FULTON VMP40, VMP49.5, VMP50, VMP80, VMP100 Installation, Operation And Maintenance Manual

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Installation Operation And

Fulton VMP

Maintenance Manual

VMP-STEAM-GAS_IOM_2016-1007-REV1

Serial # : ___________________________

Model # : ___________________________

Fulton Order # : ___________________________

Sold To : ___________________________

Job Name : ___________________________

Date : ___________________________

(Vertical Multi-Port) Gas Fired Steam Boilers 40-150 HP

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ProductBulletin

Product Bulletin

2010-001PB

The Fulton Companies 972 Centerville Road Pulaski, N.Y. 13142

Date: January 22, 2010

Subject: Water Chemistry Requirements for Fulton Steam Products

Products: ICS/ICX, FB-A, FB-F, FB-S, VMP, PVLP, PHP, Electric Steam

Boilers and Unfired Steam Generators

Please note that the water chemistry is different for carbon steel vs. stainless steel pressure vessels and vertical vs. horizontal orientation.

Effective immediately, please use the limits below. Should you have any questions, please do not hesitate to contact Fulton at 315-298-5121.

Water Chemistry Requirements for Fulton Steam Products (to 300 psig MAWP)

NOTES:

*This is a minimum temperature. Feedwater temperatures below 200F will require an oxygen scavenger.

** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.

+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible.

++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or

orange tinge.

ND: None Detected.

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 6.0-9.5 8.5-10.5 8.5-10.5

Feedwater Temperature

140F* --- --- 140F* --- ---

Hardness as CaCO

<2ppm <10 ppm <15 ppm <2 ppm <10 ppm <15 ppm

Chlorides --- --- --- --- 50 ppm 50 ppm

Tota l Alkalinity

--- <300 ppm <500 ppm --- <300 ppm <500 ppm

Tota l Dissolved Solids

--- <2000 ppm <3000 ppm --- <2000 ppm <3000 ppm

Suspended Solids

No visual turbidity**

No visual

turbidity**

Total Organic Carbon

No sheen No foam+

No sheen

No foam+

No sheen No foam+

Iron Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Colorless

liquid++

Dissolved Oxygen

<1ppm* ND ND <5ppm ND ND

Visual Oil ND ND ND ND ND ND

Conducivity (uS/cm)

--- <2985 <4477 --- <2985 <4477

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VMP IOM

Contents

Section

Maintenance

PAGE 31

Parts and Warranty

PAGE 35

Operation

PAGE 17

Installation

PAGE 9

Safety Warnings and Precautions

PAGE 3

Page 6

VMP IOM

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VMP IOM

Section

Safety Warnings and Precautions

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VMP IOM

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VMP IOM

Safety Warnings and Precautions

This manual is provided as a guide to the correct operation and maintenance of your Fulton Gas Fired Steam Boiler, and should be permanently available to the staff responsible for the operation of the gas fired boiler.

These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.

The requirements and instructions contained in this section generally relate to the standard Fulton Gas Fired Steam Boiler. When installing a packaged unit, this entire section should be read to ensure that the installation work is carried out correctly.

Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing:

a) Material inspections. b) Manufacturing process inspections. c) ASME welding inspections. d) ASME hydrostatic test inspection. e) Electrical components inspection. f) Operating test. g) Final Engineering Inspection h) Crating inspection.

All units are crated for fork lift transport. Once uncrated, all units can be transported with a forklift. Under no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of any Fulton Boiler.

Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy equipment.

The customer should examine the boiler for any damage, especially the refractories. It is the responsibility of the installer to ensure

all parts supplied with the boiler are fitted in a correct and safe manner.

NOTE

The installation of the Fulton Gas Fired Steam Boiler should be carried out by competent personnel in accordance with the standards of the National Fire Protection Association, National or Canadian Electrical Code. All state and 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 be consulted prior to installation.

WARNING

Operating the boiler beyond its design limits can damage the boiler and can also be dangerous. Do not operate the boiler outside its limits. Do not try to upgrade the boiler performance by unapproved modifications. Unapproved modifications can cause injury and damage. Contact your Fulton dealer before modifying the boiler.

WARNING

A defective boiler can injure you or others. Do not operate a boiler which is defective or has missing parts. Make sure that all maintenance procedures are completed before using the boiler. Do not attempt repairs or any other maintenance work you do not understand. Obtain a Service Manual from Fulton or call a Fulton Service Engineer.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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VMP IOM

Safety Warnings and Precautions

For Your Safety

The following WARNINGS, CAUTIONS, and NOTES appear in various sections of this manual.

They are repeated on these safety summary pages as an example and for emphasis.

WARNINGS must be observed to prevent serious injury, or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted.

It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS, and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment.

WARNING

Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels. A means to cool boiler blowdown water to <140

F prior to discharging to floor drains is required for personnel and equipment protection.

WARNING

Only properly trained personnel should install and maintain water gauge glass and connections. Wear safety glasses during installation. Before installing, make sure all parts are free of chips and debris. Gauge glass valves must be fully open to prevent boiler water damage if a gauge glass breaks.

WARNING

Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.

WARNING

DO NOT TAMPER WITH THE SAFETY FEATURES OF THE LOW WATER SAFETY CUT OFF.

WARNING

When shutting down the boiler for any extensive repairs, shut off main disconnect switches on both the boiler and the feed water pump.

WARNING

Do not clean the gauge glass while pressurized. Ensure gauge glass valves are fully shut prior to glass removal.

WARNING Do not allow anyone to operate, service or repair this equipment unless they fully understand all applicable sections of this manual.

CAUTION

To prevent corrosion fatigue at the feedwater nozzle or cold end corrosion, boiler feed water must be at least 140

F prior to entry into the boiler.

CAUTION A temperature exceeding 100oF in the boiler room may cause premature failure of electrical components in the boiler control panel.

CAUTION The water chemistry in the boiler must be kept within limits outlined in this manual. Failure to do so will likely cause premature boiler pressure vessel failure and poor steam quality.

NOTE

After installation is complete and prior to operation the pressure vessel should be cleaned or boiled out per instructions included in this manual.

NOTE

a) The fused disconnect switch that controls the feed water pump should be kept in the “on” position at all times during the boiler operation as well as during the non-operating period of the boiler.

b) This switch should be turned “off” only when repairs or adjustments should be made.

NOTE

The feedwater pump will continue to operate until the water reaches the correct level in the boiler. This level is approximately the center of the water gauge glass.

NOTE

To ensure that your Fulton Steam Boiler is kept operating safely and efficiently, follow the maintenance procedures set forth in Section 4 of this manual.

NOTE

If only the top refractory is to be changed, the bottom refractory need not be removed.

NOTE

The boiler blow off operation should be done once during the day when the boiler is at 10 PSIG or less.

NOTE

After a new Fulton Boiler has been in operation for several months, pieces of burned metal will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation. This is a normal condition and does not affect the efficiency or the life of the boiler in any way.

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Safety Warnings and Precautions

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VMP IOM

Section

Installation

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Installation

Gas Train Assembly

Burner Alignment Tabs

Burner Plate Assembly

Top Plate Assembly

Secondary Air Damper

Flue Cover Plate

Lifting Hook(s)

Stainless Steel Ring

Flue Outlet

O.P.C.

H.P.C.

Transformer

Scroll

Burner Motor

Steam Gauge Assembly

Gauge Glass Valve

Gauge Glass and Protector Rods

Gauge Glass Valve

Water Column

Bottom Refractory

Clean Out Opening

VMP IOM

Top Refractory

Turbulator

Feedwater Inlet

Blowdown Outlet

Control Box

Fiberglass Insulation

Outside Jacket

Blowdown Outlet

Handhole

Castable Refractory Insulation

O.P.C. = Operating Pressure Control

H.P.C. = High Pressure Control

Artwork Revision 2017-0927

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Fulton Vertical MultiPort Steam Boilers

(Standard Burners)

Fulton Models: VMP40, VMP49.5, VMP50, VMP60,

VMP80, VMP100, VMP130 and VMP150

Product Data Submittal

Models VMP 40 49.5 50 60 80 100 130 150

Unit Size: BHP 40 49.5 50 60 80 100 130 150 A. Boiler Diameter IN 50.5 55 55 55 63 69 76.5 76.5

MM 1283 1397 1397 1397 1600 1753 1943 1943

B. Boiler Height IN 84 91 91 97 100 100 115 115

MM 2133 2312 2312 2464 2540 2540 2921 2921

C. Boiler Depth IN 90 100 100 100 114 119 128 130

MM 2286 2540 2540 2540 2896 3022 3251 3302

D. Boiler Height w/trim IN 107 112 112 118 124 126 135 141

MM 2718 2832 2832 2984 3150 3200 3429 3582

E. Overall Boiler Width IN 56 62 62 62 68 74 84.5 84.5

MM 1422 1575 1575 1575 1727 1880 2146 2146

F. Flue Outlet Diameter IN 12 12 12 12 14 14 14 16

MM 305 305 305 305 356 356 356 407

G. To Center of Flue Outlet IN 79 86 86 92 95 95 107 107

MM 2006 2184 2184 2237 2413 2413 2718 2718

H. Feedwater Inlet IN 35 35 35 35 35 35 39 39

MM 889 889 889 889 889 889 991 991

J. Blowdown Outlet IN 17 18 18 18 18 18 22 22

MM 432 457 457 457 457 457 559 559

K. Height to Steam Outlet

IN 73 77 77 84 89 89 102 102

MM 1854 4956 4956 2134 2260 2260 2591 2591

L. Min. Clearance to Ceiling IN 110 115 115 125 130 132 145 145

MM 2794 2921 2921 3175 3302 3353 3683 3683

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions. NOTE: Minimum clearance is 24” to the side and back and 36” in front of unit.

1. The boiler may be fitted with a 90

elbow spool piece making the steam outlet connection higher.

Dimensions

Top View

Side View

Front View

11 VMP IOM

Steam

Outlet

Minimum Clearance

For Burner Removal

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Specifications

Models VMP 40 49.5 50 60 80 100 130 150

Unit Horsepower 40 49.5 50 60 80 100 130 150

Boiler Connections

Steam Outlet 15 PSI - 150# Flanged IN 4 4 4 4 6 6 * 6 * 6

MM 101 101 101 101 152 152 203 203

Steam Outlet 150 PSI IN NPT 3 3 3 3 3 3 4 4

MM 76 76 76 76 76 76 101

Feedwater Inlet IN NPT 1 1 1 1 1 1.25 1.25 1.25

MM 25 25 25 25 25 31 32 32

Blowdown Outlet (2) IN NPT 1.5 1.5 1.5 1.5 1.5 2 2 2

MM 38 38 38 38 38 51 51 51

Water Column Blowdown IN NPT 1 1 1 1 1 1 1 1

MM 25 25 25 25 25 25 25 25

Surface Blowdown IN NPT .75 .75 .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19 19 19

Safety Valve 150 PSI Inlet IN NPT .75 1 1 1 1.25 1.25 1.5 1.5

MM 19 25 25 25 31 31 38 38

Safety Valve 150 PSIOutlet IN NPT 1 1.25 1.25 1.25 1.5 1.5 2 2

MM 25 31 31 31 38 38 51 51

Safety Valve 15 PSI Inlet (2) IN NPT 1.25 1.25 1.25 1.25 1.5 1.5 2 2

MM 31 31 31 31 38 38 51 51

Safety Valve 15 PSI Outlet IN NPT 1.5 1.5 1.5 1.5 2 2 2 2

MM 38 38 38 38 51 51 51 51

Natural Gas Connection IN 1.5 1.5 1.5 2 2 2 2 2

MM 38 38 38 51 51 51 51 51

Light Oil Connection IN .25 .25 .25 .25 .25 .25 .375 .375

MM6666 669.59.5

Burner Motor (Gas) HP 1.5 1.5 1.5 1.5 3 3 10 10

KW 1.1 1.1 1.1 1.1 2.2 2.2 7.5 7.5

Burner Motor (Oil/Combo) HP 2 2 2 2 3 3 10 10

KW 1.5 1.5 1.5 1.5 2.2 2.2 7.5 7.5

Approximate Weights

Shipping Weights (approx.) LB 5775 6550 6575 7370 8000 9500 12350 12350

KG 2620 2972 2980 3340 3630 4310 5600 5600

Operating Weight (approx.) LB 6720 8850 8209 9227 11760 14525 20135 20135

KG 3050 4015 3720 4190 5330 6590 9130 9130

**Ratings Sea Level to 3000 FT. (914 M)

Output 1000 BTU/HR 1340 1656 1673 2009 2678 3347 4353 5022

1000 KCAL/HR 338 417 422 506 675 843 1097 1266

Steam Output LBS/HR 1380 1708 1725 2070 2760 3450 4485 5175

KG/HR 626 775 783 939 1252 1565 2035 2348

Water Content GAL 172 274 242 270 383 518 810 810

LITERS 651 1038 916 1022 1450 1960 3066 3066

Approximate Fuel Consumption at Rated Capacity+ Natural Gas FT

/HR 1595 1972 1992 2392 3188 3985 5200 5978

M3/HR 45 56 56 68 90 113 147 169

LP Gas FT

/HR 638 788 797 957 1275 1594 2080 2391

M3/HR 18 22 23 27 36 45 59 68

Light Oil GPH 11.0 13.9 14.0 17.0 22.8 28.0 37.0 42.0

LPH 41.6 52.6 53 64.3 87 106 140 159 Gas Pressure Required Standard Burners Min. IN W.C. 7 7 7 7 9 9 40 40 Gas Pressure Required Standard Gas Train Max. IN W.C. 13 13 13 13 27 27 5 psig 5 psig

Electrical Requirements/Amps for Burner Motors

208V, 50/60 CY, 3 Phase (Gas/Oil) 6.6/7.5 6.6/7.5 6.6/7.5 6.6/7.5 10.6 10.6 30.8 30.8 230V, 50/60 CY, 3 Phase (Gas/Oil) 6.0/6.8 6.0/6.8 6.0/6.8 6.0/6.8 9.6 9.6 28 28 460V, 50/60 CY, 3 Phase (Gas/Oil) 3.0/3.4 3.0/3.4 3.0/3.4 3.0/3.4 4.8 4.8 14 14

* Steam separator or dual steam nozzle design required. **Ratings - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2and at 100 Degrees C +Consumption based on natural gas 1000 BTU/FT3; Propane 2500, and Light Oil 140,000 BTU/GAL.

vmpstd-pds-2010-1008

NOTE: 7” - 11” wc gas pressure is required during run for 40-60 HP boilers with standard burners. 9”-11” wc gas pressure is required during run for 80-100 HP boilers with standard CSD-1 burners, 40” W.C. is required for 130-150 HP Specifications & dimensions are approximate. We reserve the right to change without notice.

