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

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INSTALLATION,

OPERATION, AND

MAINTENANCE MANUAL

VSRT Series

Vertical Spiral-Rib Tubeless Boiler

9.5 HP - 250 HP

Serial/ National
Board Number

Model

Fulton Order

Owner

Site Name

Date

VSRT-IOM-2022-0728

Ful o

t n

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Summary of Contents for VSRT Series

Page 1: ...STALLATION OPERATION AND MAINTENANCEMANUAL VSRT Series Vertical Spiral Rib Tubeless Boiler 9 5 HP 250 HP Serial National Board Number Model Fulton Order Owner Site Name Date VSRT IOM 2022 0728 F ul o t n ...

Page 2: ......

Page 3: ...3 1 Start UpPreparation InstallationReview 3 2 Start UpService 3 2 PrepareforInitialStart Up 3 3 PerformBoil Out 3 3 BOILOUTPROCEDURE 3 3 SequencesofOperation GasFiredBurners 3 4 SEQUENCEOFOPERATION MODULATEDBURNER 3 4 FlameProgrammers 3 5 FLAMESAFEGUARDCONTROL 3 5 SiemansLinkagelessModulation 3 5 SiemansLMV3ControllerNavigation 3 5 CommissioningTheUnit 3 7 ADJUSTINGTHEPROFILE 3 7 OperatingControl...

Page 4: ...BURNERASSEMBLYFORVSRT100 250BHP 4 9 EXAMINETHEVENTINGSYSTEM 4 12 RecommendedAnnualMaintenance 4 12 AfterAllRepairs 4 12 Troubleshooting 4 13 ServiceDocuments 5 1 Start Up Installation OperationReportforFultonSteamBoilers 5 2 VerticalSteamBoilerAnnualMaintenanceChecklist 5 11 Notes 5 13 ...

Page 5: ...Questions PleaseContactYourLocalManufacturer sRepresentative 1 1 INTRODUCTION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE TROUBLESHOOTING 4 SERVICEDOCUMENTS 5 ...

Page 6: ...n literature on stickers and labels and any additional safety precautions that apply Follow all safety codes and wear appropriate safety protection Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation WARNING Do not operate or allow others to operate service or repair this equipment unless you they fully understand all applicable sections of this manual ...

Page 7: ...ive operation and conditions WARNING After checking controls by manual adjustment always ensure they are reset to their proper settings Follow proper lockout tagout procedures for the electrical gas and water connections If any Manual Reset limit device trips DO NOT reset without determining and correcting the cause Manual Reset Limits may include flame safeguard high or low gas pressure high temp...

Page 8: ... by a qualified individual prior to commissioning the unit When opening any drains on the equipment or piping system steps should be taken to avoid scalding burning of personnel due to hot fluids Whenever possible the system should be cooled prior to opening any drains Post these instructions in an appropriate place near the equipment and maintain in good legible condition WARNING Boiler blowdown ...

Page 9: ...els on the boiler in clean legible condition All connections and safety devices both mechanical and electrical must be kept clean with ease of access for inspection use and maintenance 4 CAUTION Maintenance procedures for this equipment should be completed by trained personnel Appropriate training and instruction are available from the Fulton Service Department at 315 298 5121 or your local Fulton...

Page 10: ... CAUTION Do not use the equipment as support for ducted air piping Ducted piping must be supported independently of the equipment Do not run the pump dry Irreparable damage to the seal can result Prime the pump in accordance with the manufacturer s instructions Never operate the pump with a closed discharge valve After adjusting components in the fuel or air delivery system combustion emissions mu...

Page 11: ...Questions PleaseContactYourLocalManufacturer sRepresentative 2 1 INSTALLATION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE TROUBLESHOOTING 4 SERVICEDOCUMENTS 5 ...

Page 12: ...s Code latest edition Authorities having jurisdiction should be consulted before installations are made Where required by local codes the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 3 Since an external electrical source is utilized the boiler when installed must be electrically ground i...

Page 13: ...earances and Serviceability section of this manual 11 Place equipment in a well ventilated room See EquipmentVentilation Combustion Air Requirements section of this manual 12 Ensure there is adequate clearance around the unit to provide access for operators and maintenance personnel to access all parts of the equipment per local jurisdictional requirements Ensure also that clearance provides for c...

Page 14: ...rface Blowdown in mm 75 19 NPT 75 19 NPT 75 19 NPT 75 19 NPT 75 19 NPT M HighWater Protection in mm 75 19 NPT 75 19 NPT 75 19 NPT 75 19 NPT 75 19 NPT N Single Source Power P Combustion Air Inlet in mm 3 5 8 92 4 102 6 152 6 152 6 152 R Aux Water Column Conn in mm 1 25 NPT 1 25 NPT 1 25 NPT 1 25 NPT 1 25 NPT 50 60 BHP 80 BHP 100 125 BHP 250 BHP Description Size Type Size Type Size Type Size Type A ...

Page 15: ... 3 100 3 100 5 100 5 100 5 100 5 800 11 485 11 485 22 500 OperatingWeight LBS 1920 3 500 3 500 4 100 4 100 7 864 7 864 7 864 9 080 18 975 18 975 36 369 ShippingWeight LBS 1850 2 900 2 900 3 400 3 400 6 000 6 000 6 000 6 700 11 800 11 800 23 000 FloodedWeight LBS 2000 3 850 3 850 4 400 4 400 8 600 8 600 8 600 9 710 19 925 19 925 38 988 Electric Power Requirements Voltage 120 6 1 120 60 1 120 60 1 1...

