INSTALLATION AND OPERATION MANUAL
Vertical Multi-Port
Hot Water Boilers
Model VMP-W
40 -150 HP
Serial/ National
Board Number
Model
Fulton Order
Sold To
Job Name
Date
VMPW-IOM-2012-1001
VMPW-IOM-2012-1001
TABLE OF CONTENTS
Introduction |
1-1 |
Overview.............................................................................................................. |
1-2 |
Warnings & Cautions............................................................................................ |
1-2 |
Disclaimers and Local Codes ................................................................................ |
1-2 |
Installation |
2-1 |
Placement & Rigging........................................................................................... |
2-2 |
Clearances & Serviceability.................................................................................. |
2-4 |
Environment,Ventilation and Combustion Air Requirements ............................ |
2-4 |
Utilities................................................................................................................. |
2-6 |
THE GAS SUPPLY.......................................................................................................................... |
2!6 |
THE OIL SUPPLY ........................................................................................................................... |
2!7 |
Electrical Supply................................................................................................... |
2-8 |
Water Supply........................................................................................................ |
2-8 |
INSTALL WATER PIPING............................................................................................................... |
2!8 |
Water Chemistry Requirements........................................................................... |
2-9 |
PREVENT OXYGEN CONTAMINATION........................................................................................ |
2!10 |
ELIMINATE SYSTEM AIR ............................................................................................................ |
2!10 |
Piping Speci" cations.......................................................................................... |
2-11 |
Insulation ........................................................................................................... |
2-12 |
System Interfaces............................................................................................... |
2-12 |
FILL CONNECTION...................................................................................................................... |
2!12 |
Assembly of Multi-Skid Systems........................................................................ |
2-12 |
Stack and Flue.................................................................................................... |
2-13 |
EXHAUST SIDE WALL VENTING ................................................................................................ |
2!15 |
Testing................................................................................................................ |
2-16 |
Operation |
3-1 |
Start-Up Preparation & Installation Review........................................................ |
3-2 |
Start-Up Service................................................................................................... |
3-3 |
Initial Start-Up ..................................................................................................... |
3-4 |
COMBUSTION............................................................................................................................... |
3!4 |
Flame Programmers ............................................................................................ |
3-5 |
Operating Controls ............................................................................................... |
3-5 |
WATER RELIEF VALVE................................................................................................................... |
3!5 |
WATER OUTLET VALVE................................................................................................................. |
3!5 |
TEMPERATURE CONTROL ........................................................................................................... |
3!5 |
OPERATING TEMPERATURE AQUASTAT ...................................................................................... |
3!5 |
HIGH LIMIT AQUASTAT/HIGH TEMPERATURE LIMIT.................................................................. |
3!6 |
AIR SAFETY SWITCH .................................................................................................................... |
3!6 |
PROBE TYPE LOW WATER CUT!OFF............................................................................................. |
3!6 |
Optional Circulating Pump Switch....................................................................... |
3-6 |
CycleTesting......................................................................................................... |
3-6 |
Before Leaving the Installation............................................................................ |
3-6 |
Maintenance |
4-1 |
Daily Maintenance Schedule................................................................................ |
4-2 |
Weekly Maintenance Schedule............................................................................ |
4-2 |
Monthly Maintenance Schedule.......................................................................... |
4-2 |
Recommended Semi-Annual Maintenance Schedule......................................... |
4-3 |
Recommended Annual Maintenance Schedule .................................................. |
4-5 |
Procedure for Primary Air Adjustment/Inspection.............................................. |
4-6 |
Procedure for Secondary Air Adjustment/Inspection.......................................... |
4-6 |
Procedure for Flame Scanner Adjustment........................................................... |
4-7 |
GAS UNIT...................................................................................................................................... |
4!7 |
OIL UNIT ...................................................................................................................................... |
4!7 |
Procedure for Removing/Cleaning the Burner .................................................... |
4-8 |
Procedure for Soot Cleaning................................................................................. |
4-8 |
After All Repairs or Maintenance ......................................................................... |
4-9 |
Troubleshooting................................................................................................... |
4-9 |
Warranty & Parts |
5-1 |
StandardWarranty for Fulton Boilers................................................................... |
5-3 |
Parts ..................................................................................................................... |
5-4 |
0-1
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
TABLE OF CONTENTS
VMPW-IOM-2012-1001
0-2
© The Fulton Companies 2012
INTRODUCTION
INTRODUCTION |
1 |
|
|
INSTALLATION |
2 |
|
|
OPERATION |
3 |
|
|
MAINTENANCE |
4 |
|
|
WARRANTY & PARTS |
5 |
|
|
1-1
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INTRODUCTION
VMPW-IOM-2012-1001 |
SECTION 1 |
Overview
Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:
♣Material inspections
♣Manufacturing process inspections
♣American Society of Mechanical Engineers (ASME) welding inspection
♣ASME hydrostatic test inspection
♣Electrical components inspection
♣Operating test
♣Final engineering inspection
♣Crating inspection
Warnings & Cautions
WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.