The Fulton Companies 972 Centerville Road Pulaski, New York 13142 Call 315-298.5121 Fax 315-298.6390 www.fulton.com

11a VMP IOM

Page 17

Fulton Vertical MultiPort Steam Boilers

(Low Emissions Burners)

(<20 PPM NOx)

Fulton Models: VMP40, VMP49.5, VMP50, VMP60,

VMP80, and VMP100

Product Data Submittal

Models VMP 40 49.5 50 60 80 100

Unit Size: BHP 40 49.5 50 60 80 100 A. Boiler Diameter IN 49 55 55 55 63 69

MM 1245 1397 1397 1397 1600 1753

B. Boiler Height IN 84 91 91 97 100 100

MM 2133 2312 2312 2464 2540 2540

C. Boiler Depth IN 90 100 100 100 114 119

MM 2286 2540 2540 2540 2896 3022

D. Boiler Height w/trim IN 107 112 112 118 124 126

MM 2718 2832 2832 2984 3150 3200

E. Overall Boiler Width IN 56 62 62 62 68 74

MM 1422 1575 1575 1575 1727 1880

F. Flue Outlet Diameter IN 12 12 12 12 14 14

MM 305 305 305 305 356 356

G. To Center of Flue Outlet IN 79 86 86 92 95 95

MM 2006 2184 2184 2237 2413 2413

H. Feedwater Inlet IN 35 35 35 35 35 35

MM 889 89 889 889 889 889

J. Blowdown Outlet IN 17 18 18 18 18 182

MM 432 457 457 457 457 457

K. Height to Steam Outlet

IN 73 77 77 84 89 89

MM 1854 4956 4956 2134 2260 2260

L. Min. Clearance to Ceiling IN 123 135 135 144 147 147

for Burner Removal MM 3124 3429 3429 3658 3734 3734

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions. NOTE: Minimum clearance is 24” to the side and back and 36” in front of the unit.

1. The boiler may be fitted with a 90

elbow spool piece making the steam outlet connection higher.

Dimensions

Top View

Side View

Front View

12 VMP IOM

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Specifications

Models VMP 40 49.5 50 60 80 100

Unit Horsepower 40 49.5 50 60 80 100

Boiler Connections

Steam Outlet 15 PSI IN 4 4 4 4 6 6 150# Flanged MM 101 101 101 101 152 152 Steam Outlet 150 PSI IN NPT 3 3 3 3 3 3 150# Flanged MM 76 76 76 76 76 76 Feedwater Inlet IN NPT 1 1 1 1 1 1.25

MM 25 25 25 25 25 31

Blowdown Outlet IN NPT 1.5 1.5 1.5 1.5 1.5 2

MM 38 38 38 38 38 51

Water Column Blowdown IN NPT 1 1 1 1 1 1

MM 25 25 25 25 25 25

Surface Blowdown IN NPT .75 .75 .75 .75 .75 .75

MM 19 19 19 19 19 19

Safety Valve 150 PSI Inlet IN NPT .75 1 1 1 1.25 1.25

MM 19 25 25 25 31 31

Safety Valve 150 PSIOutlet IN NPT 1 1.25 1.25 1.25 1.5 1.5

MM 25 31 31 31 38 38

Safety Valve 15 PSI Inlet (2)@ IN NPT 1.25 1.25 1.25 1.25 1.5 1.5

MM 31 31 31 31 38 38

Safety Valve 15 PSI Outlet (2) IN NPT 1.5 1.5 1.5 1.5 2 2

MM 38 38 38 38 51 51

Natural Gas Connection IN 1.5 1.5 1.5 2 2 2

MM 38 38 38 51 51 51

Burner Motor HP 5 5 5 5 5 7.5

KW 3.7 3.7 3.7 3.7 3.7 5.6

Approximate Weights

Shipping Weights (approx.) LB 6575 7375 7375 8170 8800 10300

KG 2982 3345 3345 3706 3992 4672

Operating Weight (approx.) LB 8659 9684 9684 10671 12051 14700

KG 3928 4393 4393 4840 5466 6668

Ratings Sea Level to 3000 FT. (914 M)

Output 1000 BTU/HR 1340 1656 1673 2009 2678 3347

1000 KCAL/HR 338 417 422 506 675 843

Steam Output** LBS/HR 1380 1708 1725 2070 2760 3450

KG/HR 626 775 783 939 1252 1565

Water Content GAL 172 274 242 270 383 518

LITERS 651 1038 916 1022 1450 1960

Approximate Fuel Consumption at Rated Capacity+ Natural Gas FT

/HR 1595 1972 1992 2392 3188 3985

M3/HR 45 56 56 68 90 112 Gas Pressure Required Min. IN W.C. 30 30 30 40 40 40 Gas Pressure Required Max. PSIG. 5 5 5 5 5 5

Electrical Requirements/Amps for Burner Motors

208V, 60 CY, 3 Phase 16.7 16.7 16.7 16.7 16.7 24.2 230V, 60 CY, 3 Phase 15.2 15.2 15.2 15.2 15.2 22.0 460V, 60 CY, 3 Phase 7.6 7.6 7.6 7.6 7.6 11.0

* Steam separator or dual steam nozzle design required. Consult factory for availability. **Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2and at 100 Degrees C

+Consumption based on natural gas 1000 BTU/FT3and 20 ppm NOx@ 3% CO2burner.

vmp40-100le-pds-2010-1008

The Fulton Companies 972 Centerville Road Pulaski, New York 13142 Call 315-298.5121 Fax 315-298.6390 www.fulton.com

12a VMP IOM

Page 19

Fulton Vertical MultiPort Steam Boilers

(Low Emissions Burners)

(<30 PPM NOx)

Fulton Models: VMP130 and VMP150

Product Data Submittal

Models VMP 130 150

Unit Size: BHP 130 150 A. Boiler Diameter IN 76.5 76.5

MM 1943 1943

B. Boiler Height IN 115 115

MM 2921 2921

C. Boiler Depth IN 128 130

MM 3251 3302

D. Boiler Height w/trim IN 135 149

MM 3429 3785

E. Overall Boiler Width IN 84.5 84.5

MM 2146 2146

F. Flue Outlet Diameter IN 14 16

MM 356 407

G. To Center of Flue Outlet IN 107 107

MM 2718 2718

H. Feedwater Inlet IN 39 39

MM 991 991

J. Blowdown Outlet IN 22 22

MM 559 559

K. Height to Steam Outlet

IN 102 102

MM 2591 2591

L. Min. Clearance to Ceiling IN 155 155

for Burner Removal MM 3937 3937

M. Height to top of FGR Loop IN 121 121

MM 3073 3073

Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions.

NOTE: Minimum clearance is 24” to the side and back and 36” in front of unit.

1. The boiler may be fitted with a 90

elbow spool piece making the steam outlet

connection higher.

Dimensions

13 VMP IOM

Page 20

Specifications

The Fulton Companies 972 Centerville Road Pulaski, New York 13142 Call 315-298.5121 Fax 315-298.6390 www.fulton.com

Models VMP 130 150

Unit Horsepower 130 150

Boiler Connections

Steam Outlet 15 PSI - 150# Flanged IN * 6 * 6

MM 152 152 Steam Outlet 150 PSI IN NPT 6 6 150# Flanged MM 152 152 Feedwater Inlet IN NPT 1.25 1.25

MM 32 32 Blowdown Outlet IN NPT 2 2

MM 51 51 Water Column Blowdown IN NPT 1 1

MM 25 25 Surface Blowdown IN NPT .75 .75

MM 19 19 Safety Valve 150 PSI Inlet IN NPT 1.5 1.5

MM 38 38 Safety Valve 150 PSIOutlet IN NPT 2 2

MM 51 51 Safety Valve 15 PSI Inlet (2)@ IN NPT 2 2

MM 51 51 Safety Valve 15 PSI Outlet (2) IN NPT 2 2

MM 51 51 Natural Gas Connection IN 2.5 2.5

MM 63 63 Burner Motor HP 10 10

KW 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 FT

/HR 5182 5978

M3/HR 146 169 Gas Pressure Required Min. IN W.C. 21 21 Gas Pressure Required Max. PSIG 5 5

Electrical Requirements/Amps for Burner Motors

208V, 60 CY, 3 Phase 30.8 30.8 230V, 60 CY, 3 Phase 28 28 460V, 60 CY, 3 Phase 14 14

* Steam separator or dual steam nozzle design required. Consult factory for availability. **Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2and at 100 Degrees C

+Consumption based on natural gas 1000 BTU/FT

and 20 ppm NOx@ 3% O2burner.

vmp130-150le-pds-2010-1008

13a VMP IOM

Page 21

VMP IOM

Locating the Boiler

a. The boiler should be located in dry

surroundings on a level base, making sure that there is sufficient room around the boiler to enable the operator and/or the maintenance engineer to gain access to all parts of the boiler. Check location for ease of water supply and electrical connections.

b. Place the boiler on a non combustible

floor with clearances to unprotected combustible materials, including plaster or combustible supports.

c. It is necessary to have the following

vertical clearance from the floor to the ceiling for removal of the burner for servicing:

Minimum Vertical Clearances BHP IN MM

40 110 2794 50 115 2921 60 125 3175

80 130 3302 100 130 3302 130 145 3683 150 145 3683

The Gas Supply

a. Gas Piping should be installed in

accordance with National Fuel Gas Code, ANSI-Z223-1-1984 or latest addenda and any other local codes which may apply. In Canada gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/or local codes.

b. Install a dirt trap ahead of all of the gas

valves.

c. The pipe and the fittings used must be

new and free of dirt or other deposits.

d. The piping must be of the proper size to

ensure adequate gas supply to the gas head assembly. Consult your gas company for specific recommendations.

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: see “e”

above. Propane not available for LoNOx boilers.

g. When making gas piping joints, use a

sealing compound resistant to the action of liquefied petroleum gases. Do not use teflon tape on gas line threads.

h. The main and the pilot gas pressure

regulators must be vented to the atmosphere.

i. After gas piping is completed carefully

check all piping connections, (factory and field), for gas leaks. Use a soap and water solution.

CAUTION

Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly with clean water after leak check has been completed.

j. The boiler must be disconnected at the

boiler shut off valve from the gas supply piping system during any pressure testing of the system at pressure in excess of 1/2 PSIG-14" W.C.

k. The boiler must be isolated from the gas

supply piping system by closing the shut-off cock during any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 PSIG--14" W.C.

Installation

Page 22

Installation

For units equipped with Flue Gas Recirculation (FGR), the ducting must be insulated.

WARNING

CAUTION

Do not exceed the rated pressure of the fuel train.

The Gas Supply For LE Models

A minimum of 40” w.c. gas pressure is required at the inlet of the gas train while operating for the 40-100HP; 60” w.c. for the 130-150HP boiler.

Basic Boiler, Condensate Tank, and Blow-Down Separator

NOTE

Where a condensate return tank is to be fitted:

1. This should be vented to a safe location.

2. This should have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature.

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 such vessels. If in doubt consult a Fulton Representative for advice.

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a. Make sure two check valves are

installed between the boiler and pump (one check valve is supplied with the unit).

b. In a closed system an end of the line

trap should be installed.

c. There are four blow-down valves on the

boiler: Two main bottom blow-down valves, the gauge glass blow-down valve, and the water column blow-down valve. All blow-down connections must be piped to blow-down seperator.

All these procedures should be done in accordance with state and/or local codes. The water column blow-down valve and the gauge glass blow-down valve should be connected to the main blow-down line.

Steam Supply

Pipe the steam supply line from the top right side of the boiler.

Steam Safety Valve

1. Before installing, be sure that all pipes and connections have been blown clean. Pipe compound or dope is used on external threads only. Be sure inlet of valve is free of any foreign material.

2. Do not use a pipe wrench! When making installation, use proper type and size wrench.

3. The valve should be installed in a vertical upright position in the connection provided on the top left side of the boiler with no unnecessary intervening pipe. Under no circumstances should there be a shut off valve or restriction of any kind between the safety valve and the connection provided.

4. Do not cap or plug drain hole in the side of valve body.

5. Since the purpose of this safety valve is to protect against an overpressure situation, it will loudly discharge hot steam in doing so. Therefore, it is recommended that a discharge pipe be securely installed and run to a safe point of disposal.

6. When a discharge pipe is used, it must be of a pipe size equal to or greater than that of the valve outlet. Use schedule 40 discharge pipe only. Do not use schedule 80, extra strong or double extra strong discharge pipe or connections. It must be as short and straight as possible and so arranged as to avoid undue stress on the valve. It must have an ample provision for draining condensate at or near the valve outlet. It must terminate freely to atmosphere with no intervening valve of any description and it must be securely anchored and supported.

Steam Pressure Gauge Assembly

The gauge should be facing front towards the panel box and/or operator of the boiler.

Except as noted, each assembly or any of its component parts may be oriented, other than as shown to provide improved operating clearances and/or view of gauge. Before installing steam gauge on the siphon, add a small amount of water to the siphon to create a water seal to buffer the gauge element. This must be done to prevent inaccurate pressure readings and /or premature failure of the gauge. Install the steam gauge into the siphon on the water column.

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Blow-Down Valve

There are four blow-down valves on the boiler: Two main bottom blow-down valves, the gauge glass blow-down valve, and the water column blow-down valve. All blowdown connections must be piped to blowdown seperator.

Feed Water Piping

1. Provisions must be made for adequate water supply and properly sized piping. Piping must be done in compliance with all local codes. The following chart may be used as a guideline for sizing.

BHP Minimum Water

Supply Piping Size

IN MM

40 1 25 50 1 25 60 1 25

80 1 25 100 1.25 31.7 130 1.25 31.7 150 1.25 31.7

2. When feeding the boiler using a return system, the city water pressure should not exceed 40 PSI. A pressure reducing valve should be installed a head of the return tank when above this pressure.

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 strain or distortion will result.

4. Do not use the pump as a piping support. It is critical that the pipe be independently supported near the pump so no strain will be transmitted to the unit.

5. Connect the feed water stop valve to the feed water pipe at the rear of the boiler and pipe it to the return system.

Water Column

Install the piping from the water column and water gauge glass to a safe blow-down point.

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Page 25

Water Gauge and Gauge Glass Installation Instructions

NOTE

Keep gauge glass in original packaging until ready to install.

1. Verify the proper gauge has been supplied.

2. Examine the gauge glass and packings carefully for damage before installation. Do not use the glass if it contains any scratches, chips, or any other visible signs of damage.

3. Do not subject the gauge glass to bending or torsional stresses.

4. Apply teflon tape or pipe dope to pipe threads. Install top gauge fitting (fitting without a drain valve) into the uppermost tapping. Wrench tighten the fitting until it is snug and the glass outlet is pointing at five o’clock (about 1/8 turn from its final downward vertical position).

