FULTON Vantage VTG Series User manual

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
Sold To
Job Name
Date
VTG-IOM-2013-0815

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VTG-IOM-2013-0815 TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Product Overview................................................................................................. 2-2
Placement & Rigging........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-4
Install BoilerTrim ................................................................................................. 2-6
InstallWater Piping.............................................................................................. 2-6
MeetWater Chemistry Requirements.................................................................. 2-9
PREVENT OXYGEN CONTAMINATION..........................................................................................29
ELIMINATE SYSTEM AIR ............................................................................................................210
Fill the BoilerWithWater ................................................................................... 2-10
Install Gas Piping................................................................................................ 2-10
COMPONENTS REQUIRINGVENTILATION TOTHE OUTDOORS.................................................213
Install Condensate Drain.................................................................................... 2-14
Install pH Neutralization Kit............................................................................... 2-15
Install Oil Piping................................................................................................. 2-15
OIL PIPING FOR DUAL FUEL BOILERSWITH THE RIELLO BURNER .......................................215
Hydraulic Connections ....................................................................................... 2-18
Oil Pump Priming .............................................................................................. 2-18
Oil Filtration........................................................................................................ 2-18
Venting............................................................................................................... 2-18
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM..............................................................221
AIR PIPED FROM OUTSIDE BOILER ROOM................................................................................221
ExhaustVenting ................................................................................................. 2-22
COMMONVENTING LAYOUTS FORVANTAGE............................................................................222
VENTINGTERMINATIONS..........................................................................................................225
WALL THIMBLE INSTALLATION.................................................................................................226
HORIZONTALVENTTERMINATION............................................................................................227
Removing an Existing Boiler ............................................................................. 2-27
Electrical Connections ....................................................................................... 2-28
Assembly of Fulton Multi-Skid Systems............................................................. 2-28
Operation 3-1
Perform Pre-Start-Up Inspection......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
CommissionThe Boiler......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION.................................................................................33
Siemens LMV36 and LMV37 Control.................................................................... 3-4
OPERATING POINTS ONTHE SIEMENS LMV CONTROL...............................................................34
NORMAL OPERATION ..................................................................................................................34
INITIAL PROGRAMMING .............................................................................................................34
COMMISSIONINGTHE UNIT.........................................................................................................35
Siemens LMV51 Control....................................................................................... 3-6
OPERATING POINTS ONTHE SIEMENS LMV CONTROL...............................................................36
NORMAL OPERATION ..................................................................................................................36
PREIGNITION .............................................................................................................................36
SETTING PILOT FOR BOILERS EQUIPPEDWITH A PILOT..........................................................37
SETTING MAIN BURNER IGNITION..............................................................................................38
RESETTING THE ALARM...............................................................................................................38
SETTING MODULATION ...............................................................................................................39
SETTING LOW FIRE.......................................................................................................................39
SETTING THE COMPLETE TURNDOWN RANGE .........................................................................310
OperatingTemperatures and Fuel Selection...................................................... 3-11
Temperature Controller Instructions.................................................................. 3-11
SC500 TEMPERATURE CONTROLLER BASIC PROGRAMMING ................................................311
YOKOGAWA UT 32A BASIC PROGRAMMING: ...........................................................................312
SIEMENS RWF40 BASIC PROGRAMMING.................................................................................313
Access toVariable Speed Drive Blower Motor .................................................. 3-14
TEST OF IGNITION SAFETY SYSTEM..........................................................................................315
PerformTest of LowWater Cut O ..................................................................... 3-15
PerformTest of Limit Controls ........................................................................... 3-15
PerformTest of Low Gas Pressure Switch .......................................................... 3-16
PerformTest of High Gas Pressure Switch.......................................................... 3-16
General Operation of the Boiler ......................................................................... 3-16
Maintenance 4-1
General................................................................................................................. 4-2
Daily Maintenance and Inspection Schedule ...................................................... 4-2
Weekly Maintenance and Inspection Schedule .................................................. 4-2
Monthly Maintenance and Inspection Schedule................................................. 4-2
PROCEDURE FOR CLEANINGTHE AIR INLET FILTER LOW EMISSIONS BURNERS ..................43
Annual Maintenance and Inspection Schedule................................................... 4-3
ANNUAL REMOVAL AND INSPECTION OF LE BEKAERT BURNER...............................................44
Verication ofTorque Settings on Fireside Access Doors ..................................... 4-4
Inspecting/Cleaning the Flue Passages ............................................................... 4-7
BOILERS FIRING ON #2 OIL, B100 BIODIESEL, DIGESTER GASES OR ANY OTHER SUBSTANCE
BESIDES NATURAL GAS OR PROPANE.........................................................................................47
PROCEDURE FOR ACCESSING THE DUPLEX STAINLESS STEEL FLUE PASSAGES........................47
Replacing a Servomotor and Related Components............................................. 4-7
Ignition Pilot Adjustment - Dual Fuel Burners..................................................... 4-8
FOR UNITSWITH RIELLO RLS100130E BURNER......................................................................48
FOR UNITSWITH RIELLO RLS160E BURNER ............................................................................48
After All Repairs and Maintenance ...................................................................... 4-8
Troubleshooting................................................................................................... 4-8

