FULTON VMP40 Installation, Operation And Maintenance Manual
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FULTON VMP40 Installation, Operation And Maintenance Manual

Gas fired steam boilers
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Installation Operation And
Maintenance Manual
VMP-STEAM-GAS_IOM_2016-1007-REV1
Serial # : ___________________________
Model # : ___________________________
Fulton Order # : ___________________________
Sold To : ___________________________
Job Name : ___________________________
Date : ___________________________
Fulton VMP
(Vertical Multi-Port)
Gas Fired Steam Boilers
40-150 HP

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Summary of Contents for FULTON VMP40

  • Page 1 Fulton VMP Installation Operation And Maintenance Manual (Vertical Multi-Port) Gas Fired Steam Boilers VMP-STEAM-GAS_IOM_2016-1007-REV1 40-150 HP Serial # : ___________________________ Model # : ___________________________ Fulton Order # : ___________________________ Sold To : ___________________________ Job Name : ___________________________ Date : ___________________________...
  • Page 3 Effective immediately, please use the limits below. Should you have any questions, please do not hesitate to contact Fulton at 315-298-5121. Water Chemistry Requirements for Fulton Steam Products (to 300 psig MAWP) Carbon Steel Stainless Steel...
  • Page 5 Contents Safety Warnings Section and Precautions PAGE 3 Installation PAGE 9 Operation PAGE 17 Maintenance PAGE 31 Parts and Warranty PAGE 35 VMP IOM...
  • Page 6 VMP IOM...
  • Page 7 Safety Warnings Section and Precautions VMP IOM...
  • Page 8 VMP IOM...

  • Page 9: Safety Warnings And Precautions

    The customer should examine the boiler for any damage, especially This manual is provided as a guide to the correct operation and maintenance of your Fulton Gas Fired Steam Boiler, and should be the refractories. It is the responsibility of the installer to ensure...
  • Page 10 Do not allow anyone to operate, service or repair this NOTE equipment unless they fully understand all applicable sections After a new Fulton Boiler has been in operation for several of this manual. months, pieces of burned metal will be found in the space at the bottom of the boiler.
  • Page 11 Safety Warnings and Precautions VMP IOM...
  • Page 12 VMP IOM...
  • Page 13 Section Installation VMP IOM...

  • Page 14: Installation

    Installation Burner Alignment Tabs Gas Train Assembly Transformer Burner Plate Assembly Top Plate Assembly Secondary Air Damper Scroll Burner Motor Flue Cover Plate Steam Gauge O.P.C. * Lifting Hook(s) Assembly Gauge Glass H.P.C. * Stainless Steel Ring Valve Gauge Glass and Protector Rods Flue Outlet Gauge Glass...
  • Page 15 Fulton Vertical Product Data Submittal MultiPort Fulton Models: VMP40, VMP49.5, VMP50, VMP60, Steam Boilers VMP80, VMP100, VMP130 and VMP150 (Standard Burners) Dimensions Models VMP 49.5 Unit Size: 49.5 A. Boiler Diameter 50.5 76.5 76.5 1283 1397 1397 1397 1600 1753...

  • Page 16: Specifications

    NOTE: 7” - 11” wc gas pressure is required during run for 40-60 HP boilers with standard burners. 9”-11” wc gas pressure is required during run for 80-100 HP boilers with standard CSD-1 burners, 40” W.C. is required for 130-150 HP Specifications & dimensions are approximate. We reserve the right to change without notice. The Fulton Companies 972 Centerville Road vmpstd-pds-2010-1008 Pulaski, New York 13142 Call 315-298 .
  • Page 17 Fulton Vertical MultiPort Product Data Submittal Steam Boilers Fulton Models: VMP40, VMP49.5, VMP50, VMP60, (Low Emissions Burners) VMP80, and VMP100 (<20 PPM NOx) Dimensions Models VMP 49.5 Unit Size: 49.5 A. Boiler Diameter 1245 1397 1397 1397 1600 1753 B. Boiler Height...
  • Page 18 **Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM and at 100 Degrees C +Consumption based on natural gas 1000 BTU/FT and 20 ppm NO @ 3% CO burner. The Fulton Companies 972 Centerville Road Pulaski, New York 13142 Call 315-298 . 5121 Fax 315-298 . 6390 vmp40-100le-pds-2010-1008 www.fulton.com...
  • Page 19 Fulton Vertical MultiPort Product Data Submittal Steam Boilers Fulton Models: VMP130 and VMP150 (Low Emissions Burners) (<30 PPM NOx) Dimensions Models VMP Unit Size: A. Boiler Diameter 76.5 76.5 1943 1943 B. Boiler Height 2921 2921 C. Boiler Depth 3251 3302 D.
  • Page 20 **Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM and at 100 Degrees C +Consumption based on natural gas 1000 BTU/FT and 20 ppm NO x @ 3% O 2 burner. The Fulton Companies 972 Centerville Road Pulaski, New York 13142 vmp130-150le-pds-2010-1008 Call 315-298 .

