FULTON Vantage VTG Series Installation And Operation Manual
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FULTON Vantage VTG Series Installation And Operation Manual

Condensing hydronic boilers standard, dual fuel, and low emissions models 2,000,000 - 6,000,000 btu/hr 504k - 1.5 mm kcal/hr
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INSTALLATION AND
OPERATION MANUAL
Vantage (VTG)
Condensing Hydronic Boilers
Standard, Dual Fuel, and Low Emissions Models
2,000,000 - 6,000,000 BTU/HR
504k - 1.5 MM kCal/HR
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
VTG-IOM-2016-1214

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Summary of Contents for FULTON Vantage VTG Series

  • Page 1 INSTALLATION AND OPERATION MANUAL Vantage (VTG) Condensing Hydronic Boilers Standard, Dual Fuel, and Low Emissions Models 2,000,000 - 6,000,000 BTU/HR 504k - 1.5 MM kCal/HR Serial/ National Board Number Model Fulton Order Owner Site Name Date VTG-IOM-2016-1214...

  • Page 3: Table Of Contents

    Ignition Pilot Adjustment - Dual Fuel Burners ............. 4-7 Electrical Connections ..................2-40 FOR UNITS WITH RIELLO RLS-100-130E BURNER ..............4-7 Assembly of Fulton Multi-Skid Systems............. 2-41 FOR UNITS WITH RIELLO RLS-160E BURNER ................4-7 After All Repairs and Maintenance ..............4-7 Operation Troubleshooting ....................
  • Page 4 TABLE OF CONTENTS VTG-IOM-2016-1214 Warranty & parts Standard Warranty for Fulton Vantage Hydronic Boilers ........Parts ........................5-4 © The Fulton Companies 2016...

  • Page 5: Introduction

    INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 6: Overview

    Code ANSI Z223.1/NFPA 54 latest edition, and the specific should it replace existing codes or standards which may be instructions in this manual. Authorities having jurisdiction applicable. Fulton reserves the right to change any part of should be consulted prior to installation. this installation, operation and maintenance manual.

  • Page 7: Installation

    INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 8: Product Overview

    The Fulton Vantage hot water boiler is an automatic, fuel-fired, ultra high- jurisdictional/professional codes and efficiency boiler. The boiler can either be of the sealed combustion/direct vent regulations.

  • Page 9: Placement & Rigging

    Proper placement of your Fulton product is essential. Attention paid to regulations. the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble-free installation, operation, and maintenance.

  • Page 10: Clearances And Serviceability

    Authorities the VTG-5000 which requires an 8 inch (203.2 mm) side having jurisdiction should be consulted before clearance. Custom configurations may not allow 1 inch installations are made. (25.4 mm) side clearance. © The Fulton Companies 2016...
  • Page 11 INSTALLATION SECTION 2 VTG-IOM-2016-1214 Standard / Low 36 IN 24 IN (91.4 CM) (61 CM) Emissions Models 1 IN TOP VIEW (25.4 MM) EACH SIDE TYPICAL 24 IN (61 CM) RECOMMENDED HOT WATER OUTLET HOT WATER OUTLET COMBUSTION AIR INLET COMBUSTION AIR INLET SIDE VIEW COLD WATER INLET...

  • Page 12: Install Boiler Trim

    1 (25.4) 1 1/4 (31.75) valve itself. » Be piped to avoid danger of scalding personnel. Note: Valve is shipped loose and must be installed by the con - tractor. FIGURE 2 - SAFETY VALVE LOCATION © The Fulton Companies 2016...

  • Page 13: Install Water Piping

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 Install Water Piping WARNING All information in this manual is for All water supplies contain some solids, dissolved gases or dissolved minerals. reference and guidance purposes, These may cause corrosion, deposition and/or fouling of equipment. To prevent and does not substitute for required these contaminants from impacting boiler performance, valve operation and professional training, conduct,...

  • Page 14: Variable Primary Piping Arrangement

    Proper control strategy must be used to ensure flow paths in the hydronic loop and residual heat in the pressure vessel © The Fulton Companies 2016...
  • Page 15 UNLESS OTHERWISE NOTED: This design and DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: this drawing may be (SEE NOTE 4) The Fulton Companies drawings are M. BERWALD 7/7/2014 DIMENSIONS ARE IN INCHES VANTAGE BOILER PRIMARY ONLY TOLERANCES ON covered by one or...
  • Page 16 Note: Sample piping layout (P&ID) is a general representation of system installation. Good practice should be used in system design, including but not limited to adequate pipe/valve sizing and natural flow path for system water. 2-10 © The Fulton Companies 2016...

