FULTON VSRT Series Installation, Operation And Maintenance Manual
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FULTON VSRT Series Installation, Operation And Maintenance Manual

Vertical spiral-rib tubeless boiler
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INSTALLATION,
OPERATION, AND
MAINTENANCE MANUAL
Vertical Spiral-Rib Tubeless Boiler
F ul o t n
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
VSRT Series
9.5 HP - 250 HP
VSRT-IOM-2022-0728

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Summary of Contents for FULTON VSRT Series

  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL VSRT Series Vertical Spiral-Rib Tubeless Boiler 9.5 HP - 250 HP F ul o t n Serial/ National           Board Number Model Fulton Order Owner Site Name...

  • Page 3: Table Of Contents

    System Piping Testing ..................2-49 Procedure for Cleaning Water Probes ..............4-2 Assembly of Fulton Multi-Skid Engineered Systems ......... 2-49 Flame Scanner Adjustment for Fulton Gas Fired Steam Boilers ......4-4 Before Leaving The Installation ................2-54 Recommended Daily Maintenance Schedule ............4-4 Recommended Weekly Maintenance Schedule ..........
  • Page 4 Recommended Annual Maintenance ..............4-12 After All Repairs ....................4-12 Troubleshooting ....................4-13 Service Documents Start-Up: Installation & Operation Report for Fulton Steam Boilers ....5-2 Vertical Steam Boiler Annual Maintenance Checklist ........5-11 Notes ........................5-13 © Fulton Group N.A., 2022...

  • Page 5: Introduction 1-1 Operation

    INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE & TROUBLESHOOTING SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 6: Overview

    This manual is provided as a guide to the correct operation and maintenance powered down prior to attempting of your Fulton equipment, and should be read in its entirety and be made replacement or service of electrical components or connections of the permanently available to the staff responsible for the operation of the boiler.

  • Page 7: Receiving Inspection

    INTRODUCTION SECTION 1 VSRT-IOM-2022-0728 WARNING Receiving Inspection After checking controls by manual adjustment, always ensure they are reset The customer should examine the equipment for any damage. It is the to their proper settings. responsibility of the installer to ensure all parts supplied with the equipment are fitted in a correct and safe manner.
  • Page 8 Whenever possible, the system should be cooled prior to opening any drains. Post these instructions in an appropriate place near the equipment and maintain in good legible condition. © The Fulton Companies 2022...
  • Page 9 Fulton Service Department corrosive to certain types of metals. the equipment. at (315) 298-5121 or your local Fulton Clean all piping thoroughly after Representative. completing the leak check. For reasons of safety, the hot...

  • Page 10: Disclaimers And Local Codes

    If emissions are improper, adjust combustion following the appropriate procedure in this manual. Should you suspect that the boilers flue passage ways have become blocked, contact your authorized Fulton representative. © The Fulton Companies 2022...

  • Page 11: Installation

    INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE & TROUBLESHOOTING SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 12: Product Overview

    ASME Boiler and Pressure Vessel Codes, for its corresponding classification, should If any questions arise, contact Fulton before proceeding. The information be followed in all cases. Jurisdictional contained in this installation, operation and maintenance manual is subject to authorities must be consulted prior to change due to continuous product improvement.