♣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 e!ectiveness.
All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.
Disclaimers and Local Codes
This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta! responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali"ed installers and service personnel. Trained personnel are responsible for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali•ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci•c to this product.
When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jursidictional authorities prior to installation.
Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence
of such requirements, in the US to the National Fuel Gas Code ANSI Z2231/NFPA 54 latest edition, and the speci"c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.
When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).
1-2
© The Fulton Companies 2012
INSTALLATION
INTRODUCTION |
1 |
|
|
INSTALLATION |
2 |
|
|
OPERATION |
3 |
|
|
MAINTENANCE |
4 |
|
|
WARRANTY & PARTS |
5 |
|
|
2-1
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INSTALLATION
VMPW-IOM-2012-1001 |
SECTION 2 |
! WARNING
All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable
jurisdictional/professional codes and regulations.
Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi•cant health hazards,
including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o€ered by the CDC and
OSHA for more information, including Personal Protective Equipment recommendations.
This boiler is certi•ed for indoor installation only.
A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.
The equipment must be installed on a non-combustible surface.
Do not store or use gasoline or other •ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.
4 CAUTION
Do not allow weight to bear on equipment components to prevent damage.
Placement & Rigging
Proper placement of your Fulton Product (see Figure 1, and Tables 1 and 2) is essential. Attention paid to the following points will save a great deal of di!culty in the future. Correct placement is the "rst step to trouble-free installation, operation and maintenance.
Adhere to the following for equipment placement and rigging:
1.Consult authorities with jurisdiction over any national or local codes (including but not limited to National Fire Protection Agency (NFPA), American National Standards Institute (ANSI), Underwriters Laboratories (UL), SCA, and ASME, which might be applicable to boiler applications before beginning.
2.Make appropriate determinations for placement, based on the following:
♣Check building speci"cations and Table 2 for unit weights.
♣Ensure the equipment is to be placed on a non-combustible level base with adequate clearances from combustible materials. See Clearances &
Serviceability section.
♣Locate boiler as close as possible to the place where the heat will be used in order to keep pipe work costs to a minimum.
♣Ensure that there is adequate clearance around the unit to provide access for operators and maintenance personnel to all parts of the
equipment. Ensure also that clearance provides for component removal for maintenance. See Clearances & Serviceability section. The equipment should be placed in a suitable boiler house or well ventilated separate room through which personnel do not normally pass. The layout should eliminate tra!c in potentially hazardous areas. For instance, the service engineer or the operator should not have to pass exposed, hot pipe work to make adjustments to the boiler controls.
♣Ensure the equipment is to be placed in such a way that the electrical components are protected from exposure to water or excessive humidity.
♣Ensure the boiler is located a safe distance from the fuel oil tank (if applicable).
3.Determine rigging procedure, based on the following:
♣Units are shipped and crated for forklift transport. Once uncrated, all units can be transported with a forklift and/or lifting lugs at the top of the boiler. All skidded units can be moved with forklifts.