Page 16: ...oupN A Inc 2022 INSTALLATION VSRT IOM 2022 0728 SECTION2 2 6 85 3 4 75 3 4 MIN HEIGHT 99 7 8 BURNER PULL CLEARANCE N 86 1 8 G H J K FIGURE 1 9 5 HP MODEL VSRT DIMENSIONS FRONT SIDE VIEW ALL DIMENSIONS IN INCHES ...

Page 17: ...ctYourLocalManufacturer sRepresentative SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 7 FIGURE 2 9 5 HP MODEL VSRT DIMENSIONS RIGHT SIDE VIEW ALL DIMENSIONS IN INCHES RIGHT SIDE VIEW 4 15 16 21 15 16 63 5 8 A B R L M 53 3 16 D ...

Page 18: ...16 36 1 8 SEE NOTES 24 MIN WIDTH INSTALLED FOOTPRINT C E 4 3 4 F 39 7 8 MIN MAX 49 1 2 SEE NOTE 11 P Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical panels Note 9 Fulton recommends 36 clearance between openings of all boilers 18 clearance of handholes and 18 from exhaust stack Note 11 Local codes supercede Fulton recommended clearances ...

Page 19: ...ive SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 9 FIGURE 4 10 15 HP MODEL VSRT DIMENSIONS FRONT SIDE VIEW ALL DIMENSIONS IN INCHES 22 7 8 98 1 2 CLEARANCE REQUIRED FOR BURNER REMOVAL 41 3 8 AIR INLET 73 5 8 FUEL INLET 74 STEAM OUTLET 70 MIN HEIGHT P K J G N H ...

Page 20: ...STALLATION VSRT IOM 2022 0728 SECTION2 2 10 FIGURE 5 10 15 HP MODEL VSRT DIMENSIONS RIGHT SIDE VIEW ALL DIMENSIONS IN INCHES RIGHT SIDE VIEW 5 BOTTOM BLOWDOWN 22 3 8 FEEDWATER 71 5 8 S R V 76 3 8 43 1 16 EXHAUST STACK B A L R D M ...

Page 21: ...NS IN INCHES SEE NOTE 9 SEE NOTES 3 AND 11 32 1 2 MINIMUM WIDTH 58 1 4 7 1 16 22 7 8 55 1 8 E C P F K 7 1 8 Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical panels Note 9 Fulton recommends 36 clearance between openings of all boilers 18 clearance of handholes and 18 from exhaust stack Note 11 Local codes supercede Fulton recommended clearances ...

Page 22: ...RT IOM 2022 0728 SECTION2 2 12 FIGURE 7 20 HP MODEL VSRT DIMENSIONS FRONT SIDE VIEW ALL DIMENSIONS IN INCHES 21 1 16 110 CLEARANCE REQUIRED FOR BURNER REMOVAL 82 3 4 FUEL INLET 85 5 8 STEAM OUTLET 57 5 8 AIR INLET 79 1 8 MIN HEIGHT K J G N H ...

Page 23: ...rer sRepresentative SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 13 FIGURE 8 20 HP MODEL VSRT DIMENSIONS RIGHT SIDE VIEW ALL DIMENSIONS IN INCHES RIGHT SIDE VIEW 5 BOTTOM BLOWDOWN 22 3 8 FEEDWATER 51 EXHAUST STACK 80 7 8 S R V 85 5 8 B A R L D M ...

Page 24: ... E C F 7 1 8 H Note 3 Fulton recommends a Minimum clearance of 36 in front of the electrical panels Note 9 Fulton recommends 36 clearance between openings of all boilers 18 clearance of handholes and 18 from exhaust stack Note 11 Local codes supercede Fulton recommended clearances FIGURE 9 20 HP MODEL VSRT DIMENSIONS TOP SIDE VIEW ALL DIMENSIONS IN INCHES ...

Page 25: ...ve SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 15 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 REQUIRED FOR BURNER REMOVAL K FIGURE 10 30 HP MODEL VSRT DIMENSIONS FRONT VIEW ALL DIMENSIONS IN INCHES ...

Page 26: ...2 INSTALLATION VSRT IOM 2022 0728 SECTION2 2 16 FIGURE 11 30 HP MODEL VSRT DIMENSIONS RIGHT SIDE VIEW ALL DIMENSIONS IN INCHES 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 ...

Page 27: ...TE 4 SEE NOTES 3 AND 11 C E P F 32 1 2 MINIMUM WIDTH 62 59 7 8 7 1 8 7 1 8 24 1 8 S E E N O T E S 4 A N D 1 1 T Y P H H Note 3 Fulton recommends a Minimum clearance of 36 in front of the electrical panels Note 9 Fulton recommends 36 clearance between openings of all boilers 18 clearance of handholes and 18 from exhaust stack Note 11 Local codes supercede Fulton recommended clearances ...

Page 28: ...2022 INSTALLATION VSRT IOM 2022 0728 SECTION2 2 18 FIGURE 13 40 50 60 HP MODEL VSRT DIMENSIONS FRONT VIEW ALL DIMENSIONS IN INCHES FRONT VIEW 28 3 16 F P N G J H K 65 5 8 99 13 16 130 CLEARANCE REQUIRED FOR BURNER REMOVAL ...

Page 29: ...E 14 40 50 60 HP MODEL VSRT DIMENSIONS SIDE VIEW ALL DIMENSIONS IN INCHES RIGHT SIDE VIEW 21 3 8 64 5 8 99 3 16 103 1 2 NOTES 1 2 3 4 5 6 7 8 9 10 STEA 100 ALL LOC FULT OF E FULT OPE AND PLEA INFO INST ALL ALL WE R AND TO C EQU FACT ADD REC THE DIR LOC CLE A R L D 96 5 8 MINIMUM INCOMING GA BURNER MOTOR WITH V B ...