5. Install the bottom gauge fitting (the fitting with a drain valve) until it is snug and the glass outlet is pointing directly upward. Verify top and bottom fittings are threaded into the tappings the same number of turns (distance A=distance B).

6. Remove glass packing nut, friction washer and glass packing from the fittings, and place them, in the same order, on to both ends of the gauge glass. Push both packings about an inch up the gauge glass.

7. Gently insert one end of the glass into the top gauge fitting. Keeping the glass inside the top fitting, gently rotate the top gauge fitting clockwise until vertically aligned with the bottom gauge fitting, then inset glass into bottom fitting until glass bottoms out on the shoulder inside the bottom fitting.

8. Carefully raise glass about 1/16” and slide lower glass packing down until the glass packing contacts the lower gauge fitting. DO NOT allow the glass to remain in contact with any metal!

9. Carefully slide upper glass packing up as far as possible.

10.Hand tighten both glass packing nuts, then tighten 1/2 turn more by wrench. Tighten only enough to prevent leakage. DO NOT OVER TIGHTEN! If any leakage should occur, tighten slightly, a quarter turn at a time, checking for leakage after each turn.

11.Install the protective guard, and utilize automatic ball checks where necessary to help prevent injury in case of glass breakage.

WARNING

Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and/or property damage.

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Water Supply

Feed water contains solids and dissolved gases. These may promote formation of scale; foaming, priming, surging, and solids in steam; corrosion and pitting; or caustic embrittlement. To prevent this, feedwater must be studied individually and treated accordingly by reputable professionals specializing in this field. It is strongly recommended that a competent water treatment company be consulted prior to the installation of the boiler.

The purpose of this treatment should be to provide quality feedwater to the boiler such that corrosion and deposition in the boiler will be minimized. Dissolved oxygen, high TDS levels and low pH can all be major causes of corrosion. Untreated hardness is the major cause of scale deposits. Poor quality feedwater will require increased blow-down and increased chemical treatment costs to prevent boiler corrosion and scaling.

One way to lower the amount of dissolved oxygen in the boiler feed water is the feedwater preheating option. This option injects live steam into the feedwater to increase the water temperature to at least 180 degrees F (82 degrees C) which removes oxygen from the water.

TDS can be controlled by increasing the number and/or duration of blow downs per day from one to four.

The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or sludge accumulations. Oxygen is corrosive. See

the Warranty Section of this manual for full details.

Recommended Water Treatment

a. Following are recommendations for feed

water and boiler water. Contact your local water treatment professional for testing and treatment recommendations. It is very important that a strict water treatment program be followed.

Feedwater:

Dissolved Oxygen..............less than 0.05 ppm

pH Value.............................9-11 (tested at room

temperature)

*Hardness ..........................less than 25 ppm

in the form of CACO

Oil........................................none

Suspended Solids..............none

Organic Matter ...................less than 5.0 ppm

Total Dissolved Solids .......less than 300ppm

Boiler Water:

Alkalinity ........................less than 300 ppm in the

form of CACO

Chloride.........................less than 500 ppm

pH Value .......................9 to 11 (tested at room

temperature)

Total Dissolved Solids..... 2,000 ppm maximum

Hardness.......................less than 50.0 ppm

Dissolved Oxygen ........none

Suspended Solids.........40 ppm

ppm = parts per million; CACO3=Calcium Carbonate; PO4=Phosphate; SiO2=silicon dioxide; * 1 Grain Hardness = 17.118 ppm Therefore: 70 ppm = 4.10 grains hardness

b. It is critical that the boiler pH be alkaline

(9-11) whenever water is in the boiler. Solids that enter in with the feed water concentrate in the boiler. Daily boiler blow down is recommended to prevent corrosion and/or deposits from forming.

Glossary of Water Supply Corrosives and Inhibitors

DISSOLVED OXYGEN

Oxygen that is dissolved in the feedwater will cause the steel in the boiler and the feedwater system to be attacked by the water in a manner described as “pitting”. The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide. Once pitting starts, it may be extremely hard to arrest. Pitting can proceed at a surprisingly rapid rate and can occur not only in the boiler proper, but also in pre-boiler equipment such as economizers, feedwater heaters, and feedwater lines.

SUSPENDED SOLIDS

Suspended solids are the undissolved matter in water, including dirt, silt, rust and any other insoluble matter. Normally suspended solids are expressed in terms of turbidity.The presence of suspended solids in cooling water can increase impingement type corrosion. Suspended solids may also deposit in low velocity areas and create differential aeration cells. Pitting can result. The most common cause of high suspended solids is high hardness feedwater piping corrosion and inadequate blow-down rate.

In line filters, or various types of pretreatment can be used to lower the suspended solids level. Various polymers assist in holding solids in suspension. Boiler blow-down is the best way to control suspended solids.

ALKALINITY

Alkalinity is the capacity of a water to neutralize acids. Common water alkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, and silicate. These alkalinities, especially bicarbonates and

carbonates, break down to form carbon dioxide in steam, which is a major factor in the corrosion on condensate lines. High alkalinity also causes foaming and carry over in boilers.

Both foaming and carry over cause erratic boiler operation. When foaming occurs an anti-foam should be added or increased. The reason for the high alkalinity should be determined. It may result from lack of sufficient blow-down. Pretreated makeup water and condensate should also be checked. quite often the source of alkalinity is an overdose of alkaline internal water treatment chemical.

pH is a measure of the degree of acid or base of solution. Neutral pH ranges of 6.5-

7.5 will have negative influence on the corrosion rate of carbon steel. A low pH can result in corrosion of metals, while a high pH can result in scale formation. Optimal boiler pH is 9-11, slightly alkaline

In order to control boilers and equipment used for the external treatment of make up water, it is essential that frequent reliable pH measurements be made.

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CHLORIDES/CHLORINE

Chlorides are generally considered detrimental in stainless steel systems only. Stress corrosion cracking can occur from high chlorides.

High chlorine levels can cause severe corrosion. Corrosion from chlorine can be controlled by removal via carbon filtration. City water can contain high levels of chlorine.

OIL

Oil is not a natural constituent of boiler water; still it can frequently enter a system through leaks in a condenser or other heat exchanger. Oil can also enter a system through the lubrication of steam driven reciprocating equipment. Whatever the source, the presence of oil in boiler water is undesirable.

Foaming is one indication of oil in boiler water. Its presence can also be confirmed by first shaking a bottle containing boiler water. If oil is present foam will result. To ensure the foaming is being caused by oil, add a small amount of powdered activated carbon to the bottle containing the boiler water and shake. Little or no foam will appear if the foaming is caused by oil.

Often oil in boiler water will originate in the condensate. This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken. Boiler and boiler system piping boil out procedure are designed to rid a system of oil contamination.

IRON (OXIDES)

Iron in any of its oxide or complex forms is undesirable in boiler water. It is very difficult to disperse so that it can be removed the bottom blow-down lines.

Iron in its various forms can originate in the raw water makeup, condensate return water, or form directly in the boiler as a result of corrosion. Most iron oxide originates outside the boiler. It concentrates in the boiler and it tends to collect in stagnant areas. If a boiler is using raw water makeup, iron is almost certain to be a major component of developing scale or sludge deposits.

WATER HARDNESS

Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents. Water hardness is a primary source of scale in boiler equipment. Hardness is removed by water softeners or RO/DI systems. It can also be treated with various chemical treatments (i.e. Phosphates).

FEEDWATER

Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler. Hot (>180°F) feedwater, free of hardness, solids and oxygen will yield the most protection to a boiler.

CONDENSATE

Condensate is condensed steam that is normally low in dissolved solids. Hence, it does not contribute to the dissolved solid content of the feedwater. In addition, condensate is very expensive to waste. It's been chemically treated, heated, pumped, converted to steam, and condensed. This costs money and when condensate is returned to the boiler, money is saved.

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Electrical Requirements

1. Connect wiring as shown in the wiring diagram which is furnished inside the electrical control panel box.

2. Be sure to install a separate disconnect for each piece of equipment. The disconnects should be installed in compliance with the NEC (National Electric Code) and all local codes.

3. Connections for an optional audible alarm are provided in the control panel and are clearly indicated on the diagram.

Fresh Air Supply for Boiler

It is most important to provide free access of air to the boiler. To burn fuel properly, it requires one square inch opening of fresh air for every 3,000 BTU input of fuel. (6.4cm

for

every 756 Kcal).

Proper ventilation of the boiler room is essential for good combustion. Install two fresh air openings, one at a low level 24” (610 mm) from floor and one at a higher level in the boiler room wall.This will provide a flow of air to exhaust the hot air from the boiler room. Boiler room temp not to

exceed 100°F.

The following openings are recommended for each size boiler:

Make Up Air Openings

BHP FT

40 5 .46 50 5 .46 60 7.5 .69 80 12.5 1.11

100 16 1.49 130 21 1.95 150 24 2.23

Be sure total BHP = proper make up air opening size.

These measurements are subject to state and local regulations. The installation of exhaust fans in a boiler room is not recommended.

An exhaust fan, or similar equipment can create down draft in the stack or restrict the burner’s air supply which will result In poor combustion. It is essential that only fresh air is allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint, in the combustion system can create hazardous conditions.

Conventional Venting

The stack should rise continuously to the connection with the chimney, and should contain no more than two bends at 45° angles or less. If required as the result of space limitations, one 90° elbow can be fitted at the back of the boiler. There should be two feet of straight, horizontal flue before any bends or turns. Any alternative stack arrangement must supply a negative .02 .04” W.C. pressure (0.508 to 1.016 mm) with the burner off.

The run in the total distance of stack ducting, as measured in a straight line from the outlet of the boiler to the outlet of the stack, should not exceed 70% of the rise. With the exception of a duct run described in Item a, horizontal sections of ducting must be avoided, and should not exceed four feet of total run.

The stack and chimney must be constructed from material that is rated for 1000°F operating temperature. Check all local codes for exact requirements.

Adequate provision must be made for the support of the weight of the chimney and stack to avoid having too great a load imparted to the flue outlet connection of the boiler.

The proper flue size and draft control is most important for proper burner operation. The flue must be as large or larger than the outlet on the boiler. Avoid flue piping and elbows by placing the boiler as close as possible to the chimney.

A mechanical draft regulator should be installed in the flue outlet. Do not install the draft regu-lator prior to the first turn of the flue.

BHP Boiler Flue Size

IN MM

40, 50, 60 12 305

80, 100, 130 14 356

150 16 406

The installer should check the draft with a meter at negative .02 -.04” W.C. pressure (0.508 to 1.016 mm) with the burner off.

Installation

Page 29

Corrosion of flue pipe

In the case of a combustion flue pipe, acid may develop over a long period of time per the following process. Chlorine containing gases, such as halocarbon refrigerants, carbon tetrachloride, trichloroethylene, or perchloroethylene, when drawn into combustion air are broken down into elemental chlorine gas which exits up the flue pipe. If the flue pipe is cold, as it would be if the combustion process had been off for some time, the water vapor condenses in the flue pipe during the first few minutes of ignition and the chlorine in the combustion gas dissolves in the water forming hydrochloric acid. As the combustion system flue line increases in temperature, the water vapor no longer condenses because the flue temperature is above the dew point of the combustion gas.

The combustion gas then dries out (dehydrates) the hydrochloric acid solution leaving behind dry chloride salt.

When the next cold start-up occurs, the process repeats except that more and more chloride collects and concentrates along the flue. As the quantity of chloride increases it does not dehydrate completely as the flue heats up and a corrosive poultice develops which attacks the steel and will also attack the boiler.

Concentration levels of 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 creates carbon dioxide which may condense in a cold flue to form carbonic acid.

Installation Check Points

1. Make sure all piping connections are complete and tight.

2. Make sure the pressure controls are adjusted properly.

3. Make sure all electrical connections in the control panel box, the water column, and elsewhere are secure.

4. Make sure the door in the boiler room is closed. Combustion air contaminates can cause damage to the boiler jacket and stack.

NOTE

After installation is complete and prior to operation the pressure vessel should be cleaned.

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Installation

Blower

Air Gate

Electric Control

Panel

Gas Train Available with Optional

High-Low-Off, or Modulation

Primary steam outlet

(Valve not shown)

Safety Valve(s)

Exhaust stack

adapter

Control circuit

transformer

Gas Valve

Modulation

Motor

Gas Regulator

Scroll

Lifting Lug

Pressure Switch

UV Scanner

Ignition

Electrode

Ignition

Transformer

Page 30

Cleaning (Boil out) the Pressure Vessel

After the boiler has been installed and before it is placed in service it is advisable to purge the pressure vessel of any oil film,dirt, or other impurities. Clean the pressure vessel as follows:

1. Isolate the boiler from the system by shutting off the main steam valve.

2. Remove the steam safety valve.

3. Mix washing soda with water in a onegallon container and pour it into the boiler through the steam safety valve opening.

4. The mixture of washing soda to water is as follows:

Boiler Size Soda

40, 50, 60 4 lb (1,814g)

80 5 lb (2270g) 100 7 lb (3178g) 130 9 lb (4080g) 150 10.5 lb (4760g)

5. Replace the steam safety valve.

6. Fill the boiler with water. Water level is

about center in the water gauge glass.

7. Generate 15 PSI (1.054 kg/cm 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 drain or a safe discharge point for the first week of operation.

) of

CAUTION

Do not store halogenated hydrocarbons in or near the boiler room. In general, ensure that the boiler area is in conformance with established boiler room requirements. Review national and local codes.

We cannot emphasize enough the importance of proper water treatment: Water analysis should be made by a competent water treatment concern and their recommendations should be followed.

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Section

Operation

4 5

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Starting the Gas Fired Boiler

STOP! Make sure you have read and followed all previous safety information.

Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required.

In general, ensure that the boiler area is in conformance with established boiler room requirements. Review national and local codes.

Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down.

1. Close the blow-down valves.

2. Close the water gauge drain valve.

3. Open main steam stop valve at the top of the boiler.

4. Open the water feed valve on the boiler.

5. Open valves on makeup water line to return if return system is used.

6. Place feedwater pump fused switch in the "on" position.

NOTE

The pump will continue to operate until the water reaches the correct level in the boiler. This level is approximately the center of the water gauge glass.

7. Activate the boiler power on switch, located on the side of the panel box.

8. With the unit full of water the low water safety relay(s) will be in a lock-out mode. Press the low water safety relay manual reset button located on the side of the control panel box.

Gas Burner Set Up

1. Open the manual gas cocks on the pilot and main lines of the gas head.

2. Switch on the main power to the burner. The water level relay is equipped with a manual reset. Depress the button on the box.

3 The flame programmer is the

main control in the panel box. The programmer in conjunction with a sensing device, either a flame rod or a UV scanner, "supervises" the ignition sequence - proves the flame is satisfactory, and finally"monitors" the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to "lock-out" and the burner will shut down.