© The Fulton Companies 2013
TABLE OF CONTENTS VTG-IOM-2013-0815
0-2
Warranty & Parts 5-1
StandardWarranty for FultonVantage Hydronic Boilers .....................................5-3
Parts ..................................................................................................................... 5-5
STANDARD  MAXON BURNER....................................................................................................56
DUAL FUEL  RIELLO BURNER .....................................................................................................59
LOW EMISSIONS  BEKAERT BURNER.......................................................................................513
ANNUAL MAINTENANCE KITS...................................................................................................517
SPARE PARTS KITS......................................................................................................................520

Questions? Call [phone], or visit us online at www.fulton.com 1-1
INTRODUCTION
INTRODUCTION
1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2013
INTRODUCTION VTG-IOM-2013-0815 SECTION 1
1-2
Overview
Prior to shipment, the following inspections and tests are
made to ensure the highest standards of manufacturing for
our customers:
Material inspections
Manufacturing process inspections
American Society of Mechanical Engineers (ASME)
welding inspection
ASME hydrostatic test inspection
Electrical components inspection
Operating test
Final engineering inspection
Crating inspection
This manual is provided as a guide to the correct operation
and maintenance of your Fulton equipment, and should be
read in its entirety and be made permanently available to the
sta responsible for the operation of the boiler. It should not,
however, be considered as a complete code of practice, nor
should it replace existing codes or standards which may be
applicable. Fulton reserves the right to change any part of
this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment
can be hazardous and requires trained, qualied installers
and service personnel. Trained personnel are responsible
for the installation, operation, and maintenance of this
product, and for the safety assurance of installation,
operation, and maintenance processes. Do not install,
operate, service or repair any component of this
equipment unless you are qualied and fully understand
all requirements and procedures. Trained personnel
refers to those who have completed Fulton Service School
training specic to this product.
When working on this equipment, observe all warnings,
cautions, and notes in literature, on stickers and labels, and
any additional safety precautions that apply. Follow all safety
codes and wear appropriate safety protection. Follow all
jurisdictional codes and consult any jurisdictional authorities
prior to installation.
Warnings & Cautions
WARNINGS and CAUTIONS appear in various chapters of this
manual. It is critical that all personnel read and adhere to all
information contained in WARNINGS and CAUTIONS.
WARNINGS must be observed to prevent serious injury
or death to personnel.
CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
eectiveness.
All Warnings and Cautions are for reference and guidance
purposes, and do not substitute for required professional
training, conduct, and strict adherence to applicable
jurisdictional/professional codes or regulations.
Disclaimers and Local Codes
Installation of the equipment shall conform to all the
requirements or all national, state and local codes established
by the authorities having jurisdiction or, in the absence
of such requirements, in the US to the National Fuel Gas
Code ANSI Z223.1/NFPA 54 latest edition, and the specic
instructions in this manual. Authorities having jurisdiction
should be consulted prior to installation.
When required by local codes, the installation must conform
to the American Society of Mechanical Engineers Safety Code
for Controls and Safety Devices for Automatically Fired Boilers
(ASME CSD-1).
The boiler heat exchanger is manufactured and stamped
in accordance with ASME Boiler and Pressure Vessel Code,
Section IV for a maximum allowable working pressure and
operating temperature of 160 psig (1103 kPa) and 210 F (99 C)
respectively. Aquastats are set at 200 F (93 C). Operating > 190
F (88 C) is not recommended.

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INSTALLATION
INTRODUCTION
1
INSTALLATION
2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2013
2-2
INSTALLATION VTG-IOM-2013-0815 SECTION 2
ã WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Crystalline silica may be present
in components of this equipment.
Exposure to crystalline silica may
pose signicant health hazards,
including but not limited to eye and
respiratory system damage. Per
the Centers for Disease Control and
Prevention (CDC) and Occupational
Safety and Health Administration
(OSHA), appropriate Personal
Protective Equipment must be worn
to minimize exposure to hazardous
substances. Refer to most current
guidelines oered by the CDC and
OSHA for more information, including
Personal Protective Equipment
recommendations.
Ð CAUTION
This boiler is certied for indoor
installation only. NEMA 3R
conguration is available as a
factory option; this boiler may not be
retrotted.
This boiler is not designed for use in
systems where water is continuously
replenished. The warranty is valid for
closed loop systems only.
Fulton cannot be held responsible
for the selection, engineering,
installation, or sizing of any
additional equipment or components
of the hydronic heating system.
Product Overview
Prior to the performance of installation, operation, or maintenance procedures,
personnel should become familiar with the equipment (Table 1) and its
components.
The Fulton Vantage hot water boiler is an automatic, fuel-red, ultra high-
eciency boiler. The boiler can either be of the sealed combustion/direct vent
type or utilize conventional combustion air intake and ue methods.
The boiler is capable of sidewall venting when the appropriate venting materials
are used, and when permitted by local code requirements.
The Fulton Vantage boiler is certied to Underwriters Laboratories (UL) 795
Issue 2006/10/27 Edition 6 UL Standard for Safety Commercial-Industrial Gas
Heating Equipment. The boiler heat exchanger is manufactured and stamped
in accordance with American Society of Mechanical Engineers (ASME) Boiler
and Pressure Vessel Code, Section IV for a maximum allowable working pressure
and temperature of 160 psi (1103 kPa) and 210 F (99 C) respectively. All Vantage
boilers are hydrostatically tested, test red and shipped as a complete packaged
unit.
Fuel, water and electrical connections are similar to other boilers of this type.
There are various burner and control congurations available with the Vantage
boiler. Please be aware of which burner and control conguration has been
designed specically for your application.
This Vantage boiler is to be installed as part of a hydronic heating system. A
qualied engineer must be consulted for the selection of the equipment and
components of the heating system. Various system conditions can result in
incorrect heat distribution to users of the heating system.
Each Vantage Boiler is supplied with the following:
Integrated combustion supervision and temperature operating control
Operating and high temperature probes in presure vessel
Low water probe in pressure vessel
ASME safety relief valve
Installation and Operation Manual
Test re report
Separate wiring diagram
Combustion Air Adapter
Temperature and pressure (T&P) gauge
1 can touch up paint
Reducing bushing for safety relief valve