♣If means of lifting are not available, place rollers beneath the frame of the equipment for guidance to the position of where it is to be installed.
♣Under no circumstances allow weight to bear on the jacket, control panel, burner, fuel train or fan housing of any Fulton boiler.
♣Tagged support legs on boiler are for shipping purposes only. These must be removed at time of installation, and may not be used to mount or anchor boilers.
2-2
© The Fulton Companies 2012
SECTION 2 |
VMPW-IOM-2012-1001 |
INSTALLATION
TABLE 1! DIMENSIONS! REFER TO FIGURE 1
Model VMP-W |
40 |
50 |
60 |
80 |
100 |
130 |
150 |
|
|
|
|
|
|
|
|
Unit Size BHP |
40 |
50 |
60 |
80 |
100 |
130 |
150 |
|
|
|
|
|
|
|
|
A. Boiler Diameter |
|
|
|
|
|
|
|
IN |
49 |
55 |
55 |
63 |
69 |
76.5 |
76.5 |
MM |
1245 |
1397 |
1397 |
1600 |
1753 |
1943 |
1943 |
|
|
|
|
|
|
|
|
(B) Boiler Height |
|
|
|
|
|
|
|
IN |
84 |
91 |
97 |
100 |
100 |
115 |
115 |
MM |
2133 |
2312 |
2464 |
2540 |
2540 |
2921 |
2921 |
|
|
|
|
|
|
|
|
(C) Boiler Depth |
|
|
|
|
|
|
|
IN |
90 |
100 |
100 |
114 |
119 |
128 |
130 |
MM |
2286 |
2540 |
2540 |
2896 |
3022 |
3251 |
3302 |
|
|
|
|
|
|
|
|
(D) Boiler Height With Trim |
|
|
|
|
|
|
|
IN |
107 |
113 |
119 |
125 |
125 |
149 |
149 |
MM |
2718 |
2870 |
3023 |
3175 |
3175 |
3785 |
3785 |
|
|
|
|
|
|
|
|
(E) Overall Boiler Width |
|
|
|
|
|
|
|
IN |
56 |
62 |
62 |
68 |
74 |
84.5 |
84.5 |
MM |
1422 |
1575 |
1575 |
1727 |
1880 |
2146 |
2146 |
|
|
|
|
|
|
|
|
(F) Flue Outlet Diameter |
|
|
|
|
|
|
|
IN |
12 |
12 |
12 |
14 |
14 |
14 |
14 |
MM |
305 |
305 |
305 |
356 |
356 |
356 |
356 |
|
|
|
|
|
|
|
|
(G) To Center of Flue Outlet |
|
|
|
|
|
|
|
IN |
79 |
83 |
89 |
95 |
95 |
107 |
107 |
MM |
2006 |
2108 |
2261 |
2413 |
2413 |
2718 |
2718 |
|
|
|
|
|
|
|
|
(H) Return Water Inlet Height |
|
|
|
|
|
|
|
IN |
20.3 |
20.3 |
20.3 |
20.3 |
20.3 |
23.6 |
23.6 |
MM |
516 |
516 |
516 |
516 |
516 |
599 |
599 |
|
|
|
|
|
|
|
|
(J) Water Outlet |
|
|
|
|
|
|
|
IN |
73.8 |
77.8 |
83.8 |
89.8 |
89.8 |
101.1 |
101.1 |
MM |
1870 |
1980 |
2130 |
2280 |
2280 |
2570 |
2570 |
|
|
|
|
|
|
|
|
(K) Min. Clearance to Ceiling for Burner Removal |
|
|
|
|
|
|
|
IN |
123 |
135 |
144 |
147 |
147 |
155 |
155 |
MM |
3124 |
3429 |
3658 |
3734 |
3734 |
3937 |
3937 |
|
|
|
|
|
|
|
|
All data is approximate. Fulton reserves the right to change data without prior notice.
