FULTON VMP-W 40 -150 HP, VMP-W Installation And Operation Manual

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

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

Standard Warranty for Fulton Boilers................................................................... 5-3

Parts ..................................................................................................................... 5-4

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

Cycle Testing ......................................................................................................... 3-6

Before Leaving the Installation ............................................................................ 3-6

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

0-1

TABLE OF CONTENTS VMPW-IOM-2012-1001

0-2

INTRODUCTION

INSTALLATION

1

2

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

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

1-1

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

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.

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

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).

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.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

1

2

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

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

2-1

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.

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.

4 CAUTION

Do not allow weight to bear on equipment components to prevent damage.

2-2

§ 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.

SECTION 2 VMPW-IOM-2012-1001 INSTALLATION

F

E

C

G

K

D

B

J

A

H

H.H.

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

MM

(B) Boiler Height

IN

MM

(C) Boiler Depth

IN

MM

(D) Boiler Height With Trim

IN

MM

(E) Overall Boiler Width

IN

MM

(F) Flue Outlet Diameter

IN

MM

(G) To Center of Flue Outlet

IN

MM

(H) Return Water Inlet Height

IN

MM

(J) Water Outlet

IN

MM

(K) Min. Clearance to Ceiling for Burner Removal

IN

MM

49

1245

84

2133

90

2286

107

2718

56

1422

12

305

79

2006

20.3

516

73.8

1870

123

3124

55

1397

91

2312

100

2540

113

2870

62

1575

12

305

83

2108

20.3

516

77.8

1980

135

3429

55

1397

97

2464

100

2540

119

3023

62

1575

12

305

89

2261

20.3

516

83.8

2130

144

3658

63

1600

100

2540

114

2896

125

3175

68

1727

14

356

95

2413

20.3

516

89.8

2280

147

3734

69

1753

100

2540

119

3022

125

3175

74

1880

14

356

95

2413

20.3

516

89.8

2280

147

3734

76.5

1943

115

2921

128

3251

149

3785

84.5

2146

14

356

107

2718

23.6

599

101.1

2570

155

3937

76.5

1943

115

2921

130

3302

149

3785

84.5

2146

14

356

107

2718

23.6

599

101.1

2570

155

3937

All data is approximate. Fulton reserves the right to change data without prior notice.

FIGURE 1 MODEL VMPW DIMENSIONS/SPECIFICATIONS REFER TO TABLES 1 AND 2

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

2-3

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.

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

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.

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

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 MM

Safety Valve Inlet IN MM

Natural Gas Connec on IN MM

Water Supply & Return Connec ons* IN MM

Ra ngs (sea level to 3000  /914 m) Output 1000 BTU/HR 1000 KCAL/HR

Water Content GAL Liters

Light Oil Connec on

IN MM

Burner Motor

HP Wa! s

Approximate Weights

Shipping Weight LB KG

Opera ng Weight LB KG

Approximate Fuel Consump on at Rated Capacity+

Natural Gas

3

FT

3

M

LP Gas

3

FT

3

M

Light Oil GPH LPH

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

1.5

38.1

1.25

31.8

1.5 38

4 102

1356 342

210 795

Model VMP-W STANDARD MOTOR

.25 6

1.5 1119

5775 2620

7526 3414

1595 45

638 18

11

41.6

1.5

38.1

1.25

31.8

1.5 38

4 102

1693 427

290 1098

.25 6

1.5 1119

6575 2980

8994 4080

1992 56

797 23

14 53

1.5

38.1

1.25

31.8

2 51

4 102

2033 512

315 1192

.25 6

1.5 1119

7370 3340

9997 4535

2392 68

957 27

17

64.3

2

50.8

1.5

38.1

2 51

4 102

2710 683

440 1665

.25 6

3 2237

8000 3636

11670 5294

3188 90

1275 36

23 87

2

50.8

1.5

38.1

2 51

4 102

3387 853

602 2278

.25 6

3 2237

9500 4318

14520 6587

3985 113

1594 45

28 106

2

50.8

1.5

38.1

2.5 63

4 102

4405 1110

920 3482

.375

9.5

10 7460

12,350 5601

20023 9083

5182 147

2080 59

37 140

2

50.8

1.5

38.1

2.5 63

4 102

5081 1280

920 3482

.375

9.5

10 7460

12,500 5675

20172 9150

5978 169

2381 68

42 159

* 150 pound ﬂ anged.

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

CONTINUED ON NEXT PAGE

2-5

INSTALLATION VMPW-IOM-2012-1001 SECTION 2

Model VMP-W Low Emissions (LE) MOTOR

Model VMP-WModel 40 50 60 80 100 130 150

Model VMP-W 40 50 60 80 100 130 150

Burner Motor **

HP Wa! s

Approximate Weights

Shipping Weight LB KG

Opera" ng Weight

LB KG

Approximate Fuel Consump! on at Rated Capacity+

Natural Gas

3

FT

3

M

Required Gas Pressure (IN. W.C./PSIG)

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

230V 60 CY 3 Phase 15.2 15.2 15.2 15.2 22 Consult Factory

460V 60 CY 3 Phase 7.6 7.6 7.6 7.6 11 Consult Factory

Speciﬁ ca" ons and dimensions are approximate. We reserve the right to change data without prior no" ﬁ ca" 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.

5 3730

6575 2982

8659 3928

1595 45

5 3730

7373 3345

9684 4393

1992 56

5 3730

8170 3706

10671 4840

2392 68

5 3730

8800 3992

12051 5466

3188 90

5 3730

10300 4672

14700 6668

3985 113

Consult Factory

12800 5806

20585 9337

5182 147

Consult Factory

12800 5806

20585 9337

5978 169

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)

40 1 (.09)

50 1 (.09)

60 1.5 (.14)

80 4 (.37)

100 4 (.37)

130 5 (.46)

150 7.5 (.69)

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

¡ 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

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, shuto 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.

¡ The Oil Supply

! 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.

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.

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.

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

2-7

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 over- or 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

¡ 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 pressure-

reducing (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

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:

! 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.

» 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

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

2-9

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.

¡ Prevent 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

¡ Eliminate 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.