Questions? Call [phone], or visit us online at www.fulton.com 2-3
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
ã WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Competent personnel in accordance
with all applicable local codes
should carry out the installation
of the Fulton equipment. All state
and jurisdictional codes beyond the
scope of the applicable ASME Boiler
and Pressure Vessel Codes, for its
corresponding classication, should
be followed in all cases. Jurisdictional
authorities must be consulted prior to
installation.
A competent rigger experienced in
handling heavy equipment should
handle rigging your equipment into
position.
The equipment must be installed on a
non-combustible surface.
Failure to provide required and
safe access to the equipment
could impede commissioning and
maintenance. Service technicians
are instructed not to commence
commissioning if hazardous
conditions exist.
Failure to provide proper minimum
clearances between equipment and
combustible materials may result in
re.
Ð CAUTION
Do not allow weight to bear on
equipment components to prevent
damage.
The customer should examine the equipment for any damage. It is the
responsibility of the installer to ensure all parts supplied with the equipment are
tted in a correct and safe manner.
Placement & Rigging
Proper placement of your Fulton product is essential. Attention paid to
the following points will save a great deal of diculty in the future. Correct
placement is the rst step to trouble-free installation, operation, and
maintenance.
Adhere to the following for placement and rigging:
1. Check building specications for permissible oor loading. Use Table 1 for
unit reference.
2. Conform to all the requirements of all national, state and local codes
established by the authorities having jurisdiction and/or the U.S. to the
National Fuel Gas Code, latest edition. Authorities having jurisdiction
should be consulted before installations are made. Where required by local
codes, the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically
Fired Boilers (ASME CSD-1).
3. Since an external electrical source is utilized, the boiler, when installed,
must be electrically ground in accordance with the National Electric Code,
American National Standards Institute (ANSI) National Fire Protection
Association (NFPA) 70, latest edition.
4. Standard Vantage boilers are certied for indoor installation only. National
Electrical Manufacturers Association (NEMA) 3R Conguration is available
as an option from the factory, but an existing boiler cannot be retrotted
for outdoor installation.
5. Install so that all system components are protected from water (dripping,
spraying, rain, etc.) and debris (dry wall dust, insulation particles, etc.)
during boiler operation and service.
6. Install on a level, non-combustible surface in the vertical position. Concrete
is strongly recommended.
7. Provide combustion and ventilation air in accordance with applicable
provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section
5.3, Air for Combustion and Ventilation.
8. Locate the boiler so that the air supply and exhaust piping between the
boiler and outside wall/roof are within the maximum lengths for horizontal
or vertical venting if sealed combustion will be used. See Clearances and
Serviceability section of this manual.