  • Page 13: Clearances And Serviceability

    9. Never allow weight to bear on the jacket, control panel, 36 (915) 15 (458) 185 (4.7) trim, burner, fuel train or fan housing of any Fulton – boiler. Use only lifting eyes or fork holes for movement. NOTE: The vertical clearance from the floor to the ceiling is for removal of the burner for servicing the VSRT 9.5-80 and for...
  • Page 14 1 (25) 1 (25) 1 (25) Note: *Shipped loose; size depends on trim pressure. **Use of B-vent with the Fulton VSRT boiler requires purchase of the high temperature vent limit switch part number 2-30-100414 © Fulton Group N.A., Inc. 2022...
  • Page 15 Please jurisdiction for exact code compliance. consult the factory for project specific estimates if additional 3. Fulton recommends minimum clearance of 36” in front of options or accessories are required. electrical panels. 8. Local codes can supercede Fulton recommended clearance.
  • Page 16 BURNER PULL CLEARANCE 86 1/8 85 3/4 75 3/4 (MIN HEIGHT) FIGURE 1 - 9.5-HP MODEL VSRT DIMENSIONS - FRONT SIDE VIEW (ALL DIMENSIONS IN INCHES)   © Fulton Group N.A., Inc. 2022      ...
  • Page 17 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 63 5/8 53 3/16 21 15/16 RIGHT SIDE VIEW 4 15/16 FIGURE 2 - 9.5-HP MODEL VSRT DIMENSIONS - RIGHT SIDE VIEW (ALL DIMENSIONS IN INCHES) Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 18 12 3/4 4 1/16 4 1/16 4 3/4 36 1/8 Note 3: Fulton recommends a minimum clearance of 36” in front of the electrical panels. Note 9: Fulton recommends 36” clearance between openings of all boilers, 18” clearance of handholes, and 18” from exhaust stack.
  • Page 19 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 22 7/8 98 1/2 CLEARANCE REQUIRED FOR BURNER REMOVAL (74)* (STEAM OUTLET) (MIN HEIGHT) 73 5/8 (FUEL INLET) 41 3/8 (AIR INLET)      FIGURE 4 - 10/15-HP MODEL VSRT DIMENSIONS - FRONT SIDE VIEW (ALL DIMENSIONS IN INCHES) Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 20 VSRT-IOM-2022-0728 76 3/8* 71 5/8 (S.R.V.) 43 1/16 (EXHAUST STACK) 22 3/8 (FEEDWATER) (BOTTOM BLOWDOWN) RIGHT SIDE VIEW FIGURE 5 - 10/15-HP MODEL VSRT DIMENSIONS - RIGHT SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-10 © Fulton Group N.A., Inc. 2022...
  • Page 21 7 1/8 NOTE 7 1/16 55 1/8 22 7/8 Note 3: Fulton recommends a minimum clearance of 36” in front of the electrical panels. Note 9: Fulton recommends 36” clearance between openings of all boilers, 18” clearance of handholes, and 18” from exhaust stack.
  • Page 22 OUTLET) 82 3/4 79 1/8 (FUEL INLET) (MIN HEIGHT) 57 5/8 (AIR INLET)     FIGURE 7 - 20-HP MODEL VSRT DIMENSIONS - FRONT SIDE  VIEW (ALL DIMENSIONS IN INCHES) 2-12 © Fulton Group N.A., Inc. 2022...
  • Page 23 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 85 5/8* 80 7/8 (S.R.V.) (EXHAUST STACK) 22 3/8 (FEEDWATER) RIGHT SIDE VIEW (BOTTOM BLOWDOWN) FIGURE 8 - 20-HP MODEL VSRT DIMENSIONS - RIGHT SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-13 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 24 7 1/8 NOTE 7 1/16 58 7/16 21 1/16 Note 3: Fulton recommends a Minimum clearance of 36” in front of the electrical panels. Note 9: Fulton recommends 36” clearance between openings of all boilers, 18” clearance of handholes, and 18” from exhaust stack.
  • Page 25 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 CLEARANCE REQUIRED FOR BURNER REMOVAL 86 3/8 (STEAM OUTLET) 79 1/16 (MINIMUM HEIGHT) (74) (FUEL INLET) 49 1/4 (AIR INLET) FRONT VIEW FIGURE 10 - 30-HP MODEL VSRT DIMENSIONS - FRONT VIEW (ALL DIMENSIONS IN INCHES) 2-15 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 26 SECTION 2 VSRT-IOM-2022-0728 87 3/8 81 5/8 (S.R.V.) (EXHAUST STACK) 22 5/16 (FEEDWATER) RIGHT SIDE VIEW (BOTTOM BLOWDOWN) FIGURE 11 - 30-HP MODEL VSRT DIMENSIONS - RIGHT SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-16 © Fulton Group N.A., Inc. 2022...