NOTE

To reset the boiler burner after a “Lock out” signal, push the reset button on the control.

Operation

IMPORTANT:

IMPORTANT When commissioning this boiler, firing rate must remain at low fire during first 4 hours of operation. The output may then be increased 7% to 10% per hour, until a firing rate of 75% is reached. The 75% firing rate should be maintained for 3 to 4 hours.

Page 35

Operation

WARNING

For units equipped with Flue Gas Recirculation (FGR), the ducting must be insulated.

4. When the pilot flame is established, the flame rod (or ultra-violet scanner) senses the voltage which is created in the flame between the flame rod and the gas nozzle (ground). This signal is transmitted back to the flame programmer which opens the main gas valve giving a main flame.

5. All Fulton propane or butane boilers and Fulton natural gas boilers 50 HP and above are standardly furnished with UV Scanners.

a. If the installation is new or the burner

has been disassembled, the burner may not fire at the first attempt due to air which must be purged from the gas lines. This will result in the burner flame programmer going to lockout. Repeat the procedure for starting the burner.

b. The main gas valve will remain open

as long as there is a demand for heat and the flame is carrying a sufficient signal to the flame programmer.

c. If the flame is not established at the

start, the safety switch in the flame programmer control will open the contacts and shut off the burner.

d. Push the reset button on the control

to reset. If trouble persists, it may be necessary to check the flame rod setting or the UV scanner. See Maintenance Section 4 for procedure to check flame rod setting or UV Scanner.

Gas Burner Set Up For LE Models

a. Open the manual gas cocks on the pilot

and main lines of the gas head.

b. Switch on the main power to the burner.

The water level relay is equipped with a manual reset. Depress the button on the box.

c. The flame programmer is the main

control in the panel box. The programmer in conjunction with a UV scanner “supervises” the ignition sequence proves the flame is satisfactory, and finally “monitors” the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to “lock-out” and the burner will shut down.

d. When the pilot flame is established,

ultra-violet scanner senses the flame. This signal is transmitted back to the flame programmer which opens the main gas valve giving a main flame.

e. If the installation is new or the burner

f. The main gas valve will remain open as

long as there is a demand for heat and the flame is carrying a sufficient signal to the flame programmer.

g. If the flame is not established at the

start, the safety switch in the flame programmer control will open the contacts and shut off the burner.

h. Push the reset button on the control to

reset. If trouble persists, it may be necessary to check the UV scanner. See Maintenance Section for procedure to check UV Scanner.

WARNING

Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.

Gas Burner Set Up For Boilers Equipped with Modulation

1. Modulation is available as an option on Fulton gas fired steam boilers for 40 150 HP units.

2. Boilers equipped with modulation will have the linkage rod disconnected between the modulation motor and the gas butterfly valve for shipment.

NOTE

If Seiman linkageless modulation is ordered, no mechanical linkage rod is required, thus none provided.

3. Mount the gas train on the pipe nipple of the burner plate with the gas train inlet directly facing over the panel box. Reconnect the linkage from the butterfly valve to the modulation motor.

4. The end of the linkage arm that attaches to the butterfly valve will have a notch on both sides of it, where the swivel collar should be centered. This setting was based on factory test fire conditions.

5. Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics.

6. The modulating burner will have a modulation lock switch to enable you to lock the firing sequence anywhere along the firing rate from low to high.

7. Depending on the combustion characteristics, it may be necessary to adjust both linkage arms. To adjust the linkages, unscrew the swivel collar and move the linkage rod in the appropriate direction.

8. Standard modulating burners will have a proportioning pressure control in addition to the standard operating pressure control that will send a 0-135 ohm signal to the modulation motor to adjust the firing rate. Both operating pressure controls should have the same setting.

9. NEMA 4 units will use a digital pressure controller with transducer as the operating pressure control which sends a 0ma signal to the modulation motor to control firing rate.

Gas Burner Set Up For Boilers Equipped with High-Low-Off

1. A gas fired burner equipped for highlow-off firing is available as an option on Fulton gas fired steam boilers for 40 150 HP units.

2. Boilers that have a high-low-off firing rate will have a linkage between the high-low gas valve and the primary air gate. This valve is equipped with a spring return.

3. The linkage will be disconnected from the gas valve for shipment.

4. Mount the gas train on the pipe nipple of the burner plate with the gas train inlet directly facing over the panel box. Reconnect the linkage from the primary air gate to the high-low gas valve.

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5. The end of the linkage arm that goes to the gas valve will have a notch on both sides of where the swivel collar should be centered. This setting was based on factory test fire conditions.

6. Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics.

7. To adjust the linkage, unscrew the swivel collar and move the linkage rod in the appropriate direction. The high-lowoff configuration comes with two operating pressure controls.

8. Set the low operating pressure control to approximately 60% of your desired set point and the main operating pressure control to your desired set point.

WARNING

Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.

Primary Air Adjustment for Fulton Gas Fired Steam Boilers

1. The primary air adjustment or main air control is located at the fan housing face. This control is used to supply the burner with excess air needed to facilitate good combustion. Too much or too little air will result in poor combustion. It is important to make sure the lowest level of excess oxygen is present while still maintaining a high level of carbon dioxide and negligible carbon monoxide. Using a CO

or O

tester it is possible to determine the percent of excess air in the combustion mixture.

2. It is a good policy on a gas fired unit to have between 3.5% and 4% oxygen present in the combustion. This will give you 10.5% to 9.5% carbon dioxide. The carbon monoxide level should always be less than 400 PPM.

Secondary Air Adjustment Procedure for Fulton Gas Fired Steam Boilers

1. The secondary air control adjustment is located on the top, right-hand side of the 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

pulling the damper open more air is forced down the blast tube and less on the outside wall of the deflector face and fire chamber.

2. It is important in the combustion process to maintain proper air mixtures between the outer surface and center of the blast tube area. On most boilers the damper is locked in a wide open position. However, if it is necessary to close the damper, care should be taken to close the damper slowly and no more than

/4 of the distance of the swing of the damper assembly.

3. A visual examination down the blast tube should reveal that no heat, flames or fumes are backing up through the burner plate area. If they are, the secondary damper must be opened up once again. Failure to remove the flame or gases from the blast tube area can cause a backfire as well as cause premature failure of electrodes, flame rods, and other burner components.

4. A visual inspection down the burner view port should also show the fire completely covering the furnace walls. If the fire is tunneling down or is not to the outside wall of the furnace, the efficiency will drop off. Close the secondary air damper until tunneling stops.

Operation

Primary Air Adjustment is located at the fan housing face.

Blast Tube Viewing Port

Burner Viewing Port

Secondary Air Adjustment

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Operation

Boiler Controls

a. Flame safeguard burner control

This is the main control in the panel box. The programmer in conjunction with a sensing device, either a flame rod or an ultra violet scanner, "supervises" the ignition sequence - proves the flame is satisfactory - and finally "monitors" the established flame. Should any fault occur, either during the ignition sequence or during normal running, the programmer will immediately go to "lock-out" and the burner will shut down.

b. Low Water Cut-Off - Probe Type

Cuts off the unit when water level is too low after a 3 second time delay to avoid nuisance shut downs. As a standard feature, Fulton boilers are equipped with ASME CSD-1 Code controls which include a manual reset feature on the burner low water cut off relay and ASME CSD-1 Code controls also feature an independent second low water cut off relay. Press the low water reset button and the boiler will start.

CAUTION

Do not tamper with the safety features of the low water safety cut out.

c. Pressure Relief Valve

Limits the maximum operating pressure of the boiler.

d. Operating Steam Pressure Control

Located in the control panel box and connected to the steam pressure gauge assembly by means of a copper tube. The pressure control regulates the on/off cycle of the burner, shutting the burner off when maximum pressure is reached and switching on when the steam 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 not seat. For added safety all Fulton boilers are equipped with gauge glass protectors.

f. High Limit Pressure Control

Located in the control panel box and connected to the water column assembly by means of a copper tube. The pressure is usually set 10 to 15 PSI (.703 - 1.054 kg/cm

) above the operating pressure, but below the maximum pressure of the pressure relief valve. If the pressure exceeds the high limit pressure control setting, the boiler will automatically shut off. The high limit pressure control must be manually reset by depressing the plunger located on top of the control.

g. Air Pressure Switch

Mounted on the burner scroll, this switch is operated by the pressure of air entering the burner through the throat of the scroll. Absence of air, or insufficient pressure, will prevent the switch completing the circuit, thus preventing the burner from operating.

WARNING

When stopping the boiler for any extensive repairs, shut off main disconnect switches on both the boiler side as well as the feed water side.

NOTE

To ensure that your Fulton Steam Boiler is kept operating safely and efficiently, follow the maintenance procedures set forth in Section 4 of this manual.

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Air and Gas Adjustment for LE Models

The low emission burner can be best described as a fuel staged, multi-radial injection type. Two air/gas ratio electro servo actuators control the fuel supplied to this burner. A radial blade type fan supplies the air. A direct-coupled reversing actuator modulates the air which in turn regulates the fuel input. No mechanical linkage is utilized with this system. As a safety device, a thermocouple is placed in the small partial premix area of the burner to monitor temperature. It is used in conjunction with a temperature limit that should be set between 600° and 700°F.

Commissioning/Start Up for LE Models

WARNING

Commissioning/Start Up by a nonFulton authorized person will void the product warranty.

Before commissioning the boiler, verify with authorized personnel that the gas lines have been purged.

SIEMENS LMV LINKAGELESS BURNER MANAGEMENT SYSTEM (If Equipped)

The Siemens LMV system is a fully packaged burner management system, linkageless control and first out annunciator.

When operating the Siemens LMV systems, all changes are made through the Siemens AZL display. The left and right arrow keys are used for scrolling through the menu and changing controller parameters. Enter accepts the menu and parameter changes.

It is possible to return to the main menu at any time by repeatedly pressing Escape. When running the boiler, the status of the burner is to be monitored with the Siemens AZL display.

If at any time the burner control locks out on a fault condition and the red flame failure light illuminates:

• Read the diagnostic feedback on the AZL display, address the fault if possible.

• Press escape on the AZL once.

• Press enter on the AZL to reset the control. The red light should go out.

If the fault persists contact Fulton.

If the boiler has a dual fuel burner, the burner setup procedures on the following pages must be performed for each fuel.

LMV Control for LE Models

NOTE

The following procedure must be repeated for each fuel the boiler is equipped to operate on.

PRE-IGNITION STEPS

1. Verify the main burner switch is in the OFF position. If the boiler has dual fuels, verify the fuel selector switch is turned to the correct fuel.

2. Supply power to the boiler. The AZL will display “system test” and then move to the main menu.

3. Select PWLogin, press Enter. Select AccessServ. Press Enter. (This type of step will be shown as PWLogin > AccessServ for the remainder of this section. Enter the service passwords using the arrow key. The password is case sensitive. The case of a letter can be changed by pressing the other arrow key. (For example, if you used the right arrow key to get to the letter A, press the left arrow key 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. Select ProgramStop. Press Enter. Change the Program Stop to 44 Interv1 by using the arrow keys. Confirm the change by pressing Enter. This will set the burner management system to a ‘pilot hold’ setting.

Verify that the current value “curr” changes to 44 Interv 1.

The full list of program stops are: 24:Air damper in the prepurge position 32:Traveling to the FGR position (if the unit

is equipped with FGR)

36:Ignition position (before pilot ignition) 44:Ignition position (after pilot ignition) 52: Ignition position (after main burner ignition) 72:Air damper in the postpurge position 76:Traveling to the FGR position (if the unit

is equipped with FGR)

5. Press Escape 4 times to get back to the main menu.

6. Under ManualOperation > Setload, change the load to 0% by using the arrow keys. Press enter and verify the 0% has been acknowledged in the “curr” field.

7. Press Escape once to get back to the ManualOperation menu.

8. Under Auto/Manual/Off, change the operation to Burner On by using the arrow keys. Press enter and verify that “Burner On” is acknowledged in the current field.

9. Press Escape twice to get back to the main menu.

10. Increase the setpoint on the temperature controller to create a heat demand.

11.Turn the main burner switch to the

Local

or On position.

NOTE

If the burner loses flame while driving to a point then:

• Turn the main ON/OFF switch to OFF. Reset the loss of flame fault. Press Escape on the AZL once. Press Enter on the AZL to reset the control The red light on the panel box door should go out.

• Adjust the air and gas servos for that point while the burner is off. Follow steps 28-29.

• Turn the main ON/OFF switch to ON.

23.Under Params&Display > RatioControl ProgramStop, change the program stop

to deactivated by using the arrow keys. Confirm that ‘deactivated’ is acknowledged in the current field.

24.This change will allow the burner to modulate. The burner will now drive to low fire. Remember, it is only important at this stage to set low fire to be stable and with clean combustion. Exact setting is to be performed once high fire is confirmed.

25.Press Escape 5 times to get back to the main menu.

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26. You can observe the status of the burner by going to OperationalStat > NormalOperation.

27. Verify the flame signal on the display, measure input if fuel meter is available. If not, match last elbow pressures and combustion from test fire sheet. Adjust the burner as needed. To adjust the servo position, follow steps 28-29.

SETTING LOW FIRE

NOTE

As soon as a servo position is altered, the servo will move to that position. Only change servo settings by a maximum of 0.5° at a time before verifying combustion.

28.Go to Params&Display > RatioControl > GasSettings (or Oil Settings, depending on the current fuel) > CurveParams.

29.Wait for the spinning line on the left to disappear. Press Enter. The number 1 should appear to the right of the cursor, this is the Point Number.

Press Enter once. Select ChangePoint by pressing the arrow keys to highlight and then press Enter to select. This will cause the servo motors to move to this low fire point.

Check combustion and adjust the servo motors as required. To adjust a servo motor, arrow to it and press Enter. Then adjust the setting as required and press Enter. You can now adjust another servo motor if needed.

When combustion is properly set for that point, press Escape once more. If it asks you to store the point, press Enter. Note the AZL will only ask to save if either servo value has been altered.

Low fire is now set and stored.

SETTING THE COMPLETE RANGE

a. Remember it is only necessary to

approximate the setting through the modulation range until high fire conditions are established.

b. Press Enter once more to have access

to the point number field. Increase the point number by one and press Enter. Select ChangePoint and press Enter. The servos will now move to that point.

c. Verify combustion is satisfactory.

d. Measure input or monitor last elbow

pressure. Verify that these points are in general correspondence with the test fire sheet. Repeat step b. until the point position has a load value of 100%. You are now at high fire. Verify combustion is per test fire sheet.