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-4
TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS
MODEL VTG
2000 2000DF 2500 2500DF 3000 3000DF 3500 3500DF 4000 4000DF 5000 5000DF 6000 6000DF
Specications
2000LE 3000LE 4000LE
Input Million BTU/Hr.
kW
2
586
2
586
2.5
733
2.5
733
3
879
3
879
3.5
1026
3.5
1026
4
1172
4
1172
5
1465
5
1465
6
1758
6
1758
Fuel Cons. @ rated cap: (Nat. Gas) FT3/Hr.
M3/Hr
2,000
56.6
2,000
56.6
2,500
70.8
2,500
70.8
3,000
84.9
3,000
84.9
3,500
99.1
3,500
99.1
4,000
113 . 2
4,000
113 . 2
5,000
141.5
4750
134.5
6,000
169.9
6,000
169.9
Fuel Cons. @ rated cap.: (#2 Oil) GPH
LPH
NA
NA
14.3
54.1
NA
NA
14.3
54.1
NA
NA
21.4
81.0
NA
NA
21.4
81.0
NA
NA
28.6
108.2
NA
NA
27.17
102.8
NA
NA
42.8
162.0
Output at AHRI Test Condition BHP
KCal/h
57
4.8
57
4.8
69
5.8
69
5.8
86
7.25
86
7.25
96
8.0
96
8.0
116
9.7
116
9.7
138
11. 6
138
11. 6
168
14.1
168
14.1
Electrical Req. (Amps) 230V, 60Hz, 3 Phase 6.8 13.4 12.9 16.1 12.9 16.1 18.5 16.1 18.5 16.1 23 29.2 23 29.2
460V, 60Hz, 3 Phase 3.4 6.7 6.5 8.1 6.5 8.1 9.3 8.1 9.3 8.1 11 16.6 11 16.6
Water Content Gal
Liters
147
556.4
147
556.4
147
556.4
147
556.4
215
813.8
215
813.8
215
813.8
215
813.8
275
1041
275
1041
275
1041
275
1041
480
1817
480
1817
Dry Weight LB
KG
3,800
1724
3,800
1724
3,800
1724
3,800
1724
5,200
2359
5,200
2359
5,200
2359
5,200
2359
5,800
2631
5,800
2631
5,800
2631
5,800
2631
9,950
4513
10,800
4899
Operating Weight LB
KG
5,100
2314
5,100
2314
5,100
2314
5,100
2314
7,000
3175
7,000
3175
7,000
3175
7,000
3175
8,100
3674
8,100
3674
8,100
3674
8,100
3674
13,950
6327
14,800
6713
Dimensions
A. Boiler Width IN
CM
30.5
77.5
30.5
77.5
30.5
77.5
33.6
85.3
34.65
88.0
34.5
87.6
34.6
87.8
34.5
87.6
40.5
102.8
40.5
102.8
40.5
102.8
40.5
102.8
50.5
128. 2
50.5
128. 2
B. Overall Boiler Height IN
CM
64
162.5
64
162.5
76
193
72.8
184.9
87
220.9
70.5
179.0
83.9
213.1
76.1
193.2
87.6
222.5
78
198.1
87.6
222.5
79.5
201.9
90
228.6
90
228.6
C. Overall Boiler Depth IN
CM
108
274.3
122
309.8
108
274.3
120
304.8
120
304.8
132
335.2
120
304.8
132
335.2
124
314.9
136
345.4
136
345.4
136
345.4
155
393.7
155
393.7
D. Flue Outlet Diameter IN
CM
10
25.4
10
25.4
10
25.4
10
25.4
12
30.4
12
30.4
12
30.4
12
30.4
14
35.5
14
35.5
14
35.5
14
35.5
14
35.5
14
35.5
E. Air Inlet Diameter IN
CM
8
20.3
10
25.4
10
25.4
10
25.4
10
25.4
10
25.4
10
25.4
10
25.4
12
30.4
12
30.4
12
30.4
12
30.4
12
30.4
12
30.4
F. Water Inlet/Outlet Diameter IN
CM
4
10.1
4
10.1
4
10.1
4
10.1
4
10.1
4
10.1
4
10.1
4
10.1
6
15.2
6
15.2
6
15.2
6
15.2
6
15.2
6
15.2
G. Min. Clearance to Ceiling IN
CM
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
24
60.9
H. Overall Height (w/o blower) IN
CM
68.1
172.9
64
162.5
64
162.5
68.1
172.9
76.2
193.5
70.5
179.0
76.2
193.5
76.2
193.5
78.5
199.3
78.0
198.1
79.5
201.9
79.5
201.9
90
228.6
90
228.6
Clearances and Serviceability
Adhere to the following for clearances and serviceability:
1. All local and national codes (NFPA, ANSI, UL, CSA,
ASME) must be followed for proper clearances and
serviceability for your boiler or heater. Authorities
having jurisdiction should be consulted before
installations are made.
2. Appropriate front, back, side and top clearances must
be maintained (Figure 1). This will allow access around
the equipment to facilitate maintenance and a safe
* Alternate gas pressure arrangements may apply. Please verify gas pressure ratings for your boiler by viewing the boiler name plate.
** Typical 120 VAC controls allow for a +10% and a -15% voltage uctuation.
***Standard congurations. Alternate voltages available as an option; please consult factory.
Note: All dimensions are approximate and are subject to change without notice.
The use of propane may be allowable with concentrations up to 5% propylene, also referred to as HD5. O-standard grades of propane are not permitted. Contact
factory for more information.

Questions? Call [phone], or visit us online at www.fulton.com
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
2-5
FIGURE 1  VIEWS OF VANTAGE HYDRONIC BOILER STANDARD, LOW EMISSIONS AND DUAL FUEL MODELS
TOP VIEW
SIDE VIEW
Standard / Low
Emissions Models
24 IN
(61 CM)
24 IN
(61 CM)
RECOMMENDED
COMBUSTION AIR INLET
COLD WATER INLET
EXHAUST OUTLET
CONDENSATE DRAIN
HOT WATER OUTLET
COMBUSTION AIR INLET
COLD WATER INLET
EXHAUST OUTLET
CONDENSATE DRAIN
HOT WATER OUTLET
1 IN
(25.4 MM)
EACH SIDE
TYPICAL
36 IN
(91.4 CM)
COMBUSTION AIR INLET
COLD WATER INLET
EXHAUST OUTLET
CONDENSATE DRAIN
HOT WATER OUTLET
TOP VIEW
SIDE VIEW
1 IN
(25.4 MM)
EACH SIDE
TYPICAL
Dual Fuel
Models
36 IN
(91.4 CM)
24 IN
(61 CM)
24 IN
(61 CM)
RECOMMENDED