Page 30: ...D 10 SEE NOTE 4 SEE NOTES 4 AN D 10 TYP H H 28 3 16 9 84 1 4 67 3 8 49 MIN WIDTH C E F P S M K 9 Note 3 Fulton recommends a minimum clearance of 36 in front of the electrical panels Note 4 Fulton recommends 36 clearance between openings of all boilers 18 clearance of handholes and 18 from exhaust stack Note 10 Local codes supercede Fulton recommended clearances ...

Page 31: ...N2 VSRT IOM 2022 0728 INSTALLATION 2 21 FIGURE 16 80 HP MODEL VSRT DIMENSIONS FRONT VIEW ALL DIMENSIONS IN INCHES FRONT VIEW 112 1 2 FUEL INLET 143 1 2 CLEARANCE REQUIRED FOR BURNER REMOVAL 131 5 8 STEAM OUTLET G J H K 24 3 4 29 1 N 110 1 8 MIN HEIGHT 69 5 8 AIR INLET ...

Page 32: ...RT IOM 2022 0728 SECTION2 2 22 FIGURE 17 80 HP MODEL VSRT DIMENSIONS SIDE VIEW ALL DIMENSIONS IN INCHES RIGHT SIDE VIEW D 10 P H H 22 3 8 FEEDWATER 76 3 4 EXHAUST STACK 112 7 8 S R V 132 1 8 A R D L 5 3 4 BOTTOM BLOWDOWN B 110 1 8 MIN HEIGHT ...

Page 33: ...CTION2 VSRT IOM 2022 0728 INSTALLATION 2 23 FIGURE 18 80 HP MODEL VSRT DIMENSIONS TOP VIEW ALL DIMENSIONS IN INCHES SEE NOTES 3 AND 10 SEE NO TES 4 AND 10 TYP H H SEE NOTES 4 9 66 MIN 79 3 84 MAX 86 13 16 M E 29 1 8 S P F 49 MIN WIDTH 9 7 8 9 7 8 C 137 1 16 87 7 8 ...

Page 34: ... FultonGroupN A Inc 2022 INSTALLATION VSRT IOM 2022 0728 SECTION2 2 24 FIGURE 19 100 125 HP MODEL VSRT DIMENSIONS FRONT VIEW ALL DIMENSIONS IN INCHES FRONT VIEW 126 72 3 8 FUEL INLET 75 5 8 AIR INLET ...

Page 35: ...CTION2 VSRT IOM 2022 0728 INSTALLATION 2 25 FIGURE 20 100 125 HP MODEL VSRT DIMENSIONS SIDE VIEW ALL DIMENSIONS IN INCHES TOP LEFT SIDE VIEW BURNER PULL CLEARANCE 3 1 4 BOTTOM BLOWDOWN 59 5 8 FEEDWATER 125 1 16 EXHAUST A B G H J K L P 147 3 8 STEAM OUTLET 147 7 8 N ...

Page 36: ... 0728 SECTION2 2 26 FIGURE 21 100 125 HP MODEL VSRT DIMENSIONS TOP VIEW ALL DIMENSIONS IN INCHES SEE NOTES 3 AND 9 62 3 4 MIN WIDTH BURNER PULL CLEARANCE 126 100 1 4 62 7 8 102 3 4 75 1 4 28 1 4 26 7 8 C D E E F J 11 11 SEE NOTES 4 9 SE E N O T E S 4 9 ...

Page 37: ...ContactYourLocalManufacturer sRepresentative SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 27 FIGURE 22 250 HP MODEL VSRT DIMENSIONS FRONT VIEW ALL DIMENSIONS IN INCHES FRONT VIEW 139 1 8 TOP FLUE CONNECTION M ET 106 N D ...

Page 38: ...FultonGroupN A Inc 2022 INSTALLATION VSRT IOM 2022 0728 SECTION2 2 28 RIGHT SIDE VIEW 144 3 4 SRV 164 1 2 E 3 7 8 BOTTOM BD FIGURE 23 250 HP MODEL VSRT DIMENSIONS RIGHT SIDE VIEW ALL DIMENSIONS IN INCHES ...

Page 39: ...cturer sRepresentative SECTION2 VSRT IOM 2022 0728 INSTALLATION 2 29 FIGURE 24 250 HP MODEL VSRT DIMENSIONS TOP VIEW ALL DIMENSIONS IN INCHES 129 7 16 14 1 4 TYP B B 106 13 16 46 7 8 17 47 51 TYP 2 5 16 35 11 16 n84 5 8 1 1 4 57 7 8 C D 17 ...

Page 40: ...opening area must take into account the space taken up by louvers expanded metal etc If positive forced ventilation make up air flow is adopted you must ensure that there will be no appreciable pressure variation in the equipment room Adhere to the following to meet ventilation and combustion air requirements 1 Install two fresh air openings one at a low level 24 610 mm from the floor and one at a...

Page 41: ...ing delivery of gas at a relatively constant pressure and calorific content This ensures efficient and reliable combustion The packaged gas train is configured to operate at specific gas pressure requirements The standard requirements are detailed inTable 3 Do not modify the factory gas train If gas pressure not shown on table contact factory NOTE Alternate or custom configurations may have differ...

Page 42: ...llowing for gas piping installation 1 See Table 5 for required natural gas pipe size based on overall length of pipe from the meter plus equivalent length of all fittings Approximate sizing may be based on 1 020 BTU for 1 cubic foot of natural gas 2 Install a manual gas shutoff valve not supplied prior to the boiler 3 Piping must be installed such that no piping stresses are transmitted to the boi...

Page 43: ...down range This includes all boilers on at full fire to one boiler on at low fire ElectricalConnectionsandDevices NOTE This boiler is factory configured for site voltage and is not intended for field conversion See data plate on rear of boiler cabinet for rating The boiler is designed to operate within the following limits at the connection terminals AC power supplied is within 10 of the motor rat...