  • Page 17: Meet Water Chemistry Requirements

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 WARNING Meet Water Chemistry Requirements All information in this manual is for reference and guidance purposes, System water chemistry requirements are as follows: and does not substitute for required professional training, conduct, ƒ pH: Range of 8.5 - 10.5 and strict adherence to applicable ƒ...

  • Page 18: Prevent Oxygen Contamination

    The gas train components are UL certified to operate at specific gas pressure requirements. The specific requirements for each boiler are called out on the boiler nameplate, located on the back of the boiler. Parameters depend on fuel(s) for which the boiler is designed. 2-12 © The Fulton Companies 2016...
  • Page 19 OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact 4. The boiler must be disconnected at the boiler manual shutoff valve your Fulton representative prior to (located at the end of the supplied gas train) from the gas supply piping operation.

  • Page 20: Components Requiring Ventilation To The Outdoors

    The termination must be a minimum of 3 ft (0.9 m) from a source of ignition. The SKP25 regulating gas valve does not require ventilation to the outdoors. 2-14 © The Fulton Companies 2016...

  • Page 21: Install Condensate Drain

    A condensate drain trap is intended for use with the Fulton Vantage boiler. ƒ Single Boiler Drain Trap The single boiler condensate drain trap is Fulton Part Number 4-57-005500. The drain trap must be configured one per boiler, with a maximum capacity of 4.0 MM BTU/hr. See Figure 5 and 9.

  • Page 22: Multiple Boilers Sharing A Common Drain Trap

    ƒ Multiple Boilers Sharing A Common Drain Trap The exhaust vent installer should be The multiple boiler condensate drain trap is Fulton Part Number 4-57-000440. familiar with Federal Codes as well The maximum capacity to attach per condensate drain trap is 12 MM BTU/hr as local codes and regulations.
  • Page 23 The items shown in DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: drawings are this drawing may be M. BERWALD The Fulton Companies DIMENSIONS ARE IN INCHES 2/18/2014 2/28/2014 CONDENSATE DRAIN PIPIN FOR SINGLE VANTAGE UPDATED CONNECTION FOR CONDENSATE A.A. TOLERANCES ON...
  • Page 24 ƒ For multiple boiler installation, maintain a minimum pipe size of 1 inch (25.4 mm) for the header piping. ƒ The maximum number of units to attach per condensate drain kit is 12mm BTU total. DETAIL A CONDENSATE DRAIN KIT 2-18 © The Fulton Companies 2016...
  • Page 25 1 " N.P.T. OUTLET 1 " N.P.T. INLET 6 " LEFT VIEW FRONT VIEW RIGHT VIEW FIGURE 7 - FULTON PH NEUTRALIZING KIT 3/8" (TYP.) 1/4" WATER SUPPLY CONNECTION 10 11/16 10 1/8 7 3/4 6 1/2 1 3/8 1 1/2...
  • Page 26 (A) pH Kit Outlet ” ” (B) Condensate Drain Kit 4-57-004400 4-57-005500 (C) Drain Outlet ” ” (D) pH Kit Inlet ” ” (E) pH Neutralization Kit 4-50-000008 4-50-000008 (F) Drain Inlet 1” ” 2-20 © The Fulton Companies 2016...

  • Page 27: Install Ph Neutralization Kit

    ASTM D396 only, commonly known as #2 fuel oil. DO NOT USE JP-8, GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact your Fulton representative prior to operation. 2-21 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 28 10. The tank is higher than the pumping unit (A): The distance “P” must not exceed 33 ft (10 m) in order to avoid subjecting the pump’s seal to excessive strain; the distance “V” must not exceed 13 ft (3.94 m) in order to permit 2-22 © The Fulton Companies 2016...

  • Page 29: Multiple Burner Installations

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 WARNING pump self priming even when the tank is almost completely empty. See Figure 16. All information in this manual is for 11. The tank is lower than the pumping unit (B): Pump suction pressures higher reference and guidance purposes, than 13”Hg for Suntec oil pump must not be exceeded.
  • Page 30 102-435 PSI (703 - 3000 k Pa) Maximum Suction 13 “ Hg Oil Viscosity Range 3 – 75 cSt Maximum Fuel Oil 302 F (150 C) Temperature Pressure Calibration at the 365-385 PSI (2516.6 - 2654.5 kPa) Factory 2-24 © The Fulton Companies 2016...