2-10

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

SECTION 2 VMPW-IOM-2012-1001 INSTALLATION

boiler supply.

5. On multi-zoned systems (or a system with both space and domestic water heating), air elimination must be provided either in the common piping or on every loop.

6. When the boiler is installed at a higher level than baseboard radiation (if used), air elimination must be provided directly above the unit.

Piping Speciﬁ cations

For piping, the basic considerations are: the design temperature, the pressure

retained by the pipe, the  uid in the pipe, the load resulting from thermal expansion or contraction, impact or shock loads imparted such as water hammer, external loads, wind loads and vibration from equipment.

Adhere to the following for piping installation:

1. Ensure the arrangement of the piping and its appurtenances takes into consideration the location of other structures and equipment adjacent to the piping, which may result in freezing interference and/or damage as a result of expansion, contraction, vibration, or other movements.

2. Consider the appropriate location and orientation of valves necessary for safe operation and isolation of the piping. Valves are used in piping systems to stop and start the  ow of  uids, to regulate  ow, to prevent the back  ow, and to relieve excessive pressure build up in the piping.

! 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.

The vent line connection on the gas pressure regulator must be piped to outdoor air by the installer in accordance with National Fuel Gas Code, ANSI Z2231-1991 or latest addenda. In Canada, gas installations must be in accordance with the current CAN/CGA B149.1 and 2 and/or local codes.

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Use an appropriate leak test solution. Clean all piping thoroughly after completing the leak check.

3. Ensure all piping and piping components are suitable for the design temperatures, pressure and  uid used in the system.

4. Ensure all pipework is constructed from seamless mild steel pipe, Schedule 40 or Schedule 80 as required by code and/or application; or copper if system parameters allow.

5. During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system.

6. Provide expansion joints or properly designed and sited loops to accommodate thermal expansion. Thermal expansion should be calculated using the maximum possible utilization  uid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will expand approximately 1 “ per 100’ over a 100° F temperature rise (1 mm per meter over 100 C rise).

7. Provide supports and anchors for all pipes where necessary to prevent undue stresses from being placed on items of equipment, including pumps, valves, and the boiler. Supports and anchors which will not interfere with thermal expansion should be chosen.

8. Cut screw threads carefully and accurately. If possible, new tools should be used. It is recommended that GR5 or higher tensile steel bolts be used for all  anged joints.

9. Use gaskets to make all  anged connections. Gasketing material must be

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

2-11

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.

Hot pipework and vessels must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury.

suitable for use with the pressure, temperatures and  uids in the system. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer.

10. Install high point bleeds at all high points in the system piping. 1/2” x 12” nipples welded in the top of the piping with ball valves and plugs attached are to be used.

11. Install all pipes with a pitch to facilitate draining and venting.

Insulation

After the appropriate system tests have been satisfactorily completed (see Testing section of this manual), all hot pipework and vessels must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury. For inspection and maintenance purposes,

leave pumps,  anges, valves and  ttings uninsulated but suitably shielded for safety. Removable insulation may also be used over these components.

System Interfaces

Proper selection and installation of the components in the system will ensure proper and safe operation of the boiler. Consult Fulton representative or contact Fulton at (315) 298-5121.

¡ Fill Connection

The system is usually  lled from the lowest point, with the aid of a pump. On skidmounted units, a  ll connection is provided in the inlet piping to the pump.

Pressure Gauges

The range in which readings are expected to fall should comprise mid-scale on the pressure gauge chosen. Pressure gauges must be able to withstand overpressure equal to the rating of the safety relief valves, normally 100 psig.

NOTE: ´ The Water temperature pressure gauge should not be altered in any way.

Assembly of Multi-Skid Systems

Adhere to the following for multi-skid engineered systems:

1. Refer to the Fulton mechanical/electrical drawings during assembly.

2. Ensure that equipment orientation allows for operation interface and maintenance.

3. Align the skids as shown on the drawings ensuring that skid fasteners (skid joint angles) are matched. The skid joint angles are a matched set and the edges of the fasteners should be exactly aligned.

2-12

SECTION 2 VMPW-IOM-2012-1001 INSTALLATION

NOTE: ´ Do not bolt the skids to the housekeeping pad/ oor until all of the piping

has been reassembled and tightened.

4. Ensure the skids are level and  at before fastening the skids together with the supplied bolts. The skids should be leveled front to back, side to side and corner to corner. Failure to properly level the skids will result in piping misalignment. A level or laser level should be used to verify skid alignment (when a standard level is used, the length should be appropriate for the skid). If assembling multi-component support stands, attach sections using the supplied bolts through the tank frame mounting plates. These should be hand tight until all of the piping is assembled. Note: skids are leveled at the factory using a laser level.

5. Connect the piping between the skids by matching the union connections and/or  ange stamps and tightening. Refer to the mechanical drawing

as necessary to con rm location of spool pieces etc. as the  ange stamps are shown on the drawing in hexagonal callouts. The  ange stamps should matched and aligned (the  ange stamps should be directly across from one another. Rotating a  ange will result in piping misalignment). Bolts should be hand tight until all of the piping is assembled. Refer to the appropriate instructions to tighten the  anges to the required torque speci cations. Support pipe runs as required.

! 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.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment.

Cements for plastic pipe should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors.

6. Ensure that a low point drain is installed in the piping.

7. Connect the conduit runs between the skids and tighten conduit connectors.

8. Locate the supplied wiring for the equipment and pull wiring through the appropriate conduit runs. Electrical wires are labeled for easy landing. Connect all wiring per the Fulton supplied electrical drawings.

9. If a header is supplied, mount the header as shown in the mechanical drawing.

NOTE: ´ For piping supplied in sections, make up and connect hand tight until all

sections are in place to ensure sections align properly. Sections are match marked for reassembly.

10. Tighten all connections.

11. Pneumatically test the piping (at 15 psig maximum) prior to  lling the systems.

12. Check bolts and connections for tightness after the  rst heat up cycle. Retorquing may be required.

No shuto of any kind may be placed between the safety relief valve and the equipment, or in the discharge pipe between such valve and the atmosphere. Doing so may cause accidental explosion from overpressure.