Page 44: ...r name plates and local electrical codes 8 Connect power to the terminal strip as supplied on the inside of the panel box NOTE Single skid systems are generally shipped completely pre wired 9 Multiple skid systems may require wiring between the skids Please note that Fulton will run conduit and wire the devices on each skid For devices that are disconnected for shipping the wire will be left at th...

Page 45: ... 30 75 PSIG and 8 000 12 000 ft min for high pressure steam 75 PSIG and above Carbon Steel Stainless Steel Parameter Feedwater Vertical Boiler SteamPacWater Horizontal Boiler SteamPacWater Feedwater Vertical Boiler SteamPacWater Horizontal Boiler SteamPacWater pH 7 5 9 2 8 5 10 5 8 5 10 5 6 0 9 2 8 5 10 5 8 5 10 5 FeedwaterTemperature 140 F 60 C 140 F 60 C Hardness as CaCO3 2ppm 10 ppm 15 ppm 2ppm...

Page 46: ... the boiler feed water is to preheat the feedwater This option injects live steam into the feedwater to increase the water temperature to 180 F 82 C or higher which removes oxygen and carbon dioxide from the water It is ideal to have the water temperature above 200 F 93 C for atmospheric vented tank as long as the feedwater pumps and other associated components are rated for the temperature Be sur...

Page 47: ...om chlorides can also be controlled by increasing the amount of corrosion inhibitor or changing to a more effective inhibitor 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 o...

Page 48: ...re build up in the piping Consideration should be given to the appropriate location and orientation of valves necessary for safe operation and isolation of the piping 3 All piping and piping components used should be suitable for the design temperatures pressure and fluid used in the system 4 During the installation ensure that no dirt water or residue from welding is left in the system 5 Expansio...

Page 49: ...welded flanged 150 Feedwater between the pump and the boiler steampac Sch 80 SA 53A or B or 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 the orifice shall be sch 80 Stainless Steel pipe and the first elbow shall be an extra heavy Stainless Steel el...

Page 50: ...NEXT PAGE SURFACE BLOWDOWN DRAIN FAST OPENING VALVE BLOWDOWN VALVE SHUT OFF VALVE CHECK VALVE STACK TE Q SURFACE BLOWDOWN GAS INLET STEAM SAMPLE PORT VENT WATER SAMPLE PORT TUBING FOR SIGHT GLASS DRAIN 30 OR 5 PIPE DIAMETERS WHICHEVER IS GREATER STEAM OUTLET VALVE SAFETY RELIEF VALVE HIGH WATER OVERFLOW CONNECTION ...

Page 51: ...S CONDENSATE RETURNS VENT TO ATMOSPHERE 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 DRAIN FEEDWATER PUMP FEEDWATER TANK BLOWDOWN TANK STEAM PREHEAT CONNECTION PUMP DISCHARGE GAUGE RECOMMENDED FIGURE 26 NEAR BOILER PIPING CONTINUED FROM PREVIOUS PAGE ...

Page 52: ...ressure of the pump must be 3 over the boiler safety valve setting and include the necessary additional pressure to overcome piping losses 3 See Feedwater Instruction Manuals for detailed instructions TheFeedWaterPiping Where the feed water piping is to be fitted adhere to the following 1 Size makeup water piping adequately to provide proper water supply Do not reduce feedwater piping smaller than...

Page 53: ...ry intervening piping between the boiler and the valve 5 Do not cap or plug the weep hole on the side of the safety valve 6 Ensure that the valve is vented to a safe location 7 A discharge pipe shall be of a pipe size equal to or greater than the outlet of the safety valve 8 Consult local codes for combined safety valve pipe sizing 9 Minimize discharge piping fittings and overall piping run to avo...

Page 54: ... valve set pressure TheWaterColumnAndWaterGaugeGlass When installing the water column and gauge glass connections refer to Figure 26 adhere to the following 1 Inspect the water gauge glass to ensure that the glass is free of cracks or chips Do not subject the gauge glass to bending or torsional stresses 2 Install the piping from the water column and gauge glass to a safe blow off vessel of approve...

Page 55: ...e leak stops 11 When provided install the protective guard over the gauge glass assembly 12 The gauge glass valves are fitted with ball checks Make sure that the valves are fully open to ensure that the ball check will function properly in the event that the gauge glass breaks 13 Install drain piping from water bottle and lower water gauge glass fitting to the boiler blow off piping Stack FlueConn...

Page 56: ...sible for the effects such adverse conditions may have on the operation of the boilers 3 The required minimum air space clearances also apply to electrical wires and any kind of building insulation 4 Listed termination parts must be used 5 Select the air intake point of penetration where a minimum of 1 4 per foot 6 35 mm per 3 m upward pitch can be maintained 6 It is recommended to install a mesh ...

Page 57: ...00051 G 17 100051 STAGGER ENTRANCES MIN 3 EXTEND BAFFLE ABOVE LAST ENTRANCE 3 SECTION A A TOTAL RISE ROOF ROOF BAFFLE CLEANOUT DOOR EXPANSION JOINTS AS REQUIRED DRAFT REGULATOR RECOMMENDED 60 45 MIN DRAFT REGULATOR RECOMMENDED MINIMUM 6 ABOVE ANY STRUCTURE WITHIN 30 INSTALL APPROPRIATE WEATHER CAP SUPPORT AS NECESSARY THIS DISTANCE MUST NOT EXCEED 25 OF TOTAL RISE ...