  • Page 31: Burner Fuel Oil Train Piping Detail

    UNLESS OTHERWISE NOTED: This design and drawings are The items shown in this DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: The Fulton Companies DIMENSIONS ARE IN INCHES proprietary and are the drawing may be covered by T. CORSON 01/20/15 1/29/16...
  • Page 32 L(ft) RLS-100-130E O (inch) (for use with VTG-2000DF to VTG-4000DF) (ft) 1/2” 5/8” L(ft) O (inch) (ft) 3/8” 1/2” 5/8” +6.6 +4.8 +3.3 +6.6 +1.6 +3.3 +1.6 -1.6 -3.3 -1.6 -4.8 -3.3 -6.6 -6.6 2-26 © The Fulton Companies 2016...
  • Page 33 INSTALLATION SECTION 2 VTG-IOM-2016-1214 (INSTALLED HORIZONTALLY) (HANDLE REMOVED) FIGURE 17 - SYSTEM USING COMMON OIL PIPING FOR MULTIPLE BOILERS Note: All installations must be in compliance with local and national codes. Typical installation diagrams con- tained in this manual are for reference purposes only. 2-27 Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 34: Oil Pump Priming

    4. The maximum pressure values stated in Table 5 are typically, although not necessarily limited to, approximately 35 feet (10.6 meters) with 4 elbows of connection size piping. Alternative arrangements may be appropriate where determined by the venting designer to be within 2-28 © The Fulton Companies 2016...
  • Page 35 8. Site specific conditions not addressed in this manual may require additional precautions or design considerations. Consult your local Fulton Representative and venting supplier for recommendations. NOTEE: Consult your venting pipe supplier for assistance with sizing of vent –...
  • Page 36 Damage to the heat exchanger due to poor combustion air quality is not covered under warranty. 17. In Canada, for recommended practice, refer to CSAB1 2-30 © The Fulton Companies 2016...

  • Page 37: Combustion Air Supply From The Boiler Room

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 WARNING ƒ Combustion Air Supply From the Boiler Room All information in this manual is for Adhere to the following for installation: reference and guidance purposes, and does not substitute for required 1. Adequate free access of combustion air and ventilation must be supplied to professional training, conduct, and strict the boiler room in accordance with local codes and NFPA 54/ANSI Z233.1, adherence to applicable jurisdictional/...

  • Page 38: Air Piped From Outside Boiler Room

    The cement must not show gelation, stratification, or separation that cannot be removed by stirring. 6. Adhere to procedure for cementing joints (per ASTM D2855). 2-32 © The Fulton Companies 2016...

  • Page 39: Exhaust Venting

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 WARNING 7. Avoid sidewall exhaust with roof terminated intake air. This can lead to reverse stack effect when the boiler is idle. All information in this manual is for reference and guidance purposes, and does not substitute for required Exhaust Venting professional training, conduct, and strict adherence to applicable jurisdictional/...
  • Page 40 2. Supplying combustion air with individually piped other equipment. Examples include steam boilers, intake vents or neutral pressure boiler room air is water heaters, generators, and other types of Fulton recommended when venting into a common exhaust equipment. system. For common exhaust vent applications where combustion air intake (CAI) vents are also combined 3.

  • Page 41: Venting Terminations

    2. To prevent the possible re-circulation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations, etc. Fulton cannot be held responsible for the Do not locate the vent termination too close to shrubbery as flue products may stunt effects such adverse conditions may have on the operation of the boilers.
  • Page 42 7. A 45° reducing tee or elbow in the direction of flow is recommended. Straight or 90° tees must not be used. 8. Do not use boot tees or bull head tees. 9. Vantage boilers cannot be common vented with other ISOMETRIC VIEW equipment. 2-36 © The Fulton Companies 2016...
  • Page 43 INSTALLATION SECTION 2 VTG-IOM-2016-1214 FIGURE 20 - ROOF PENETRATION DETAILS ( 122 CM ) NOTE: AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS. MIN 4FT / 122 CM ABOVE AIR INTAKE PIPING SCREENED INLET...
  • Page 44 AIR INTAKE AND EXHAUST TERMINATION SHOULD BE LOCATE INTAKE WALL PENETRATION SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS UPWIND OF EXHAUST PIPING RECIRCULATION DURING DIFFERENT WIND CONDITIONS AIR INTAKE WALL PENETRATION 4 ft. (122 CM) WIND DIRECTION 2-38 © The Fulton Companies 2016...

  • Page 45: Roof Vent Termination

    INSTALLATION SECTION 2 VTG-IOM-2016-1214 4. Pass the vent pipe through the thimble from the SCREW OR BOLT EACH THIMBLE COLLAR TO WALL (TYPICAL 4 PLACES) ORIENT CLAMPS AND COLLAR AS REQUIRED outside and join to the rest of the vent system. Seal the PIPE RETAINING CLAMP, TYPICAL EACH SIDE...