Discharge from safety relief valve must be con gured so that there is no danger of scalding personnel or causing equipment damage. Provisions must be made to properly drain safety relief valve discharge piping.

For reasons of safety, the hot exhaust gas duct and chimney must be insulated or shielded within the locality of the heater in compliance with local codes and regulations.

Stack and Flue

An appropriately sized stack should be connected to the  ue gas outlet at the boiler. The proper  ue size and draft control is most important for proper burner operation. See Table 4.

Stack and chimney must be constructed from material that is rated for 1000 F

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

4 CAUTION

The stack arrangement and draft conditions should be in accordance with the information in this manual for proper performance of the equipment.

2-13

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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

4 CAUTION

Boilers damaged due to adverse water conditions are not covered by warranty.

The weight of all piping must be properly supported. Failure to support piping may result in equipment damage and/or system leakage.

Piping must take into consideration potential for freezing interference and/ or damage as a result of expansion, contraction, vibration, or other movements.

Dirt, water, and/or other debris in the piping system after welding may result in equipment failure.

To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the section of the chimney duct within the building should be insulated.

operating temperature. Check all local codes for requirements.

The  ue must be as large or larger than the outlet on the vessel. Avoid  ue piping and elbows by placing the equipment as close as possible to the chimney.

TABLE 4  MINIMUM FLUE SIZES

Model Minimum Flue Size

inches (mm)

40 12 (305)

50 12 (305)

60 12 (305)

80 14 (356)

100 14 (356)

130 14 (356)

150 16 (406)

Adhere to the following for stack and  ue installation (see Figure 2):

1. Ensure the stack rises continuously to the connection at the chimney and contains no more than two bends at 45 degree angles or less. If required,

as a result of space limitations, one 90 degree elbow (or tee) can be  tted at the back of the vessel.

2. Ensure 2 feet (0.6 m) of straight, horizontal  ue before any change in direction,  tting or draft regulator. This is to prevent potential pilot or main  ame failures due to back pressure build up during ignition. Any alternative stack arrangement must supply negative 0.02 to 0.04”wc.

3. Ensure 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, does not exceed 25% of the rise. With the exception of the duct run previously described, horizontal sections of ducting must be avoided and should not exceed 4 feet (1.2 m) total. See Figure 2.

4. Ensure the stack, chimney, and any components associated with the stack, such as heat reclaimers or assist fans, are constructed from material that is rated for a 1000 F (538 C) operating temperature.

5. Ensure the stack and chimney material complies with all applicable codes.

6. Make adequate provisions for the support of the weight of the chimney and stack to avoid having a load imparted to the outlet connection of the equipment.

2-14

7. Ensure the draft, when  ring, is negative and constant. A reading of -0.02 to -0.04”wc (-0.508 to -1.016 mm) when the unit and stack are cold usually

indicates su cient draft. When the unit is running and the stack is hot, the draft should read -0.04 to -0.08 “wc (-1.016 to -1.524 mm) negative.

8. The installation of a draft regulator by the client/contractor is recommended at all installations. This will help to maintain the required draft. The placement of the draft regulator should be as shown in Figure 3. Insulate the section of the chimney duct within the building.

SECTION 2 VMPW-IOM-2012-1001 INSTALLATION

Roof

Minimum

6' Above

Any Structure

Within 30'

Support As

Necessary

Install Appropriate Weather Cap

Horizontal Run 2'

Draft Regulator (If Necessary)

Expansion Joints As Required

Horizontal Run 2'

60¡

(45¡ Min.)

Cleanout

Door

Cleanout

Door

Cleanout

Door

This Distance Must Not Exceed 70% Of Total Rise

Baffle

3'

30¡

Max

Stagger

Entrances

A A

A-A

Total

Rise

9. Concentration levels of only a few ppm of chlorine containing compounds in combustion air can produce serious corrosion of the  ue over long periods of time. High chlorine containing compounds such as carbon tetrachloride or perchloroethylene would be prime suspects.

¡ Exhaust Side Wall Venting

Boilers for which sidewall venting (Figure 4) may be utilized are propane, natural gas, or combination propane and natural

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

FIGURE 2  TYPICAL STACK ARRANGEMENT

gas sizes 10 to 30 HP.

Adhere to the following for installations requiring sidewall venting:

1. Flue vent piping must be pitched upward at ¼ in (6.35

mm) per one foot (3.048 m) of length.

2. An UL-approved draft fan must be installed to provide su cient draft (-0.02 to -0.04” wc) to safely vent products of combustion.

2-15

INSTALLATION VMPW-IOM-2012-1001 SECTION 2

Air Flow Safety Switch

U.L. Approved Induced Draft Fan

Side Wall

Vent

Termination

(By Others)

Side Wall Vent (By Others)

FIGURE 3  TYPICAL SIDEWALL VENTING

3. The draft fan should be located as close to the  ue outlet as possible.

4. Draft regulation su cient to lower the draft to between

-0.02 to -0.04 “ wc may be required. The draft regulator must be between the boiler and the fan.

5. The draft fan shall have an air  ow proving switch wired in series with the boiler air safety switch.

6. The sidewall vent total length from boiler exhaust to termination shall not exceed 35 feet (10.6 m) with 4 elbows maximum.

Testing

Upon completion of the installation, perform the following testing:

1. A pneumatic test of water piping not exceeding 15 psig.

2. Leak tests at all welds and joints to ensure that the system is free from leaks.

2-16

OPERATION

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE WARRANTY & PARTS

3

4 5

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

3-1

OPERATION VMPW-IOM-2012-1001 SECTION 3

! 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.

Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are quali ed to operate/maintain the equipment.

Defective or improperly installed equipment is hazardous. Do not operate equipment which is defective or improperly installed.

Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts. Make sure all repairs or maintenance procedures are completed before using the equipment. Do not attempt repairs or any other maintenance work you do not understand.

4 CAUTION

Installation in accordance with the guidelines within the manual should be fully completed before performing the initial start-up; and start-up must be complete prior to putting the unit into service. Starting a unit without the proper piping, venting or electrical systems can be dangerous and may void the product warranty.