  • Page 21: Locating The Boiler

    Installation g. When making gas piping joints, use a Locating the Boiler The Gas Supply sealing compound resistant to the action a. The boiler should be located in dry a. Gas Piping should be installed in of liquefied petroleum gases. Do not use surroundings on a level base, making accordance with National Fuel Gas teflon tape on gas line threads.
  • Page 22 CAUTION as maintain proper return tank regulations covering such vessels. If in temperature. Do not exceed the rated pressure of doubt consult a Fulton Representative the fuel train. for advice. VMP IOM...

  • Page 23: Steam Supply

    Installation a. Make sure two check valves are installed between the boiler and pump (one check valve is supplied with the unit). b. In a closed system an end of the line trap should be installed. c. There are four blow-down valves on the boiler: Two main bottom blow-down valves, the gauge glass blow-down valve, and the water column blow-down...

  • Page 24: Blow-Down Valve

    Installation Blow-Down Valve Water Column There are four blow-down valves on the Install the piping from the water column and boiler: Two main bottom blow-down valves, water gauge glass to a safe blow-down point. the gauge glass blow-down valve, and the water column blow-down valve.
  • Page 25 Installation Water Gauge and Gauge 10.Hand tighten both glass packing nuts, WARNING then tighten 1/2 turn more by wrench. Improper installation or maintenance of Glass Installation Tighten only enough to prevent leakage. gauge glass and connections can cause Instructions DO NOT OVER TIGHTEN! If any immediate or delayed breakage resulting leakage should occur, tighten slightly, a in bodily injury and/or property damage.

  • Page 26: Water Supply

    Pitting can proceed at a surprisingly rapid rate and can occur not only in the The Fulton Warranty does not cover boiler proper, but also in pre-boiler damage or failure that can be attributed...
  • Page 27 Installation CHLORIDES/CHLORINE Often oil in boiler water will originate in the WATER HARDNESS condensate. This contaminated condensate Chlorides generally considered Water hardness is the measure of should be directed to the sewer until the detrimental in stainless steel systems only. calcium and magnesium content as source of the oil is determined and corrective Stress corrosion cracking can occur from...

  • Page 28: Electrical Requirements

    Installation Electrical Requirements 1. Connect wiring as shown in the wiring diagram which is furnished inside the electrical control panel box. 2. Be sure to install a separate disconnect for each piece of equipment. The disconnects should be installed in compliance with the NEC (National Electric Code) and all local codes.

  • Page 29: Installation Check Points

    Installation Corrosion of flue pipe When the next cold start-up occurs, the Installation Check Points process repeats except that more and more In the case of a combustion flue pipe, acid 1. Make sure all piping connections are chloride collects and concentrates along may develop over a long period of time per complete and tight.
  • Page 30 Cleaning (Boil out) the Pressure Vessel After the boiler has been installed and before it is placed in service it is advisable to purge the pressure vessel of any oil film,dirt, or other impurities. Clean the pressure vessel as follows: 1.
  • Page 31 VMP IOM...
  • Page 33 Section Operation VMP IOM...