  • Page 46: Electrical Connections

    Depending on motor manufacturer, a 208V rated motor may not be able to ƒ run below the design voltage. Adhere to the following when making electrical connections: 1. Install wiring and ground in boiler in accordance with authority having 2-40 © The Fulton Companies 2016...

  • Page 47: Assembly Of Fulton Multi-Skid Systems

    Adhere to the following for multi-skid engineered systems: NOTEE: For piping supplied in sections, make up and connect – 1. Refer to the Fulton mechanical/electrical drawings hand tight until all sections are in place to ensure sections during assembly. align properly. Sections are match marked for reassembly.
  • Page 48 INSTALLATION SECTION 2 VTG-IOM-2016-1214 2-42 © The Fulton Companies 2016...

  • Page 49: Operation

    OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 50: Perform Pre-Start-Up Inspection

    When all air has escaped and only water is impacted part of the control system. discharged, close the zone valve. When all zones have been purged (one at a time), close the vent on the combination shutoff/purge valve. © The Fulton Companies 2016...

  • Page 51: Commission The Boiler

    OPERATION SECTION 3 VTG-IOM-2016-1214 WARNING 5. At this point, the system has been initially filled. However, air pockets may still remain at high points in the system and in heating loops above Crystalline silica may be present the level of the combination shut/off purge valve. It is quite possible, in components of this equipment.

  • Page 52: System Design And Boiler Operation

    ƒ Operating Points on the Siemens LMV Control Commissioning/Start up by a non- Fulton authorized person will void the Vantage boilers receive a factory Test Fire Report. This includes nine operating product warranty. points pre-programmed in the Siemens LMV control by the factory. Parameter...
  • Page 53 OPERATION SECTION 3 VTG-IOM-2016-1214 FIGURE 23 - SIEMENS AZL DISPLAY Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 54: Steps To Enter Parameters

    Press the enter (i/reset) button to enter the selected parameter level. ƒ Adjusting Fuel/Air Curve (Natural Gas or Propane or Modulating #2 Fuel Oil) NOTEE: Fulton Vantage boilers are factory test fired and pre-programmed with values in the fuel/air curve (P0- ignition to P9-high – fire). NOTEE: Modulating #2 Fuel Oil applies to models VTG-5000DF/VTG-6000DF only.
  • Page 55 OPERATION SECTION 3 VTG-IOM-2016-1214 1) Confirm position of the fuel selection switch where applicable. 2) Enter the password and parameter “400” will flash. 3) Press the enter (i/reset) button 2 times. a. “P1” will flash and the curve point will be displayed. –...

  • Page 56: Adjusting Fuel/Air Curve (Multistage #2 Fuel Oil - Vtg-2000Df To Vtg-4000Df)

    VTG-IOM-2016-1214 ƒ Adjusting Fuel/Air Curve (Multistage #2 Fuel Oil – VTG-2000DF to VTG-4000DF) NOTEE: Fulton Vantage boilers are factory test fired and pre-programmed with values in the fuel/air curve (P0- ignition to P9-high – fire). With the burner on follow the below steps for making field changes to the fuel/air curve points. A calibrated flue gas analyzer is required to complete these steps and must be properly inserted into the boiler flue exhaust vent while making changes to the fuel/air curve points.

  • Page 57: Viewing Flame Signal Intensity

    OPERATION SECTION 3 VTG-IOM-2016-1214 5) Stage “P1” to “P2on” press the “+” button to change to the next stage. d. “P2on” is the switch on point for stage two. When the angle (actuator) exceeds this point, the fuel oil valve for the 2nd stage is switched on. 6) Stage “P2on”...

  • Page 58: Manual Control (Manual Request For Output)

    5) Press and hold the – and + for 3 seconds to return to automatic mode. a. The output will no longer flash, oP: will be displayed on the left solid and the operating percentage will be displayed on the right. 3-10 © The Fulton Companies 2016...

  • Page 59: Viewing Total Burner Start-Ups

    OPERATION SECTION 3 VTG-IOM-2016-1214 ƒ Viewing Total Burner Start-ups 1) Press and hold the “F” and “A” buttons simultaneously. 2) “400” will flash. Press the “-“button to scroll to “100”. a. Press the enter i/reset button b. Press the “+” button until parameter 166 is flashing, press the enter i/reset button.