F 
C
E
K
G |
D |
B |
|
J |
|||
|
|
||
|
A |
|
|
|
H.H. |
|
|
|
|
H |
FIGURE 1 !MODEL VMP!W DIMENSIONS/SPECIFICATIONS "REFER TO TABLES 1 AND 2#
2-3
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INSTALLATION
VMPW-IOM-2012-1001 |
SECTION 2 |
! WARNING
All information in this manual is for reference and guidance purposes, and does not substitute for required
professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.
Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.
Failure to provide proper minimum clearances between equipment and combustible materials may result in •re.
The installation of an exhaust fan in the boiler room is not recommended. An exhaust fan or similar equipment can create a downdraft in the stack or restrict the burner’s air supply and result in poor combustion. It is essential only fresh
air be allowed to enter the combustion air system. Foreign substances such as combustible volatiles and lint may create hazardous conditions.
Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.
×NOTE: When calculating ventilation requirements, heat losses from the Fulton equipment (and other equipment) should be considered.
Clearances & Serviceability
Adhere to the following for equipment clearances and serviceability:
1.Ensure appropriate front, back, sides and top clearances are met. This will allow access around the equipment to facilitate maintenance and a safe work environment, and ensure technicians will commission the unit. Technicians will not commence commissioning if hazardous conditions exist.
2.Place boiler with clearances to unprotected combustible materials, including plaster or combustible supports, not less than the following:
♣Heater Front: 36 in. (914 mm)
♣Heater Sides and Rear: 18 in. (457 mm)
♣Heater top: 24 in. (610 mm)
♣Allow for additional minimum clearances for personnel access and burner removal, as necessary.
♣Verify that all clearances are acceptable with the local ordinances.
Environment, Ventilation and Combustion Air
Requirements
It is critical to provide free access of air to the boiler. To burn fuel properly, it requires one square inch opening for every 3,000 BTU input of fuel (6.4 cm2 for every 756 kCal).
Adhere to the following to meet ventilation and combustion air requirements:
1.Install two fresh air openings, one at a low level, 24”(610 mm) from the
!oor, and one at a higher level on the equipment room wall. This will provide a !ow of air to exhaust the hot air from the equipment room.
2.Ensure the equipment room air supply openings are kept clear at all times.
2-4
© The Fulton Companies 2012
SECTION 2 |
VMPW-IOM-2012-1001 |
INSTALLATION
TABLE 2 ! SPECIFICATIONS "REFER TO FIGURE 1#
Model VMP-W |
|
40 |
50 |
|
60 |
80 |
100 |
130 |
150 |
|
|
|
|
|
|
|
|
|
|
Boiler Connec•ons |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Safety Valve Outlet |
|
|
|
|
|
