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Fulton VMP

(Vertical Multi-Port)

Gas Fired Steam Boilers

40-150 HP

Installation Operation And

Maintenance Manual

VMP-STEAM-GAS_IOM_2016-1007-REV1

Serial # : ___________________________

Model # : ___________________________

Fulton Order # : ___________________________

Sold To : ___________________________

Job Name : ___________________________

Date : ___________________________

Содержание VMP100

Страница 1: ...ration And Maintenance Manual VMP STEAM GAS_IOM_2016 1007 REV1 Serial ___________________________ Model ___________________________ Fulton Order ___________________________ Sold To ___________________________ Job Name ___________________________ Date ___________________________ ...

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Страница 3: ... 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 Parameter Carbon Steel Stainless Steel Feedwater Vertical Boiler Steam Pac Water Horizontal Boiler Steam Pac Water Feedwater Vertical Boiler Steam Pac Water Horizontal Boiler Steam Pac Water pH 7 5 9 5 8 5 10 5 8 5 10 5 6 ...

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Страница 5: ...VMP IOM 1 Contents Section 4 Maintenance PAGE 31 5 Parts and Warranty PAGE 35 3 Operation PAGE 17 2 Installation PAGE 9 1 Safety Warnings and Precautions PAGE 3 ...

Страница 6: ...2 VMP IOM ...

Страница 7: ...VMP IOM 3 Section 1 Safety Warnings and Precautions 4 5 3 2 ...

Страница 8: ...4 VMP IOM ...

Страница 9: ...e 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 jurisdictional 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 ...

Страница 10: ...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 140o F prior to entry into the boiler CAUTION A temperature ...

Страница 11: ...VMP IOM 7 Safety Warnings and Precautions ...

Страница 12: ...8 VMP IOM ...

Страница 13: ...VMP IOM 9 Section 2 Installation 4 5 3 1 ...

Страница 14: ...ttom Refractory Blowdown Outlet Clean Out Opening Transformer Scroll Burner Motor Steam Gauge Assembly Water Column Gauge Glass Valve Gauge Glass Valve Gauge Glass and Protector Rods Control Box Fiberglass Insulation Outside Jacket Handhole Castable Refractory Insulation O P C Operating Pressure Control H P C High Pressure Control To O P C To H P C Blowdown Outlet Burner Alignment Tabs Artwork Rev...

Страница 15: ...r 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 Outlet1 IN 73 77 77 84 89 89 102 102 MM 1854 4956 4956 2134...

Страница 16: ...ut 1000 BTU HR 1340 1656 1673 2009 2678 3347 4353 5022 1000 KCAL HR 338 417 422 506 675 843 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 FT3 HR 1595 1972 1992 2392 3188 3985 5200 ...

Страница 17: ...iameter 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 Outlet1 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 1...

Страница 18: ... 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 1...

Страница 19: ...07 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 Outlet1 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...

Страница 20: ...r HP 10 10 KW 7 4 7 4 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 FT3 HR 5182 5978 M3...

Страница 21: ...quate gas supply to the gas head assembly Consult your gas company for specific recommendations e 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 f For propane or butane gas...

Страница 22: ...return tank temperature 3 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 Instruction Manual for detailed instructions NOTE Care should be taken to ensure that the blow down receptacle used meets the regulations covering s...

Страница 23: ... connection provided 4 Do not cap or plug drain hole in the side of valve body 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...

Страница 24: ...y water pressure should not exceed 40 PSI A pressure reducing valve should be installed a head of the return tank when above this pressure 3 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 s...

Страница 25: ... 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 bott...

Страница 26: ...er Daily boiler blow down is recommended to prevent corrosion and or deposits from forming Glossary of Water Supply Corrosives and Inhibitors DISSOLVED OXYGEN Oxygen 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 enoug...

Страница 27: ...ystem 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 return water or form directly in the boiler as a result of corrosion Most iron oxide originates outside the boiler It concentra...

Страница 28: ...s such as combustible volatiles and lint in the combustion system can create hazardous conditions 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 ...

Страница 29: ...tely as the flue heats up and a corrosive poultice develops which attacks the steel and will also attack the boiler Concentration levels of only 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...

Страница 30: ... 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 cm2 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 the returns to go into a floor dra...

Страница 31: ...24 VMP IOM ...

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Страница 33: ...Section 3 Operation 4 5 2 1 VMP IOM 25 ...

Страница 34: ...ed 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 burner The water level relay is equipped with a manual reset...