  • Page 60: Changing Modbus Address

    IMPORTANT: “._._” will be displayed to the right of .05. To access the Startup Counter (cycle) you must i) PRESS ENTER and the value will now be displayed. Press ESC (hold – and + arrows together) to return to the flashing .05. 3-12 © The Fulton Companies 2016...
  • Page 61 OPERATION SECTION 3 VTG-IOM-2016-1214 g) Press the + arrow and .06 will be flashing. IMPORTANT: “._._” will be displayed to the right of .06. To access the Output you must PRESS ENTER and the value will now be displayed. Press ESC (hold –...

  • Page 62: Parameter Backup

    Note: If an error occurs during the backup process, a negative value is displayed. For troubleshooting go to error code 137 to view diagnostic code. 3-14 © The Fulton Companies 2016...

  • Page 63: Parameter Restore

    OPERATION SECTION 3 VTG-IOM-2016-1214 ƒ Parameter Restore 1. Press and hold “F and A” until Code is displayed a. Then enter unit national board number press enter once complete. 2. “400: Set” will be displayed a. Press the “-“arrow two times until “100: PArA” is displayed.

  • Page 64: Operating Temperatures And Fuel Selection

    No minimum return water temperature Propane No minimum return water temperature #2 Fuel Oil 140°F (60°C) B100 Bio-Diesel 100°F (38°C) #2 Fuel Oil with guaranteed <15 100°F (38°C) ppm Sulfur (ultra-low sulfur) Digester Gas/Alternative Fuels Consult Factory 3-16 © The Fulton Companies 2016...

  • Page 65: Temperature Controller Instructions

    ` CHANGE SET POINT 1. Set Point Mode is accessed through the switch selection or BMS screen Non-Fulton product information is for reference purposes only. No Fulton selection. document should substitute for full Min. Loop Temp: Minimum setpoint temperature at which the boiler can ƒ...

  • Page 66: Yokogawa Ut 32A Basic Programming

    The smaller the Integral (I) value, the more quickly the boiler will react to a change in temperature. 4. Use arrows to navigate to Derivative (d). Default setting is “OFF”. Alteration is not recommended. 5. Pressing DISP will take return you to front screen. 3-18 © The Fulton Companies 2016...

  • Page 67: Access To Variable Speed Drive Blower Motor

    – NOTEE: Some Fulton Vantage Low Emissions Designs include a Variable Frequency and strict adherence to applicable Drive (VFD). The VFD is a Telemechanique Altivar 21 style. jurisdictional/professional codes and regulations.

  • Page 68: Perform Test Of Limit Controls

    Vantage boilers should be operated and controlled so the boiler cycles less than 12,000 times per year. Vantage boilers should be operated and controlled so that the temperature differential across the boiler does not exceed 100°F (38°C). 3-20 © The Fulton Companies 2016...

  • Page 69: Maintenance

    MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 70: General

    Daily, Weekly and Monthly Maintenance and Inspection (Fulton considers the regulations. following to be good practice for any boiler, and is applicable to the full line of Vantage boilers). It is also good practice for any boiler installation to perform...

  • Page 71: Annual Maintenance And Inspection Schedule

    Exposure to crystalline silica may pose significant health hazards, on the tubes. Consult Fulton Heating Solutions immediately if there is a including but not limited to eye and concern.

  • Page 72: Annual Removal And Inspection Of Le Bekaert Burner

    Appropriate training and instructions 2. Shut off gas supply. are available from the Fulton Service Department at (315) 298-5121 or 3. Disconnect the gas union and properly support the gas train. It may be your local Fulton Heating Solutions possible to remove just the gas actuator from the valve body to gain access Representative.
  • Page 73 1-13/16” socket and ¾ x ½” adapter (U.S. only; these were ƒ provided from the factory and should be stored in a safe place in the boiler room). If these components have been misplaced, please contact Fulton to purchase replacement components. Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 74 MAINTENANCE SECTION 4 VTG-IOM-2016-1214 WARNING The VTG-2000 through VTG-5000 Fulton part numbers are 2-22-000570 (socket) and 2-22-000571 (adapter). For VTG-6000, All information in this manual is for the socket part number is is 2-22-000572. It is a 1 ” Deep...