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-6
work environment. An 1 inch (25.4 mm) side clearance
is acceptable between boilers. Custom congurations
may not allow 1 inch (25.4 mm) side clearance.
3. Ensure all labels on the boiler will be fully visible for
maintenance and inspection.
4. Do not place any boiler room accessories, or other
components, on the Vantage skid.
Install Boiler Trim
Each Vantage boiler is supplied with a safety relief valve
sized in accordance with ASME requirements. Adhere to the
following installation requirements:
1. The safety relief valve (Figure 2) must:
» Be connected to the coupling located in the
top of the boiler.
» Be installed in the vertical position.
NOTE:Safety relief valve size is determined by trim
pressure and is supplied in the trim kit along with
appropriate bushing, inlet and outlet sizes. See Table 2.
2. The discharge pipe must:
» Not have a diameter less than the full area of
the valve outlet.
» Be as short and straight as possible and so
arranged as to avoid undue stress on the valve.
» Be supported by means other than the safety
valve itself.
» Be piped to avoid danger of scalding
personnel.
NOTE:Each boiler is equipped with a pressure-
temperature gauge to be installed in the outlet piping
section of the boiler. Gauge must not be isolated from
the boiler by any valve.
TABLE 2  SAFETY RELIEF VALVE INLET AND OUTLET SIZES
Model Trim Pressure
PSI (kPa)
Inlet Size
inch (mm)
Outlet Size
inch (mm)
VTG-2000,
2500
(DF, LE)
30 (206.84) 1 1/4 (31.75) 1 1/2 (38.1)
60 (413.69) 1 (25.4) 1 1/4 (31.75)
100 (689.48) 3/4 (19.05) 1 (25.4)
125 (861.84) 3/4 (19.05) 1 (25.4)
160 (1103.16) 3/4 (19.05) 1 (25.4)
VTG-3000,
3500
(DF, LE)
30 (206.84) 1 1/2 (38.1) 2 (50.8)
60 (413.69) 1 1/4 (31.75) 1 1/2 (38.1)
100 (689.48) 1 (25.4) 1 1/4 (31.75)
125 (861.84) 1 (25.4) 1 1/4 (31.75)
160 (1103.16) 3/4 (19.05) 1 (25.4)
VTG-4000,
5000
(DF, LE)
30 (206.84) 2 (50.8) 2 1/2 (63.5)
60 (413.69) 1 1/2 (38.1) 2 (50.8)
100 (689.48) 1 1/4 (31.75) 1 1/2 (38.1)
125 (861.84) 1 (25.4) 1 1/4 (31.75)
160 (1103.16) 1 (25.4) 1 1/4 (31.75)
VTG-6000
(DF)
30 (206.84) 2 (50.8) 2 1/2 (63.5)
60 (413.69) 1 1/2 (38.1) 2 (50.8)
100 (689.48) 1 1/4 (31.75) 1 1/2 (38.1)
125 (861.84) 1 1/4 (31.75) 1 1/2 (38.1)
160 (1103.16) 1 (25.4) 1 1/4 (31.75)
Install Water Piping
All water supplies contain some solids, dissolved gases or
dissolved minerals. These may cause corrosion, deposition
and/or fouling of equipment. To prevent these contaminants
from impacting boiler performance, valve operation and
general pipe longevity, each location must be analyzed and
treated accordingly.
Adhere to the following for water piping installation (See
Figure 3):
1. Isolation valves are recommended on both water
connections for ease of service.
2. Install piping so that the boiler is not supporting any
additional piping.
3. Install manual purging valves in all loops and zones.
Install a pressure-reducing (automatic ll) valve in the
cold water ll line to the boiler system. Check that the
proposed operation of zone valves, zone circulator(s)
and diverting valves will not isolate air separator(s) and/
or expansion tank(s) from the boiler. Clearance from hot
water pipes to combustibles must be at least 6 inches
(152 mm).