Start-Up Preparation & Installation Review

Review the installation section of this manual carefully. Con rm accordance with the Installation guidelines, including:

1. You have read and followed all safety information.

2. The equipment area is in conformance with established boiler room requirements. Review national and local codes.

3. There are no obstructions left in the  uid circuit from pressure leak testing

such as blanking plates in  anged joints.

4. Boiler is located with the proper clearances as shown in Installation section of this manual.

5. Relief valves have been properly piped to  oor drains.

6. Flue gas from the boiler is properly vented.

7. Combustion air openings are not obstructed in any way and have adequate capacity.

8. There are no  ammable liquids, materials or hazardous fumes present in the environment.

9. Nothing was damaged or knocked loose during shipment and installation. Inspect the main gas train and trim assembly to be sure they were not damaged during shipment or installation.

10. Local authorities where approval for start-up is required have been

noti ed. In some localities,  nal inspection of services may be required.

11. Installation checklist is complete.

} FILL AND AIR REMOVAL PROCEDURE

1. Close combination shuto /purge valve in supply, all drain cocks, the

shuto valve for the pressure reducing ( ll) valve, and all manual air vents.

2. Open all other system shuto valves and one of the zone valves, the vent on the combination shuto / purge valve and the shuto valve to the pressure-reducing ( ll) valve.

“Factory Trained Personnel” refers to someone who has attended a Fulton Service

School speci cally for the equipment covered in this manual.

3-2

3. Water will now begin to  ll the system. Air will escape through the vent on the combination shuto / purge valve. Continue  lling until a constant stream of water (no bubbling) is discharged from the vent.

4. Close the zone valve on the purged loop, and open the zone valve on the next loop to be purged. When all air has escaped and only water is discharged, close the zone valve. When all zones have been purged (one at a time), close the vent on the combination shuto /purge valve.

5. At this point, the system has been initially  lled. However, air pockets may still remain at high points in the system and in heating loops above the level of the combination shut/o purge valve. It is quite possible,

SECTION 3 VMPW-IOM-2012-1001 OPERATION

depending on the particular system that all piping above the combination

shuto /purge valve still contains air. If manual vents are installed on the system high points, these should be opened to vent these locations. When only water is discharged from all vents, the initial purging is complete.

6. Open the combination shuto / purge valve (keep the vent closed). With the gas shuto valve closed, turn on power to the boiler and operate the circulator. Circulate the system water for approximately 30 minutes to move all air to the automatic air separation point.

7. Again, open manual air vents at high points of heating loop until a constant stream of water is discharged from the vent. Close the vent and make sure it’s watertight. Repeat procedure for all high points and for every zone.

8. Check temperature/pressure indicator reading, which should equal the pressure-reducing ( ll) valve set pressure. No more water should be entering the system. Close the shuto valve on the cold-water  ll line.

9. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system, repair leaks and re ll/purge the system. If no pressure drop is detected for a period of two hours under pressure, the system may be considered watertight.

! 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

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately

call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

10. When purging is completed, make sure the following are open— combination shut-o /purge valve, shuto valve to pressure reducing ( ll valve), shuto valve in cold water  ll line, and shuto valve in return line.

11. Make sure the following are closed - all drain cocks, the vent on the combination shuto -purge valve, & all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler.

12. Open fuel shuto valve, allowing fuel to  ow to the boiler.

Start-Up Service

If start-up service has been included in the order, the factory should be contacted after the installation has been successfully completed and approved by the client’s representative or engineers. Where possible, contact the factory at least three weeks before a Fulton service engineer is required on site.

Consider the following in preparation for your on-site visit:

1. All procedures covered in manual sections Start-Up Preparation and Fill the System, including installation review, air testing of piping, pump alignment (where applicable), and  lling the system must be completed before the service person’s arrival.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

2. Depending on the size of the system and the amount of service time contracted, start-up service includes  ring the boiler, checking, verifying and adjusting all safety settings.

3. Careful preparation can expedite the commissioning of your boiler. Most delays can be avoided by following the instructions in this manual. Failure to complete required procedures properly can result in the need for further

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

3-3

OPERATION VMPW-IOM-2012-1001 SECTION 3

! 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.

service time, at extra cost to the customer.

4. Service people will not commence start-up if there are obvious system

de ciencies. However, start-up service in no way constitutes a system design check or approval of the installation.

5. In addition to commissioning the boiler, the service person will also familiarize heater room personnel with the operation of all Fulton equipment. Personnel must be quali ed to understand the basic operation and function of controls.

Initial Start-Up

Adhere to the following:

1. Turn on the main power fuse switch.

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

NOTE: ´ The Low Water Control will also be activated when the boiler is powered

on. With the unit full of water, the Low Water Relay requires manual reset.

3. If for any reason the water leaves the unit the Low Water Control will

automatically turn the burner o , and if audible alarm is installed, alarm will activate.

When opening any drains on the equipment or piping system, steps should be taken to avoid scalding/ burning of personnel due to hot  uids. Whenever possible, the system should be cooled prior to opening any drains.

Use only your hand to turn valve handles. Never use tools. If the handle will not turn by hand, don’t try to repair. Forced or attempted repair may result in  re or explosion.

WHAT TO DO IF YOU SMELL GAS : Do not use matches, candles,  ame or other sources of ignition to check for gas leaks. Do not try to light the 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  re department.

¡ Combustion

It is critical for all personnel to be familiar with start up, controls, and shutdown procedures.

} STARTING THE BURNER  GAS

1. Verify incoming gas pressure.

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

3. Switch on the main power to the burner. If the water level relay is equipped with a manual reset. If the boiler was in a low water condition, the manual reset button must be pressed.

4. Check motor rotation.

5. Start the burner by turning on the switch on the outside of the panel box. The blower motor will begin to deliver air into the furnace.

6. When su cient air pressure has built up in the blower housing, the air

switch located on the top side of the blower housing will make contact and after a seven-second delay, will allow the ignition transformer and pilot valve to operate. This creates pilot  re.

7. When the pilot  ame is established, the  ame rod or UV scanner senses the electrical current (microamps). The signal is transmitted to the protectorelay, which opens the main gas valve for full  re.