Page 58: ...AL RISE STAGGER ENTRANCES MIN 3 EXTEND BAFFLE ABOVE LAST ENTRANCE 3 30 MAX BAFFLE CLEANOUT DOOR MINIMUM 6 ABOVE ANY STRUCTURE WITHIN 30 EXPANSION JOINTS AS REQUIRED DRAFT REGULATOR RECOMMENDED 60 45 MIN SUPPORT AS NECESSARY ROOF ROOF SECTION A A G 17 100018 INSTALL APPROPRIATE WEATHER CAP FIGURE 29 VSRT 250 BHP TYPICAL STACK ...

Page 59: ...sting Upon completion of the installation adhere to the following for system piping testing 1 Perform a pressure test 2 Perform soap tests at all welds and joints to ensure that the system is free from leaks AssemblyofFultonMulti SkidSystems Adhere to the following for multi skid engineered systems 1 Refer to the Fulton mechanical electrical drawings during assembly 2 Ensure that equipment orienta...

Page 60: ... 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 DURING DIFFERENT WIND CONDITIONS AIR INLET NOTE 1 When using horizontal runs follow a 1 4 per foot rise to run ratio 2 Maintain minimum 9 22 86 cm air space clearances to combustables wires and insulat...

Page 61: ...S CAUTION AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS NOTE MAINTAIN MINIMUM 9 22 86 CM AIR SPACE CLEARANCES TO COMBUSTABLES WIRES AND INSULATION 4 FT 122 CM MINIMUM BETWEEN INLET EXHAUST OPENING SEE BELOW AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPERATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECI...

Page 62: ...LLY EXPECTED LEVEL SCREENED INLET MIN 4 FT MIN 4 FT 122 CM ABOVE AIR INTAKE PIPING EXHAUST STACK IS DOWNWIND OF AIR INTAKE OPENING AIR INLET EXHAUST OUTLET APPROVED VENT MATERIAL NOTE AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS TYPICAL ROOF PENETRATIONS SUGGESTED TERMINATION CONFIGURATIONS G 17 100019 ...

Page 63: ...ONS 48 IN 122 CM MINIMUM 10 FT 305 CM MINIMUM AIR INTAKE WALL PENETRATION EXHAUST PIPE WALL PENETRATION AIR INTAKE EXHAUST PIPES WALL PENETRATION CLEARANCES CAUTION AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS NOTE 1 MAINTAIN MINIMUM 9 23 CM AIR SPACE CLEARANCE TO COMBUSTABLES WIRES AND INSULATION 2 WHE...

Page 64: ...nd flanged factory connections which may loosen during shipment 11 Pneumatically test the piping at 15 psig 103 kPa maximum prior to filling the systems 12 Check bolts and connections for tightness after the first heat up cycle Retorquing may be required BeforeLeavingtheInstallation Before leaving the installation adhere to the following 1 Check all controls to ensure they are operating properly 2...

Page 65: ...Questions PleaseContactYourLocalManufacturer sRepresentative 3 1 OPERATION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE TROUBLESHOOTING 4 SERVICEDOCUMENTS 5 ...

Page 66: ...nt in the environment 10 Nothing was damaged or knocked loose during installation Inspect the main gas train and trim assembly to be sure they were not damaged during installation 11 Installation Checklist provided with equipment is complete Start UpService If start up service has been included in the order the factory should be contacted after the installation has been successfully completed and ...

Page 67: ... known as washing soda or soda ash Na2CO3 is a sodium salt of carbonic acid Called washing soda soda crystals or sal soda in the detergent section of stores it effectively removes oil and grease Trisodium phosphate TSP E339 is an excellent degreaser and alternative to washing soda It is a white granular or crystalline solid highly soluble in water producing an alkaline solution The item of concern...

Page 68: ...n Beginning from an off state and assuming there is a load on the system call for heat when turning the switch to on the following will be the sequence of operations 1 The flame programmer will engage the blower motor and begin to open the air butterfly to the purge position The air switch will prove flow and once all devices are in purge position speed and the air switch is made the flame program...

Page 69: ...ystems all changes are made through the Siemens AZL display When running the boiler the status of the burner is to be monitored with the Siemens AZL display see below 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 to the main menu at any time by repeatedly pressing Escape...

Page 70: ...t flashing 7 Use the button to decrease the value or button to increase the value 8 Once the desired value has been set press the Enter button The number will stop flashing 9 Press the and buttons together to back out of the parameter level when finished 10 Press the or buttons to scroll to the next section of the program 11 Repeat this process until all parameters have been reviewed and set 12 On...

Page 71: ...eached the Ignition Position PH36 press the button This will allow the boiler to ignite the pilot flame Once the pilot is established the boiler will transfer to main flame 6 You will be at P0 P0 is the start of the profile and the Ignition position 7 Make changes to the fuel profile Three changes will need to be made fan output fuel and air settings To make changes Safely drive the unit to the hi...

Page 72: ...ter 701 index 03 In this example 0 is the Class UK use ONLY 7 0 1 04 10 to display parameter 701 index 04 In this example 10 is the Phase 7 0 1 05 22 to display parameter 701 index 05 In this example 22 is the Startup number 7 0 1 06 _ _ to display parameter 701 index 06 In this example _ _ indicates no Load firing rate Fault History Key Red indicates Flashing 7 0 1 07 0 to display parameter 701 i...

Page 73: ...manual for the VSRT 250 Burner combustion 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 More Input SKP 25 Adjustment More Input Less O2 Less Input More O2 PressureModulationController ADJUSTMENT OF THE YOKOGAWA UT 32A OPERATING CONTROLLER FOR VSRT 9 ...

Page 74: ...ock 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 screen To adjust the PID settings follow the steps below 1 Pressing the Fn button will directly bring you to the PID parameters 2 P will be displayed 3 Pressing the will display I 4 Pressing the again will display d 5 Pressing DISP will return to SP 6 P Proportio...