  • Page 75: Inspecting/Cleaning The Flue Passages

    Please contact Fulton’s service department for more Inspecting/Cleaning the Flue Passages information and instructions, as requirements vary by model and burner selection.
  • Page 76 FIGURE 29 - RLS-160 BURNER ELECTRODE POSITION FOR GAS FIGURE 27- RLS-100-130E BURNER ELECTRODE POSITION FOR GAS OPERATION OPERATION Electrode Ignition Pilot FIGURE 28 - RLS-160 BURNER ELECTRODE AND IGNITION PILOT FIGURE 30 - RLS-160 BURNER ELECTRODE POSITION FOR OIL LOCATIONS OPERATION © The Fulton Companies 2016...
  • Page 77 Air in pilot gas line Have the boiler attempt to light up to three times. If the boiler fails to light, call Fulton. Ignitor failure 1. Check the gap between the top of the electrode and the pilot tube wall. The gap should be 1/16”...
  • Page 78 When the water temperature falls below the high-limit temperature, the boiler will that the other limits are satisfied. remain locked out until the controller is manually reset. 4-10 © The Fulton Companies 2016...
  • Page 79 MAINTENANCE SECTION 4 VTG-IOM-2016-1214 PROBLEM CAUSE CHECK Low Air Flow Supply indi- Low Air is annunciated if the airflow switch detects The air switch has been factory set and should not cated on low air switch be adjusted in the field. low airflow through the boiler.
  • Page 81 WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 82 WARRANTY & PARTS SECTION 5 VTG-IOM-2016-1214 © The Fulton Companies 2016...
  • Page 83 ` PARTS WARRANTY Fulton will repair or replace any part of the Vantage boiler found to be defective in workmanship or material within 18 months of shipment from the factory or 12 months from start up (whichever comes first). Fulton shall be notified in writing as soon as any defect becomes apparent. Defective parts must be returned to Fulton for evaluation and warranty consideration.
  • Page 84 Fulton Companies. When ordering replacement parts, please have recommended for this equipment. Use of non-factory authorized parts the model number and serial number of your Fulton boiler ready. Factory-direct may jeopardize safety and system replacement parts must be used to ensure proper equipment operation and performance, and voids the product adherence with warranty requirements.
  • Page 86 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 fluid heat transfer systems.
  • Page 87 ModSync SE BACnet Network Addressing BACnet Description Range Type Units Object ID Lead Boiler Position Analog Value Outdoor Air Temperature 0 to 250 Analog Value Deg. F Supply Temperature 0 to 250 Analog Value Deg. F Return Temperature (If Applicable) 0 to 250 Analog Value Deg.
  • Page 88 Boiler 3 Alarm Status 0 - Off Binary Input 1 – On Boiler 3 Outlet Temperature 0 to 250 Analog Input Deg. F Boiler 3 Firing Rate 0 to 100 Analog Input Boiler 4 Local/Remote Switch 0 - Local Binary Input 1 –...
  • Page 89 1 – On Boiler 8 Outlet Temperature 0 to 250 Analog Input Deg. F Boiler 8 Firing Rate 0 to 100 Analog Input Boiler 1 Isolation/Pump Status 0 – Disabled Binary Input 1 – Enabled Boiler 2 Isolation/Pump Status 0 – Disabled Binary Input 1 –...
  • Page 90 Alarm Chart Alarm Code Description No Alarm Outdoor Air RTD Sensor Error Loop Temperature RTD Sensor Error Boiler 1 Alarm Boiler 2 Alarm Boiler 3 Alarm Boiler 4 Alarm Boiler 5 Alarm Boiler 6 Alarm Boiler 7 Alarm Boiler 8 Alarm Boiler 1 Monitor Alarm Boiler 2 Monitor Alarm Boiler 3 Monitor Alarm...
  • Page 91 Boiler 2 High Gas Pressure Boiler 3 High Gas Pressure Boiler 4 High Gas Pressure Boiler 5 High Gas Pressure Boiler 6 High Gas Pressure Boiler 7 High Gas Pressure Boiler 8 High Gas Pressure Boiler 1 Safety Loop Alarm Boiler 2 Safety Loop Alarm Boiler 3 Safety Loop Alarm Boiler 4 Safety Loop Alarm...
  • Page 92 Installation, Operation & Maintenance Manual ModSync Sequencing System For Use with the ModSync SE...
  • Page 93 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 94 Outdoor Reset Configuration ...................... 32  Alarm Status ..........................33  Lead / Lag Configuration 1 ......................34  Lead / Lag Configuration 2 ......................35  Lead / Lag Configuration 3 ......................36 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 95 ModSync Alarms ............................. 49 Backing up the Program .......................... 49 Battery Replacement ..........................49 Common Troubleshooting Issues......................50 PARTS AND WARRANTY ..........................51 ModSync Limited Warranty ........................51 Specifications ............................52 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 96: Introduction

    SECTION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 97 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 or regulations. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 98: Modsync Features