3-4

SECTION 3 VMPW-IOM-2012-1001 OPERATION

NOTE: ´ For new installations/burner has been disassembled, the burner may not

 re upon  rst attempt because air must be cleared from gas lines. The burner protectorelay may go into lockout mode; allow a period of one minute to elapse, then repeat procedure for starting the burner.

} STARTING THE BURNER  OIL

1. Open the oil line’s shut-o valves.

2. Verify oil is present at the oil pump.

3. Switch on main power to burner. If the boiler was in a low water condition, the manual reset button must be pressed.

4. Start the burner by turning on the switch on the outside of the panel box. The blower motor will begin to deliver air into the furnace.

5. As the blower starts, the magnetic oil valve is energized, allowing the oil pump to deliver fuel for ignition.

6. If the protectorelay does not sense  ame via the CAD cell or UV scanner

located on the top of the burner in approximately 15 seconds, it will shut down the burner.

! 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.

Do not attempt to start the equipment for any testing prior to  lling and purging the vessel. A dry  re will seriously damage the equipment and may result in property damage or personnel injury and is not covered by warranty. In

case of a dry  ring event, shut o the fuel supply and allow the vessel to cool to room temperature before  uid is reintroduced to the pressure vessel.

Flame Programmers

Refer to inserts provided.

Operating Controls

¡ Water Relief Valve

The Water Relief Valve releases extra pressure.

¡ Water Outlet Valve

The Water Outlet Valve serves as the isolation valve for the system.

¡ Temperature Control

The Temperature Control is a digital indicating control used to turn the boiler on

and o , and to control the  ring rate when the boiler is modulated. The digital display will show both the boiler process temperature and the boiler setpoint.

¡ Operating Temperature Aquastat

4 CAUTION

A quali ed installer, service agency or the gas supplier must perform installation and service on the fuel delivery system.

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

Never attempt to operate equipment that has failed to pass all the safety checks.

After checking controls by manual adjustment, make sure they are always reset to their proper settings. Contact your Fulton dealer before modifying the equipment.

The Operating Temperature Aquastat controls the working temperature of the boiler. This is an ASME CSD-1 code control which will turn the boiler o when the water temperature exceeds its setpoint. It is an auto-reset control.

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

3-5

OPERATION VMPW-IOM-2012-1001 SECTION 3

! WARNING

This boiler is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand.

Operating this equipment beyond its design limits can damage the equipment and can be dangerous. Do not operate the equipment outside of its limits. Do not try to upgrade the equipment performance through unapproved modi cations. Unapproved modi cations may cause injury, equipment damage, and will void the warranty.

Check daily that the equipment area is free and clear of any combustible materials, including  ammable vapors and liquids.

Do not tamper with safety features provided by the operating controls.

Should overheating occur or the gas supply fails to shut o , manually shut o the gas supply external to the equipment .

¡ High Limit Aquastat/High Temperature Limit

The High Limit Aquastat/High Temperature Limit prevents over-temperature conditions. This is an ASME CSD-1 code control which includes a manual reset feature for over-temperature. Press the manual reset button when the temperature drops to reset the control.

¡ Air Safety Switch

This switch is controlled by the pressure of air entering the burner. This switch proves that the blower fan is delivering combustion air.

¡ Probe Type Low Water Cut-Oﬀ

The Low Water Cut-O shuts down the unit when the water level is too low, after a three-second time delay to prevent nuisance shut downs. Fulton boilers are equipped with ASME CSD-1 Code controls which include a manual reset feature on the burner low water cut o relay. Press the low water reset button to reset the control, and the boiler will start.

Optional Circulating Pump Switch

The fused switch that controls the circulating pump should be kept in the ON position at all times during boiler operation and non-operating mode of the boiler. It should be placed in the OFF position when repairs or adjustments must be made.

4 CAUTION

Operation of the circulating pump for any

amount of time without  rst bleeding will result in equipment damage.

For all systems containing boilers or un red steam generators, the water chemistry in the boiler (generator) must be kept within required limits. Failure to do so may cause premature pressure vessel failure and poor steam quality and will void the warranty.

If any “Manual Reset” limit device trips DO NOT reset without determining and correcting the cause. (Manual Reset Limits may include:  ame safeguard, high or low gas pressure, high temperature limit, low water).

Never tamper with low water (liquid level) cuto sensors or circuitry.

Cycle Testing

The boiler should be cycled tested and automatically allowed to go through its normal starting sequence several times to verify that all components are functioning properly. This will also verify that combustion is set properly so that

boiler light o has a smooth transition from ignition to main  ame.

A minimum of 10 cycles should be met without any  ame failures, with combustion readings comparable to the factory test  re sheet and no interlocks causing the boiler to shutdown.

Before Leaving the Installation

1. Check all controls to insure they are operating properly. Cycle the boiler several times by raising and lowering operating temperature on the thermostat.

2. Make sure the installation complies with all applicable codes.

3. Turn switch to OFF position.

3-6

SECTION 3 VMPW-IOM-2012-1001 OPERATION

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

3-7

OPERATION VMPW-IOM-2012-1001 SECTION 3

3-8

MAINTENANCE

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE

WARRANTY & PARTS

3

4

5

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

4-1

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

! 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.

Follow all proper lockout/tagout procedures for service.

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.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

Daily Maintenance Schedule

Daily maintenance and inspection must include the following:

1. Observe operating temperature and general conditions.

2. Make sure that the  ow of combustion and ventilating air to the boiler is not obstructed.

3. Ensure boiler area is free and clear of any combustible materials, including  ammable vapors and liquids.

Weekly Maintenance Schedule

Weekly maintenance and inspection must include the following:

1. Check inlet gas pressure at the beginning of the gas train.

2. Observe the conditions of the main  ame. A normal high  re  ame shows an orange screen with a blue halo. In Low  re, the burner should display a reddish-orange glow.

3. Correct air adjustment is essential for the e cient operation of this boiler. If an adjustment to the combustion is necessary, the  ue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions. Refer to Procedure for Primary Air Adjustment/

Inspection and Procedure for Secondary Air Adjustment/Inspection

sections of this manual.