|
|
|
|
IN |
|
1.5 |
1.5 |
|
1.5 |
2 |
2 |
2 |
2 |
MM |
|
38.1 |
38.1 |
|
38.1 |
50.8 |
50.8 |
50.8 |
50.8 |
|
|
|
|
|
|
|
|
|
|
Safety Valve Inlet |
|
|
|
|
|
|
|
|
|
IN |
|
1.25 |
1.25 |
|
1.25 |
1.5 |
1.5 |
1.5 |
1.5 |
MM |
|
31.8 |
31.8 |
|
31.8 |
38.1 |
38.1 |
38.1 |
38.1 |
|
|
|
|
|
|
|
|
|
|
Natural Gas Connec•on |
|
|
|
|
|
|
|
|
|
IN |
|
1.5 |
1.5 |
|
2 |
2 |
2 |
2.5 |
2.5 |
MM |
|
38 |
38 |
|
51 |
51 |
51 |
63 |
63 |
|
|
|
|
|
|
|
|
|
|
Water Supply & Return Connec•ons* |
|
|
|
|
|
|
|
|
|
IN |
|
4 |
4 |
|
4 |
4 |
4 |
4 |
4 |
MM |
|
102 |
102 |
|
102 |
102 |
102 |
102 |
102 |
|
|
|
|
|
|
|
|
|
|
Ra•ngs (sea level to 3000 •/914 m) Output |
|
|
|
|
|
|
|
|
|
1000 BTU/HR |
|
1356 |
1693 |
|
2033 |
2710 |
3387 |
4405 |
5081 |
1000 KCAL/HR |
|
342 |
427 |
|
512 |
683 |
853 |
1110 |
1280 |
|
|
|
|
|
|
|
|
|
|
Water Content |
|
|
|
|
|
|
|
|
|
GAL |
|
210 |
290 |
|
315 |
440 |
602 |
920 |
920 |
Liters |
|
795 |
1098 |
|
1192 |
1665 |
2278 |
3482 |
3482 |
|
|
|
|
|
|
|
|
|
|
|
Model VMP-W STANDARD MOTOR |
|
|
|
|
|
|||
|
|
|
|
|
|
|
|
|
|
Light Oil Connec•on |
|
|
|
|
|
|
|
|
|
IN |
|
.25 |
.25 |
|
.25 |
.25 |
.25 |
.375 |
.375 |
MM |
|
6 |
6 |
|
6 |
6 |
6 |
9.5 |
9.5 |
|
|
|
|
|
|
|
|
|
|
Burner Motor |
|
|
|
|
|
|
|
|
|
HP |
|
1.5 |
1.5 |
|
1.5 |
3 |
3 |
10 |
10 |
Wa!s |
|
1119 |
1119 |
|
1119 |
2237 |
2237 |
7460 |
7460 |
|
|
|
|
|
|
|
|
|
|
Approximate Weights |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Shipping Weight |
|
|
|
|
|
|
|
|
|
LB |
|
5775 |
6575 |
|
7370 |
8000 |
9500 |
12,350 |
12,500 |
KG |
|
2620 |
2980 |
|
3340 |
3636 |
4318 |
5601 |
5675 |
|
|
|
|
|
|
|
|
|
|
Opera•ng Weight |
|
|
|
|
|
|
|
|
|
LB |
|
7526 |
8994 |
|
9997 |
11670 |
14520 |
20023 |
20172 |
KG |
|
3414 |
4080 |
|
4535 |
5294 |
6587 |
9083 |
9150 |
|
|
|
|
|
|
|
|
|
|
Approximate Fuel Consump•on at Rated Capacity+ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Natural Gas |
|
|
|
|
|
|
|
|
|
FT3 |
|
1595 |
1992 |
|
2392 |
3188 |
3985 |
5182 |
5978 |
M3 |
|
45 |
56 |
|
68 |
90 |
113 |
147 |
169 |
LP Gas |
|
|
|
|
|
|
|
|
|
FT3 |
|
638 |
797 |
|
957 |
1275 |
1594 |
2080 |
2381 |
M3 |
|
18 |
23 |
|
27 |
36 |
45 |
59 |
68 |
Light Oil |
|
|
|
|
|
|
|
|
|
GPH |
|
11 |
14 |
|
17 |
23 |
28 |
37 |
42 |
LPH |
|
41.6 |
53 |
|
64.3 |
87 |
106 |
140 |
159 |
|
|
|
|
|
|
|
|
|
|
Min. Gas Pressure Required; In. W.C. |
|
7 |
7 |
|
7 |
9 |
9 |
40 |
40 |
|
|
|
|
|
|
|
|
|
|
Max Gas Pressure Required (Standard Gas Train) In. W.C. |
|
13 |
13 |
|
13 |
27 |
27 |
10 psig |
10 psig |
|
|
|
|
|
|
|
|
|
|
Electric Power Requirements/Amps for Burner Motor |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
208V 50/60 CY 3 Phase (Gas/Oil) |
|
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 |
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 |
4.8 |
4.8 |
14 |
14 |
|
|
|
|
|
|
|
|
|
|
CONTINUED ON NEXT PAGE
* 150 pound flanged.