    The ModSync can be configured for automatic or manual control of the boilers. The Manual features help to decrease the boiler commissioning time by assisting with verification of the communication interface. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 99 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 100: Installation

    SECTION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 101: Location

    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 or regulations. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 102: Temperature Sensors

    Sheath Diameter: 38 Length: Supply Sensor (4”); Outdoor Air Sensor (2”) Type: 303 Stainless Steel Threaded Fitting: ¼” NPT Figure 2 – Temperature Sensors: Outdoor Air (Left) and Hydronic Supply/Return (Right) Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 103 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 104: Operation

    SECTION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 105: Sequence Of Operations

    OPERATION SECTION 3 MODSYNC-IOM-2016-APR Sequence of Operations Designed to maximize the efficiency of a multiple boiler hydronic loop, the ModSync resets the loop temperature based on Outdoor Temperature. The hydronic boilers are sequentially This manual is provided as a guide staged on at low fire, if additional heat is required;...

  • Page 106: Screen Descriptions

    The ModSync touch screen allows for screen navigation and parameter input by simply touching inside the rectangle that outlines the associated variable. Indicator Displays Parameter Inputs (Adjustable Settings) Screen Navigation Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 107: Main Menu Screen

    Figure 4 – Main Menu Screen (Color) System Status Screen Setpoint / Outdoor Reset Configuration Screen Lead / Lag Configuration Screens System Configuration Menu Alarm Status Screen Setback Schedule Screens Trending Screen Information Screen Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 108: System Status Screen

    (0% = minimum or no boilers required, 100% = all boilers required at high fire). The rate of increase/decrease of the control variable is determined by the supply temperature as compared to the setpoint and the PID settings. Hydronic “Boiler Config” Configuration Screens  Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 109 Mode: Touchscreen option that allows the user to select the operation mode of each boiler. In Auto mode the ModSync will include the boiler in the Lead Lag sequence, determine when the boiler is enabled, and control the Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 110: System Configuration Menu

    See figure 7. Figure 7 – System Configuration Menu *The System Configuration screen is also another location to find the serial number of the ModSync. System and Scaling Screen 1  Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 111 Screen Contrast: Adjusts the brightness of the screen. 20 – darkest, 100 – brightest.  Temp Scaling: Change the ModSync between Celsius and Fehrenheit.  Modulation Mode: Determines how the ModSync will control the boilers. See below. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 112 The lead boilers firing rate will continue to increase independently of the other boilers as the other boilers firing rates increase as well. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 113 %. Note that if the Low Fire % is 0% and the low fire position of the boiler is 20% the boiler will only go to its actual low fire position. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 114  Interface Selection: Allows the selection of the boiler type. Used if boilers are added/removed or changed after the ModSync has been installed. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 115: Password And Screen Saver

    Screen Saver: When enabled the ModSync will load a screen saver if the screen has not been touched before the Dim Timer expires. Once the screen saver has loaded just touch the screen again to load to the Main Menu. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 116: Maintenance Configuration Screen 1

    This function is for display purposes only and does not affect the operation of the boilers. In order to reset the remaining hours press and hold the last serviced button for 5 seconds. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 117: Sensor Configuration

     BMS Value: Shows the current temperature value being read from the sensor or the value being written by the BMS through the communication protocol. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 118: Bms Configuration

    Update Settings button and the message will change to communication settings updated. The ModSync is now properly configured with settings selected. Transmit and Receive values to the right are available to show communication status. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 119: Alarm Configuration

    Monitor Alarm after the adjustable time delay. This is to allow the boiler to rejoin the sequence if an auto reset limit is the reason for the boiler being locked out on a Monitor Alarm condition. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 120: Setback Schedule

    Mode Select: Displays the current mode and allows the user to select the mode when the mode is in Manual mode.  Shoulder Mode/Design Mode: Allows the ModSync to switch between two sets of lead lag settings based on outdoor temperature. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 121: Setpoint Configuration Without Outdoor Reset

    DHW Min Setpoint: If the ModSync is in DHW mode and the current setpoint is less than the DHW Min Setpoint then the ModSync will raise the setpoint up to the DHW Min Setpoint until the ModSync is no longer in DHW mode. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 122: Setpoint Configuration With Outdoor Reset

     Outdoor Temp Deviation: Outdoor Temp Deviation is how many degrees the outdoor air temperature needs to drop before the ModSync will re-enable the boilers out of Outdoor Temp Disable. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 123: Outdoor Reset Configuration

    Occupied Mode: Determines the setpoint curve when the ModSync is in Occupied Mode based on the Setback Schedule.  Unoccupied Mode: Determines the setpoint curve when the ModSync is in Unoccupied Mode based on the Setback Schedule. Outdoor Reset Outdoor Temp Occupied Unoccupied Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 124: Alarm Status