Monthly Maintenance Schedule

The following steps should be carried out monthly:

1. Make sure main power switch is o before starting work. I

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.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

4-2

2. Test low gas pressure switch and high gas pressure switch, if applicable.

3. Clean water pump strainers (not standard).

4. Check scanner and ignition electrodes.

5. Check starter contacts. Burned or pitted contacts should be replaced. Do not use sand paper or  le to clean.

6. View  ame detection strength via the boiler control.

7. Test high-limit temperature control by reducing setting below the operating temperature. Burner should shut o . Return high limit to previous setting. Then press the manual reset.

8. Test operating temperature control by reducing temperature setting as necessary to check burner operation.

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

Recommended Semi-Annual Maintenance Schedule

The following steps should be carried out semi-annually:

1. Clean the gas burner assembly:

» Disconnect the gas head from the burner by disconnecting the

union. Withdraw the burner assembly and clean the ignition electrode.

» Check that the settings of the gap, if applicable, and ignition

electrode are accurate.

» Reassemble the burner assembly and check the scanner setting.

» Check the combustion e ciency of the burner and adjust if

necessary.

2. Check electrical controls and motors for correct operation.

3. Check water pump for correct operation.

4. Shut o the boiler completely and drain.

5. Replace hand hole gaskets as follows:

» Remove the hand hole assembly using a 1-1/4” tee handle

wrench or 1-1/4” 1/2” drive socket wrench. See Figure 4. Remove the old gasket and thoroughly clean the surface on the boiler and the plate.

! 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.

Never use open  ame or other sources of ignition to check for gas leaks.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

FIGURE 4  REMOVE ASSEMBLY WITH TEE HANDLE WRENCH

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.

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

4-3

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

4 CAUTION

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.

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

6. Fit the hand hole assembly as follows:

» Place the gasket on the hand hole plate and ensure that it is

seating correctly. Do not use any grease, lubricant, or adhesive.

» Position the plate in the boiler. Set the yoke and tighten the

securing nut su ciently enough to provide a snug  t. Verify the position of the plate in the boiler, then make it hand tight and then snug with wrench about 1/4 turn. Do not compress excessively. See Figures 5 and 6.

» Re ll the boiler with fresh water.

FIGURE 5  CORRECT PRESSURE ON GASKET

FIGURE 6  OVERCOMPRESSED GASKET

4-4

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

4 CAUTION

Recommended Annual Maintenance Schedule

All information in this manual is for

The following steps should be carried out annually:

1. Have combustion (CO2, O2, CO) and input checked by appropriate personnel. See Procedure for Primary Air Adjustment/Inspection and Procedure for Secondary Air Adjustment/Inspection sections of this manual.

reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

2. Clean  ues as follows:

» Remove the burner and  ue cover plate.

» Wire brush  ue passages. See Figure 7.

» Remove clean-out plugs at lowest part of unit (See Figure 8) and

clean the bottom of combustion chamber.

» Remove all soot from the top, and from the clean out plugs at the

bottom, with a vacuum cleaner.

» Replace clean out plugs carefully so as not to damage insulation.

NOTE: ´ Dirty  ues can cause air  ow restrictions resulting in poor combustion and

loss of e ciency.

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

If  ame and/or gas is permitted to exist in the blast tube area, back ring and destruction of electrodes may result. Ensure primary air adjustment is adequate to avoid this condition.

FIGURE 7  WIRE BRUSHING THE FLUE PASSAGES

FIGURE 8  REMOVING CLEAN OUT PLUGS

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

4-5

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

! 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.

Follow proper lockout / tag out procedures for the electrical, gas and water connections. Use caution when lifting heavy parts.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative..

Procedure for Primary Air Adjustment/Inspection

The primary air adjustment control is located at the top righthand side of the burner assembly. This damper-type air controller is used to introduce air to the fuel supply of the burner. The purpose of the primary air adjustment is to

proportionally divide the air to the center or outer  re chamber.

It is important to the combustion process to maintain proper air mixtures between the outer service and the center of the blast tube area. Fire should be on the outside wall and not the blast tube area. Damper positions are as follows:

§ Open: Most of the air is forced down the blast tube, and less air is going

down the outside wall of the de ector face and  re chamber.

§ Closed: Less air is forced down the blast tube, and most of the air is going

down the outside wall of the de ector face and  re chamber.

NOTE: ´ If it is necessary to close the damper due to a rumbling  re, close it slowly

and no more than 1/4th of the distance of the swing of the damper assembly.

Perform inspections as follows:

1. Visually inspect down the blast tube. If heat,  ames, or fumes are backing up through the burner plate area, the damper must be opened up.

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 a ect the e ciency or the life of the boiler in any way.

2. Visually con rm, via the sight glass, that  re is completely covering the walls. If the  re is tunneling down or is not on the outside wall, e ciency will drop. If required, use a micro-amp meter to verify  re signal as damper is moved. Adjust as necessary.

Procedure for Secondary Air Adjustment/Inspection

The secondary 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 for good combustion.

It is important to ensure that the lowest level of excess oxygen is present, while still maintaining a high level of carbon dioxide and no carbon monoxide. It is best to measure the  ue gas burn with the stack in excess of 420 F (216 C).

Perform inspections as follows:

1. Use an O2 or CO2 test kit to determine the percent of excess air in the combustion mixture. Adjust main air control as needed to reach optimal e ciencies. Generally a boiler stack area is used to measure the percent of oxygen and carbon dioxide in the fuel.

4-6

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

2. Adhere to the following:

Gas-Fired Unit It is a good policy to have 3.5-4.0% excess oxygen, which will

provide 10.5-9.5% excess carbon dioxide.

Oil-Fired Unit It is a good policy to have 4.0% excess oxygen, which will

provide 11.0% excess carbon dioxide.

Verify that carbon monoxide level is zero. To do this, use a

Bacharach sni er and CO tubes to prove a clean burn.

Note: Actual values may change when boiler is installed and connected to appropriate stack. Refer to

factory test  re sheet for original factory settings.

3. To increase the oxygen in the burner, open air adjustment to right. To reduce the secondary air, move air adjustment to the left.