  • Page 34: Operation

    Operation Starting the Gas Fired Boiler STOP! Make sure you have read and followed all previous safety information. Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required. In general, ensure that the boiler area is in conformance with established boiler room requirements.
  • Page 35 Repeat to adjust both linkage arms. To adjust 5. All Fulton propane or butane boilers and Fulton natural gas boilers 50 HP and the procedure for starting the burner. the linkages, unscrew the swivel...
  • Page 36 Primary Air Adjustment the outside wall of the deflector face and fire chamber. for Fulton Gas Fired Steam Boilers 2. It is important in the combustion process to maintain proper air mixtures between 1.

  • Page 37: Boiler Controls

    CSD-1 Code controls also feature an any other position than full open, the ball independent second low water cut off will not seat. For added safety all Fulton WARNING relay. Press the low water reset button boilers are equipped with gauge glass When stopping the boiler for any and the boiler will start.
  • Page 38 The red light should go out. is equipped with FGR) modulates the air which in turn regulates If the fault persists contact Fulton. the fuel input. No mechanical linkage is 5. Press Escape 4 times to get back to the utilized with this system.
  • Page 39 Operation 26. You can observe the status of the 30.If operating on gas, adjust the incoming BEFORE LEAVING THE INSTALLATION burner by going to OperationalStat > gas pressure at the main gas regulator Check all controls to insure they are NormalOperation.

  • Page 40: Glossary Of Terms

    Operation IMPORTANT CAUTION During startup insure that adequate gas When commissioning this boiler, firing rate pressure is supplied to the main valves. must remain at low fire during first The indicator on the actuator should never reach the bottom of the indicator 4 hours of operation.
  • Page 41 Section Maintenance VMP IOM...

  • Page 42: Maintenance

    Maintenance Burner Alignment Tabs Gas Train Assembly Transformer Burner Plate Assembly Top Plate Assembly Secondary Air Damper Scroll Burner Motor Flue Cover Plate Steam Gauge O.P.C. * Lifting Hook(s) Assembly Gauge Glass H.P.C. * Stainless Steel Ring Valve Gauge Glass and Protector Flue Outlet Gauge Glass...
  • Page 43 Maintenance NOTE To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to. WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box, the electrical supply to the boiler must be disconnected.
  • Page 44 Fulton gas fired boilers to improve the signal. designed to bring quick and effective flame transfer to the fire wall. The ring 3. If the scanner is found to be should fit securely and tight against the defective, replace.
  • Page 45 When Artwork Revision 2017-0927 installed the outer edges must be sealed with insulcrete - a castable refractory mix available from the Fulton factory. It is not necessary to reinstall the shipping clips. 9. Install the stainless steel combustion ring, burner assembly, and clean out plug.
  • Page 46 Pilot Adjustment for 4. Also note the location of the jumper on Recommended Daily the left side of the motor. Fulton LoNOx Burner. Maintenance Schedule 5. Loosen the allen screws on the motor 1. Close downstream shut off valve. The following procedures should be carried end of the motor to valve coupling.
  • Page 47 NOTE sand paper or file to clean. lever. Fulton recommends that the feedwater treatment should be added between the 5. Clean water traps and strainers in fuel 2. Drain condensate tank and clean tank pump and the boiler.

  • Page 48: Recommended Annual Maintenance Schedule

    Section 7 of this manual. The following lists cover the most common troubles that may occur on the Fulton gas fired boilers. Refer to left hand column of the chart to locate the problem. Determine...

  • Page 49: High Pressure Limit Switch

    Boiler Safety Testing – Fulton Vertical Steam Boilers High Pressure Limit Switch:  With the burner on and the boiler under pressure, lower the set pressure on the switch until it trips and shuts down the burner. Ensure the pressure that the switch trips at is the same as the boiler operating pressure.