Page 75: ...ckwise from the desired set point 1 2 full turns Cycle the boiler multiple times to be sure that no nuisance fault occurs AirFilterSafetySwitch VSRT 9 5 80 250 To test perform the following 1 Disconnect power to boiler 2 Remove air supply from the air switch and turn on the boiler 3 Once the boiler is in the purge process the safety interlock should appear and shut down the burner 4 Turn the burne...

Page 76: ... start pump LowWaterCut Off Each cutoff device shall be installed to prevent startup and to cut off the boiler fuel or energy supply automatically prior to the fall of the water level below the lowest visible level of the gauge glass Standard low water cutoff devices are Fulton level probes Alternate cutoff devices are MM 150 MM 157 MM 193 7b Fulton probe type low water cutoff devices have a built...

Page 77: ...rform the following to test 1 With burner on and the boiler under pressure lower the set pressure on the switch until it trips and shuts down the burner Be sure that the pressure is the same as the boiler operating pressure 2 To test the manual reset button wait until the boiler has fully completed the post purge phase Once the boiler is in standby position reset the switch to the original set poi...

Page 78: ...the valve is in any other position the ball will not set PROOF OF CLOSURE IF APPLICABLE TO YOUR MODEL 1 Disconnect power to the boiler 2 While the boiler is off remove the common wire to the proof of closure POC switch on the oil gas valve 3 Restore power to the boiler The boiler should immediately lock out on alarm due to the POC being disconnected 4 Disconnect power and reconnect the POC wire 5 ...

Page 79: ...ic flow unit 0 400 0 130 Delete display of error history to delete the display set to 1 then to 2 5 2 0 141 Operating mode BACS 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 Baud rate for Modbus 0 9600 1 19200 0 1 1 147 Parity for Modbus 0 none 1 odd 2 ...

Page 80: ...rs etc undefined delete curves 1 G mod 2 Gp1 mod 3 Gp2 mod 4 Lo mod 5 Lo 2 stage 6 Lo 3 stage 7 G mod pneu 8 Gp1 mod pneu 9 Gp2 mod pneu 10 LoGp mod 11 LoGp 2 stage 12 Lo mod 2 fuel valves 13 LoGp mod 2 fuel valves 14 G mod pneu without actuator 15 Gp1 mod pneu without actuator 16 Gp2 mod pneu without actuator 17 Lo 2 stufig without actuator 18 Lo 3 stufig without actuator 19 G mod only gas actuat...

Page 81: ...as Pre purge time 20 s 60 s 30 s 226 Gas Pre ignition time 0 2 s 60 min 2 s 227 Gas Safety time 1 TSA1 0 2 s 10 s 5 s 229 Gas time to respond to pressure faults inTSA1 0 2 s 9 8 s 1 8 s 230 Gas Interval 1 0 2 s 60 s 5 s 231 Gas Safety time 2 TSA2 0 2 s 10 s 5 s 232 Gas Interval 2 0 2 s 60 s 2 0 s 233 Gas Afterburn time 0 2 s 60 s 8 s 234 Gas Post purge time 0 2 s 108 mi 15 s 237 Gas pressure switc...

Page 82: ...e 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 s 60 s 10 s 246 Gas Waiting time gas shortage 0 2 s 60 s 10 s 400 Ratio Curves 401 Ratio control curve fuel actuator 0 90 402 Ratio control curve air actuator 0 90 403 Ratio control curveVSD 20 100 500 Ratio Control 501 No flame positions fuel actuator Index 0 no load...

Page 83: ...or history 701 725 06 Load 0 100 900 Process Data 903 Current output Index 0 fuel Index 1 air 0 100 0 922 Incremental position of actuators Index 0 fuel Index 1 air 50 150 0 935 Absolute speed 0 65535 0 936 Standardized speed 200 200 942 Active load source 0 255 947 Result of contact sensing bit coded 0 255 950 Required relay state bit coded 0 255 954 Intensity of flame 0 100 960 Actual flow rate ...

Page 84: ... FultonGroupN A 2022 OPERATION VSRT IOM 2022 0728 SECTION3 3 20 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 85: ...Questions PleaseContactYourLocalManufacturer sRepresentative 4 1 MAINTENANCE INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE TROUBLESHOOTING 4 SERVICEDOCUMENTS 5 ...

Page 86: ... is being treated by chemical compounds make sure that this treatment is carried out carefully and according to the supplier s instructions ProcedureforCleaningWaterProbes 1 To clean probe in the boiler shell and probes in water column 2 Make sure there is no pressure in the boiler during the removal of the probes 3 Remove one probe using a 7 8 socket clean with very fine emory cloth and replace i...

Page 87: ...TER CUT OFF BOILER WATER COLUMN AUXILIARY LOW WATER CUT OFF A B C D 1 D 2 FIGURE 34 PROBE LENGTHS FOR VSRT Note Depending on model and date manufactured AUX LOWWATER CUT OFF off may enter boiler from the side or top of boiler If your water column does not appear as pictured there will be no internal water column probes to be cleaned or replaced other than the ALWCO ...

Page 88: ...arried out daily as recommended maintenance They are designed to prevent the buildup of scale silt or sludge in the bottom of the boiler and in the pipes leading to the water gauge In addition to these procedures the advice of a water treatment supplier should be sought and followed An ASME SectionVIII blowdown tank must be provided 1 Blow down the boiler each morning by starting the boiler and ge...

Page 89: ...e showing on the steam pressure gauge 2 With 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 primary low water cutoff device in the water column assembly and or the boiler shell Manual reset of the secondary low water cutoff device is requi...

Page 90: ...ler cabinet 2 If debris has plugged or contaminated the filter the filter must be replaced NOTE Operating the burner with the combustion air inlet filter removed will void the burner warranty A clean filter of the same Fulton part number type size and style must be installed while the boiler is in operation 3 3 Return the filter to its original position in the slot verify orientation RecommendedSe...

Page 91: ...r must be cold and the water level must below the pipe connection 16 Remove the hand holes and inspect the interior of the vessel for scale or sludge deposits See Figure 36 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 4 CAUTION If the gasket leaks while pressure is ...

Page 92: ...er with fresh water FIGURE 39 OVERCOMPRESSED GASKET InspectionandMaintenanceof thePilotAssembly Your boiler is equipped with an interrupted pilot This pilot uses gas from the pilot gas train and combustion air The pilot is ignited via a spark from the ignition electrode 1 Remove the pilot assembly This can be done with the burner in place Shut the manual valve in the pilot line and ensure that pow...

Page 93: ...le coupler You should now be able to lift the burner straight out of the burner plate NOTE Do not remove burner plate as gasket will need replacement if it is moved 2 Inspect and Clean the Burner The burner should be clean and free of dust This can be accomplished using compressed air Blow compressed air through the mesh from the outside in then empty any contaminates inside the burner can Inspect...

Page 94: ...minates inside the burner can If there is evidence of deterioration or corrosion replace immediately The burner must be removed to perform a thorough inspection and cleaning Vacuum out the debris from the burner inside after complete Inspect the burner for signs of local overheating or soot If soot is present either the pilot or the main burner is not running the proper fuel air ratio and the comb...

Page 95: ...y position the burner on the floor jack Slowly insert the burner into the furnace adjust jack height to install burner parallel with floor Once burner is fully seated on the studs reinstall the grade 2H nuts and Belleville washers Torque each nut to 45 ft lbs in two stages using the specified pattern 3 Re Install Burner After cleaning burner scrape old gasket from burner and premix plate and insta...

Page 96: ...tion 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 water chemistry expert for recommendations 4 Provide annual inspection by a qualified ASME boiler inspector as required by local codes 4a VSRT 9 5 meets the requirements of California Title 8 Subchapter 2 Article 5 Section 771 Boilers Not Sub...

Page 97: ...ck for gas pressure and for intermittent supply problems See Table 3 for appropriate gas pressures required at the head of the train LooseWire Connection Check connections to all components Flame Failure Power Supply Check fuse or circuit breaker Reset or replace as necessary Gas Supply Check for gas pressure and for intermittent supply problems See Table 3 for appropriate gas pressures required a...

Page 98: ...nd 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 at times Scale on probes Check and clean or replace as necessary Bad pump contactor Check to see if contactor is being powered Check to see if contactor coil is pulling in Replace if necessary Bad pump moto...

Page 99: ... Be sure to check all combustion points GasValve AdjustedToo Low Lean Unstable Flame Check CO2 and O2 levels Check pressure at outlet of the valve If too negative adjust gas valve as necessary Draft Check draft with a gauge Draft should be within the range of 0 25 w c to 1 50 w c May need to install a barometric damper Dirty Flue Check flue for carbon buildup or blockage Clean flue passages with b...

Page 100: ...m traps 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 or replace as necessary Perc cleaning solvent in boiler Clean boiler with washing soda Scale build up or lime deposits Call water treatment professional and consult factory Too much compound in s...

Page 101: ...lated 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...

Page 102: ... FultonGroupN A Inc 2022 MAINTENANCE TROUBLESHOOTING VSRT IOM 2022 0728 SECTION4 4 18 PAGE LEFT INTENTIONALLY BLANK ...

Page 103: ...Questions PleaseContactYourLocalManufacturer sRepresentative 5 1 SERVICEDOCUMENTS INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 SERVICEDOCUMENTS 5 ...

Page 104: ...TED BY NATURAL MEANS VENTS CONNECTIONS IF MECHANICAL MEANS OF VENTILATION ARE USED INTERLOCK PRESENT BOILER CLEARANCE IS SUITABLE FOR MAINTENANCE ACCESS IS PROVIDED TO THE TOP OF BOILER INSPECTION OPENINGS ELECTRICAL SUPPLY VOLTAGE TO EQUIPMENT SKID VOLTAGE SUPPLIED MEETS EQUIPMENT SPECIFICATION INDIVIDUAL EQUIPMENT IS FUSED PROPERLY WALL MOUNTED DISCONNECTS PROVIDED AT READY ACCESS E STOP AT THE ...

Page 105: ...T PUMP IS BLED AND PRIMED ISOLATION VALVE IS INSTALLED PUMP IS SERVICEABLE PUMP HAS RECIRCULATION LINE FOR DEAD HEAD PROTECTION IF CONTINUOUS RUN RETURN TANK SIZE OF RETURN TANK MAKEUP WATER SUPPLY PRESSURE VENT CONNECTION FREE TO ATMOSPHERE TERMINATED TO SAFE AREA SAME SIZE AS TANK OUTLET LEVEL CONTROLS ARE INSTALLED CORRECTLY PREHEAT KIT INSTALLED STEAM PRESSURE SUPPLIED DEAERATOR TANK SAFETY VA...

Page 106: ...ODEL OPERATION TYPE FUEL TYPE PILOT TYPE BLOWER MOTOR SAFETY VALVE IS PIPED TO SAFE LOCATION BURNER BLOWER MOTOR HORSEPOWER BURNER BLOWER MOTOR VOLTAGE NAMEPLATE VOLTAGE MATCHES SUPPLIED VOLTAGE BLOWER ROTATION IS CORRECT BLOWER SIZE AIR PICK UP OR COLLAR USED FUEL OIL PUMP SAFETY VALVE IS PIPED TO SAFE LOCATION OIL PUMP IS BLED AND PRIMED FILTER AND SHUTOFF VALVE BEFORE OIL PUMP CHECK VALVE INSTA...

Page 107: ...UMP MAKE MODEL BACK PRESSURE VALVE MAKE MODEL OIL NOZZLE SIZE SPRAY PATTERN SPRAY ANGLE NOTE 28 1 PSIG VOLTAGE FROM NEUTRAL GROUND Y N ______________________ 3 PHASE POWER L1 L2 L2 L3 L1 L3 FEED WATER SYSTEM FEED WATER PUMP ARRANGEMENT 1 PER STEAMPAC REDUNDANT ETC DO THE PUMPS HAVE BYPASS ORIFICES CONTINUOUS OR ON OFF FEED WATER PUMPS DA OR RETURN TANK MODEL STEAM PRESSURE TO DA TANK OR PREHEAT KI...

Page 108: ...1 FEED MANUFACTURER AND MODEL CHEMICAL 2 NAME CHEMICAL 2 FEED INJECTION LOCATION CHEMICAL 2 FEED MANUFACTURER AND MODEL CHEMICAL 3 NAME CHEMICAL 3 FEED INJECTION LOCATION CHEMICAL 3 FEED MANUFACTURER AND MODEL WATER SOFTENER MANUFACTURER AND MODEL RO DI WATER YES NO SAFETY CHECKS CHECK PROPER OPERATION OF ALL SAFETIES AND DOCUMENT OK AND SETTINGS BELOW OP CHECK SET PT HIGH LIMIT PRESSURE SWITCH OP...

Page 109: ... 75 100 AIR GATE POSITION GAS VALVE POSITION INCOMING GAS PRESSURE MANIFOLD GAS PRESSURE OVER BURNER PRESSURE NOx CORRECTED TO 3 O2 O2 CO2 CO PPM AMBIENT AIR TEMPERATURE STACK TEMPERATURE OPERATING PRESSURE DRAFT FLAME SIGNAL OIL COMBUSTION AT OPERATING TEMPERATURE LINKAGE FIRING RATE 0 25 50 75 100 AIR GATE POSITION HAUCK VALVE POSITION PUMP PRESSURE NOZZLE PRESSURE O2 CO2 CO PPM AMBIENT AIR TEMP...

Page 110: ...ON FUEL PRESSURE OVER BURNER PRESSURE O2 CO2 CO NOx 3 AMBIENT TEMPERATURE STACK TEMPERATURE STACK DRAFT FLAME SIGNAL 1 2 3 4 5 6 7 8 9 10 11 OIL BACK PRESSURE SMOKE OPERATING PRESSURE COMBUSTION SETTINGS GAS 1 LINKAGELESS FIRING POSITION FUEL POSITION AIR POSITION AUX POSITION VSD POSITION INCOMING GAS PRESSURE FUEL PRESSURE OVER BURNER PRESSURE O2 CO2 CO NOx 3 AMBIENT TEMPERATURE STACK TEMPERATUR...

Page 111: ...rer sRepresentative SECTION5 VSRT IOM 2022 0728 SERVICEDOCUMENTS 5 9 START UP INSTALLATION OPERATION REPORT FOR FULTON STEAM BOILERS PAGE 8 OF 9 GENERAL COMMENTS REGARDING INSTALLATION OTHER FUEL BURNING EQUIPMENT ETC SUMMARY OF WORK PERFORMED ...

Page 112: ...FULTON STEAM BOILERS PAGE 9 OF 9 STATUS OF PARTS SHIPPED DATE COMMENTS TO BE COMPLETED IN EACH FIELD AS REQUIRED PART NUMBER DESCRIPTION SHIPPED TO SITE INSTALLED CUSTOMER TO RETURN DAY DATE HOURS TRAVELED HOURS WORKED MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY CUSTOMER TO RETURN SPARE PARTS REQUIRED ...

Page 113: ...ice Bulletin s addressed where applicable COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE COMPLETE fill in tables below Combustion verification completed adjust as necessary Safety checks table completed Waterside inspection hand hole gaskets replaced CLEAN NEEDS TO BE CLEANED WATER CHEMISTRY Verify water chemistry is within spec...

Page 114: ... 161 Total Faults P 162 Operating Hours P 166 Number of Startups Controller Hours COMBUSTION SETTINGS Fuel Type is Natural Gas FIRING POSITION P0 LIGHT P1 P2 P3 P4 P5 P6 P7 P8 P9 100 Fuel Position Air Position VFD Position VFD Hertz VFD Ampere Supply Gas Pressure InWC Manifold Gas Pressure InWC MV Downstream Gas InWC Fan Discharge Pressure InWC Wet Stack Analyzer O2 Dry Burner Sensor O2 CO2 CO ppm...

Page 115: ...Questions PleaseContactYourLocalManufacturer sRepresentative SECTION5 VSRT IOM 2022 0728 SERVICEDOCUMENTS 5 13 NOTES ...

Page 116: ... FultonGroupN A 2022 SERVICEDOCUMENTS VSRT IOM 2022 0728 SECTION5 5 14 NOTES ...

Page 117: ...Questions PleaseContactYourLocalManufacturer sRepresentative SECTION5 VSRT IOM 2022 0728 SERVICEDOCUMENTS 5 15 NOTES ...

Page 118: ...tion Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from Fulton Group N A Inc Fulton Steam Solutions Inc Fulton Heating Solutions Inc FultonThermal Corporation are part of Fulton Group N A Inc a global manufacturer of steam hot water and thermal fluid heat transfer systems Fulton Group N A Inc 2022 ...

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