30.If operating on gas, adjust the incoming gas pressure at the main gas regulator to match the test fire report. Adjust the gas servo motor to change the last elbow pressure to match the test fire report. Adjust the air servo motor to adjust the emissions as needed. If operating on oil, adjust the oil pump and air pressure regulator to match the pressures on the test fire sheet. Adjust the oil servo until the oil flow rate matches the test fire sheet. Adjust the air servo to match the test fire sheet.

31.Repeat step 28 but start at the high fire point number. Continually decrease the point number after combustion has been verified at each point.

32.Once all the points have been verified, press Escape until you are back to the main menu.

33.You can observe the status of the burner by going to OperationalStat > NormalOperation.

34.Turn the main ON/OFF switch to OFF. The control will now postpurge.

35.Follow steps 3-20 again to verify ignition with the new gas pressures.

36.Turn the main burner switch to OFF. The control will now post purge.

37. Change the operation to Automatic under

ManualOperation > Auto/Manual/Off

and press Enter and confirm Automatic is entered in the current field.

38.Press Escape twice to get back to the main menu.

39. Under Updating > ParamBackup, select LMV51 - AZL. This will store all of the adjustments that have been made in the LMV base module to the display. If the base module were to fail, the display can be used to download all of the parameters into a new base module.

40.Press Escape 4 times. Select PW Logout, the password is now logged out.

41.Press Escape twice. Select OperationalStat > NormalOperation. The control is now on the normal operational display screen.

42.The boiler is now ready to run. Adjust your setpoint on the temperature control to the desired temperature and turn the main ON/OFF switch to ON for the burner to operate.

BEFORE LEAVING THE INSTALLATION

Check all controls to insure they are operating properly. Cycle the boiler several times. Make sure the installation complies with all applicable codes.

NOTE

Decreasing the primary will typically decrease the NOx levels. If the primary is decreased too much, stability may be compromised.

a. Start the boiler and check for stable

combustion at low fire. Refer to the test fire sheet for acceptable parameters.

b. Adjust secondary servo air/gas if

needed to bring combustion into an acceptable range. Adjust carefully as this is the main fuel adjustment.

c. After a stable flame is achieved and the

combustion is within the test fire sheet parameters, manually and slowly drive the servo’s motor to high fire insuring that the combustion readings stay within the given parameters. Adjust secondary servo as needed.

d. If the last elbow pressure is above or

below the stated requirement on the test fire sheet, adjust the combustion air damper to bring the last elbow pressure inline. The gas pressure is directly proportional to the air pressure and therefore, increasing the air pressure to the burner will increase the gas input proportionally.

e. Manually drive the unit back to low fire

and check combustion.

f. If the combustion is outside of the test

fire parameters for the servo, adjust the secondary.

g. After the unit is brought back into range,

manually drive the unit back to high fire.

h. Adjust secondary air/gas ratio slightly if

needed.

i. Repeat this procedure 2 or 3 times until

you obtain consistency in high and low fire combustion.

j. In most cases, the primary gas should

only be adjusted if the unit is unstabe at low fire and/or NOx are not acceptable at low fire.

Operation

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CAUTION

During startup insure that adequate gas pressure is supplied to the main valves. The indicator on the actuator should never reach the bottom of the indicator window. In the event that this happens, adjustability will be lost. See minimum incoming gas pressure requirement on the test fire sheet. The SKP10 actuator functions only as on/off. When activated, the indicator will reach the bottom of the indication window. The main gas pressure regulator is only used to comply with standard regulations and therefore uses a high outlet pressure spring that is set at the max. The SKP70 fuel valves have a built in regulator function.

Glossary of Terms

PRIMARY GAS

The smaller gas line injects fuel at the burner head.

SECONDARY GAS

The main gas line inject fuel prior to the burner head.

REVERSING ACTUATOR

Used for positioning control inlet damper, combustion air.

AIR/GAS RATIO CONTROLLING ACTUATOR

Regulates gas flow according to air pressure.

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Section

Maintenance

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Maintenance

Gas Train Assembly

Burner Alignment Tabs

Burner Plate Assembly

Top Plate Assembly

Secondary Air Damper

Flue Cover Plate

Lifting Hook(s)

Stainless Steel Ring

Flue Outlet

O.P.C.

H.P.C.

Transformer

Scroll

Burner Motor

Steam Gauge Assembly

Gauge Glass Valve

Gauge Glass and Protector

Gauge Glass Valve

Water Column

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Top Refractory

Turbulator

Bottom Refractory

Feedwater Inlet

Blowdown Outlets

Clean Out Opening

Control Box

Fiberglas Insulation

Outside Jacket

Blowdown Outlet

Handhole

Castable Refractory Insulation

O.P.C. = Operating Pressure Control

H.P.C. = High Pressure Control

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NOTE

To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to.

WARNING

Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.

Procedure for Cleaning Water Probes

Clean probe on top of boiler shell and probes in water column. Make sure there is no pressure on the boiler during the removal of the probes. Remove one probe, clean with very fine emory cloth and replace it before removing another to assure no probe mix ups that would change the control functions.

For replacement purposes, installed probe lengths are indicated in the chart below. For a universally adaptable plug and probe which can be cut to length in the field to fit all boilers, order Part No. 2-20-017.

A=7

/4 IN / 184 mm

B=9

/4 IN / 235 mm

C= 11

/4 IN / 286 mm

D = 4 IN / 102 mm

“D” is located in the boiler pressure vessel.

Maintenance

ABCD

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Maintenance

Gas Train Assembly

Ignition Electrode

Blast Tube Viewing Port

Burner Plate

Burner Alignment Tab

Scanner Location

Gas Orifice Assembly

Burner Viewing Port

Blast Tube

Flame Scanner Adjustments for Fulton Gas Fired Steam Boilers

1. Flame scanner adjustments are made with the detectors installed and the burner running. It is essential to obtain optimum flame signal detection for safe and continual operation of the control relay.

2. If a scanner is inoperable, it may prove the detector is working and only an adjustment to the pilot flame is needed to improve the signal.

3. If the scanner is found to be defective, replace.

NOTE

The scanner is located on the outside edge of the burner top plate for 40, 80, and 100 HP.

4. For the RM7800 Series use a keyboard display module or volt meter. The flame safeguard will require a 1.25 VDC signal to pull in the main flame. Then a maximum signal should be obtained on main flame (5.0 VDC).

Top Plate

Deflector

5. Adjustments to establish a good signal may include the following items:

a. Primary and secondary air adjustments.

b. Increasing the pilot gas through the

pilot gas regulator.

Checking the Stainless Steel Combustion Ring on Fulton Gas Fired Steam Boilers

1. The stainless steel combustion ring in Fulton gas fired boilers are designed to bring quick and effective flame transfer to the fire wall. The ring should fit securely and tight against the furnace wall for best results.

2. The ring should be inspected for distortion in the event of poor combustion which could result in flame failures.

Stainless Steel Combustion Ring (40-100)

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Maintenance

Furnace Refractory Replacement Procedure

1. Remove the burner plate and top plate assembly up and out of the air to air heat exchanger.

2. Remove the stainless steel combustion ring from the furnace .

3. Remove the clean-out plugs from the bottom sides of the boiler. The boiler has two clean out plugs, one is located at the bottom of the boiler to the right hand side of the panel box. The second one is 180 degrees on the opposite side of the boiler.

4. Break off the top holding clips that were used to keep the refractory in position during shipping. The boiler has welded flat bars beneath the top refractory. These bars will have to be cut to change the lower refractory. Rewelding of the bars will be required prior to installation of the top refractory. For the lower refractory you will also need to break off the top holding clips that were used to keep the refractory in position during shipment.

5. Break up the top and/or bottom refractories and remove the pieces from the boiler through the clean-out

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.

plugs.

Gas Train Assembly

Air Deflector

Stainless Steel

Combustion

Chamber Ring

Top Castable

Refractory

Turbulator

Bottom

Castable

Refractory

Handhole

8. Lower the bottom refractory down the furnace with wire fastened around the refractory in three positions. When the refractory is close to position, it can be tipped by maneuvering the wire to drop it flat on the holding clips. If the refractory will not tip, it may have to be removed and again rounded and beveled.

9. Install the top refractory in the same manner as the bottom refractory. When installed the outer edges must be sealed with insulcrete - a castable refractory mix available from the Fulton factory. It is not necessary to reinstall the shipping clips.

9. Install the stainless steel combustion ring, burner assembly, and clean out plug.

10.Normal operation can be resumed immediately.

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Pilot Adjustment for Fulton LoNOx Burner.

1. Close downstream shut off valve.

2. Start boiler and check flame signal on pilot, lock programmer into pilot hold.

3. Adjust air and gas regulator as needed to obtain a strong pilot signal.

4. Slowly open downstream shut off valves and take the flame programmer off of hold.

Main Flame Adjustment For LE Models

1. Place a combustion analyzer in the exhaust of the boiler.

2. Do not adjust main gas regulator. To increase fuel to the burner, the servos that control modulating gas valves require adjustment.

Burner Tile Replacement For LE Models

1. Remove scroll assembly.

2. Break off top holding clips.

3. Remove ceramic fiber burner tile.

4. Replace burner tile bottom holding clips if needed.

5. Replace with new burner tile.

6. Carefully replace scroll assembly so that the ceramic fiber burner tile is not damaged.

Servo Motor Replacement For LE Models

If it is determined that a servo motor needs to be replaced, the first step in this process is to verify the model number of the new servo motor is the same as the old servo motor.

The model number starts with the letters SQM and is displayed on a label on the side of the motor. Once the new motor has been verified to be correct, turn power to the boiler off.

1. Turn off all electricity to the boiler.

2. Remove the cover on the servo motor to be changed.

3. Remove the green wiring plugs and the conduit termination point from the motor by pulling them towards you. A black grounding wire runs from the motor to the conduit termination point. Pull it off from the conduit termination point.

4. Also note the location of the jumper on the left side of the motor.

5. Loosen the allen screws on the motor end of the motor to valve coupling.

6. Unbolt the motor from the mounting bracket and remove the motor.

7. Turn the valve so it is in the closed position and can rotate clockwise to open.

8. Mark the coupling or valve shaft if needed so the position of the valve can be determined when the servo motor is installed.

9. Bolt the new servo motor on to the mounting bracket with the motor shaft inserted into the coupling.

10. Rotate the valve shaft/coupling assembly closed as stated above.

11.While holding the valve closed, tighten the allen screws on the coupling.

12. Install the wired green wiring plugs and the conduit termination point on the new motor. Connect the black grounding wire from the motor to the conduit 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. Press Escape twice to clear the fault from the screen.

16. Press Escape to get to the main menu. Under Params&Display > Actuators > Addressing, select either the gas actuator or air actuator depending upon which was replaced. The control will run an actuator check then display ‘Start Address Assignment with ENTER’. Press Enter. The display will then have you press the addressing button on the actuator. This is the red button on the actuator. The screen will then display ‘Actuator Address Assignment Successful’.

17.Press Escape until the main menu is reached. Under OperationalStat >

Status/Reset, reset the fault.

CAUTION

The boiler emissions may not be correct after changing the servo motor. Verify the emissions throughout the range of modulation. If emissions are off, the servo motor can be adjusted by following the procedure in the Commissioning the Boiler section of this manual.

18. Attach cover to servo motor.

Recommended Daily Maintenance Schedule

The following procedures should be carried out daily. They are designed to prevent the build up of scale, silt, or sludge in the bottom of the boiler and in the pipes leading to the water gauge. In addition to these procedures, the advice of a water treatment supplier should be sought and followed. An ASME Section VIII blow-down receptacle must be provided for the appropriate pressure.

1. Blow down the boiler each morning by starting the boiler and generating not more than 10 PSI (.703 kg/cm

) of steam. Turn on tap water to blow-down separator, then open the boiler blowdown valves for approximately 10 seconds, then close the valve. Shut off tap water to blow-down separator.

Blow Down Boiler Daily. Shown is the blow down "Y" valve.

NOTE

If the boiler is being operated automatically on a time clock, the blowdown operation may be done once during the working day and once at the end of the day when at 10 PSIG or less.

2. Blow down water column each morning when boiler is at 10 PSI (.703 kg/cm

) by opening the water column and the water gauge blow-down valves for approximately 5 seconds, then close the valves.

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3. If the feed water is being treated by compounds, make sure that this treatment is carried out carefully and according to the manufacturer's instructions.

NOTE

Fulton recommends that the feedwater treatment should be added between the pump and the boiler.

4. When first starting the boiler each day, make sure ignition and burner are working properly.

5. Check water level in sight glass.

6. Check to be sure feed water pump is working.

7. For float type water level control, blow down float chamber.

Recommended Weekly Maintenance Schedule

Check that the low water cut-off relay is operating correctly in the following manner:

1. Make sure that the boiler is cool with little or no pressure showing on the steam pressure gauge.

2. With the burner operating, open the boiler blow-down valves. When the water drops below the required level (note the level in the water gauge glass) the burner should shut off; this is when the water level falls below the low water electrode in the water column assembly and/or the boiler shell. Manual reset of the low water relay is required.

Recommended Monthly Maintenance Schedule

WARNING

Make sure main power switch is off before starting work.

1. Cleaning the water gauge glass:

CAUTION

Do not clean the gauge or gauge glass while pressurized or in operation.

a. Clean the water gauge glass using a

commercial non-abrasive glass cleaner. Use diluted acids such as hydrochloric (muriatic) acid when regular cleaners do not seem to work. Do not use wire brushes or any other abrasive materials which could scratch the glass. If any leakage is evident, replace the gaskets.

b. Always replace the high impact

plastic gauge glass protector which is standard on all Fulton Boilers.

2. Clean water pump strainers.

3. Check scanner or flame rod and ignition electrodes.

4. Check starter contacts. Burned or pitted contacts should be replaced. Do not use sand paper or file to clean.

5. Clean water traps and strainers in fuel lines.

6. Check operation of all steam traps on condensate return system.

7. Remove brass pipe plug at the cross connection below water column and clean nipple into boiler. Boiler must be cold and water level below pipe.

Recommended SemiAnnual Maintenance Schedule

1. Cleaning the gas burner assembly:

a. Disconnect the gas head from the

burner by disconnecting the union. Remove the burner plate screws.

Withdraw the burner assembly and clean the flame rod and ignition electrode.

b. Check that the settings of the flame

rod, if applicable, and ignition electrode correspond to those in the illustration below.

c. Reassemble the burner assembly

and check the flame rod setting or scanner setting.

d. Check the combustion efficiency of

the burner and adjust if necessary.

e. Clean probe on top of boiler shell and

probes in water column. There must be no pressure on the boiler during the removal of the probes.

f. Check refractories for soot or

breakage and inspect the stainless steel ring (50-100 HP only).

g. With the boiler under no more than 15

PSI pressure, check that the steam safety valve is operating by lifting the lever.