Страница 35: ...et 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 1 Modul...

Страница 36: ...ed on the top right hand side of the burner assembly This damper type air controller is used to introduce air to and through the blast tube of the burner The purpose of the secondary air adjustment is to proportionately divide the air to the 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 ...

Страница 37: ...team pressure falls below a predetermined level e Sight 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 n...

Страница 38: ...he other arrow key For example if you used the right arrow key to get to the letter A press the left arrow key 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 Display Press Enter Select RatioControl Press Enter...

Страница 39: ...ve 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 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 Automat...

Страница 40: ...d 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 ...

Страница 41: ...VMP IOM 33 Section 4 Maintenance 5 3 2 1 ...

Страница 42: ...Bottom Refractory Blowdown Outlets Clean Out Opening Transformer Scroll Burner Motor Steam Gauge Assembly Water Column Gauge Glass Valve Gauge Glass Valve Gauge Glass and Protector Control Box Fiberglas Insulation Outside Jacket Handhole Castable Refractory Insulation O P C Operating Pressure Control H P C High Pressure Control To O P C To H P C Blowdown Outlet Burner Alignment Tabs Artwork Revisi...

Страница 43: ...ll 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 b...

Страница 44: ...Then a maximum signal should be obtained on main flame 5 0 VDC 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 brin...

Страница 45: ... 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 7 The bottom refractory has the largest hole while the top refractory has the smallest 8 Lower the bottom refractory down the furnace with wire fastened around the refractory in three positions Wh...

Страница 46: ... wired green wiring plugs and the conduitterminationpointonthenewmotor Connect the black grounding wire from the motor to the conduit termination 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 P...

Страница 47: ...me rod and ignition electrodes 4 Check starter contacts Burned or pitted contacts should be replaced Do not use sand paper or file to clean 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 Rec...

Страница 48: ... Schedule 1 Have combustion CO2 O2 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 b Remove inner plate and turbultors 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 ...

Страница 49: ...boiler operation This can lead to a potentially dangerous situation Close both the main gas supply isolation valve and gas pilot line isolation valve Turn the boiler to the on position The boiler will proceed through the ignition sequence Once burner control completes the ignition sequence the burner control should display fault code for pilot flame failure During the pilot sequence burner control...

Страница 50: ...o steam pressure in the boiler or not more than 10 PSI Shut off the make up water supply to the boiler Open the blow down valve at the back of the boiler to allow the water level to slowly drop until and 1 of water level is visible sight glass and close the blow down valve The first LWCO control will drop out within 3 seconds and cut off the boiler fuel or energy supply This LWCO control is typica...

Страница 51: ...ycle the burner and observe for proper operation Proof of Closure Disconnect power to the boiler While the boiler is off remove the common wire to the proof of closure switch and install a wire nut on the end of switch or wrap in tape to properly protect the wire Turn power to the boiler back on The boiler should immediately lock out on alarm due to the POC being disconnected Disconnect power and ...

Страница 52: ...p 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 fu...

Страница 53: ...uretrol Disconnect all 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 r...

Страница 54: ...acuum 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...

Страница 55: ... 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 ...

Страница 56: ... steam 2 High boiler TDS Drain boiler and flush system Refill and increase blow down carryover rate frequency 3 High level of water Consult water treatment expert and adjust to boiler treatment chemicals recommended levels 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...

Страница 57: ...46 VMP IOM ...

Страница 58: ...VMP IOM 47 Section 5 Parts and Warranty 4 3 2 1 ...

Страница 59: ... 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 Ibs minimum Use for making refractories 2 21 015 Buckeye Stamping for Bot...

Страница 60: ...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...

Страница 61: ... 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 G...

Страница 62: ...ight 120 V NEMA 4 0 02 0 01 2 45 411 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...

Страница 63: ...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...

Страница 64: ... Plate Gasket Strip 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 Extension 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 ...

Страница 65: ...54 VMP IOM Parts and Warranty ...

Страница 66: ...t 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 install...

Страница 67: ......

Страница 68: ... 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 representative of Fulto...

Страница 69: ...Companies The Fulton Companies 972 Centerville Road Pulaski New York USA 13142 Call 315 298 5121 Fax 315 298 6390 www fulton com Fulton Heating Solutions Inc Fulton Boiler Works Inc Fulton Thermal Corporation are part of the Fulton Group of Companies manufacturers of high grade industrial commercial heat transfer products VMP STEAM GAS IOM_2016 1007 REV1 ...

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