2-5
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INSTALLATION
VMPW-IOM-2012-1001 |
SECTION 2 |
Model VMP-W Low Emissions (LE) MOTOR
Model VMP-WModel |
40 |
50 |
60 |
80 |
100 |
130 |
150 |
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Model VMP-W |
40 |
50 |
60 |
80 |
100 |
130 |
150 |
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Burner Motor ** |
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HP |
5 |
5 |
5 |
5 |
5 |
Consult |
Consult |
Wa!s |
3730 |
3730 |
3730 |
3730 |
3730 |
Factory |
Factory |
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Approximate Weights |
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Shipping Weight |
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LB |
6575 |
7373 |
8170 |
8800 |
10300 |
12800 |
12800 |
KG |
2982 |
3345 |
3706 |
3992 |
4672 |
5806 |
5806 |
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Opera"ng Weight |
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LB |
8659 |
9684 |
10671 |
12051 |
14700 |
20585 |
20585 |
KG |
3928 |
4393 |
4840 |
5466 |
6668 |
9337 |
9337 |
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Approximate Fuel Consump!on at Rated Capacity+ |
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Natural Gas |
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FT3 |
1595 |
1992 |
2392 |
3188 |
3985 |
5182 |
5978 |
M3 |
45 |
56 |
68 |
90 |
113 |
147 |
169 |
Required Gas Pressure (IN. W.C./PSIG) |
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Minimum/Maximum |
30/10 |
30/10 |
40/10 |
40/10 |
40/10 |
60/10 |
60/10 |
208V, 60 CY, 3 Phase |
16.7 |
16.7 |
16.7 |
16.7 |
24.2 |
Consult Factory |
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230V 60 CY 3 Phase |
15.2 |
15.2 |
15.2 |
15.2 |
22 |
Consult Factory |
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460V 60 CY 3 Phase |
7.6 |
7.6 |
7.6 |
7.6 |
11 |
Consult Factory |
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Specifica"ons and dimensions are approximate. We reserve the right to change data without prior no"fica"on. Design condi"ons based on 160 F return and 180 F supply.
+ Consump"on based on natural gas 1000 Btu/$3.
** Sub 20 ppm; for lower requirements, consult factory.
3.See Table 3 for minimum make up air openings required for each model.
TABLE 3! MINIMUM MAKE UP AIR OPENING REQUIREMENTS
Model |
Fresh Air Opening FT2 (M2) |
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40 |
1 (.09) |
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50 |
1 (.09) |
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60 |
1.5 (.14) |
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80 |
4 (.37) |
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100 |
4 (.37) |
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130 |
5 (.46) |
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150 |
7.5 (.69) |
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4.If positive forced ventilation is adopted, ensure that there will be no appreciable pressure variation in the equipment room.
5.Avoid ventilation which creates a negative pressure in the building as it will seriously a!ect combustion and proper operation of the burner. Please note that exhaust fans or similar equipment can create a down draft in the chimney or starve the burner’s air supply. Either case may result in poor combustion or nuisance
failures. A properly designed make-up air system in the equipment room will preclude these possibilities and is
required to maintain proper combustion.
6.Eliminate potential for high risk situations for particulate matter to be in the combustion air supply (e.g., as a result of construction and maintenance activities).
Utilities
ϒ The Gas Supply
Adhere to the following for gas supply installation:
1.Install gas piping in accordance with all applicable codes.
2.Ensure pipe and "ttings used are new and free of dirt or other deposits.
3.Ensure piping is of the proper size for adequate gas supply to the gas head assembly. Consult your gas company for speci"c recommendations.
4.When making gas piping joints, use a sealing compound resistant to the action of lique"ed petroleum gases. Do not use Te#on tape on gas line heads.
2-6
© The Fulton Companies 2012
SECTION 2 |
VMPW-IOM-2012-1001 |
INSTALLATION
5.Ensure no piping stresses are transmitted to the equipment. The equipment shall not be used as a pipe anchor.
6.Ensure all vent connections on diaphragms, gas valves, pressure regulators, and pressure switches (gas-•red units) are vented per local code.
7.On gas-•red units with NFPA 85 valve trains, ensure the vent valve is piped to atmosphere per local code.