  • Page 27 32 1/2 (MINIMUM WIDTH) 7 1/8 NOTE 7 1/8 24 1/8 Note 3: Fulton recommends a Minimum clearance of 36” in front of the electrical panels. Note 9: Fulton recommends 36” clearance between openings of all boilers, 18” clearance of handholes, and 18” from exhaust stack.
  • Page 28 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 28 3/16 CLEARANCE REQUIRED FOR BURNER REMOVAL 99 13/16 65 5/8 FRONT VIEW FIGURE 13 - 40/50/60-HP MODEL VSRT DIMENSIONS - FRONT VIEW (ALL DIMENSIONS IN INCHES) 2-18 © Fulton Group N.A., Inc. 2022...
  • Page 29 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 MINIMUM INCOMING GA BURNER MOTOR WITH V NOTES STEA 100° FULT OF E FULT 103 1/2 99 3/16 PLEA INFO 96 5/8 INST 64 5/8 WE R TO C FACT 21 3/8 RIGHT SIDE VIEW FIGURE 14 - 40/50/60-HP MODEL VSRT DIMENSIONS - SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-19 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 30 67 3/8 49 (MIN WIDTH) NOTE 84 1/4 28 3/16 Note 3: Fulton recommends a minimum clearance of 36” in front of the electrical panels. Note 4: Fulton recommends 36” clearance between openings of all boilers, 18” clearance of handholes, and 18” from SEE NOTES 3 AND 10 exhaust stack.
  • Page 31 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 29 1 143 1/2 CLEARANCE 131 5/8 REQUIRED FOR BURNER (STEAM OUTLET) REMOVAL 110 1/8 112 1/2 (MIN (FUEL INLET) HEIGHT) 69 5/8 (AIR INLET) 24 3/4 FRONT VIEW FIGURE 16 - 80 HP MODEL VSRT DIMENSIONS - FRONT VIEW (ALL DIMENSIONS IN INCHES) ...
  • Page 32 110 1/8 (MIN HEIGHT) 76 3/4 (EXHAUST STACK) 22 3/8 (FEEDWATER) RIGHT SIDE VIEW 5 3/4 (BOTTOM BLOWDOWN) FIGURE 17 - 80 HP MODEL VSRT DIMENSIONS - SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-22 © Fulton Group N.A., Inc. 2022...
  • Page 33 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 (87 7/8) 66 MIN 79 3/84 MAX 49 (MIN WIDTH) 9 7/8 NOTES 4 & 9 9 7/8 (137 1/16) 86 13/16 29 1/8 SEE NOTES 3 AND 10 FIGURE 18 - 80 HP MODEL VSRT DIMENSIONS - TOP VIEW (ALL DIMENSIONS IN INCHES) 2-23 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 34 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 (126) 72 3/8 75 5/8 (FUEL (AIR INLET) INLET) FRONT VIEW FIGURE 19 -100/125 HP MODEL VSRT DIMENSIONS - FRONT VIEW (ALL DIMENSIONS IN INCHES) 2-24 © Fulton Group N.A., Inc. 2022...
  • Page 35 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 147 7/8 147 3/8 (STEAM OUTLET) 125 1/16 (EXHAUST) 59 5/8 (FEEDWATER) LEFT SIDE VIEW 3 1/4 (BOTTOM BLOWDOWN)           FIGURE 20 -100/125 HP MODEL VSRT DIMENSIONS - SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-25 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 36 62 3/4 (MIN WIDTH) 28 1/4  62 7/8 100 1/4* 26 7/8 (126) SEE NOTES 3 AND 9 FIGURE 21 - 100/125 HP MODEL VSRT DIMENSIONS - TOP VIEW (ALL DIMENSIONS IN INCHES) 2-26 © Fulton Group N.A., Inc. 2022...
  • Page 37 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 139 1/8 (TOP FLUE CONNECTION) FRONT VIEW FIGURE 22 - 250 HP MODEL VSRT DIMENSIONS - FRONT VIEW (ALL DIMENSIONS IN INCHES) 2-27 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 38 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 (164 1/2)* 144 3/4* (SRV) 3 7/8 RIGHT SIDE VIEW (BOTTOM BD) FIGURE 23 - 250 HP MODEL VSRT DIMENSIONS - RIGHT SIDE VIEW (ALL DIMENSIONS IN INCHES) 2-28 © Fulton Group N.A., Inc. 2022...
  • Page 39 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 106 13/16 57 7/8 14 1/4 (TYP.) 1 1/4 84 5/8 (TYP.) 129 7/16 46 7/8 2 5/16 35 11/16 FIGURE 24 - 250 HP MODEL VSRT DIMENSIONS - TOP VIEW (ALL DIMENSIONS IN INCHES) 2-29 Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 40: Equipment Ventilation & Combustion Air Requirements