    Figure 20 – Alarm Status Screen Trending  The trending screen allows for comparison and charting of the Loop, Setpoint, and Outdoor Temperatures. Figure 21 – Trend Screen Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 125: Lead / Lag Configuration 1

    1 and so on. This may mean that the lead boiler may not change if the current lead boiler has the lowest number of hours. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 126: Lead / Lag Configuration 2

    Lead Boiler Start Deviation: Defines how many degrees below setpoint before the ModSync will enable the Lead boiler.  Lead Boiler Stop Deviation: Defines how many degrees above setpoint before the ModSync will disable the lead boiler. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 127: Lead / Lag Configuration 3

    CV for each additional boiler. Boiler Position Lead Lag 1 Lag 2 Lag 3 Lag 4 Start CV: Stop CV: Example start and stop CV percentages based on the settings in Figure 24 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 128 CV value from driving up prior to the lead boiler starting. It is recommended that the value be equal to or greater than the lead boiler start deviation. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 129 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 130: Network

    SECTION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 131: Network Parameter Configuration And Address Listings

    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 or regulations. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 132: Port 2 Wiring Diagram (Slave) Rj-11 Type Serial Port

    Port 2 Wiring Diagram (Slave) RJ-11 Type Serial Port Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 133: Boiler Modbus Network (Port 3)

    Boiler Addressing: In order to communicate to the ModSync correctly the boilers will need to be addressed correctly at their local control. The ModSync is always address 1 so each boilers address will be boiler number plus 1. Boiler Number Modbus Address Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 134 The back center of the SOLA Display will contain the connections for the Modbus networks COM1 and COM2. COM 2 will most commonly be used in these setups for the ModSync connection. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 135 ModSync. Select the tab and enable the port that is to be used, make sure the Modbus address you wish you use is within the defined range and select a baud rate of 19200. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 136 *** If you do not select ‘Save’ before leaving the Setup screen your new settings will not take effect. *** In some cases you must cycle power to the panel; this will refresh the ports and make sure that the new settings are in effect. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 137 Red, Flashing Internal error OCI412.10 Orange, Steady Standby (Connection failure between OCI and LMV) Green, Steady Standby (Connected and ready to operate) Green, Flashing Modbus Communication No LED 24VDC Power missing. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 138: Maintenance

    SECTION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 139 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 or regulations. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 140: Modsync Alarms

    It is recommended that the battery be replaced every 3-5 years to prevent issues such as loss of program or customer settings. Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 141: Common Troubleshooting Issues

    Modbus communication, ModSync settings or settings at the local boiler control. If the ModSync shows a call for heat but the boilers to not fire a Monitor Alarm could be seen at the ModSync. SECTION Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 142: Parts And Warranty

    INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS AND WARRANTY ModSync Limited Warranty Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

  • Page 143: Specifications

    It should not, however be considered as a Please contact Fulton at 315-298-8510 before shipping back any parts for complete code of practice, nor testing/warranty verification. A Return Material Authorization (RMA) Number and...
  • Page 144 Modbus: Shielded 6-pin modular connector for ModSync port connection Analog: 4 shielded 24-gauge wires Digital I/O: 18 gauge wire (Blue - 24VDC+, Yellow - 24 VDC-) Standard Warranty for Synex ModSync Controls  Parts Warranty Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 145 The warranty is valid for the original installation and original owner only Part # Description Panel Box 2-45-001033 NEMA 4 16x14x8 with cutout and back panel Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 146 RS-232/485 Converter Module for LMV 3 2-45-001041 RS-232/485 Converter Module for LMV 5 Sensors and Accessories 4-30-000500 Outdoor Sensor Kit 2-40-000823 2" RTD Low Temperature 2-40-000855 2" RTD High Temperature Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 147 120VAC Control Relay (Ice Cube) 2-40-000096 Relay Base 2-45-000022 3 Position Switch 2-45-000309 2 Position Switch 2-40-000715 24VAC Transformer/Power Supply 2-40-000334 Honeywell Resistor Kit 2-45-000595 Hawkeye Current Sensing Switch 2-45-001040 24VDC Power Supply Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 148 Questions? Call (315) 298-8510, or visit us online at www.fulton.com...
  • Page 149 Synex Controls. ©Synex Controls 2017 6288 Running Ridge Rd Syracuse, NY 13212 Call: (315) 298-8510 www.fulton.com Questions? Call (315) 298-8510, or visit us online at www.fulton.com...

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