8.During any pressure testing of the system at pressures in excess of 1/2 psig (14 inch W.C.), isolate the boiler with the manual shuto€ valve (located at the end of the supplied gas train) from the gas supply piping system.
9.Ensure the supply pressure is regulated by a non-stacking, tight, shut- o€ regulator.
10.Arrange gas piping so that it does not interfere with any cover or burner, inhibit service or maintenance, or prevent access between unit and walls or another unit.
11.After gas piping is completed and before wiring installation is started, carefully check all piping connections, (factory and •eld), for gas leaks. Use an appropriate leak test solution.
ϒThe Oil Supply
Adhere to the following for installation:
1.Fuel pipes must be of approved materials and of a diameter suitable for the quantity of oil being delivered to the burner. Vacuum must not exceed 10 in. (254 mm) of mercury at the pump inlet. Maximum inlet pressure to oil pump is 3 PSIG.
2.Make fuel connection in accordance with the details on the enclosed fuel pump cut sheet.
3.Ensure fuel oil piping is in accordance with local/national requirements.
4.Meet the maximum pressure allowed at the fuel oil pump inlet per the National Fire Protection Association (NFPA).
5.Oil pumps are of a two-line design system, requiring a return line and a supply line. The oil pump is factory set per Test Fire Sheet. Do not alter the setting without consulting the factory.
6.A stop valve, a check valve, and an oil •lter must be installed on the oil supply line.
7.Ensure there are no loose •ttings. Loose •ttings in the fuel oil line will permit air to enter the fuel line and cause improper •ring.
! WARNING
A quali•ed installer, service agency or the gas supplier must perform installation and service on the fuel delivery system.
Do not use matches, candles, €ame or other sources of ignition to check for gas leaks.
What to do if you smell gas:
Do not try to light the appliance. Do not touch any electrical switch.
Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the •re department.
When making gas piping joints, maintain proper ventilation to reduce breathing hazards.
An exhaust fan may draw products of combustion into the work environment creating a possible hazard to personnel.
4 CAUTION
It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the combustion air inlet must be piped to an outside location. Failure to do so will void the warranty.
To avoid failures due to poor combustion, ensure make-up air system is properly designed.
2-7
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INSTALLATION
VMPW-IOM-2012-1001 |
SECTION 2 |
! WARNING
All information in this manual is for reference and guidance purposes, and does not substitute for required
professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.
4 CAUTION
Loose !ttings in the fuel oil line will permit air to enter the fuel line and cause improper !ring.
Electrical Supply
Adhere to the following for electrical supply installation:
1.Locate electrical schematic diagram, a copy of which is inside of the panel box.
2.Ensure the information on the electrical drawing corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no overor under-voltage exceeding 10% of the nominal value.
3.Install a separate fuse switch for the contactor and a separate fuse switch for the circulating pump. If pump motor is 3/4 HP or larger, install an across-the-line starting switch ahead of the circulating pump motor.
4.Install wiring and ground in equipment in accordance with authority having jurisdiction or in absence of such requirements the National Electrical Code, ANSI/NFPA.
5.Provide a fused disconnect sized for the unit. Size fuses according to motor name plates and local electrical codes.
6.Connect power to the terminal strip as supplied on the inside of the panel box.
Water Supply
ϒ Install Water Piping
All water supplies contain some solids, dissolved gases or dissolved minerals. These may cause corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly.
Adhere to the following for water piping installation:
1.Isolation valves and unions are recommended on both water connections for ease of service.
2.Install piping so that the boiler is not supporting any additional piping.
3.Install manual purging valves in all loops and zones. Install a pressurereducing (automatic !ll) valve in the cold water !ll line to the boiler system. Check that the proposed operation of zone valves, zone circulator(s) and diverting valves will not isolate air separator(s) and/ or expansion tank(s) from the boiler. Clearance from hot water pipes to combustibles must be at least 6 inches (152 mm).