    (one square inch of free area per 2,000 BTU/hr input per NFPA & BOCA). Free opening area must take into account the space taken up by louvers, expanded metal, etc. 2-30 © Fulton Group N.A., Inc. 2022...

  • Page 41: Combustion Air Filter (Vsrt 9.5, 80-250 Bhp Only)

    When inlet gas pressure exceeds the maximum on the boiler name plate, a line When calculating ventilation requirements, gas pressure regulator is required to step the gas pressure down to an acceptable heat losses from the Fulton equipment (and pressure. other equipment) should be considered.
  • Page 42 6700 5500 4600 6 (152.4) 6.07 (154.17) 10.10 (3.07) 23.60 (7.19) ----- ----- ----- ----- 20200 16503 12766 8 (203.2) 7.98 (202.69) 13.30 (4.05) 29.10 (8.86) ----- ----- ----- ----- 41200 33660 29128 2-32 © Fulton Group N.A., Inc. 2022...
  • Page 43 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 WARNING 7. The pipe and the fittings used must be new and free of dirt or other deposits. Do not use matches, candles, flame or other sources of ignition to check for gas 8. Piping must be of the proper size to ensure adequate gas supply. It is leaks.
  • Page 44 10. If the unit is not skid-mounted at the factory, the client/contractor is required to wire the feed water pump starter. – NOTE: If the pump motor is not supplied by Fulton, the motor starter may not be supplied. 2-34 © Fulton Group N.A., Inc. 2022...
  • Page 45 (0-30 PSIG), 6,000 – 8,000 ft./min. for medium pressure steam (30 -75 PSIG), and 8,000 – 12,000 ft./ min. for high pressure steam (75 PSIG and above). TABLE 6 - WATER CHEMISTRY REQUIREMENTS FOR FULTON BOILERS Carbon Steel Stainless Steel...
  • Page 46 >7.5 prior to entering the boiler. Failure to neutralize the RO/DI will void the PV warranty and cause high general corrosion rates. The Fulton Warranty does not cover damage or failure that can be attributed to excessive corrosion, scale or fouling.
  • Page 47 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 ƒ Glossary of Water Supply Terms frequently enter a system through leaks in a condenser or other heat exchanger. Oil can also enter a system through Dissolved Oxygen: Oxygen that is dissolved in the feedwater the lubrication of steam driven reciprocating equipment. will cause the steel in the boiler and the feedwater system to Whatever the source, the presence of oil in boiler water is be attacked by the water in a manner described as “pitting”.
  • Page 48 No additional loads should be applied to any factory connection. 7. Gaskets must be used to make all flanged connections. Gasketing material must be suitable for use with the pressure, temperatures and fluids in the 2-38 © Fulton Group N.A., Inc. 2022...
  • Page 49 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 system. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. 8. High point bleeds/air vents are to be installed at all high points in the system piping. 9.
  • Page 50 SURFACE BLOWDOWN WATER SAMPLE PORT SURFACE BLOWDOWN DRAIN CHECK SHUT OFF VALVE VALVE TUBING FOR SIGHT GLASS DRAIN FAST OPENING BLOWDOWN VALVE VALVE FIGURE 25 - NEAR BOILER PIPING (CONTINUED ON NEXT PAGE) 2-40 © Fulton Group N.A., Inc. 2022...
  • Page 51 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 VENT TO ATMOSPHERE CONDENSATE RETURNS OVERFLOW VENT TO ATMOSPHERE FEEDWATER SIGHT MAKEUP TANK GLASS WATER SUPPLY COOLING WATER INLET STEAM PREHEAT CONNECTION THERMOMETER TEE FOR CHEMICAL BLOWDOWN QUILL INJECTION TANK THROTTLING THERMOMETER GLOBE VALVE CHECK SHUT OFF VALVE VALVE FEED TANK...
  • Page 52 3% over the boiler safety valve allowed by local jurisdiction. setting and include the necessary additional pressure to overcome piping losses. 6. Do not insulate the blowdown tank. 3. See Feedwater Instruction Manuals for detailed instructions. 2-42 © Fulton Group N.A., Inc. 2022...
  • Page 53 10. Do not support discharge piping with the safety valve. Discharge piping must be supported adequately by appropriate means. 11. Fulton recommends the use of a drip pan elbow, as this provides the needed drainage and isolation from expansion as required.
  • Page 54 BALL CHECK VALVE VESSEL WALL GUARD WASHER PACKING GLAND GLASS PACKING FRICTION WASHER) GAUGE GLASS GLASS PACKING ASME AUTOMATIC BALL CHECK VALVE BOTTOM DRAIN GAUGE VALVE FITTING FIGURE 27 - SIGHT GAUGE GLASS 2-44 © Fulton Group N.A., Inc. 2022...