2. Drain condensate tank and clean tank by flushing with hose. Check float valve operation.

3. Check electrical controls and motors for correct operation.

4. Check water pump for correct operation.

5. Shut off the boiler completely and drain.

6. Remove the hand holes and inspect the interior of the vessel for scale or sludge deposits. The amount of deposits will indicate the efficiency of the water treatment being used. The frequency of the inspection will depend on the condition of the water side of the boiler.

7. Replace hand hole gaskets using the following procedure:

a. Remove the hand hole assembly

using a 1

/4 " tee handle wrench or 1

/4 " drive socket wrench.

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b. Remove the old gasket and

thoroughly clean the surface on the boiler and the plate.

c. Fit the hand hole assembly as follows:

i. Place the gasket on the hand hole plate and ensure that it is seating correctly. Do not use any grease, lubricant, or adh esive.

ii. Position the plate in the boiler. Set the yoke and tighten the securing nut sufficiently enough to provide a snug fit. Verify the position of the plate in the boiler, then make it hand tight and then snug with wrench about

/4 turn.

Do not compress excessively.

Illustration shows correct pressure on gasket.

iii. If the gasket leaks while pressure is being built up, tighten only enough to stop leakage. Never tighten more than necessary to prevent leakage. Excessive tightening may shorten the life of the gasket.

Illustration shows over-compressed gasket.

d. Refill the boiler with fresh water.

NOTE

Recommended Annual Maintenance 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

from the clean out plugs at the bottom with a vacuum cleaner.

e. Replace clean out plugs carefully so

as not to damage insulation and replace burner and flue cover plates.

3. Flush boiler out if necessary. See Section 2 for proper procedure for "Cleaning the Pressure Vessel."

4. Provide annual inspection by a qualified ASME Boiler inspector.

Troubleshooting

The following trouble shooting guide will assist in the diagnosis and the correction of minor field problems. It contains instructions and information necessary to locate and isolate possible troubles which occur during normal operation. It should be used in conjunction with the unit wiring diagram and the component literature provided in Section 7 of this manual.

The following lists cover the most common troubles that may occur on the Fulton gas fired boilers. Refer to left hand column of the chart to locate the problem. Determine which cause, listed in the center column, that represents the problem by performing the corrective action as listed in the right hand column titled “REMEDY”.

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Boiler Safety Testing – Fulton Vertical Steam Boilers

High Pressure Limit Switch:

 With the burner on and the boiler under pressure, lower the set pressure on the switch until it

trips and shuts down the burner. Ensure the pressure that the switch trips at is the same as the boiler operating pressure.

 To test the manual reset button, wait until the boiler has fully completed the post purge phase.

Once the boiler is in the standby position, reset the switch to the original set point.

 Press the manual reset switch on the pressuretrol. This will ensure that the manual reset switch is

functioning correctly. The burner should not start until the reset button is pressed.

Operating Pressure Limit Switch:

 With the boiler under pressure, lower the set pressure on the switch until it trips and shuts down

the burner. Be sure that the pressure that the switch trips at is the same as the boiler operating pressure.

 This switch is an auto reset.  Reset the switch to the original set point. The burner should turn back on automatically.

Flame Scanner:

 Verify that the flame scanner is observing flame with the burner running.  Turn boiler to the off position.  NOTE

o Do not shut off gas supply with 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 should not display any flame signal during scanner test

with gas valves turned to the off position. If flame signal is present, troubleshooting will be required to identify cause of the spark pickup.

 Turn the boiler to the off position and open the gas pilot line isolation valve while leaving the

main gas isolation valve in the closed position. This will allow for the burner to cycle through the pilot sequence and test main flame failure. The burner control should display fault code for main flame failure. Turn the boiler off after this test is complete.

o Typically on boilers 30 HP and below, the pilot flame will be sufficient to allow the

boiler to cycle through the main flame test. If this occurs, slowly shut the pilot line isolation valve. This will cause the boiler to fail on main flame.

 Once the boiler has completed the post purge cycle, turn the boiler to the off position. Open the

main gas supply valve, turn the boiler to the on position and resume normal operation.

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Low Water Cutoffs:

Definition: 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 part of the gauge glass.

Standard low water cutoff is Fulton level probes. Alternate cutoffs are MM-63, MM-150, MM-157, MM-193-7b, etc. All cutoffs are tested in the same manner as described below.

When testing the low water cutoff devices, it is important that the boiler feed pump is turned off to allow for proper draining. Remember to turn the pumps back on when level cutoff testing is complete.

Testing of Low Water Cutoff Controls: Your Fulton steam boiler is equipped with two automatic Low-Water Cut-Off (LWCO) controls. Each

LWCO will prevent startup and cut off the boiler fuel or energy supply automatically when the surface of the water falls to a level not lower than the lowest visible part of the gage glass. One control is set to function ahead of the other. The standard Fulton LWCO control utilizes a water level probe and incorporates a 3 seconds time delay to prevent short cycling. Optional float type LWCO controls may also be used on the boiler.

The LWCO controls can be tested by lowering the water in the boiler. The test should be done with zero 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 ¾” 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 typically configured to automatically reset when the adequate water level in the boiler is restored. Some local jurisdictions require this LWCO control to be a manual reset.

Open the blow-down valve at the back of the boiler to allow the water level to slowly drop until 1/8” to

1/4” of water level is visible sight glass and close the blow down valve. The second LWCO control will

drop out within 3 seconds and cut off the boiler fuel or energy supply. This LWCO control is configured for manual reset. When the adequate water level in the boiler is restored you have to momentarily press the LWCO manual reset button to enable operation of the boiler.

Air Switch:

 To test the air switch, first turn the boiler to the off position.  Once the boiler is off, remove the air supply from the air switch and turn on the boiler. Once the

boiler is in the purge process, the safety interlock should appear and shut down the burner.

 Turn the burner off and reattach the air switch air supply.  Reset the flame programmer.  Cycle the boiler multiple times to be sure that no nuisance faults occur.

Page 51

Low Gas Pressure Switch:

 Bring boiler to high fire (100% firing rate)  Increase the dial on the low gas pressure switch until it trips and locks out the boiler  Make note of the pressure that the burner shuts down at  Once the gas switch trips, set the pressure switch to 50% lower than the value that the switch

tripped at – Example: gas switch trips at 10 in. w.c., set the switch to 5 in. w.c.

 Reset the switch and flame programmer  Cycle the burner and observe for proper operation

High Gas Pressure Switch:

 Bring boiler to low fire (0% firing rate)  Decrease the dial on the high gas pressure switch until it trips and locks out the boiler  Make note of the pressure that the burner shuts down at  Once the switch trips, set the pressure switch to 50% higher than the value that the switch tripped

at – Example: gas switch trips at 10 in. w.c., set the switch to 15 in. w.c.

 Reset the switch and flame programmer  Cycle 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 reconnect the POC wire  Turn power to the boiler back on and reset any flame programmer faults  Cycle the burner and observe for proper operation

Flashback Protection:

 Locate the flashback protection device and change the setting to the lowest setting. This is

typically 32 deg. F.

o To change the setting, the “Set/Reset” button must be pressed as the wheel is rotated

 The device will generate an alarm  Reset the device to the factory temperature setting. This is typically 750 deg. F for standard

steam units.

 Try to turn on the burner. It should not work as the reset button on the control has not yet been

pressed.

 Press the reset button on the controller. The boiler should now operate correctly.

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VMP IOM

Troubleshooting Gas-Fired Boilers

PROBLEM CAUSE REMEDY

Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.

2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks in porcelain. If found,replace.

3. Transformer Check voltage between transformer leads at terminal block to be sure transformer is being powered.

4. Flame Safeguard Control Check voltage between ignition terminal and neutral. Check must be made before control locks out on safety. If no power, replace control.

5. Faulty Air Switch Check for bad air switch by jumpering the two air switch leads at the terminal block. If the boiler starts and runs with these terminals jumpered, the air switch should be replaced.

6. Gas Valve Sticking (Pilot) Check for dirt in valve or orifice and clean if necessary. Check for faulty actuator or valve and replace if necessary.

7. Gas Supply Check for gas pressure and for intermittent supply problems. Gas pressure for natural gas should be 3-1/2" W.C. plus fan pressure at the elbow to the burner and 7" to 11" W.C. at the head of the train.

8. Loose wire connection Check connections to all components.

Flame Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.

2. Gas Supply Check for gas pressure and for intermittent supply problems. Gas pressure for natural gas should be 3-1/2" W.C. plus fan pressure at the elbow to the burner and 7" to 11" W.C. at the head of the train.

3. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks in porcelain; if found, replace.

4. Primary Air Adjustment Check air adjustment.

5. UV Scanner Adjustment Check for dirt on flame scanner and clean. Check for proper location of detector.

6. Flame Safeguard Control Check voltage at terminal leading to main gas valve. If no power, replace the control.

7. Loose wire at fuel valve circuit Tighten wiring connections.

8. Contact open on air Adjust to proper setting.

safety switch

9. Scanner wiring reversed Change to correct terminals.

at panel box.

Burner Cut-Off 1. Power Supply Check fuse or circuit; reset or replace, as necessary.

2. Gas Supply Check to be sure main gas cock is not closed. Check coil in gas valve with OHM meter. Replace if faulty. Check gas regulator setting and readjust as necessary. Check inlet gas pressure and increase or decrease as necessary.

3. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment Readjust if necessary. Check for cracks in porcelain; if found replace.

4. Air Switch Check for bad air switch by jumpering the two air switch leads at the terminal block. If the boiler starts and runs with these terminals jumpered, the air switch should be replaced.

5. Gas Valve Sticking (Pilot) Check for dirt in valve or orifice and clean if necessary. Check for faulty actuator or valve and replace if necessary.

6. Weak Amplifier Replace.

7. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator.

8. Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight glass shows the proper water level. If there is no power at this terminal, the control is bad and must be replaced.

9. Dirty or defective UV Scanner Clean or replace.

Maintenance

Page 53

PROBLEM CAUSE REMEDY

Poor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in

pieces. Clean or replace as necessary.

2. S.S. Ring Check to be sure ring is present and fits tight against the furnace wall.

3. Primary Air Adjustment Check air adjustment. Air/fuel mixture may be off. Open primary air so fire is to outside wall of furnace.

4. Secondary Air Adjustment Check main air adjustment to see if it is loosened up. Adjust as necessary and tighten plate in position. Check CO2and O2levels.

5. Draft Check draft with a gauge. Draft should be a -.02 " to -.04" W.C. with burner off or -.04" to -.06" when operating. May need to install a barometric damper.

6. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.

7. Negative Room Pressure Make sure no exhaust fans are running in the boiler room.

Burner back fires 1. Refractories Check refractories to see if they are plugged with soot or broken in

pieces. Replace as necessary.

2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment Readjust if necessary. Check for cracks in porcelain; if found replace.

3. Draft Check draft with a gauge. Draft should be a -.02 " to -.04" W.C. with burner off or -.04" to -.06" when operating. May need to install a barometric damper.

4. Negative Room Pressure Make sure no exhaust fans are running in the boiler room.

Boiler will not 1. Gas Supply Check gas pressure coming into gas train. If low, contact gas company. maintain pressure Check coil in gas valve with AMP meter. Replace if bad.

Check gas regulator setting and readjust as necessary.

2. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.

3. Pressuretrol Disconnect 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 refractories to see if they are cracked or broken in pieces. Replace as necessary.

6. Steam traps blowing through Check traps to see if they are clean or replace as necessary.

7. Boiler size. Boiler may be undersized.

Boiler is Surging 1. Steam traps blowing through Check traps to see if they are clean or replace as necessary.

2. High organic in boiler Drain and clean boiler with washing soda per instruction manual.

(i.e. Perc or oil)

3. High boiler TDS Drain boiler and flush system. Refill and increase blow-down rate/frequency.

4. Too much water akalinity Have water tested by water treatment company, lower boiler alkalinity

(high PH) to recommended level.

5. High sudden steam load Check total equipment horsepower required against horsepower of boiler being used. Decrease amount of equipment being used at one time, or reduce the steam flow by partially closing the steam stop valve.

6. High level of water Consult water treatment expert and adjust levels to boiler

treatment chemicals recommended levels.

Boiler Rumbles and 1. Draft problem Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with Pulsates burner off or -.04” to -.06” when operating. May need to install a

barometric damper.

Boiler pushing water 1. Steam Traps Check traps. Clean or replace as necessary. with the steam

(carryover) 2. High boiler TDS Drain boiler and flush system. Refill and increase blow-down

rate/frequency.

3. High level of water Consult water treatment expert and adjust to boiler recommended levels.

treatment chemicals

VMP IOM

Maintenance

Page 54

VMP IOM

PROBLEM CAUSE REMEDY

Pump will not cut off 1. Dirty Probes Clean or replace as necessary.

2. Relay failed Make sure relay is plugged in tightly. If so, replace water level relay.

3. Ground Connection Check for tightness and clean.

4. Probes not sensitive enough Replace probes and relays with extra sensitive ones. (RO/DI Water)

Pump runs but does 1. Vapor locking of pump Allow system to cool down, check steam traps and check to be sure not put water into boiler return lines are not insulated. Check return tank temp. If it is above

180°F (82°C) vapor locking of pump may occur. Inspect check valves. Clean and replace as needed. Replace pump with multistage centrifugal good for 250°F (121°C).

2. Impeller Adjustment Check for impeller wear and adjust per component information in

instruction manual (Burks only).

3. Pump suction plugged Remove/clean inlet strainer.

4. Plugged feed water nipple Check and clean or replace as necessary.

5. Pump undersized/worn Replace with appropriate pump.

3. Back pressure on pump Need to install repair kit on pump.

Water pump will not 1. Scale on probes. Check and clean or replace as necessary. come on at times 2. Bad Pump Contactor Check to see if contactor is being powered.

Check to see if contactor coil is pulling in. Replace if necessary.

3. Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power.

If power is present but motor does not run, replace it.

Low Fuel pressure 1. Gas pressure regulator Check and replace. Boiler Flooding 1. Pump does not shut off Dirty Probes. Clean or replace as necessary.

2. Relay failed Make sure relay is plugged in tightly. If so, replace water level relay.

3. Ground Connection Check for tightness and clean.

4. Vacuum created with boiler off As the boiler cools off, it pulls water from the system piping. To prevent

this, add a

/4" check valve on the steam gauge assembly piping,

which closes under pressure and opens under vacuum.

Troubleshooting Gas-Fired Boilers - LE Models

PROBLEM CAUSE REMEDY

Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.

2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary.

Check for proper adjustments. Readjust if necessary. Check for cracks in porcelain. If found, replace.

3. Transformer Check voltage between transformer leads at terminal block to be sure

transformer is being powered.

4. Flame Safeguard Control Check voltage between ignition terminal and neutral.

Check must be made before control locks out on safety. If no power, replace control.