4.Pipe the water supply line to the lower opening on the back of the boiler. Water stop valve should be in line between the boiler and the !rst piece of equipment. Hot water outlet should be piped to process/equipment requiring hot water. Water makeup supply should be installed. Hot water inlet should be piped to the make-up water supply.
2-8
© The Fulton Companies 2012
SECTION 2 |
VMPW-IOM-2012-1001 |
INSTALLATION
5.Pipe the water safety valve carry piping from the outlet of the valve to a safe blow-o• point.
×NOTE: Do not alter water temperature/pressure gauge assembly in any way.
6.Drain valve is connected to the lowest opening at bottom rear of boiler. Carry piping from the outlet of the valve to safe drain point. Provision should be made for easy access to drain valve of boiler.
×NOTE: The water connection on the top of the boiler is the outlet connection. The water connection on the rear of the boiler is the inlet connection.
7.Install !ltration to remove particulates if appropriate.
8.Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate.
9.Install corrosion coupon holder to assess corrosion inhibitor performance if appropriate.
×NOTE: The boiler is provided with a drain valve connection and a drain valve.
10.Heating system:
»An automatic pressure activated water make up valve with back
!ow preventer. It must be set to maintain required Net Positive Suction Head (NPSH) for re-circulating pumps, a positive system pressure at the highest point of at least 5-10 PSIG, and make up water valve should be designed to add water to the system at the outlet of the boiler and should not be fed directly into the boiler.
»Air removal equipment, including an air separator and automatic breather valves, along with a functioning expansion tank . Each must be designed to system speci!cations.
11.When used in conjunction with a refrigeration system, install the boiler so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. If the boilers are connected to heating coils (located in air handling units where they may be exposed to refrigerated air circulation) such boiler piping systems must be equipped with "ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
Water Chemistry Requirements
System water chemistry requirements are as follows:
♣pH: Range of 8.5 - 10.5
♣Oxygen: Less than 250 ppb (operating condition)
♣Total Iron/Copper: Less than 5 ppm
! WARNING
All information in this manual is for reference and guidance purposes, and does not substitute for required
professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.
2-9
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
INSTALLATION
VMPW-IOM-2012-1001 |
SECTION 2 |
! WARNING
All information in this manual is for reference and guidance purposes, and does not substitute for required
professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.
4 CAUTION
A large amount of improperly treated makeup water can cause premature failure of the heat exchanger resulting from scale build up. Scale build up will reduce the e!ciency and useful life of the boiler and is not covered under warranty.
♣Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2 mpy. Due to changing environmental restrictions a non-heavy metal ALL ORGANIC inhibitor is recommended which is designed for multi metal systems including ferrous metals and yellow metals such as copper and brass.
♣Chloride: Less than 250 ppm
Adhere to the following:
1.Refer to your water conditioning or chemical treatment supplier for analysis and recommendations for proper system conditions.
2.Follow a program with appropriate monitoring and maintenance of system water conditions as provided by your water conditioning or chemical treatment supplier.
3.Operate the boiler in a closed-loop system using water or water/glycol (not requiring a make-up water supply). A large amount of improperly treated make-up water can cause premature failure of the heat exchanger resulting from scale build up. Scale build up will reduce the e!ciency and useful life of the boiler and is not covered under warranty.
ϒPrevent Oxygen Contamination
There are several ways to prevent boiler water oxygen contamination:
♣Minimize system leaks to minimize make up water requirement
♣Do not use open tanks or "ttings
♣Do not use oxygen permeable materials anywhere in the water system
♣Repair leaks in the system quickly
♣Eliminate "ttings wherever possible
♣Use air elimination devices in system piping
ϒEliminate System Air
× NOTE: There are no built-in boiler air eliminating features.
Adhere to the following for air elimination:
1.The installation of an air separator and air eliminator (air vent) is required.
2.To prevent scale corrosion in boiler and associated piping, make up water must be kept to a minimum. This is best achieved by ensuring immediate repair of all leaks and that system pressure is maintained.
3.If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator.
4.If an air cushion type expansion tank is used, pipe tank directly into
2-10
© The Fulton Companies 2012
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