NOTE: ´ Too much oxygen will blow the pilot out. Too little oxygen will make the

boiler burn dirty.

Procedure for Flame Scanner Adjustment

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

! 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

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

Ensure that the blower/gas train assembly is fully supported during removal/cleaning or burner, as the transition elbow will be removed.

¡ Gas Unit

Perform adjustment as follows:

1. Close gas cocks on gas train assembly. This will prevent gas from going into the burner.

2. Turn boiler on while microampmeter is in place.

3. During the ignition trial period, determine if the microampmeter exceeds #1. If yes, it is likely picking up ignition interference and realignment is necessary. It may be necessary to place a reduced scanner ori ce plug into the scanner eye area.

4. Repeat steps 1 - 3 until a reading of #1 or less is achieved on the microampmeter.

5. Reopen gas cocks and adjust the scanner signal response to maximum possible signal.

¡ Oil Unit

Perform adjustment as follows:

1. Turn power to panel OFF.

2. Disconnect the hot wire to the oil valves. This will prevent the oil valves from opening.

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

4-7

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

! WARNING

Extreme caution must be exercised when checking a failing transformer. They are capable of producing very high voltages which may result in personal injury and death.

3. With microampmeter in place, turn power to the panel ON.

4. During the ignition trial period, determine if the microampmeter exceeds

#1. If yes, it is likely picking up ignition interference and realignment is necessary. It may be necessary to place a reduced scanner ori ce plug into the scanner eye area.

5. Repeat steps 1 - 3 until a reading of #1 or less is achieved on the microampmeter.

6. Turn power OFF. Hook the wire up again, and turn power ON. Start boiler to ensure the safety light is o .

Procedure for Removing/Cleaning the Burner

Perform the following steps:

1. Remove all bolts that connect the transition elbow to the burner plate, and to the scroll tube.

2. Pull burner out of unit by  ange.

3. Inspect burner and wipe o (do not scrub or use wire brush) any soot or foreign material that may have accumulated. If available, use compressed air to clear the burner. Wipe out the inside of the burner with a clean cloth.

4. Reverse removal steps for reinstallation of the burner assembly.

5. Test  re the boiler and use a combustion analyzer to ensure that the fuel/ air ratio is set correctly throughout the range. Refer to the Fulton factory test  re sheet for combustion settings.

Procedure for Soot Cleaning

Perform the following:

1. Determine if  ues are dirty by checking stack temperature with a stack

thermometer. If temperatures are in excess of 600 F (315 C) while the boiler is operating, the  ues are likely dirty/restricted in some other manner.

NOTE: ´ Usually soot cleaning is performed annually, unless the burner setting has

been altered and excessive soot has been produced as a result.

2. Remove burner and  ue cover plates.

3. Using a wire brush, carefully remove soot from  ue passages.

4. Clean out plug at lowest part of unit and clean passages between ribs and bottom of combustion chamber.

4-8

5. Remove all soot with a vacuum cleaner. This may be carried out from the top and via the inspection doors at the bottom.

6. Replace clean-out plug carefully so as not to damage insulation.

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

7. Replace burner and  ue cover plates.

After All Repairs or Maintenance

1. Follow “Pre-Start Check List” and all Safety Checks.

2. Fire the boiler and perform combustion safety checks.

3. Analyze combustion throughout the range and verify proper operation of safety devices.

Troubleshooting

Please refer to Troubleshooting tables that follow.

! 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.

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

4-9

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

Troubleshooting Gas Fired Boilers

Problem Potential Cause Potential Remedy

Burner Cut-O / Ignition Failure/ Flame Failure

Power Supply

Gas Supply

Ignition Electrodes

Bad Air Switch

Dirty or defective UV Scanner

Transformer

Flame Safeguard Control

Contact open on air safety switch

Loose Wire Connection Check connections to all components.

Scanner wiring reversed at panel box

Protectorelay

Check fuse or circuit; reset or replace, as necessary.

§ 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.

§ Check for gas pressure and for intermittent

supply problems. Gas pressure for natural gas should be 4 in to 11 in wc at the head of the train.*

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

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.

Check for debris on  ame scanner and clean or replace as needed. Ensure scanner is properly located.

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

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

Adjust to proper setting

Change to correct terminals.

Check voltage between pilot terminal and ignition terminal. Check must be made before control locks out on safety. If zero voltage, clean relay contacts and recheck for power. If no power, replace control.

* For natural gas  red boilers. Refer to the test  re sheet for all other fuels.

4-10

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

Troubleshooting Gas Fired Boilers

Problem Potential Cause Potential Remedy

Poor Combustion

Burner back  res

Refractories

Not Enough Air/Build-Up on Fan Wheel (Rich; Burner Hums)

Fuel Valve Adjusted Too High (Rich; Burner Hums)

Too Much Air (Lean; Unstable

Flame)

Gas Valve Adjusted Too Low

(Lean; Unstable Flame)

Draft

Dirty Flue

Negative Room Pressure

Refractories

Ignition Electrodes

UV Scanner

Draft

Negative Room Pressure

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

Check CO2/O2 levels. If rich, disassemble  lter housing and gas train. Look inside inlet to the fan. If there is build-up on the fan blades, clean fan. Recheck the CO2/O2 and adjust gas valve as necessary for all combustion points.

Check CO2/O2 levels. Check gas pressure at outlet of valve. If the pressure is too high, make an adjustment at the valve. Be sure to check all combustion points.

Check fan discharge pressure. If too high, adjust damper. Check CO2/O2 levels and adjust gas valve as necessary. Be sure to check all combustion points.

Check CO2 and O2 levels. Check pressure at outlet of the valve. If too negative, adjust gas valve as necessary.

Check draft with a gauge. Draft should be a -.02 in to -.04 in wc with burner o or -.04 in to -.06 in when operating. May need to install a barometric damper.

Check  ue for carbon buildup or blockage. Clean  ue passages with brush.

Make sure no exhaust fans are running in the boiler room.

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

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

Check for debris on  ame scanner and clean as needed. Check for proper location of detector.

Check draft with a gauge. Draft should be a -.02 in to -.04 in wc with burner o or -.04 in to -.06 in when operating. May need to install a barometric damper.