5. Faulty Air Switch Check for bad air switch by jum pering the two air switch leads at the

terminal block. If the boiler starts and runs with these terminals jumpered, the air switch should be replaced.

6. Gas Valve Sticking (Pilot) Check for dirt in valve or orifice and clean if necessary.

Check for faulty actuator or valve and replace if necessary.

7. Gas Supply Check for gas pressure and for intermittent supply problems. See test

fire sheet for last elbow.

8. Loose wire connection Check connections to all components.

Main Flame Fails 1. Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report.

Adjust gas servo setting.

2. Air Servo Motor not set properly Verify the over burner pressure matches the start up report.

Adjust the air servo motor.

Boiler Fails while 1. Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report. Modulating adjust gas servo setting.

2. Air Servo Motor not set properly Verify the over burner pressure matches the start up report.

Adjust air servo setting.

Maintenance

Page 55

PROBLEM CAUSE REMEDY

Flame Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.

2. Gas Supply Check for gas pressure and for intermittent supply problems.

3. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks in porcelain; if found, replace.

4. Primary Air Adjustment Check air adjustment. Air may be blowing flame away from burner head.

5. Scanner Check for dirt on flame scanner and clean. Check for proper location of detector.

6. Flame Safeguard Control Check voltage at terminal leading to main gas valve. If no power, replace the control.

7. Loose wire at fuel valve circuit Tighten wiring connections.

8. Contact open on air safety switch Adjust to proper setting.

9. Scanner wiring reversed Change to correct terminals.

at panel box

Burner Cut-Off 1. Power Supply Check fuse or circuit; reset or replace, as necessary.

3. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks in porcelain; if found, replace.

4. Scanner Check for dirt on flame scanner and clean. Check for proper location of detector.

5. Air Switch Check for bad air switch by jumpering the two air switch leads as the terminal block. If the boiler starts and runs with these terminals jumpered, the air switch should be replaced.

6. Gas Valve Sticking (Pilot) Check for dirt in valve or orifice and clean if necessary. Check for faulty actuator or valve and replace if necessary.

7. Weak Amplifier Replace.

8. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator.

9. Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight glass shows the proper water level. If there is no power at this terminal, the control is bad and must be replaced.

10. Dirty or defective UV Scanner Clean or replace.

Poor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in

pieces. Clean or replace as necessary.

2. Air Adjustment Check CO2and O2levels. Adjust Gas/Air Ratio.

3. Draft Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with burner off or -.04” to -.06” when operating. May need to install a barometric damper.

4. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.

5. Negative Room Pressure Make sure no exhaust fans are running in the boiler room.

6. Gas Servo Malset Adjust gas servo setting.

7. Air Servo Malset Adjust air servo setting.

Burner back fires 1. Refractories Check refractories to see if they are plugged with soot or broken in

pieces. Replace as necessary.

2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks i nporcelain; if found, replace.

3. UV Scanner Check for dirt on flame scanner and clean. Check for proper location of detector.

4. Draft Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with burner off or -.04” to -.06” when operating. May need to install a barometric damper.

5. Negative Room Pressure Make sure no exhaust fans are running in the boiler room.

VMP IOM

Maintenance

Page 56

VMP IOM

PROBLEM CAUSE REMEDY

Boiler will not 1. Gas Supply Check gas pressure coming into gas train. If low, contact gas company. maintain pressure 2. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.

3. Pressuretrol Disconnect all power to the controller. Disconnect the wires from the controller. Put an OHM meter between the switch terminals. Lower the set point and recheck with OHM meter. Switch should break. If the controller operates improperly, replace it.

4. Scale Built up in boiler Refer to Section 2 “Pressure Vessel Cleaning”.

5. Refractories Check refractories to see if they are cracked or broken in pieces. Replace as necessary.

6. Steam traps blowing through Check traps to see if they are clean or replace as necessary.

7. Boiler size Boiler may be undersized.

Boiler is Surging 1. Steam traps blowing through Check traps to see if they are clean or replace as necessary.

2. High organic in boiler Drain and clean boiler with washing soda per instruction manual.

(i.e. Perc or oil)

3. High boiler TDS Drain boiler and flush system. Refill and increase blow-down rate/frequency.

4. Too much water akalinity Have water tested by water treatment company, lower boiler alkalinity

(high PH) to recommended level.

6. High level of water Consult water treatment expert and adjust levels to boiler

treatment chemicals recommended levels.

Boiler Rumbles and 1. Draft problem Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with Pulsates burner off or -.04” to -.06” when operating. May need to install a

barometric damper.

Boiler pushing water 1. Steam Traps Check traps. Clean or replace as necessary. with the 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 for tightness and clean.

4. Probes not sensitive enough Replace probes and relays with extra sensitive ones.

(RO/DI Water)

Pump runs but does 1. Vapor locking of pump Allow system to cool down, check steam traps and check temp. If it is not put water into boiler to be sure return lines are not insulated.

Check return tank above 180°F (82°C) vapor locking of pump may occur. Inspect check valves. Clean and replace as needed. Replace pump with multistage centrifugal good for 250°F (121°C).

2. Impeller Adjustment Check for impeller wear and adjust per component information in instruction manual (Burks only).

3. Pump suction plugged Remove/clean inlet strainer.

4. Plugged feed water nipple Check and clean or replace as necessary.

5. Pump undersized/worn Replace with appropriate pump.

Water pump will not 1. Scale on probes Check and clean or replace as necessary. come on at times 2. Bad Pump Contactor Check to see if contactor is being powered.

Check to see if contactor coil is pulling in. Replace if necessary.

3. Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power. If power is present but motor does not run, replace it.

Low Fuel pressure 1. Gas pressure regulator Check and replace. Boiler Flooding 1. Pump does not shut off Dirty probes. Clean or replace as necessary.

2. Relay failed Make sure relay is plugged in tightly. If so, replace water level relay.

3. Ground Connection Check for tightness and clean.

4. Vacuum created with boiler off As the boiler cools off, it pulls water from the system piping. To prevent this, add a

/4” check valve on the steam gauge assembly piping,

which closes under pressure and opens under vacuum.

Maintenance

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Page 58

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Section

Parts and Warranty

Page 59

5-60-100 Instruction Manual, Fuel-Fired 2 0.91 5-60-165 Certification Papers

Boiler Shell Parts

5-12-017 Furnace Refractory 30" OD x 91/2" ID (80 HP Top) 225 102.27 5-12-018 Furnace Refractory 30" OD x 10" ID (100 HP Top) 225 102.27 5-12-019 Furnace Refractory 30" OD x 13"D (80 & 100 HP Bottom) 225 102.27 5-12-015 Furnace Refractory 24" OD x 8" ID (40 - 60 HP Top) 125 56.82 5-12-016 Furnace Refractory 24" OD X 10" ID (40- 60 HP Bottom) 125 56.82 2-12-000 Furnace Cement- 2 Ib. can 2 0.91 2-12-001 Furnace Cement - 8 Ib. can 8 3.64 2-12-002 Furnace Cement - 15 Ib. can 15 6.82 Misc Flue Cover 40-60 HP (10) 5-10-11034 Flue Cover Plate - 80 HP (10) 64 29.09 5-10-11024 Flue Cover Ring -100 HP (10) 75 34.09 5-12-003 Square Cleanout Plug 15 6.82 2-12-064 Flexitalic (HHG) Extra Heavy High Pressure 0.5 0.23 2-12-088 Blue Max HHG 0.05 0.02 5-10-804 Handhole Welding Patch 60-100 HP 1.1 0.5 2-12-004 Handhole Gasket 60-100 HP 0.05 0.02 2-11-TIL105 HandholeYoke 1.5 0.68 2-11-TIL104 3 x 4 Handhole Cover 40-100 HP (Blue) 2 0.91 4-11-028 40 -100 HP Handhole Assembly (Blue) 7 3.18 2-12-504 Blanket Insulation (Sq. ft.) 0.5 0.23 5-21-306 Steel Jacket 40-60 HP - No Holes Cut 125 56.82 5-21-308 Steel Jacket 80 HP - No Holes Cut 180 81.82 5-21-309 Steel Jacket 100 HP - No Holes Cut 205 93.18 5-21-375 Exhaust Transition (40-60 HP) 5-21-374 Exhaust Transition (80 HP) 8.5 3.86 5-21-373 Exhaust Transition (100 HP) 2-12-502 Kast Set - per Ib. (10 Ibs. minimum) - Use for making refractories 2-21-015 Buckeye Stamping for Bottom Handhole 60-100 HP 1 0.45 2-21-093 Buckeye Stamping for Upper Handhole 60-100 HP 1 0.45 2-23-171 Touch Up Paint - MICA Spray (10 oz.) 1 0.45 4-23-014 Mica Paint - Quart 2 0.91 4-23-044 Mica Paint - Gallon 7.8 3.55 2-12-504 TIW Filler Insulation per sq ft

VMP IOM

Parts and Warranty

Part No. Description Approx. Net Weight

(lbs) (kgs)

It is important that the correct replacement part is fitted to your Fulton Gas Fired Steam Boiler.

When ordering replacement or spare parts, make sure that the full information given in the Parts List is supplied, together with the following details as shown on your boiler identification plate:

1. Boiler Number

2. Boiler Type

3. Electrical Specifications

NOTE

The policy of Fulton Boiler Works, Inc. is one of continuous improvement, and therefore, we reserve the right to change prices, specifications, and equipment without notice.

Page 60

Burner Assembly - Parts (Common)

2-40-613 1.5 HP 115/230/60/1 Burner Motor 3450 RPM 40 18.18 2-40-615 1.5 HP 230/460/60/3 Burner Motor 2850/3450 RPM 31 14.09 2-40-621 3.0 HP 230/460/50/60/3 Burner Motor 2850/3450 RPM 43 19.55

2-12-014 Pyrex Plate Glass 1 " - 4 -100 HP 0.1 0.05 2-45-025 Bakelite Terminal 90° for Electrode 0.05 0.02 2-45-026 Bakelite Terminal Straight for Electrode 0.05 0.02 2-45-017 Ignition Wire - per foot 0.01 0 2-11-080 Burner Scroll Casting - 80 & 100 HP 65 29.55 5-20-061 Burner Scroll Casting - 40, 50 & 60 HP 50 22.73

Burner Fans: Size HP Applicable Fuel Hz.

2-30-421 8-3/8 x 2-1/2 x 1 40-50 Propane or nat. Gas 50/60 3.00 1.36

60 Propane or nat. Gas 50/60 3.00 1.36 2-30-826 9-15/16 x 3-1/2 x LO75 80 2-30-559 9-15/16 x 3 x LO75 100

*When ordering burner fans, check for the correct part number on the back of the fan plate.

Burner Assembly - Gas

2-40-082 Ignition Transformer - Gas 115/60 9.5 4.32 2-45-026 Straight Bakelite Terminal 0.03 0.01 4-45-010 Ignition Cable with 90° Bakelite Terminal 0.5 0.23 2-20-033 Ignition Electrode 0.4 0.18 2-30-118 Air Switch 80-100 HP 0.72 0.33 5-20-018 Burner Plate Gas - 30-60 HP 1 0.45 5-10-398 Burner Plate Gas - 80 HP 1 0.45 5-10-399 Burner Plate Gas -100 HP 1 0.45 7-20-094 Air Deflector - Gas 80 & 100 HP 65 29.55 7-20-092 Air Deflector - Gas 40 - 60 HP 45 20.45 2-40-533 Gas Pressure Switch High-Low 3.25 1.48 2-30-298 1/2" Pilot Gas Valve (80-100 HP) 1.5 0.68 2-30-312 1-1/2" Gas Valve V5055A (40-60 HP) 10.7 4.86 2-30-313 2" Gas Valve V5055A (80-100 HP) 9.85 4.48 2-30-3003 Modulating Butterfly Valve (40-60 HP) 2-30-3020 Modulating Butterfly Valve (80-100 HP) 2-30-303 1-1/2" Main Gas Valve - V48A 4.5 2.05 2-40-253 Gas Valve Body - P.O.C V5055C (40-60 HP) 11.5 5.23 2-40-254 Gas Valve Body - P.O.C V5055C (80-100 HP) 10.5 4.77 2-40- High-Low-Off Gas Valve Body 80 HP 2-40- HIgh-Low-Off Gas Valve Body 100 HP 2-40-214 Actuator Valve Body 13.70 6.23 2-40-220 Actuator Valve Body w/Proof of Closure Switch 12.8 5.82 2-30-583 High-Low-Off Gas Valve Actuator 80 and 100 HP 2-30-402 1-1/4" Vent Valve - 120V Normally Open 4.7 2.14 2-30-401 1" Vent Valve - 120V Normally Open 4.3 1.95 2-30-198 1/8" Gas Cock (Pet Cock) 0.25 0.11 2-30-111 1/2" Pilot Gas Cock 0.6 0.27 2-30-115 1-1/2 " Main Gas Cock 4.8 2.18 2-30-110 2" Main Gas Cock 16.8 7.64 2-30-102 1/2" Gas Pressure Regulator RV 48 0.7 0.32 2-30-107 1-1/2"Gas Pressure Regulator - RV 81 4.8 2.18 2-30-108 2" Gas Pressure Regulator - RV 91 8.5 3.86 7-20-298 Natural Gas Orifice - 40 HP 4 1.81 7-20-299 Natural Gas Orifice - 50 HP 4 1.81 7-20-300 Natural Gas Orifice - 60 HP 4 1.81 7-20-093 Natural Gas Orifice - 80 HP 4.5 2.04 7-20-302 Natural Gas Orifice - 100 HP 4.5 2.04 7-20-275 Propane Orifice - 40 HP 4 1.81 Misc. Propane Orifice - 50 hP 4 1.81

VMP IOM

Parts and Warranty

Part No. Description Approx. Net Weight

(lbs) (kgs)

