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

Vertical multi-port hot water boilers
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INSTALLATION AND

OPERATION MANUAL

Vertical Multi-Port
Hot Water Boilers
Model VMP-W
40 -150 HP
Serial/ National
Board Number
Model
Fulton Order
Sold To
Job Name
Date
VMPW-IOM-2012-1001

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Summary of Contents for FULTON VMP-W 40 -150 HP

  • Page 1: Operation Manual

    INSTALLATION AND OPERATION MANUAL Vertical Multi-Port Hot Water Boilers Model VMP-W 40 -150 HP Serial/ National Board Number Model Fulton Order Sold To Job Name Date VMPW-IOM-2012-1001...

  • Page 3: Table Of Contents

    HIGH LIMIT AQUASTAT/HIGH TEMPERATURE LIMIT ..............3 6 AIR SAFETY SWITCH ........................3 6 PROBE TYPE LOW WATER CUT OFF .....................3 6 Optional Circulating Pump Switch ............... 3-6 Cycle Testing ......................3-6 Before Leaving the Installation ................3-6 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 4 TABLE OF CONTENTS VMPW-IOM-2012-1001 © The Fulton Companies 2012...

  • Page 5: Introduction

    INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 6: Overview

    Code ANSI Z2231/NFPA 54 latest edition, and the speci c 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? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 8: Placement & Rigging

    WARNING All information in this manual is for Proper placement of your Fulton Product (see Figure 1, and Tables 1 and 2) is reference and guidance purposes, essential. Attention paid to the following points will save a great deal of di culty and does not substitute for required in the future.
  • Page 9 3734 3937 3937 All data is approximate. Fulton reserves the right to change data without prior notice. H.H. FIGURE 1 MODEL VMP W DIMENSIONS/SPECIFICATIONS REFER TO TABLES 1 AND 2 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 10: Clearances & Serviceability

    INSTALLATION SECTION 2 VMPW-IOM-2012-1001 ã NOTE: When calculating ventilation requirements, heat losses from the Fulton WARNING equipment (and other equipment) should be considered. All information in this manual is for reference and guidance purposes, Clearances & Serviceability and does not substitute for required...
  • Page 11 10.6 30.8 30.8 230V 50/60 CY 3 Phase (Gas/Oil) 6.0/6.8 6.0/6.8 6.0/6.8 460V 50/60 CY 3 Phase (Gas/Oil) 3.0/3.4 3.0/3.4 3.0/3.4 CONTINUED ON NEXT PAGE * 150 pound fl anged. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 12: Utilities

    A properly designed make-up air system in the petroleum gases. Do not use Te on tape on gas line equipment room will preclude these possibilities and is heads. © The Fulton Companies 2012...

  • Page 13: The Oil Supply

    6. A stop valve, a check valve, and an oil lter must be installed on the oil supply line. 7. Ensure there are no loose ttings. Loose ttings in the fuel oil line will permit air to enter the fuel line and cause improper ring. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 14: Electrical Supply

    Water stop valve should be in line between the boiler and the rst piece of equipment. Hot water outlet should be piped to process/equipment requiring hot water. Water makeup supply should be installed. Hot water inlet should be piped to the make-up water supply. © The Fulton Companies 2012...

  • Page 15: Water Chemistry Requirements

    Water Chemistry Requirements System water chemistry requirements are as follows: pH: Range of 8.5 - 10.5 Oxygen: Less than 250 ppb (operating condition) Total Iron/Copper: Less than 5 ppm Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 16: Prevent Oxygen Contamination

    3. If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator. 4. If an air cushion type expansion tank is used, pipe tank directly into 2-10 © The Fulton Companies 2012...

  • Page 17: Piping Speci Cations

    It is recommended that GR5 or higher tensile steel bolts be used for all anged joints. 9. Use gaskets to make all anged connections. Gasketing material must be 2-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 18: Insulation

    Removable insulation may also be used over these components. System Interfaces Proper selection and installation of the components in the system will ensure proper and safe operation of the boiler. Consult Fulton representative or contact Fulton at (315) 298-5121. Fill Connection The system is usually lled from the lowest point, with the aid of a pump.

  • Page 19: Stack And Flue

    See Table 4. proper performance of the equipment. Stack and chimney must be constructed from material that is rated for 1000 F 2-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 20 Model Minimum Flue Size jurisdictional/professional codes and inches (mm) regulations. 12 (305) Non-Fulton product information is for 12 (305) reference purposes only. No Fulton 12 (305) document may substitute for full 14 (356) review of documentation available from the component manufacturer.

  • Page 21: Exhaust Side Wall Venting

    (-0.02 to -0.04” wc) to safely vent Boilers for which sidewall venting (Figure 4) may be utilized products of combustion. are propane, natural gas, or combination propane and natural 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 22: Testing

    2. Leak tests at all welds and joints to ensure that the system is free from leaks. 6. The sidewall vent total length from boiler exhaust to termination shall not exceed 35 feet (10.6 m) with 4 elbows maximum. 2-16 © The Fulton Companies 2012...

  • Page 23: Operation

    OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 24: Start-Up Preparation & Installation Review

    “Factory Trained Personnel” refers to 3. Water will now begin to ll the system. Air will escape through the vent someone who has attended a Fulton Service on the combination shuto / purge valve. Continue lling until a constant School speci cally for the equipment stream of water (no bubbling) is discharged from the vent.

  • Page 25: Start-Up Service

    Where possible, contact the factory at least three weeks before a Fulton service engineer is required on site. Consider the following in preparation for your on-site visit: 1.

  • Page 26: Initial Start-Up

    5. In addition to commissioning the boiler, the service person will also and strict adherence to applicable familiarize heater room personnel with the operation of all Fulton jurisdictional/professional codes and equipment. Personnel must be quali ed to understand the basic operation regulations.

  • Page 27: Flame Programmers

    The Operating Temperature Aquastat controls the working temperature of the boiler. This is an ASME CSD-1 code control which will turn the boiler o when the water temperature exceeds its setpoint. It is an auto-reset control. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 28: High Limit Aquastat/High Temperature Limit

    The Low Water Cut-O shuts down the unit when the water level is too low, after a three-second time delay to prevent nuisance shut downs. Fulton boilers are Check daily that the equipment area equipped with ASME CSD-1 Code controls which include a manual reset feature is free and clear of any combustible on the burner low water cut o relay.
  • Page 29 OPERATION SECTION 3 VMPW-IOM-2012-1001 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 30 OPERATION SECTION 3 VMPW-IOM-2012-1001 © The Fulton Companies 2012...

  • Page 31: Maintenance

    MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 32: Daily Maintenance Schedule

    Appropriate training and instructions 8. Test operating temperature control by reducing temperature setting as are available from the Fulton Service necessary to check burner operation. Department at (315) 298-5121 or your local Fulton Thermal Representative.

  • Page 33: Recommended Semi-Annual Maintenance Schedule

    Never tighten more than necessary to prevent leakage. Excessive tightening may shorten the life of the gasket. FIGURE 4 REMOVE ASSEMBLY WITH TEE HANDLE WRENCH Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 34 All maintenance procedures should » Re ll the boiler with fresh water. be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative. In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

  • Page 35: Recommended Annual Maintenance Schedule

    Ensure primary air adjustment is adequate to avoid this condition. FIGURE 7 WIRE BRUSHING THE FLUE PASSAGES FIGURE 8 REMOVING CLEAN OUT PLUGS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 36: Procedure For Primary Air Adjustment/Inspection

    2. Visually con rm, via the sight glass, that re is completely covering the After a new Fulton Boiler has been in walls. If the re is tunneling down or is not on the outside wall, e ciency operation for several months, pieces will drop.

  • Page 37: Procedure For Flame Scanner Adjustment

    Oil Unit Perform adjustment as follows: 1. Turn power to panel OFF. 2. Disconnect the hot wire to the oil valves. This will prevent the oil valves from opening. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...

  • Page 38: Procedure For Removing/Cleaning The Burner

    4. Reverse removal steps for reinstallation of the burner assembly. 5. Test re the boiler and use a combustion analyzer to ensure that the fuel/ air ratio is set correctly throughout the range. Refer to the Fulton factory test re sheet for combustion settings.

  • Page 39: After All Repairs Or Maintenance

    2. Fire the boiler and perform combustion safety checks. professional codes and regulations. 3. Analyze combustion throughout the range and verify proper operation of safety devices. Troubleshooting Please refer to Troubleshooting tables that follow. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 40 If zero voltage, clean relay contacts and recheck for power. If no power, replace control. * For natural gas red boilers. Refer to the test re sheet for all other fuels. 4-10 © The Fulton Companies 2012...
  • Page 41 -.04 in wc with burner o or -.04 in to -.06 in Draft when operating. May need to install a barometric damper. Make sure no exhaust fans are running in the Negative Room Pressure boiler room. 4-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 42 Refer to Recommended Daily Maintenance Scale Built up in boiler section of this manual. Check refractories to see if they are cracked or Refractories broken in pieces. Replace as necessary. Boiler Size Boiler may be undersized. 4-12 © The Fulton Companies 2012...
  • Page 43 Check all lines for possible air leak in intake line Loss of oil prime and tighten. Check for possible restricted intake line. Replace. Oil Nozzle Check for clogged nozzle; clean or replace 4-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 44 Draft -0.04 to -0.06 when operating. May need to install barometric damper. Check all lines for possible air leak in intake line Loss of Prime and tighten. Check for possible restricted intake line. Replace. 4-14 © The Fulton Companies 2012...
  • Page 45 Check for slipping or broken coupling. Oil Pump Tighten or replace. Check for frozen pump shaft. Replace. If power is on, check across aquastats to verify Aquastat power through switch. If bad, replace. 4-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 46 MAINTENANCE SECTION 4 VMPW-IOM-2012-1001 4-16 © The Fulton Companies 2012...

  • Page 47: Warranty & Parts

    WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
  • Page 48 WARRANTY & PARTS SECTION 5 VMPW-IOM-2012-1001 © The Fulton Companies 2012...

  • Page 49: Standard Warranty For Fulton Boilers

    fi tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profi ts or business, even if the Fulton Companies has been advised of the possibility of such damages.

  • Page 50: Parts

    Fulton Companies. When ordering replacement parts, please have for this equipment. Use of non-factory the model number and serial number of your Fulton boiler ready. Factory-direct authorized parts may jeopardize safety replacement parts must be used to ensure proper equipment operation and and system performance, and voids the adherance with warranty requirements.
  • Page 52 Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal uid heat transfer systems.

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