Make sure no exhaust fans are running in the boiler room.

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

4-11

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

Troubleshooting Gas Fired Boilers

Problem Potential Cause Potential Remedy

Check gas pressure coming into gas train. If low, maintain pressure contact gas company. Should

Boiler will not maintain temperature

Gas Supply

Dirty Flue

Aquastat

Scale Built up in boiler

Refractories

Boiler Size Boiler may be undersized.

be 7 in to 11 in wc /natural gas. Check coil in gas valve with AMP meter. Replace if bad. Check gas regulator setting and readjust as necessary.

Check  ue for carbon buildup or blockage. Clean  ue passages with brush.

If power is on, check across aquastats to verify power through the switch. If bad, replace.

Refer to Recommended Daily Maintenance section of this manual.

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

4-12

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

Troubleshooting Oil Fired Boilers

Problem Cause Remedy

Burner Cut O / Ignition Failure/ Flame Failure

Power Supply

Transformer

Cad Cell

Protectorelay

Oil Supply

Ignition Electrodes

Primary air adjustment

Oil Valve

Oil Pump

Aquastat

Loss of oil prime

Oil Nozzle Check for clogged nozzle; clean or replace

Check fuse or circuit breaker and replace as necessary.

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

Check for ignition interference. To verify cad cell is working, place a lit candle in front of photo cell at the proper time.

Check voltage between pilot terminal and ignition terminal. Check must be made before control locks out for safety. If zero voltage, clean the relay contacts and recheck terminals for power. If no power, replace control.

Check oil level in supply tank to be sure it is not below intake line. Fill tank with oil. Check for clogged nozzle. Clean or replace.

Check electrodes for carbon buildup and clean as necessary. Check for proper adjustment; readjust if necessary. Check for cracks in porcelain; replace if cracked.

Check air adjustment. Air may be blowing  re away from  ame sensor.

Check voltage between oil valve leads at terminal block to be sure oil valve is getting power.

Check for clogged strainer or  lter. Remove and clean. Check for slipping or broken coupling. Tighten or replace. Check for frozen pump shaft. Replace.

If power is on, check across aquastats to verify power through the switch. If bad, replace.

Check all lines for possible air leak in intake line and tighten. Check for possible restricted intake line. Replace.

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

4-13

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

Troubleshooting Oil Fired Boilers

Problem Cause Remedy

Check refractories to see if they are sooted,

Poor Combustion

Burner Back Fires

Refractories

S.S. Ring

Oil Nozzle Check for clogged nozzle; clean or replace.

Primary air adjustment

Secondary Air Adjustment

Oil Pump

Draft

Dirty Flue

Refractories

Ignition Electrodes

Primary Air Adjustment

Oil Valve Check for leaky oil valve and replace.

Draft

Loss of Prime

cracked or broken in places. Clean or replace as needed.

Check to be sure ring is present and  ts tight against the furnace wall.

Check air adjustment. Air may be blowing  re

away from  ame sensor.

Check main air adjustment to see if it is loose. Adjust as needed and tighten plate in position. Check CO2 and O2 levels.

Check for clogged strainer or  lter. Remove and clean. Check for slipping or broken coupling. Tighten or replace. Check for frozen pump shaft. Replace.

Check draft with a gauge. Draft should be -0.02 to

-0.04 inches of water column with burner o , or

-0.04 to -0.06 when operating. May need to install barometric damper.

Check  ue for carbon buildup or blockage by using a stack thermometer placed within one foot of the stack leaving the boiler area. If stack temperature is in excess of 600 F while the boiler is operating, the  ues are dirty. Clean as necessary.

Check refractories to see if they are sooted or broken in places. Clean or replace as needed.

Check electrodes for carbon buildup and clean as necessary. Check for proper adjustment; readjust if necessary. Check for cracks in porcelain; replace if cracked.

Check air adjustment. Air may be blowing  re

away from  ame sensor.

Check draft with a gauge. Draft should be -0.02 to

-0.04 inches of water column with burner o , or

-0.04 to -0.06 when operating. May need to install barometric damper.

Check all lines for possible air leak in intake line and tighten. Check for possible restricted intake line. Replace.

4-14

SECTION 4 VMPW-IOM-2012-1001 MAINTENANCE

Troubleshooting Oil Fired Boilers

Problem Cause Remedy

Check oil level in supply tank to be sure it is not

Boiler will not maintain pressure

Oil Supply

Oil Nozzle Check for clogged nozzle; clean or replace.

Oil Valve

Oil Pump

Aquastat

below intake line. Fill tank with oil. Check for clogged nozzle. Clean or replace.

Check voltage between oil valve leads at terminal block to be sure oil valve is getting power.

Check for clogged strainer or  lter. Remove and clean. Check for slipping or broken coupling. Tighten or replace. Check for frozen pump shaft. Replace.

If power is on, check across aquastats to verify power through switch. If bad, replace.

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

4-15

MAINTENANCE VMPW-IOM-2012-1001 SECTION 4

4-16

WARRANTY & PARTS

INTRODUCTION

INSTALLATION

1 2

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

5

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

5-1

WARRANTY & PARTS VMPW-IOM-2012-1001 SECTION 5

5-2

SECTION 5 VMPW-IOM-2012-1001 WARRANTY & PARTS

Standard Warranty for Fulton Boilers

Warranty Valid for Models ICS/FB-A, ICW, ICX/FB-F, VMP, VMPW, FB-S, FB-L, FB-W, ICT

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

The pressure vessel is covered against defective material or workmanship for a period of ﬁ ve (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 deﬁ ned 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 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 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 notiﬁ ed 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 ofﬁ cer 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 ﬁ tness 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 proﬁ ts 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.

Effective 09.01.2010

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

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PARTS & WARRANTY VMPW-IOM-2012-1001 SECTION 5

! WARNING

Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty.

Parts

Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherance with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

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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.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of the Fulton Group of Companies, a global manufacturer

of steam, hot water and thermal  uid heat transfer systems.

The heat transfer innovators.

The Fulton Companies

972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

VMPW-IOM-2012-1001

FULTON VMP-W 40 -150 HP, VMP-W Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual