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FULTON VSRT 10 Installation And Operation Manual Download Page 87

MAINTENANCE & TROUBLESHOOTING - 4

Questions?  Call (315) 298-5121, or visit us online at  www.fulton.com

 4-27

VSRT_IOM_2018-1213

Troubleshooting Gas Fired Boilers

Problem

Cause

Remedy

Pump runs but 

does not put 

water into boiler

Vapor locking of pump

Allow system to cool down, check steam traps to make sure 

they are operating properly, and check to be sure return 

lines are not insulated. Check feedwater tank temperature. 

If it is above 180 F (82 C) vapor locking may occur, 

depending on pump selection. Inspect check valves. Clean 

and replace as needed.  Replace pump with multistage 

pump good for 250 F (121 C). 

Impeller Adjustment 

Check for impeller wear and adjust per component 

information in instruction manual (Burks/MTH only).

Back pressure on pump

Install repair kit on pump. 

Plugged feed water nipple

Check and clean or replace as necessary. 

Summary of Contents for VSRT 10

Page 1: ...NAME PROJECT MANAGER This design and drawings are proprietary and are the exclusive property of Fulton Group N A Inc The corporation does not permit their use except with prior written consent The ite...

Page 2: ......

Page 3: ...llation 2 31 Section 3 Operation 3 1 Start Up Preparation Installation Review 3 2 Start Up Service 3 2 Prepare for Initial Start Up 3 2 Perform Boil Out 3 2 Sequence of Operation Gas Fired Burners 3 3...

Page 4: ...Section 5 Warranty 5 1 StandardWarranty for Fulton Boilers 5 3 ExtendedWarranty for Fulton Skid Mounted Boilers 5 3...

Page 5: ...1 1 Section Safety Warnings 1 Installation 2 Operation 3 Maintenance Troubleshooting 4 Warranty 5...

Page 6: ...ings cautions and notes in literature on stickers and labels and any additional safety precautions that apply Follow all safety codes and wear appropriate safety protection Follow all jurisdictional c...

Page 7: ...itry Before commissioning the equipment verify with authorized personnel that gas lines have been purged Check daily that the equipment area is free and clear of any combustible materials including fl...

Page 8: ...handles Never use tools If the handle will not turn by hand don t try to repair Forced or attempted repair may result in fire or explosion Should overheating occur or the gas supply fails to shut off...

Page 9: ...to the burner and is not covered under warranty Airborne materials from construction and maintenance activities constitute a high risk situation An exhaust fan may draw products of combustion into the...

Page 10: ...ections can cause immediate or delayed breakage resulting in bodily injury and or property damage Only properly trained personnel should install and maintain gauge glass connections Wear safety glasse...

Page 11: ...2 1 Section Safety Warnings 1 Installation 2 Operation 3 Maintenance Troubleshooting 4 Warranty 5...

Page 12: ...th the intent to use sealed combustion locate boiler so that the air supply and exhaust piping between the boiler and outside wall roof are within the maximum lengths for horizontal or vertical ventin...

Page 13: ...2 716 3 645 3 764 8 728 8 728 8 728 Shipping Weight LBS 2 500 2 500 3 281 3 400 6 750 6 750 6 750 Flooded Weight LBS 3 008 3 008 3 939 4 058 9 320 9 320 9 320 Electric Power Requirements Voltage 120...

Page 14: ...ons Front Side View All dimensions in inches NOTES for Table 3 VSRT Specifications from previous page 1 Steam output LB HR From 0 PSIG at 212 F 0 kg cm at 100 C 2 All clearances are factory recommenda...

Page 15: ...NFORMATION REGARDING INSTRUCTIONS ALL DIMENSIONS INSIDE ALL DIMENSIONS INSIDE WE RESERVE THE RIGHT TO AND OR DIMENSIONS ALL I TO CHANGE BASED ON ADDI EQUIPMENT AND OR ACCESS FACTORY FOR PROJECT SPE AD...

Page 16: ...1 2 MINIMUM WIDTH 58 1 4 7 1 16 22 7 8 55 1 8 70 MIN HEIGHT NOTE REFERS E C P F K J G N 7 1 8 H Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical panels Note 9 Fulton recom...

Page 17: ...tten consent The items shown in this drawing may be covered by one or more patents of The Fulton Companies THIRD ANGLE PROJECTION TOLERANCES FRACTION WHOLE VALUE 1 PLACE DEC 2 PLACE DEC 1 8 UNLESS OTH...