  • Page 55 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 3. Install the top fitting (the fitting without the drain port) Stack & Flue Connections into the upper fitting on the water bottle using service rated sealant. Wrench tighten the fitting until it is snug Adhere to the following for stack and flue connections: and the glass outlet is pointing at about 5 o’clock (about 1/8 turn from its final downward vertical position).
  • Page 56 Fulton cannot be held responsible for the perchloroethylene would be prime suspects. effects such adverse conditions may have on the operation of the boilers.
  • Page 57 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 SECTION A-A INSTALL APPROPRIATE WEATHER CAP MINIMUM 6' ABOVE ANY STRUCTURE SUPPORT AS WITHIN 30' NECESSARY - ROOF - - ROOF - EXTEND BAFFLE ABOVE LAST ENTRANCE 3" STAGGER EXPANSION JOINTS ENTRANCES AS REQUIRED TOTAL MIN 3" RISE DRAFT REGULATOR (RECOMMENDED)
  • Page 58 MIN 3' RISE EXPANSION JOINTS AS REQUIRED DRAFT REGULATOR (RECOMMENDED) 60° (45° MIN) 30° BAFFLE CLEANOUT DOOR THIS DISTANCE MUST NOT EXCEED 25% FIGURE 29 - VSRT-250 BHP TYPICAL STACK OF TOTAL RISE 2-48 © Fulton Group N.A., Inc. 2022...
  • Page 59 Adhere to the following for multi-skid engineered systems: 1. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain 1. Refer to the Fulton mechanical/electrical drawings the pitch of the vent and provide sealing. Use adhesive during assembly.
  • Page 60 2.) Maintain minimum 9" / 22.86 cm air space clearances to combustables, wires and insulation 3.) Install support straps at 5 FT / 152 CM horizontal intervals and at elbows FIGURE 30 - ROOF PENETRATION DETAILS FOR VSRT 9.5-125 BHP 2-50 © Fulton Group N.A., Inc. 2022...
  • Page 61 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 WALL WALL TERMINATION ( WITH SCREEN ) 4 FT / 122 CM ( MINIMUM ) DO NOT PLACE INSULATION IN BETWEEN INLET & EXHAUST REQUIRED AIR SPACE CLEARANCE OPENING ( SEE BELOW ) BAND SUPPORT AIR INTAKE AND EXHAUST COLLAR TERMINATION SHOULD BE (TYP EACH SIDE)
  • Page 62 1 FT. / 30 CM (MIN) ABOVE (SUGGESTED TERMINATION CONFIGURATIONS) THE NORMALLY EXPECTED LEVEL EXHAUST STACK IS DOWNWIND OF AIR INTAKE OPENING APPROVED VENT MATERIAL AIR INLET EXHAUST OUTLET FIGURE 32 - ROOF PENETRATION DETAILS FOR VSRT-250 2-52 © Fulton Group N.A., Inc. 2022...
  • Page 63 INSTALLATION SECTION 2 VSRT-IOM-2022-0728 WALL DO NOT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE WALL TERMINATION (WITH SCREEN) 4 FT / 122 CM (MINIMUM) BETWEEN INLET & EXHAUST OPENING (SEE BELOW) AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBL TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS...
  • Page 64 SECTION 2 VSRT-IOM-2022-0728 WARNING wiring through the appropriate conduit runs. Electrical wires are labeled for easy landing. Connect all wiring per the Fulton supplied electrical All information in this manual is for drawings. reference and guidance purposes, and does not substitute for required 9.
  • Page 65 OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE & TROUBLESHOOTING SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 66 If possible, contact the factory at least two weeks before a Fulton service engineer is required on site. Careful preparation can expedite the commissioning of your boiler. Most delays can be avoided by following the instructions in this manual.
  • Page 67 Consequently, if boil out is not accomplished prior to system operation, erratic water level control and surging may occur. Fulton strongly recommends that a boiler chemical specialist be consulted for the purchase of chemicals for boiler cleaning.
  • Page 68 13. The burner will remain in the off state until the system valve, an air control valve and a variable speed drive to achieve steam pressure falls below setpoint for the burner to turndown. turn back on. © Fulton Group N.A., 2022...
  • Page 69 “Escape” (pressing the “+” and “-“ keys at the same time). Siemens LMV3 Controller Navigation Perform the following steps once you have completed first-time programming of the Siemens LMV3: Note: Fulton recommends use of the flame programmer manual/Quick Start Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 70 Guide when performing any changes on the unit flame programmer. This information is for reference purposes 1. Press and hold the F and A buttons simultaneously. You will be prompted only. Fulton Companies is not responsible for your password (####). for this product, including (but not limited to) its accuracy, reliability, and safety.