Page 61

7-20-322 Propane Orifice - 60 HP 4 1.81 7-20-094 Propane Orifice - 80 HP 4.5 2.04 7-20-095 Propane Orifice - 100 HP 4.5 2.04 2-30-180 Propane Spring RV81 .05 0.23 2-30-181 Propane Spring RV91 .05 0.23 7-30-006 Top Plate Assembly - 40, 50 & 60 HP - Natural or Propane Gas 65 29.55 7-30-000079 Top Plate - 80 HP - NG/LP 100 45.4 7-30-000081 Top Plate - 80 HP - Combo 100 45.4 7-30-000110 Top Plate - 100 HP - NG/LP 100 45.4 7-30-000112 Top Plate - 100 HP - Combo 100 45.4 7-30-000031 Burner Plate Assembly - 40, 50 HP - Natural Gas 12 5.45 7-30-000073 Burner Plate Assembly - 80 HP - Natural Gas 12 5.45 7-30-000075 Burner Plate Assembly - 80 HP - Combo 12 5.45 7-30-000173 Burner Plate Assembly - 80 HP -Propane 12 5.45 7-30-000174 Burner Plate Assembly - 80 HP - Town Gas 12 5.45 7-30-000175 Burner Plate Assembly - 80 HP - Butane 12 5.45 7-30-000115 Burner Plate - 100 HP - Gas 1 .454 7-30-000117 Burner Plate - 100 HP - Combo 1 .454 7-30-000176 Burner Plate - 100 HP -Propane 1 .454 7-30-000177 Burner Plate - 100 HP - Town Gas 1 .454 7-30-000178 Burner Plate - 100 HP - Butane 1 .454 7-54-1006 Gas Train Assembly - 40 - 50 HP - Natural Gas 70 31.82 7-54-5158 Gas Train Assembly - 80 HP - Natural Gas On/Off 100 45.45 7-54-5159 Gas Train Assembly -100 HP - Natural Gas On/Off 100 45.45 7-54-6158 Gas Train Assembly - 80 HP - Propane Gas On/Off 100 45.45 7-54-6159 Gas Train Assembly -100 HP - Propane Gas On/Off 100 45.45 7-54-8488 Gas Train Assembly 80 HP - Natural Gas High/Low/Off 100 45.45 7-54-8489 Gas Train Assembly 100 HP - Natural Gas High/Low/Off 100 45.45 7-54-7758 Gas Train Assembly 80 HP Natural Gas Modulation 100 45.45 7-54-7759 Gas Train Assembly 100 HP Natural Gas Modulation 100 45.45 7-54-8498 Gas Train Assembly 80 HP - Propane Gas High/Low/Off 100 45.45 7-54-8499 Gas Train Assembly 100 HP -Propane Gas High/Low/Off 100 45.45 7-54-8409 Gas Train Assembly 80 HP Propane Gas Modulation 100 45.45 7-54-8410 Gas Train Assembly 100 HP Propane Gas Modulation 100 45.45

Water Column

5-20-022 Fulton Water Column Bottle Casting -4-100 HP 20 9.09 2-30-151 MM 150 Pump Control 25 11.36 2-30-193 MM 150 - M/R Control 25 11.36 2-30-152 MM 150 HD Assembly 25 11.36 2-30-192 MM 150-M-HD M/R Head 25 11.36 2-12-125 MM 150-14 Gasket 0.05 0.02 2-30-136 MM 157 Pump Control and Low Water Cutoff 39.7 18.05 2-30-137 MM 53-2 Boiler Feeder and Low Water Cutoff 38.5 17.5 2-45-144 MM Mercury Switch - 2 Wire 1 0.45 2-45-143 MM Mercury Switch - 3 Wire 1 0.45 2-30-149 Water Gauge Glass Valves w/Ball Checks 1.5 0.68 2-30-047 Try Cocks 0.4 0.18 2-12-065 8-5/8" Extra Heavy Gauge Glass 0.05 0.02 2-12-008 9-1/4 Water Gauge Glass - standard 0.05 0.02 2-12-007 9-1/4" Extra Heavy Gauge Glass 0.1 0.05 2-12-017 9-1/4" Water Gauge Glass -Corning 0.05 0.02 2-12-018 10" Water Gauge Glass- MM 0.06 0.03 2-12-020 Brass Water Gauge Glass Gasket 0.0018 0 2-12-019 Rubber Water Gauge Glass Gasket 0.004 0 2-12-080 Teflon Water Gauge Gaskets 0.01 0 2-35-514 Brass Packing Nut for Gauge Glass Valve 0.1 0.05 2-30-330 Gauge Glass Protector Rods 0.04 0.02 2-12-022 Lucite Gauge Glass Guard for 9-1/4" Glass 0.4 0.18

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(lbs) (kgs)

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2-12-024 Lucite Gauge Glass Guard for 10" Glass 0.5 0.23 4-21-010 Water Column Electrode Basket & Cover 0.5 0.23 4-30-052 Set of four (4) Water Level Probes & Plugs - 80-100 HP 1.3 0.59 4-30-042 Set of 3 Water Column Probes 0.8 0.36 2-20-010 Pump Off Probe - 7-1/4 " 0.2 0.09 2-20-011 Pump On Probe - 9-1/4" 0.2 0.09 2-20-012 Low Water Probe in Water Column -11-1/4” 0.3 0.14 2-20-017 Low Water Probe in Boiler- 17-1/2” 0.5 0.23 2-21-012 Probe Cover - 2" 1 0.45 2-21-013 Probe Cover - 4" 1 0.45 2-30-398 1/4"Male-Female Ball Valve for Water Column 0.6 0.27 2-40-021 Probe Basket 0.05 0.02

Panel Box Parts

2-40-420 Fulton Pump Relay-120V 0.5 0.23 2-40-421 Fulton Burner Relay - 120V 0.5 0.23 2-40-422 Base for Fulton Pump Relay 0.25 0.11 2-40-423 Base for Fulton Burner Relay 0.25 0.11 2-12-090 Spring Retainer for burner/pump relay 0.001 0 2-40-131 General Purpose Relay (Ice Cube) - AB 0.8 0.36 2-40-096 Base for Ice Cube Relay 0.1 0.05 2-45-091 On/Off Switch 0.05 0.02 2-45-092 Manual Reset Switch 0.05 0.02 2-45-090 Night Switch for two (2) Pressuretrols 0.05 0.02 2-40-552 4" Alarm Bell 1 0.45 2-40-551 120V Transformer for Bell 1 0.45 2-45-412 AB Green Panel Light 120 V - NEMA 4 0.02 0.01 2-45-413 AB Amber Panel Light 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 0.2 Overload - AB - BSC 24 0.45 0.2 Overload - AB - BSB 42 0.45 0.2

2-40-573 Overload - 60 3RB1015-2SBO 0.45 0.2

Overload - AB - BSB 80 0.45 0.2 2-40-566 Overload - 3RB1015-2NBO 0.45 0.2 2-40-651 Overload - 3RB1025-2OBO 4-40-050 Night Heating Pressuretrol Set Up 3.5 1.59 2-40-227 Pressuretrol L404A - 2-15 PSI 1.7 0.77 2-40-228 Pressuretrol L404A - 5-50 PSI 2 0.91 2-40-229 Pressuretrol L404A - 10-150 PSI 2 0.91 2-40-230 Pressuretrol L404A - 20-300PSI 2.7 1.23 2-40-231 Pressuretrol L404C - 2-15 PSI 2 0.91 2-40-232 Pressuretrol L404C - 5-50 PSI 2 0.91 2-40-233 Pressuretrol L404C - 10-150 PSI 2 0.91 2-40-234 Pressuretrol L404C - 20-300 PSI 2.7 1.23 2-40-161 Flame Scanner (Mini-Peeper) 0.5 0.23 2-40-262 RM7800M Programmer 40-100 HP - 120 V 2.5 1.14 2-40-265 7 Second Prepurge Timer 0.1 0.05 2-40-266 30 Second Prepurge Timer 0.1 0.05 2-40-267 60 Second Prepurge Timer 0.1 0.05 2-40-269 RM7800 Amplifier - For UV Amp 0.2 0.09 2-40-161 Mini Peeper For All 7800 0.5 0.23

Parts and Warranty

Part No. Description Approx. Net Weight

(lbs) (kgs)

Page 63

2-40-270 Base For All 7800 0.5 0.23 2-40-272 Display Module for 7800 Controls English (Also Available in Spanish) 0.5 0.23 2-40-247 Remote Mounting Bracket for 7800 0.65 0.3 2-40-248 Extension Cable

Boiler Trim

2-30-396 1" Spring Loaded Check Valve - 200# 2.55 1.16 2-30-397 1-1/4" Spring Loaded Check Valve - 200# 3.8 1.73 2-30-019 1/4" Ball Valve - 200# 0.6 0.27 2-30-008 1/2" BallValve-200# 0.7 0.32 2-30-027 3/4" BallValve-200# 1.4 0.64 2-30-026 1" Ball Valve - 200# 1.75 0.8 2-30-001 1" MxF Ball Valve 200# 2 0.91 2-30-017 1-1/4" Ball Valve - 200# 3.1 1.41 2-30-018 1-1/2" Ball Valve - 200# 4.7 2.14 2-30-025 2" Ball Valve - 200# 6.35 2.89 2-30-208 3" Ball Valve - 200# 18 8.18 2-30-393 1-1/2" Y Type Blowdown Valve - 200# 8.4 3.82 2-30-394 2" Y Type Blowdown Valve-200# 13.5 6.14 2-30-023 1-1/2" Quick Action Blowdown Valve 23 10.45 2-30-024 2" Quick Action Blowdown Valve 28 12.73 2-40-133 Timer for Automatic Blowdown System 0.8 0.36 2-30-403 1-1/2" Motorized Valve for Automatic Blowoff 12.6 5.73 2-30-389 2" Motorized Valve for Automatic Blowoff 13.7 6.23 2-30-1066 1/2" Steam Solenoid Valve - 120V 2.3 1.05 2-30-122 3/4" Steam Solenoid Valve - 120V 2.5 1.14 2-30-146 1" Steam Solenoid Valve - 120V 4.5 2.05 2-30-147 1-1/4 " Steam Solenoid Valve - 120V 4.9 2.23 2-30-148 1-1/2" Steam Solenoid Valve - 120V 6.3 2.86 2-30-016 1-1/2" 15# Series 19 V-Stamped Safety Valve 2 0.91 2-30-217 2" 15# Series 19 V-Stamped Safety Valve 2.5 1.14 2-30-085 1-1/4"-150# Safety Valve 6.8 3.09 2-30-086 1-1/2"-15# Safety Valve 2 0.91 2-30-087 1-1/2"-100# Safety Valve 12.4 5.64 2-30-088 1-1/2"-125# Safety Valve 10.9 4.95 2-30-089 1-1/2"-150# Safety Valve 12.3 5.59 2-35-518 1/4" Steel Pigtail Syphon for Steam Gauge Assembly- Long 0.6 0.27 2-30-326 0-30 PSI Steam Pressure Gauge 0.5 0.23 2-30-334 0-60 PSI Steam Pressure Gauge 0.5 0.23 2-30-333 0-200 PSI Steam Pressure Gauge 0.5 0.23 2-30-332 0-300 PSI Steam Pressure Gauge 0.5 0.23 2-30-327 0-600 PSl Steam Pressure Gauge 0.5 0.23 2-12-027 Teflon Disc for 1-1/2" Y Valve 0.2 0.09 2-11-017 Brass Seat for 1-1/2" Y Valve 0.1 0.05 2-12-028 Teflon Disc for 2" Y Valve 0.2 0.09 2-11-018 Brass Seat for 2" Y Valve 0.1 0.05

Test Equipment/Tools

2-40-090 Test Leads 0.6 0.27 2-40-215 Microampmeter - W136 2 0.91 2-60-100 Jr. Amprobe - Y25 1 0.45 2-60-102 Pocket Draft Meter 1 0.45 2-60-103 All Purpose Draft Meter 3 1.36 2-60-104 CO Tester-Gas 15 6.82 2-60-105 CO Tubes 0.25 0.11 2-60-106 StackThermometer 4 1.82 2-60-108 SmokeTester-Oil 2 0.91 2-60-110 Fisher Gauge - 50 PZ 1 0.45 2-60-247 Flue Brush - Pipe Type - 2-1/2" - 100 HP 1 0.45

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(lbs) (kgs)

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2-60-248 Flue Brush - Pipe Type - 2" - 40 and 80 HP 1 0.45 5-10-397 Tee Handle Wrench 2.7 1.23 2-20-110 Fan Puller - 5/8" Hub 2 0.91

Barometric Controls

2-30-099 14" M&MG2 80 - 100 HP - Oil, Gas, Comb. 16 7.27 2-30-0415 16" M&MG2 25 11.36

Spare Parts Kits

2-12-517 Burner Plate Gasket 40, 80 and 100 HP Gas 0.06 0.03 2-12-023 Screws (11) 0.001 0.00 5-12-046 Bottom Cleanout Gasket Only 0.5 0.23 2-12-550 Combination Gasket 0.05 0.02 4-12-114 Flue Cover Plate Gasket - Strip & 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 - 80-100 HP 1 0.45 4-12-516 Gas, Oil, & Comb Gasket Kit 15 6.82 4-12-520 80-100 HP Gas, Oil, & Comb Gasket Kit 10 4.55

See the component assembly drawings to assist with parts identification.

Parts and Warranty

Part No. Description Approx. Net Weight

(lbs) (kgs)

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Standard Warranty for Fulton Boilers

(Warranty Valid for Models ICS, ICX, ICW, ICXW, VMP, VMPW, FB-A, FB-F, FB-L, FB-S, FB-W)

Five (5) Year (60 Months) Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of five (5) years from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused defective material or workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation and Operation Manual.

Parts Warranty

Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department.

General

Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind.

These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual.

No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager.

This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective.

To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

Parts and Warranty

9/9/09

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Page 68

Extended Warranty for Fulton Boilers

(Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S)

Ten (10) Year Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of ten (10) years from the date of shipment from the factory. Fulton will repair or replace at our option, F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and maintained in accordance with the Installation, Operation and Maintenance Manual. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklist to Fulton’s Service Department. This warranty covers any failure caused by defective material or workmanship, however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be maintained as outlined in the Installation, Operation and Maintenance Manual.

The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system. Generally, this system MUST include ALL of the following equipment in order for the warranty to apply.

1. Fulton boiler with model number as listed above.

2. Fulton DA or condensate return system with preheat kit.

3. Fulton blowdown tank/separator

4. Water softener

5. Chemical feed system

6. Automatic surface or bottom blowdown, which must operate to maintain TDS levels as specified in the Installation, Operation and Maintenance Manual.

Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation, Operation and Maintenance Manual

There is a $1,000 labor allowance for any failed pressure vessel that is covered under the above warranty.

Parts Warranty

Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve (12) months of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers.

General

Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind.

This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event by liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profits or business, even if Fulton has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective.

Conditions of Warranty

Warranties are only valid if the boiler is installed, operated and maintained as outlined in the Installation, Operation and Maintenance Manual. Fulton shall accept no responsibility if the equipment has been improperly installed, operated or maintained or if the buyer has permitted any unauthorized modification, adjustment, and/or repairs to the equipment. The use of replacement parts not manufactured or authorized by Fulton will void any warranty express or implied.

Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a factory certified technician. The commissioning agency must successfully complete and return the equipment Installation and Operation Checklist to Fulton’s Service department.

The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports must be produced for warranty consideration.

The warranty is valid for the original installation only in the U.S.A and Canada.

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Parts and Warranty

08/20/10

Page 69

No part of this Installation, Operation, and Maintenance

manual may be reproduced in any form or by any means without

permission in writing from the Fulton Companies.

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