Page 18: ...EXHAUST PLEASE REFER TO THE O INFORMATION REGARDIN INSTRUCTIONS ALL DIMENSIONS INSIDE ALL DIMENSIONS INSIDE WE RESERVE THE RIGHT AND OR DIMENSIONS AL TO CHANGE BASED ON AD EQUIPMENT AND OR ACC FACTOR...

Page 19: ...9 SEE NOTES 3 AND 11 21 1 16 7 1 16 32 1 2 MINIMUM WIDTH 60 9 16 58 7 16 8 LET 79 1 8 MIN HEIGHT K J G N P E C F 7 1 8 H Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical p...

Page 20: ...0 VSRT_IOM_2018 1213 Figure 7 30 HP Model VSRT Dimensions Front View All dimensions in inches FRONT VIEW 49 1 4 AIR INLET 74 FUEL INLET 79 1 16 MINIMUM HEIGHT 86 3 8 STEAM OUTLET G J H N 110 CLEARANCE...

Page 21: ...21 or visit us online at www fulton com 2 11 VSRT_IOM_2018 1213 RIGHT SIDE VIEW L M A D B 87 3 8 81 5 8 S R V 22 5 16 FEEDWATER 51 EXHAUST STACK 5 BOTTOM BLOWDOWN Figure 8 30 HP Model VSRT Dimensions...

Page 22: ...r more patents of Fulton Group N A Inc 2 OF 2 THIRD ANGLE PROJECTION 2 16 2017 2 24 2017 2 24 2017 2 24 2017 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES 1 PLACE DEC 0 03 2 PLACE DEC 0 015 3 PLACE...

Page 23: ...en consent The draw one Fulto T TOLERANCES FRACTION WHOLE VALUE 1 PLACE DEC 2 PLACE DEC 1 8 UNLESS OTHERWISE NOTED DIMENSIONS ARE IN INCHES 0 03 3 PLACE DEC SURFACE FINISH 250 MICRO INCHES 0 005 0 5 D...

Page 24: ...AND 14 FROM EXHAUST STA PLEASE REFER TO THE O M M INFORMATION REGARDING C INSTRUCTIONS ALL DIMENSIONS INSIDE D ALL DIMENSIONS INSIDE D WE RESERVE THE RIGHT TO C AND OR DIMENSIONS ALL IN TO CHANGE BASE...

Page 25: ...67 3 8 49 MIN WIDTH C E F P S M N G J H K 9 Figure 12 40 50 60HP Model VSRT Dimensions Top View All dimensions in inches Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical p...

Page 26: ...not account for the ventilation needs of the equipment room These measurements are subject to state and location regulations one square inch of free area per 2 000 BTU hr input per NBIC Free opening...

Page 27: ...be of the proper size to ensure adequate gas supply to the gas head assembly without a pressure loss Consult your gas company for specific recommendations 4 Whenmakinggaspipingjoints useasealing comp...

Page 28: ...sed disconnect sized for the unit must be provided and fitted by the client contractor if disconnect is not supplied on the panel 6 Fuses must be sized according to motor name plates and local electri...

Page 29: ...ated accordingly The treatment should provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized Thermal cycling dissolved oxygen high or low pH can all...

Page 30: ...determined It may result from lack of sufficient blow off The source of alkalinity may be due to an overdose of alkaline internal water treatment chemical pH pH is a measure of the degree of acid or...

Page 31: ...ations are the design temperature the pressure retained by the pipe the fluid in the pipe the load resulting from thermal expansion or contraction impact or shock loads imparted such as water hammer e...

Page 32: ...r SA 106B 2 5 malleable iron CL150 3 SA 234 SA 105 2 5 Threaded 3 welded flanged 150 Pump Recirculation orifice piping A length of straight pipe a minimum of 20 pipe diameters directly downstream of t...

Page 33: ...d on next page SURFACE BLOWDOWN DRAIN FAST OPENING VALVE BLOWDOWN VALVE SHUT OFF VALVE CHECK VALVE STACK TEE FOR CHEM QUILL INJECT SURFACE BLOWDOWN GAS INLET STEAM SAMPLE PORT VENT WATER SAMPLE PORT T...

Page 34: ...ERE OVERFLOW FEED TANK DRAIN THERMOMETER COOLING WATER INLET THERMOMETER SYSTEM DRAIN VENT TO ATMOSPHERE COOLING WATER INLET FOR LOW LEVEL DRAIN THROTTLING GLOBE VALVE BLOWDOWN TANK DRAIN LOW LEVEL DR...

Page 35: ...provide a capacity of 2 5 times the evaporation rate for on off pumps and 1 5 times the evaporation rate for continuous running pumps The discharge pressure of the pump must be 3 over the boiler safe...

Page 36: ...f the piping limiting safety valve discharge volume 10 Do not support discharge piping with the safety valve Discharge piping must be supported adequately by appropriate means 11 Fulton recommends the...

Page 37: ...ttom fitting It is crucial that the gauge glass valves are aligned both vertically and horizontally If not aligned they may leak 8 Insert the gauge glass into the bottom fitting until it bottoms out a...

Page 38: ...per the Fulton supplied electrical drawing 10 If a steam header is supplied mount the header as shown in the mechanical drawing Note If header is supplied in sections it should be connected hand tight...

Page 39: ...y Install Appropriate Weather Cap Horizontal Run 2 Draft Regulator If Necessary Draft Regulator If Necessary Expansion Joints As Required Horizontal Run 2 Cleanout Door 60 45 Min Cleanout Door Cleanou...

Page 40: ...alled with appropriate air space clearances to combustibles These air space clearances apply to indoor or outdoor vents whether they are open enclosed horizontal or vertical or pass through floors wal...

Page 41: ...cm above the finished grade or at least 12 inches 30 48 cm above normal snow accumulation level for applicable geographical areas 3 The termination of the vent system shall not be located in traffic...

Page 42: ...CONFIGURATIONS EXHAUST STACK IS DOWNWIND OF AIR INTAKE OPENING VSRT BOILER SIDE VIEW NOTE AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DU...

Page 43: ...INTAKE AND EXHAUST TERMINATION SHOULD BE SEPERATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENTWIND CONDITIONS OPENING1FT 30CM MIN ABOVENORMALLYEXPECTED SNOWACCUMULATIONLEVEL...

Page 44: ...2 INSTALLATION Fulton 2018 2 34 VSRT_IOM_2018 1213...

Page 45: ...3 1 Section Safety Warnings 1 Installation 2 Operation 3 Maintenance Troubleshooting 4 Warranty 5...

Page 46: ...d be contacted after the installation has been successfully completed and approved by the client s representative or engineers If possible contact the factory at least two weeks before a Fulton servic...

Page 47: ...am discharge prior to boil out completion 3 On new systems send condensate returns to the drain to ensure the new system piping has been flushed free of debris and is fully clean If debris filled cond...

Page 48: ...will purge combustion gasses from the unit for 15 seconds 12 The control will then de energize the blower motor and drive all gas and air dampers to their closed position 13 The burner will remain in...

Page 49: ...ion of the program 11 Repeat this process until all parameters have been reviewed and set 12 Once the parameters have been programmed back out to the front screen by pressing the and buttons together...

Page 50: ...lease S E r Momentarily displayed 9 5 4 0 1st parameter shown is flame signal parameter 954 7 0 1 0 1 6 2 until parameter 701 is displayed 701 is the most recent fault 725 is the oldest 7 0 1 0 1 6 2...

Page 51: ...n adjustment guidelines Up Down Fan Speed Adjustment More O2 More Input Less O2 Less Input Gas Servo Adjustment More Input Less O2 Less Input More O2 Air Servo Adjustment More O2 Less Input Less O2 Mo...

Page 52: ...the Set Enter key once the desired number is reached to lock in the set point The value will now stop flashing to signify that it is set Press the Display key to return to the Set Point SP home scree...

Page 53: ...RTER If a pump starter is supplied the pump motor starter will be located in the boiler heater panel or pump skid When the pump start button is pushed the pump motor starter will engage the pump 1 Whi...

Page 54: ...following to test 1 Verify that the flame scanner is observing flame with the burner running by confirming that a flame signal is present with a flame in the boiler 2 Shut down the burner WARNING Do n...

Page 55: ...ignition to main flame It is recommended that a minimum of 10 cycles should be met without any flame failures with combustion readings comparable to the factory test fire sheet and no interlocks causi...

Page 56: ...ACS 0 off 1 Modbus 2 reserved 0 2 1 142 Setback time in the event of communication breakdown 0 s 7200 s 1 s 143 Reserved 1 8 1 144 Reserved 10 s 60 s 30 s 145 Device address for Modbus 1 247 2 146 Bau...

Page 57: ...only gas actuator 21 Gp2 mod only gas actuator 22 Lo mod only oil actuator 1 22 3 208 Program stop 0 deactivated 1 PrePurgP Ph24 2 IgnitPos Ph36 3 interval 1 Ph44 4 interval 2 ph52 0 4 0 210 Alarm in...

Page 58: ...3 0 242 Gas Leakage test evacuation time 0 2 s 10s 3 s 243 Gas Leakage test time atm pressure 0 2 s 60 s 10 s 244 Gas Leakage test filling time 0 2 s 10s 3 s 245 Gas Leakage test time gas pressure 0 2...

Page 59: ...ndardized speed Index 0 uC1 Index 1 uC2 650 6500 Undefined 645 Configuration of analog output 0 DC 0 10 V 1 DC 2 10 V 2 DC 0 2 10 V 0 2 0 700 Error History 701 Error history 701 725 01 Code 0 255 Erro...

Page 60: ...ternal modules and display 0 255 981 Error storage Code 0 255 982 Error storage Diagnostic code 0 255 992 Error flags 0 0xFFFFFFFF Data is for reference purposes only Fulton Companies is not responsib...

Page 61: ...4 1 Section Safety Warnings 1 Installation 2 Operation 3 Maintenance Troubleshooting 4 Warranty 5...

Page 62: ...rranty issues that arise after an unqualified individual has manipulated boiler parameters will not be considered Procedure for CleaningWater Probes To clean probe on top of boiler shell and probes in...

Page 63: ...hat only 1 2 of water empty from the boiler sight glass during the 4 10 second bottom blowdown During each blowdown there should be 1 2 of level drop in the sight glass If a manual method of cooling w...

Page 64: ...nd inspection must include checking 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...

Page 65: ...nd adjust combustion to the correct settings 3 Check for proper operation of steam traps in your system 4 Check feedwater pumps for correct operation 5 Check and clean burner See next page for directi...

Page 66: ...s excessively See Figures 23 and 24 Refill the boiler with fresh water CAUTION If the gasket leaks while pressure is being built up tighten only enough to stop leakage Never tighten more than necessar...

Page 67: ...l require replacement gaskets NOTE The burner assembly drawings are located at the end of this chapter just before Troubleshooting INSPECTION CLEANING OF THE BURNER ASSEMBLY Most of the particulate ma...

Page 68: ...ow restrictions resulting in poor combustion and loss of efficiency 3 Flush boiler if necessary See Boil Out Procedure section of this manual More extensive cleaning may be required consult a local wa...

Page 69: ...2 22 290030 6 SPIRAL HOSE CLAMP CW MCMASTER 45955K73 2 EA 16 2 30 290032 VSRT 30 CBI BLOWER 1 EA 17 2 30 292030 VSRT 30 PLASTIC CYCLONE NYB 1 EA BILL OF MATERIAL ITEM PART NUMBER DESCRIPTION QTY U O...

Page 70: ...USS FLAT WASHER 2 22 000039 10 EA 1 VSRT 30 PLASTIC CYCLONE NYB 2 30 292030 17 EA 2 EYELET WIRE RING TERMINAL 16 14 AWG NYLON EXPANDED INSULATION 14RB 14 2 45 000431 21 FT 1 885 16 AWG WIRE 2 45 0009...

Page 71: ...BAND CLAMP 30010 0525 2 22 000431 12 EA 4 3 8 316 STAINLESS STEEL LOCK WASHER 2 22 000461 13 EA 2 1 4 20 x 1 A286 SOCKET HEAD CAP SCREW 2 22 290000 14 EA 1 1 4 FNPT X 1 4 MNPT BALL VALVE CSA 2 30 0002...

Page 72: ...098 16 EA 1 1 4 THREADED TEE 2 35 000204 18 EA 1 1 4 3000 PLUG 2 35 000306 19 EA 2 1 4 X 1 1 2 NPT SCH 80 NIPPLE 2 35 000394 20 EA 1 SINGLE POLE IGNITION TRANSFORMER 6KVA 120 60 2 40 000082 12 EA 1 VS...

Page 73: ...RNER GASKET 1 EA 10 2 22 000156 3 8 16 NiCu400 HEX NUT MONEL400 4 EA 13 2 22 000461 3 8 316 STAINLESS STEEL LOCK WASHER 4 EA 21 2 35 001178 3 4 X 1 1 2 NPT STAINLESS STEEL SCH 40 316L NIPPLE 1 EA 22 2...

Page 74: ...LOCK WASHER 2 EA 14 2 22 290000 1 4 20 x 1 A286 SOCKET HEAD CAP SCREW 2 EA 17 2 30 290300 WORGAS PREMIX BURNER 140MM OD PX 1803 1 EA 24 5 10 290006 VSRT TOP PLATE ASSEMBLY 1 EA 27 7 20 290030 VSRT PI...