  • Page 71: Commissioning The Unit

    WARNING Commissioning the Unit This information is for reference purposes only. Fulton Companies is not responsible Perform the following steps for commissioning the unit with the Siemens LMV3: for this product, including (but not limited to) its accuracy, reliability, and safety. No –...
  • Page 72 + to display parameter 702 7 0 2: : 8 7 Hold Return, until index "01" flashes, and release 7 0 2: + to display parameter 702, index "02" In this example "1" is the Diagnostic code © Fulton Group N.A., 2022...

  • Page 73: Operating Controls

    (3) SET/Enter key press the key in the Menu Display to ƒ Boiler pressure controller is Yokogawa UT-32A for the the Parameter Setting Display of the Menu. Press the VSRT 9.5-125 and a Fulton PLC Controller for the key in the Parameter Setting Mode to change the set VSRT-250.
  • Page 74 80 PSIG, A1 would be set to 13. Integral setting allows the boiler to reach the set point (negative) - 20. 14. Fulton standard Integral time setting is “minutes/ To adjust your “Boiler On” set point, you choose the negative seconds per repeat”...

  • Page 75: For All Models

    VSRT-IOM-2022-0728 WARNING For all Models This information is for reference purposes only. Fulton Companies is not responsible ƒ Flame Programmer for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full Refer to cut sheets for provided flame programmer.

  • Page 76: Primary Low Water Cut-Off

    Standard low water cutoff devices are Fulton level probes. Alternate cutoff devices are MM-150, MM-157, MM-193-7b. Fulton probe type low water cutoff devices have a built in 3 second time delay feature. Float type low water cutoff controllers have a 30-second delay. Test as...

  • Page 77: Secondary Low Water Cut-Off

    OPERATION SECTION 3 VSRT-IOM-2022-0728 WARNING ` SECONDARY LOW WATER CUT-OFF Do not shut off gas supply with the burner This is always a manual reset safety. running. This is extremely dangerous. Damage to the boiler/burner may occur. To test this safety: 1.

  • Page 78: Pressure Relief Valve

    1. Turn switch to Off. If burner is currently on, the unit will 2. While the boiler is off, remove the common wire to the start ramping down to low fire before turning off. 3-14 © Fulton Group N.A., 2022...
  • Page 79 2 = even *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 80 22 = Lo mod only oil actuator *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 81 Gas: Repetition limit loss of flame *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 82 Actuators *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 83 0xFFFFFFFF *Data is for reference purposes only. Fulton Companies is not responsible for this product, including (but not limited to) its accuracy, reliability, and safety. No Fulton document should substitute for full review of documentation available from the product manufacturer.
  • Page 84 OPERATION SECTION 3 VSRT-IOM-2022-0728 THIS PAGE LEFT INTENTIONALLY BLANK 3-20 © Fulton Group N.A., 2022...

  • Page 85: Maintenance & Troubleshooting

    MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE & TROUBLESHOOTING SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 86: Procedure For Cleaning Water Probes

    Probe 3-50-000702 3-50-000702 3-50-000702 3-50-000702 3-50-000702 3-50-000702 Installation and service must be performed Assembly by a qualified and knowledgeable individual, such as a Fulton representative, Part Number Length qualified installer, service agency or gas supplier. Any potential warranty issues that 2-20-000023 3"...
  • Page 87 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 TOP OF BOILER PUMP OFF PUMP ON PRIMARY LOW WATER AUXILIARY CUT OFF LOW WATER CUT OFF* Note: *Depending on model and date manufactured, AUX LOW WATER CUT OFF off may enter boiler from the side, or top of boiler.

  • Page 88: Flame Scanner Adjustment For Fulton Gas Fired Steam Boilers

    MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 CAUTION Flame Scanner Adjustments for Fulton Gas Fired If the feed water is being treated by chemical Steam Boilers compounds, make sure that this treatment is carried out carefully and according to the supplier’s instructions.

  • Page 89: Recommended Weekly Maintenance Schedule

    WARNING – NOTE: Fulton recommends that the feedwater chemical treatment should be Make sure main power switch is off before starting work. added between the pump and the boiler. 4. Check water level in sight glass.

  • Page 90: Replacing The Combustion Air Inlet Filter (Vsrt-9.5, 80-250 Hp)

    NOTE: Operating the burner with the combustion air inlet filter removed will void the burner warranty. A clean filter of the same Fulton part number (type, size and style) must be installed while the boiler is in operation. 3. 3. Return the filter to its original position in the slot, verify orientation.
  • Page 91 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 CAUTION 9. Check burner and boiler refractory for cracks. If the gasket leaks while pressure is being 10. Inspect stainless steel ring in furnace (if present) built up, tighten only enough to stop leakage. Never tighten more than necessary 11.
  • Page 92 » Remove the ignition cable from the ignition electrode » Remove the bolts holding the pilot assembly » Remove the pilot assembly by lifting straight up or horizontally (depends on model) - taking care not to lose the O-ring seal © Fulton Group N.A., Inc. 2022...
  • Page 93 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 2. Inspect the pilot assembly » Inspect the burner for signs of local overheating, or soot. If soot is present, either » Ensure that the pilot orifice is not clogged. the pilot or the main burner is not running the proper fuel air ratio, and the combustion »...
  • Page 94 » Remove 3/8” b7 nuts & Belleville washers from the proper fuel air ratio, and the combustion burner plate. controls should be checked, while local overheating will result in discolored mesh or possible detaching or sagging. 4-10 © Fulton Group N.A., Inc. 2022...
  • Page 95 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 3. Re-Install Burner. » After cleaning burner, scrape old gasket from burner and premix plate and install a new Grafoil gasket onto burner stud plate. » Once burner is fully seated on the studs, reinstall the ½”...

  • Page 96: Examine The Venting System

    8 Subchapter 2 Article 5 Section 771 ‘Boilers Not Subject to Annual Inspection’ 5. Replace the combustion air inlet filter with a new filter of the same Fulton part number (type, size, and style) on the VSRT-9.5, VSRT 80-250. After All Repairs or Maintenance 1.

  • Page 97: Troubleshooting

    MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 Troubleshooting Refer to table below for troubleshooting. Troubleshooting Gas Fired Boilers Problem Cause Remedy Power Supply Check fuse or circuit breaker. Reset or replace, as necessary. Check electrodes for carbon buildup and clean if necessary. Ignition Electrodes Check for proper adjustment.
  • Page 98 As the boiler cools off, it pulls water from the system piping. To prevent this, add a 1/4” check valve on the steam gauge Vacuum created with boiler off assembly piping, which closes under pressure and opens under vacuum. 4-14 © Fulton Group N.A., Inc. 2022...
  • Page 99 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 Problem Cause Remedy Check refractories to see if they are plugged with soot or Damaged Refractory broken in pieces. Clean or replace as necessary. Check CO2/O2 levels. If rich, disassemble filter housing and gas Not Enough Air/Build-Up on train.
  • Page 100 Dirty Probes Clean or replace as necessary. Pump will not cut Make sure relay is plugged in tightly. If so, replace water level Relay failed relay. Ground Connection Check for tightness and clean. 4-16 © Fulton Group N.A., Inc. 2022...
  • Page 101 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 Problem Cause Remedy Allow system to cool down, check steam traps to make sure they are operating properly, and check to be sure return lines are not insulated. Check feedwater tank temperature. If it is Vapor locking of pump above 180 F (82 C) vapor locking may occur, depending on pump selection.
  • Page 102 MAINTENANCE & TROUBLESHOOTING SECTION 4 VSRT-IOM-2022-0728 PAGE LEFT INTENTIONALLY BLANK 4-18 © Fulton Group N.A., Inc. 2022...