Questions? Call [phone], or visit us online at www.fulton.com 2-7
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
ã WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
The discharge from the safety relief
valve must be arranged to ensure
no danger of scalding personnel, or
equipment damage.
Provisions must be made to properly
pipe the safety relief discharge
away from the boiler to the point of
discharge.
No shuto of any kind shall be placed
between the safety relief valve
and the boiler, or in the discharge
pipe between the valve and the
atmosphere. Doing so may cause an
explosion from overpressure.
The hydronic system should never be
ushed while the boiler is attached
to the system since the debris could
accumulate in the boiler and block
water from passing through the heat
exchanger.
Ensure all labels on the boiler are
legible. All connections and safety
devices, both mechanical and
electrical, must be kept clean, with
ease of access for inspection, use and
maintenance.
Do not store or use gasoline or other
ammable vapors and liquids or
corrosive materials in the vicinity of
this or any other appliances.
4. When used in conjunction with a refrigeration system, install the boiler
so that the chilled medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from entering the
boiler. If the boilers are connected to heating coils (located in air handling
units where they may be exposed to refrigerated air circulation) such
boiler piping systems must be equipped with ow control valves or other
automatic means to prevent gravity circulation of the boiler water during
the cooling cycle.
5. Include the following in the mechanical equipment in the hydronic
heating system:
»An automatic pressure activated water make up valve with back
ow preventer. It must be set to maintain required Net Positive
Suction Head (NPSH) for re-circulating pumps, a positive system
pressure at the highest point of at least 5-10 PSIG (34.5 - 69 kPa),
and make up water valve should be designed to add water to the
system at the outlet of the boiler and should not be fed directly
into the boiler.
»Air removal equipment, including an air separator and automatic
breather valves, along with a functioning expansion tank . Each
must be designed to system specications.
NOTE:The water connection on the top of the boiler is the outlet
connection. The water connection on the rear of the boiler is the inlet
connection.
NOTE:The Fulton Vantage boiler does not require a primary/secondary
ow piping system. Although primary/secondary is an acceptable
conguration, the boiler does not have a minimum return water
temperature requirement (when ring on natural gas or propane) and the
heat exchanger will not be harmed by low ow or zero ow conditions. See
Figure 3 for a sample piping layout.
6. Install ltration to remove particulates if appropriate.
7. Install bypass chemical feeder for corrosion inhibitor maintenance if
appropriate.
8. Install corrosion coupon holder to assess corrosion inhibitor performance if
appropriate.
NOTE:The boiler is provided with a drain connection. See Figure 4.
9. Before installing a Vantage boiler into a hydronic loop, be sure that the
system piping and any other components of the system are clean and
free of debris and any foreign matter. The hydronic system is completely
ushed prior to installing the boiler itself.

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-8
FIGURE 2  SAFETY VALVE LOCATION
B
C
D
E
FIGURE 3  SAMPLE PIPING LAYOUT
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 ow path for system water.
Note: Valve is shipped loose and must be installed by the contractor.

Questions? Call [phone], or visit us online at www.fulton.com 2-9
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
Ð CAUTION
Care needs to be taken to eliminate
oxygen from the water system, as
excess oxygen in the system will
reduce the life of any boiler. The
boiler warranty does not cover heat
exchanger replacement due to oxygen
contamination of boiler water.
Heat exchanger failure due to
inappropriate water quality, foreign
matter or debris damage is not covered
under the warranty.
If the piping system attached to this
unit will be chemically cleaned, the
boiler must be disconnected from the
system and a bypass installed so that
the chemical cleaning solution does
not circulate through the boiler.
NOTE:Although motorized isolation valves are not required in a primary
only arrangement , they can help ensure system eectiveness. Proper
control strategy must be used to ensure ow paths in the hydronic loop and
residual heat in pressure vessel can be adequately dispersed when a boiler
is disabled.
Meet Water Chemistry Requirements
System water chemistry requirements are as follows:
pH: Range of 8.0 - 10.5
Oxygen: Less than 250 ppb (operating condition)
Total Iron/Copper: Less than 5 ppm
Corrosion Inhibitor: Capable of maintaining iron corrosion rates
<2 mpy. Due to changing environmental restrictions a non-heavy
metal ALL ORGANIC inhibitor is recommended which is designed for
multi metal systems including ferrous metals and yellow metals such
as copper and brass.
Chloride: Less than 250 ppm
Adhere to the following:
1. Refer to your water conditioning or chemical treatment supplier for
analysis and recommendations for proper system conditions.
2. Follow a program with appropriate monitoring and maintenance of system
water conditions as provided by your water conditioning or chemical
treatment supplier.
3. If RO/DI water is used as a source for hydronic loop water or makeup water,
it must be neutralized to a pH of 8.0 - 10.5 prior to entering the boiler.
Failure to neutralize the RO/DI water will void the pressure vessel warranty
and may cause high general corrosion rates.
The system must have an automatic pH controller to monitor and log the
levels. This must be independent of other chemical feed systems.
Makeup water pH range must be 7.5 - 8.8; the boiler water must be
maintained within pH range of 8.0 - 10.5.
4. Operate the boiler in a closed-loop system using water or water/glycol
(not requiring a make-up water supply). A large amount of improperly
treated make-up water can cause premature failure of the heat exchanger
resulting from scale build up. Scale build up will reduce the eciency and
useful life of the boiler and is not covered under warranty.
Prevent Oxygen Contamination
There are several ways to prevent boiler water oxygen contamination:
Minimize system leaks to minimize make up water requirement