Page 75: ...00041 11 EA 8 3 8 MEDIUM LOCK WASHER 2 22 000047 12 EA 8 3 8 16 X 1 1 4 HHCS SAE GR 5 BOLT 2 22 000199 13 EA 1 1 8 3000 PLUG 2 35 000249 18 EA 1 SQM33 TO 4 FULL PORT BUTTERFLY VALVE VA33 NF 400 2 40 0...

Page 76: ...P 4 LOWER BLOWER INTO HOOKS STEP 1 HARDWARE STEP 3 LIFT NEW BLOWER IN SAME MANNER AS THE OLD WAS REMOVED STEP 5 REINSTALL HARDWARE B UNSCREW ALL 4 BOLTS A HOOK A CHAIN THROUGH LIFTING EYE TO LIFT BLOW...

Page 77: ...0031 3 5 GALLON STEEL PAIL WITH LID AND LEVER LOCK RING 1 EA 6 2 35 290030 6 CYCLONE COLLECTION CHAMBER HOSE 1 FT 7 2 45 000649 COMPACT LIQUID TIGHT CORD GRIP FOR 12 26 CORD MCMASTER 69915K47 1 EA 8 2...

Page 78: ...E FOR LMV 3 2 40 000473 5 EA 1 YOKOGAWA UT32A PROCESS CONTROLLER 2 40 000863 6 EA 1 3 8 T B STRAIGHT CONNECTOR 2 45 000033 7 EA 6 3 8 DUPLEX CONNECTOR 2 45 000039 8 EA 6 1 2 STRAIN RELIEF CORD CONNECT...

Page 79: ...L2 N 1L1 1L2 1L2 N 8A KLKD FP CR03 PS USE COPPER WIRE ONLY ON THIS TERMINAL BLOCK 240 60 1 TB2 TORQUE 13 3 15 9 IN LBS JTD40 JTD40 VFD JTD40 MC2 TB1 TORQUE 5 3 7 IN LBS WLR LWSR1 LWSR2 108 108 107 107...

Page 80: ...ME PROGRAMMER 4 CONTROL RELAY 3 5 CONTROL RELAY 2 6 24v POWER SUPPLY 7 120v TERMINAL BLOCK 1 8 GROUND LUG 9 WATER LEVEL RELAY 10 LOW WATER SAFETY RELAY 1 11 LOW WATER SAFETY RELAY 2 12 FEEDWATER PUMP...

Page 81: ...ARIANTS PRESSURE GAUGE VARIANT E D F 42 41 10 43 8 8 12 15 11 PROPANE VARIANT 38 40 PRESSURE SWITCH VARIANT HIGH GAS SWITCH LOCATION PRESSURE SWITCH VARIANT LOW GAS SWITCH LOCATION 10 10 30 20 6 14 31...

Page 82: ...ALVE VA33 NF 125 2 40 001097 20 EA 1 1 1 4 DRILLED AND TAPPED THREADED ELBOW 2 20 000025 21 EA 2 3 8 COMP X 1 4 MNPT ALUMINUM 90 DEG TUBING COMPRESSION FITTING 2 35 001352 22 EA 1 SIEMENS QPH31 050M00...

Page 83: ...t to make sure the air switch is within range Gas Supply Check for gas pressure and for intermittent supply problems Gas pressure for natural gas should be 3 in to 13 8 in w c at the head of the train...

Page 84: ...itch and measure the burner fan pressure at the air pressure switch sensing port to make sure the air switch is within range Dirty or defective UV Scanner Clean or replace Water pump will not come on...

Page 85: ...lve as necessary Be sure to check all combustion points Gas Valve Adjusted Too Low Lean Unstable Flame Check CO2 and O2 levels Check pressure at outlet of the valve If too negative adjust gas valve as...

Page 86: ...ps blowing through Check traps to see if they are clean or replace as necessary Boiler Size Boiler may be undersized Boiler is Surging Steam traps blowing through Check traps to see if they are clean...

Page 87: ...ing properly and check to be sure return lines are not insulated Check feedwater tank temperature If it is above 180 F 82 C vapor locking may occur depending on pump selection Inspect check valves Cle...

Page 88: ...5 1 Section Safety Warnings 1 Installation 2 Operation 3 Maintenance Troubleshooting 4 Warranty 5 Parts 6...

Page 89: ...5 WARRANTY Fulton 2018 5 2 VSRT_IOM_2018 1213...

Page 90: ...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...

Page 91: ...ton com VSRT_IOM_2018 1213 No part of this Installation Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from Fulton The Fulton Group of com...

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