  • Page 50: Air Switch

    One control is set to function ahead of the other. The standard Fulton LWCO control utilizes a water level probe and incorporates a 3 seconds time delay to prevent short cycling. Optional float type LWCO controls may also be used on the boiler.
  • Page 51 Low Gas Pressure Switch:  Bring boiler to high fire (100% firing rate)  Increase the dial on the low gas pressure switch until it trips and locks out the boiler  Make note of the pressure that the burner shuts down at ...
  • Page 52 Maintenance Troubleshooting Gas-Fired Boilers PROBLEM CAUSE REMEDY Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary. 2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment. Readjust if necessary. Check for cracks in porcelain.
  • Page 53 Maintenance PROBLEM CAUSE REMEDY Poor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in pieces. Clean or replace as necessary. 2. S.S. Ring Check to be sure ring is present and fits tight against the furnace wall. 3.
  • Page 54 Maintenance PROBLEM CAUSE REMEDY Pump will not cut off 1. Dirty Probes Clean or replace as necessary. 2. Relay failed Make sure relay is plugged in tightly. If so, replace water level relay. 3. Ground Connection Check for tightness and clean. 4.
  • Page 55 Maintenance PROBLEM CAUSE REMEDY Flame Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary. 2. Gas Supply Check for gas pressure and for intermittent supply problems. 3. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary. Check for proper adjustment.
  • Page 56 Maintenance PROBLEM CAUSE REMEDY Boiler will not 1. Gas Supply Check gas pressure coming into gas train. If low, contact gas company. maintain pressure 2. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush. 3. Pressuretrol Disconnect all power to the controller.
  • Page 57 VMP IOM...
  • Page 58 Section Parts and Warranty VMP IOM...

  • Page 59: Parts And Warranty

    Parts and Warranty It is important that the correct replacement part is fitted to your Fulton Gas Fired Steam Boiler. When ordering replacement or spare parts, make sure that the full information given in the Parts List is supplied, together with the...
  • Page 60 Parts and Warranty Part No. Description Approx. Net Weight (lbs) (kgs) Burner Assembly - Parts (Common) 2-40-613 1.5 HP 115/230/60/1 Burner Motor 3450 RPM 18.18 2-40-615 1.5 HP 230/460/60/3 Burner Motor 2850/3450 RPM 14.09 2-40-621 3.0 HP 230/460/50/60/3 Burner Motor 2850/3450 RPM 19.55 2-12-014 Pyrex Plate Glass 1 "...
  • Page 61 Gas Train Assembly 80 HP Propane Gas Modulation 45.45 7-54-8410 Gas Train Assembly 100 HP Propane Gas Modulation 45.45 Water Column 5-20-022 Fulton Water Column Bottle Casting -4-100 HP 9.09 2-30-151 MM 150 Pump Control 11.36 2-30-193 MM 150 - M/R Control 11.36...
  • Page 62 1/4"Male-Female Ball Valve for Water Column 0.27 2-40-021 Probe Basket 0.05 0.02 Panel Box Parts 2-40-420 Fulton Pump Relay-120V 0.23 2-40-421 Fulton Burner Relay - 120V 0.23 2-40-422 Base for Fulton Pump Relay 0.25 0.11 2-40-423 Base for Fulton Burner Relay 0.25 0.11 2-12-090 Spring Retainer for burner/pump relay 0.001...
  • Page 63 Parts and Warranty Part No. Description Approx. Net Weight (lbs) (kgs) 2-40-270 Base For All 7800 0.23 2-40-272 Display Module for 7800 Controls English (Also Available in Spanish) 0.23 2-40-247 Remote Mounting Bracket for 7800 0.65 2-40-248 Extension Cable Boiler Trim 2-30-396 1"...
  • Page 64 Parts and Warranty Part No. Description Approx. Net Weight (lbs) (kgs) 2-60-248 Flue Brush - Pipe Type - 2" - 40 and 80 HP 0.45 5-10-397 Tee Handle Wrench 1.23 2-20-110 Fan Puller - 5/8" Hub 0.91 Barometric Controls 2-30-099 14"...
  • Page 65 Parts and Warranty VMP IOM...

  • Page 66: Standard Warranty For Fulton Boilers

    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...
  • Page 68 Parts Warranty Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve (12) months of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers.
  • Page 69 Pulaski, New York USA 13142 Call 315-298 . 5121 VMP-STEAM-GAS-IOM_2016-1007-REV1 Fax 315-298 . 6390 Fulton Heating Solutions, Inc., Fulton Boiler Works, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, manufacturers of high grade industrial/commercial heat transfer products. www.fulton.com...

This manual is also suitable for:

Vmp49.5Vmp50Vmp80Vmp100Vmp130Vmp60 ... Show all

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