X5 01 1 Gas shortage start prevention Check wiring to see if there is an open circuit X5 01 2 Heavy oil direct start Check wiring to see if there is an open circuit X9 04 Check that the oil...

Page 81: ...Position calculation multistep 23 Output invalid No valid output 26 Curvepoints undefined Adjust the curvepoints for all actuators 75 Internal error fuel air ratio control Data clocking check 1 Curre...

Page 82: ...the VSD is not linear Configuration of the voltage input at the VSD must accord with that of the basic unit parameter 645 3 VSD does not follow quickly enough the changes of the basic unit Check setti...

Page 83: ...Motor turns but is not standardized make standardization 83 Speed error VSD Required speed has not been reached Bit 0 Valency 1 Lower control range limitation of control Speed has not been reached be...

Page 84: ...seconds 20 for 20 seconds or 40 for 10 seconds Between the ignition point P0 and the low fire point P1 the speed change in modulating mode may be a maximum of 40 independent of the LMV2 ramp 2 Setting...

Page 85: ...across pin 5 or 6 and pin 2 0 5 V Bit 3 Valency 8 Curve too steep in terms of ramp rate Check position differential between the curvepoints and the modulating operating ramp setting parameter 544 1 M...

Page 86: ...95 Error relay supervision 3 Ignition transformer 4 Fuel valve 1 5 Fuel valve 2 6 Fuel valve 3 External power supply NO contact Check wiring 96 Error relay supervision 3 Ignition transformer 4 Fuel va...

Page 87: ...12 Fuel valve 3 13 Fuel selection Fuel 1 Reset Stuck At failure Can be caused by capacitive loads or supply of DC voltage to the mains voltage inputs The diagnostic code indicates the input where the...

Page 88: ...or occurs repeatedly replace the unit 132 Internal error EEPROM register initialization Make a reset if error occurs repeatedly replace the unit 133 Internal error EEPROM access Request synchronizatio...

Page 89: ...est timeout No loss of flame after shutdown of fuel valves 1 Check to see if there is extraneous light 2 Check wiring to see if there is a short circuit 3 Check to see if valve is leaking 165 Internal...

Page 90: ...error occurs repeatedly replace the unit 204 Phase number Program stop Program stop is active no error 205 Internal error Make a reset if error occurs repeatedly replace the unit 206 0 Inadmissible co...

Page 91: ...TI sheets These TI sheets can be found in this Appendix Note The TI sheets in this appendix can be updated replaced without revising the manuals issue number To check you have the most up to date TI...

Page 92: ...MODEL VMP 60 80 100 A Minimum Clearance 3175 3302 3353 B Overall Width 1575 1727 1880 C Overall Depth 2540 2896 3022 D Overall Height 2984 3150 3200 E Boiler Height 2464 2540 2540 F Boiler Diameter 1...

Page 93: ...L h 64 3 87 106 LPG Propane m3 h 27 36 45 Ventilation Requirements for Consumption Purposes Free Area Low Level inlet cm2 4030 5250 6520 High Level Outlet cm2 2015 2625 3260 Electrical Requirements F...

Page 94: ...igure 2 N B The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture meaning the probe is ready to be installed without any adjustment The ONLY instance a spanner should be used...

Page 95: ...rts the head and the tip The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head Locate the pin provided into the slot hole and s...

Page 96: ...own solenoid valve opens in a series of pulses until the measured value corresponds to or is lower than the set value When this is achieved blowdown finishes until the next timed sample is taken when...

Page 97: ...TDS Control Blowdown System from Fulton the equipment would normally be supplied with the controller wired and fitted to the boiler control panel with all the other parts supplied loose for piping an...

Page 98: ...ess than 5 ppm Oil None Minimum Temperature 85 C BOILER WATER water inside boiler pH Value 10 0 to 12 0 tested at room temperature Hardness Not detectable Suspended Solids Less than 100 ppm Chloride L...

Page 99: ...PENDIX B 1 1 General APPENDIX B WIRING DIAGRAMS Wiring diagrams are available from Fulton Ltd on request Boiler Fuel Controls Arrangement 1 Arrangement 2 Arrangement 3 80 150 GAS Modulating OIL Modula...

Page 100: ...VMP IOMM 2018 2 Fulton Ltd Page 92...

Page 101: ...ate 7 Make and type eg fig no of safety valve fitted Note Spare and wearing parts which have not been tested together with the system can compromise its function Installing non authorised components a...

Page 102: ...VMP IOMM 2018 2 Fulton Ltd Page 94 APPENDIX C...

Page 103: ...dant but may be supervised during the silent hours and weekends by a competent person trained to respond to an alarm Daily testing of the controls is required which can be by simulation with a weekly...

Page 104: ...until the Low Water alarm sounds the Low Water Reset buttons illuminate and the burner shuts down 3 Switch the Pump switch to the ON position 4 The pump will start and restore the water level to the n...

Page 105: ...you In all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to be incurred by us in respect of gauge or sight glasses packing glands or elect...

Page 106: ...uk VMP IOMM 2018 2 Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone 44 0 117 972 3322 Fax 44 0 117 972 3358 Email sales fulton co uk BS EN ISO 9001 2015 Company Registration 85...

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