  • Page 103: Service Documents

    SERVICE DOCUMENTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 104: Start-Up: Installation & Operation Report For Fulton Steam Boilers

    AMBIENT AIR TEMPERATURE OUTSIDE FEED WATER PUMP SUCTION/DISCHARGE PIPE WORK MEETS SPECS BOILER ROOM SAFETY VALVE(S) PIPED TO SAFE LOCATION INSULATION ARE APPROPRIATE SURFACES INSULATED? (FEED WATER TANK, DA TANK, HOT LINES?) PAGE 1 OF 9 © Fulton Group N.A., 2022...
  • Page 105 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 START-UP: INSTALLATION & OPERATION REPORT FOR FULTON STEAM BOILERS BLOW DOWN TANK VENT CONNECTION FREE TO ATMOSPHERE TERMINATED TO A SAFE AREA SAME SIZE AS TANK OUTLET COOLING KIT INSTALLED DRAIN OUTLET RUN FULL SIZE AND IN PROPER MATERIAL TO SUITABLE DRAIN...
  • Page 106 INLET PRESSURE TO FUEL OIL PUMP IS LESS THAN 3 PSIG INLET PRESSURE TO FUEL OIL PUMP IS MORE THAT -8” Hg. RECORD SAFETY VALVE IS PIPED TO SAFE LOCATION PREHEAT KIT INSTALLED & WATER PRESSURE SUPPLIED PAGE 3 OF 9 © Fulton Group N.A., 2022...
  • Page 107 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 START-UP: INSTALLATION & OPERATION REPORT FOR FULTON STEAM BOILERS OPERATION GENERAL FLAME SAFEGUARD MAKE & MODEL FLAME DETECTION DEVICE MAKE & MODEL TEMPERATURE CONTROL MAKE & MODEL MAIN GAS REGULATOR MAKE & MODEL MAIN GAS REGULATOR SPRING DEPTH PILOT GAS REGULATOR MAKE &...
  • Page 108 AIR SWITCH LWCO BURNER MOTOR OVERLOAD AIR FILTER SWITCH AUXILIARY LWCO HIGH GAS PRESSURE SWITCH BAROMETRIC DAMPER FUEL TRAIN LEAK TEST FUEL OIL OVERLOAD PUMP MOTOR OVERLOAD PAGE 5 OF 9 PAGE 5 OF 9 © Fulton Group N.A., 2022...
  • Page 109 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 START-UP: INSTALLATION & OPERATION REPORT FOR FULTON STEAM BOILERS NATURAL GAS COMBUSTION AT OPERATING TEMPERATURE (LINKAGE) FIRING RATE AIR GATE POSITION GAS VALVE POSITION INCOMING GAS PRESSURE MANIFOLD GAS PRESSURE OVER BURNER PRESSURE NOx CORRECTED TO 3% O2...
  • Page 110 FUEL POSITION AIR POSITION AUX POSITION VSD POSITION FGR POSITION FUEL PRESSURE OIL BACK PRESSURE OVER BURNER PRESSURE NOx @ 3% SMOKE AMBIENT TEMPERATURE STACK TEMPERATURE OPERATING PRESSURE STACK DRAFT FLAME SIGNAL PAGE 7 OF 9 © Fulton Group N.A., 2022...
  • Page 111 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 START-UP: INSTALLATION & OPERATION REPORT FOR FULTON STEAM BOILERS GENERAL COMMENTS REGARDING INSTALLATION (OTHER FUEL BURNING EQUIPMENT, ETC.) SUMMARY OF WORK PERFORMED: PAGE 8 OF 9 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 112 STATUS OF PARTS SHIPPED: (DATE & COMMENTS TO BE COMPLETED IN EACH FIELD AS REQUIRED) PART SHIPPED CUSTOMER CUSTOMER DESCRIPTION INSTALLED NUMBER TO SITE TO RETURN TO RETURN SPARE PARTS REQUIRED: DATE HOURS TRAVELED HOURS WORKED MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY PAGE 9 OF 9 5-10 © Fulton Group N.A., 2022...

  • Page 113: Vertical Steam Boiler Annual Maintenance Checklist

    SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 VERTICAL STEAM BOILER ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID STEAM BOILER CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY NATIONAL BOARD # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE...
  • Page 114 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. 5-12 © Fulton Group N.A., 2022...

  • Page 115: Notes

    SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 NOTES 5-13 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 116 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 NOTES 5-14 © Fulton Group N.A., 2022...
  • Page 117 SERVICE DOCUMENTS SECTION 5 VSRT-IOM-2022-0728 NOTES 5-15 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 118 Fulton Group N.A., Inc. Fulton Steam Solutions, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of Fulton Group N.A., Inc., a global manufacturer of steam, hot water and thermal fluid heat transfer systems.

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