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-10
Figure 4 Note: Valve and piping from drain connection to be provided
and installed by contractor.
Do not use open tanks or ttings
Do not use oxygen permeable materials anywhere in
the water system
Repair leaks in the system quickly
Eliminate ttings wherever possible
Use air elimination devices in system piping
Eliminate System Air
NOTE:There are no built-in boiler air eliminating
features.
Adhere to the following for air elimination:
1. The installation of an air separator and air eliminator (air
vent) is required.
2. To prevent scale corrosion in boiler and associated
piping, make up water must be kept to a minimum. This
is best achieved by ensuring immediate repair of all
leaks and that system pressure is maintained.
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 boiler supply.
5. On multi-zoned systems (or a system with both space
and domestic water heating), air elimination must be
provided either in the common piping or on every loop.
6. When the boiler is installed at a higher level than
baseboard radiation (if used), air elimination must be
provided directly above the unit.
Fill the Boiler With Water
To be sure that the boiler is not air-bound, open the pressure-
relief valve located at the rear of the boiler. Leave the relief
valve open until a steady ow of water is observed. Close the
valve and nish lling the system.
Install Gas Piping
The Vantage boiler is factory test red and combustion is
adjusted per the boiler data plate and test re sheet.
The gas train components are UL-795 certied to operate at
specic gas pressure requirements. The specic 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.
Adhere to the following for gas piping installation:
1. See Table 3 for required natural gas pipe size, based on
overall length of pipe from the meter plus equivalent
length of all ttings. Approximate sizing may be based
on 1,020 BTU for 1 cubic foot of natural gas.
2. Piping must be installed such that no piping stresses
are transmitted to the boiler. The boiler cannot be used
as a pipe anchor.
3. The boiler and all gas piping connections must be
pressure-tested and checked for leaks before being
placed into service. Test with compressed air or inert
gas if possible.
4. The boiler must be disconnected at the boiler manual
FIGURE 4  DRAIN CONNECTION AND EXHAUST CONNECTION
LOCATIONS
Pressure Vessel
Drain Connection
Exhaust
Connection
Condensate
Drain Connection

Questions? Call [phone], or visit us online at www.fulton.com 2-11
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
ã WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Do not use matches, candles, ame or
other sources of ignition to check for
gas leaks.
Failure to ensure the use of
uncontaminated air in this
equipment may be a safety hazard
and damage burner components.
Refer to current codes and standards
on the safe installation and operation
of this equipment, including NFPA
54, National Gas Fuel Code, CAN/CSA
B149 and other jursidictional codes.
Ð CAUTION
Some soap used for leak testing is
corrosive to certain types of metals.
Clean all piping thoroughly after
completing the leak check.
shuto valve (located at the end of the supplied gas train) from the
gas supply piping system during any pressure testing of the system at
pressures in excess of 1/2 psig (14 inch W.C.).
5. Step down gas pressure regulators must be able to handle the turndown
of the boiler plant. A consistent gas pressure must be supplied to boilers at
all times.
6. Gas Piping must be installed in accordance with National Fuel Gas Code,
ANSI Z223.1 1991 or latest addenda and any other local codes, which may
apply.
7. The pipe and the ttings used must be new and free of dirt or other
deposits.
8. Piping must be of the proper size to ensure adequate gas supply. A drip leg
and union connection must be installed upstream of the gas safety shut o
valves and must be a 5 inch (127 mm) minimum length.
9. Connect gas supply line to the open end of the tee on which the drip leg is
installed.
10. When making gas-piping joints, use a sealing compound resistant to
liqueed petroleum gases. Do not use Teon tape on gas line threads.
11. After gas piping is completed and before wiring installation is started,
carefully check all piping connections, (factory and eld), for gas leaks. Use
a soap and water solution.
12. The boiler must be disconnected at the boiler shut o valve from the gas
supply piping system during any pressure testing of the system.
NOTE:The vent line connection on the gas pressure regulator must be
piped to outdoor air by the installer in accordance with the National Fuel
Gas Code, ANSI Z223.1-1991 or latest addenda. In Canada gas installations
must by in accordance with the current CAN/CSA B149.1 and 2 and/or local
codes.
13. Siemens SKP25 series gas valves are standard. The SKP25 is an actuator
with gas pressure regulating capabilities. This will eliminate the use of
Maxitrol regulators integral to the Vantage fuel trains.
14. The fuel trains with the SKP25 actuator are set up for 14”wc-5 PSIG natural
gas pressure for all models except the VTG-6000 and VTG-6000DF, which
are set up for 18”wc-5 PSIG natural gas pressure.
15. The SKP25 does not guarantee a“ventless”fuel train for all Vantage models,
even though in some occasions the boilers may be installed this way.
Although the SKP25 has independent certication as a ventless regulator,
the Authority Having Jurisdiction (AHJ) may require a vent line to be
installed.
16. Vantage models featuring the Bekaert or Riello burners have pilot
assemblies. For Riello burner congurations, if vent limiters are not allowed
per the AHJ, the pilot regulator will need to be vented accordingly. Bekaert

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-12
FIGURE 5  CONDENSATE DRAIN PIPING FOR VANTAGE BOILERS
Figure 5 Notes:
Header must be level or slightly pitched toward the drain.
Header material to be galvanized steel or 316L stainless.
Header should be taken to the lowest point possible and
at least 5.5 inch (14.2 cm) drop from 1.5 inch (38.1 mm)
condensate drain kit/trap outlet.
1.5 inch (38.1 mm) condensate drain kit/trap outlet is never
to be above 1 inch boiler condensate outlet.
For multiple boiler installation, maintain and minimum pipe
size of 1 inch (25.4 mm) for the header piping.
The maximum number of units to attach per condensate
drain kit is 12mm BTU total. Detail A
0.25” U.S. TAPPING
PROVIDED FOR WATER
CONNECTION TO MAINTAIN
WATER SEAL
5.5 INCH 14.2 CM
MINIMUM
SIDE VIEW
Detail A
(condensate drain kit)

Questions? Call [phone], or visit us online at www.fulton.com
SECTION 2 VTG-IOM-2013-0815 INSTALLATION
2-13
burner congurations do not support vent limiters and
will need to be vented if required by the AHJ.
17. Vantage boilers with the SKP25 fuel train are in
compliance with CSD1 and CSA. This conguration is
also compliant with IRI, which has been replaced by GE
GAP. NFPA 85 conguration is available as an option to
comply with local codes or regulations that specically
require a vent valve.
18. Please note that custom congurations or other o
standard projects may utilize alternate fuel trains. For
these situations, refer to submittal drawings.
19. Ensure the burner will be supplied with sucient
ventilation and uncontaminated air for proper
combustion. Air contaminants include, but are not
limited to, chlorides, halogens, ourocarbons, and
construction dust. Refer to appropriate jurisdictional
codes.
Components RequiringVentilation to the
Outdoors
Although there are custom fuel train requirements available
that do not include components requiring ventilation to the
outdoors, many Vantage fuel trains will require a vent line on
the gas pressure regulator.
Follow the recommendations of the manufacturer of the
gas pressure regulator for specic instructions. General
TABLE 3  NOMINAL PIPE SIZE
Nominal
Pipe Size
ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. Pressure drop of
0.5”wc/Equivalent length of pipe (feet)
Inch (mm) Inch (mm) 90 Elb
Feet
(meter)
Tee
Feet
(meter)
20 40 60 80 100 150 200
1-1/4 (31.75) 1.380 (35.05) 3.45 (1.05) 6.9 (2.10) 950 ----- ----- ----- ----- ----- -----
1-1/2 (38.1) 1.610 (40.89) 4.02 (1.22) 8.04 (2.45) 1460 990 810 ----- ----- ----- -----
2 (50.8) 2.067 (52.50) 5.17 (1.57) 10.3 (3.13) 2750 1900 1520 1300 1150 950 800
2-1/2 (63.5) 2.469 (62.71) 6.16 (1.87) 12.3 (3.74) 4350 3000 2400 2050 1850 1500 1280
3 (76.2) 3.068 (77.92) 7.67 (2.33) 15.3 (4.66) 7700 5300 4300 3700 3250 2650 2280
4 (101.6) 4.026 (102.26) 10.10 (3.07) 20.2 (6.15) 15800 10900 8800 7500 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
FIGURE 6  FULTON PH NEUTRALIZING KIT WITHOUT PUMP

© The Fulton Companies 2013
INSTALLATION VTG-IOM-2013-0815 SECTION 2
2-14
instructions include:
Start with the vent tapping size, and as soon as is
practical increase the pipe size one diameter.
For every ten feet of pipe run, increase the pipe size one
diameter.
Protect the termination from water, dust and insects.
Install Condensate Drain
A condensate drain kit is intended for use with the Fulton
Vantage boiler. The Condensate Drain is Fulton Model Part
Number 4-57-000440.
Adhere to the following for installation:
1. The 1 inch (25.4 mm) condensate drain will be
connected to the 1 inch (25.4 mm) inlet on the drain
kit. One or more drain lines may be connected to this
inlet (max of 12 MM BTU per drain).
2. If the water supply must be temporarily disconnected,
the boilers must be turned o to prevent accidental ue
gas emission into the boiler room.
3. The condensate drain cover must be kept on at all
times, except during maintenance of the drain. This
drain should be checked regularly in your boiler
maintenance schedule.
4. A condensate collecting tank and condensate pump
will be required if a oor drain is not available to collect
condensate (collecting tank and pump are not supplied
with the boiler).
5. All piping (Figure 5) must be galvanized, or stainless
steel and should be free of leaks. Copper, carbon steel/
iron pipe, PVC or CPVC are not acceptable.
6. Connect 1 inch (25.4 mm) condensate drain(s) (at the
rear of the boiler), to the 1 inch (25.4 mm) inlet at the
base of the drain tank. The bottom of the drain kit must
be a minimum of 5.5 inch (14.2 cm) lower than the
bottom of the boiler when connected in a manifold as
shown in Figure 5, the manifold must be 5.5 inch (14.2
cm) below the condensate outlet and must remain
ooded.
7. Connect the 1.5 inch (38.1 mm) drain outlet to an
appropriate waste line following applicable codes. The
1.5 inch (38.1 mm) drain connection on the drain tank
must be the highest point prior to going to the drain.
Failure to keep drain piping lower than this point will
result in overow of the drain tank. Slope the drain pipe
away at a minimum pitch of 1 inch (25.4 mm) for every
TOP VIEW
30 3/8
[771]
12 1/2
[318]
3 13/16
[97]
(TYP.)
FRONT VIEW
1 1/2" PLASTIC FITTING
CONNECTION TO DRAIN
1" NPT
CONNECTION
TO BOILER
10 3/4
[273]
11 1/4
[286]
ISOMETRIC VIEW
2
3
1
43
1. Neutralizer Kit with Magnesium Oxide
2. Condensate Drain Kit Assembly
3. 1 1/2” by 3” NPT Stainless or Galvanized Nipple
4. 1 1/2” Stainless or Galvanized Union
FIGURE 7  FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK