FULTON VSRT Series User manual

INSTALLATION AND
OPERATION MANUAL
VSRT Series
Vertical Spiral-Rib Tubeless Boiler
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
VSRT_IOM_2018-1213
VIEW2
DRAWINGNUMBER REV
VSRT-30 SALES PDS2 -
VSRT-30 HIGH PRESSURE WITH LOW PRESSURE
OPENINGS (150 PSI) MODULATED STEAM BOILER
DESCRIPTION:
DRAWNBY:
T. KENNEDY
CHECKEDBY:
B.O.M.REVIEW
MECH.ENG:
ELEC.ENG:
APPROVEDBY:
JOBNUMBER:
PROJECTNAME:
PROJECTMANAGER:
Thisdesign and drawings
areproprietary and are the
exclusiveproperty of
FultonGroup N.A., Inc.
Thecorporation does not
permittheir use except
withprior written consent.
Theitems shown in this
drawingmay be covered by
oneor more patents of
FultonGroup N.A., Inc.
2 OF 2
THIRDANGLE PROJECTION
FultonGroup N.A., Inc
972Centerville Road
Pulaski,New York USA 13142
3/22/2017
UNLESSOTHERWISE NOTED
DIMENSIONSARE IN INCHES
R
SHEET 2 OF 2
(1)PLACE DEC. 0.03
(2)PLACE DEC. 0.015
(3)PLACE DEC. 0.005
ANGLE 0.5DEG
SURFACEFINISH
250MICRO-INCHES
TOLERANCES
FRACTION&
WHOLEVALUE
1/8

Table of Contents
Section 1: Safety & Warnings...................................................................................................................1-1
Introduction ............................................................................................................................................................................................. 1-2
Receiving Inspection............................................................................................................................................................................1-2
General Warnings, Cautions and Notes .....................................................................................................................................1-2
Steam Boiler Systems Warnings and Cautions ....................................................................................................................... 1-6
Section 2: Installation ...........................................................................................................................2-1
Product Overview..................................................................................................................................................................................2-2
Massachusetts Installations..............................................................................................................................................................2-2
Placement & Rigging............................................................................................................................................................................2-2
Clearances & Serviceability ............................................................................................................................................................... 2-2
Equipment Ventilation & Combustion Air Requirements................................................................................................2-16
Utilities.......................................................................................................................................................................................................2-17
Electrical Supply ...................................................................................................................................................................................2-18
Water Chemistry...................................................................................................................................................................................2-18
Steam Outlet..........................................................................................................................................................................................2-19
Water Supply..........................................................................................................................................................................................2-19
Piping Specications..........................................................................................................................................................................2-21
Insulation .................................................................................................................................................................................................2-25
System Interfaces.................................................................................................................................................................................2-25
Assembly of Fulton Multi-Skid Engineered Systems..........................................................................................................2-28
Stack & Flue Connections ................................................................................................................................................................2-28
Venting Terminations.........................................................................................................................................................................2-30
System Piping Testing........................................................................................................................................................................2-31
Before Leaving the Installation....................................................................................................................................... 2-31
Section 3: Operation .............................................................................................................................3-1
Start-Up Preparation & Installation Review...............................................................................................................................3-2
Start-Up Service......................................................................................................................................................................................3-2
Prepare for Initial Start-Up..................................................................................................................................................................3-2
Perform Boil-Out.................................................................................................................................................................................... 3-2
Sequence of Operation: Gas Fired Burners............................................................................................................................... 3-3
Flame Programmers.............................................................................................................................................................................3-4
Siemens Linkageless Modulation...................................................................................................................................................3-4
Commissioning the Unit........................................................ ............................................................................................................3-5
Operating Controls ...............................................................................................................................................................................3-7
Burner Settings ....................................................................................................................................................................................... 3-7
Pressure Modulation Controller...................................................................................................................................................... 3-7
Cycle Testing...........................................................................................................................................................................................3-11
Daily Start-Up........................................................................................................................................................................ ..3-11
Daily Shutdown.....................................................................................................................................................................3-11
Section 4: Maintenance & Troubleshooting...................................................................................4-1
Procedure for CleaningWater Probes.......................................................................................................................................... 4-2
Flame Scanner Adjustments for Fulton Gas Fired Steam Boilers ................................................................................... 4-2
Recommended Daily Maintenance Schedule......................................................................................................................... 4-3
Recommended Weekly Maintenance Schedule.................................................................................................................... 4-4
Recommended Monthly Maintenance Schedule................................................................................................................. 4-4
Recommended Semi-Annual Maintenance Schedule........................................................................................................4-5
Recommended Annual Maintenance Schedule....................................................................................................................4-8
After All Repairs or Maintenence ................................................................................................................................................... 4-8
Assembly Drawings and BOMs.......................................................................................................................................................4-8
Troubleshooting ..................................................................................................................................................................................4-22

Section 5: Warranty ...............................................................................................................................5-1
Standard Warranty for Fulton Boilers........................................................................................................................................... 5-3
Extended Warranty for Fulton Skid Mounted Boilers........................................................................................................... 5-3

1-1
Section
Safety & Warnings 1
Installation 2
Operation 3
Maintenance & Troubleshooting 4
Warranty 5

1  SAFETY & WARNINGS
© Fulton 2018
1-2
VSRT_IOM_2018-1213
Introduction
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 jursidictional authorities prior to installation.
Receiving Inspection
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.
General Warnings,
Cautions & Notes
The following are general WARNINGS and CAUTIONS,
which may also appear in various chapters of this
manual. It is critical that all personnel read and
adhere to all information contained in WARNINGS and
CAUTIONS throughout this manual. In addition, there
are bolded Notes throughout the manual, which are
included as additional information for essential and
eective operation and conditions.
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.
!WARNING
Do not operate, or allow others to operate, service
or repair this equipment unless you (they) fully
understand all applicable sections of this manual and
are qualied to operate/maintain the equipment.
This boiler is equipped with an ignition device, which
automatically lights the burner. Do not try to light the
burner by hand.
Prior to the commencement of any work requiring the
removal of cover plates and the opening of the control
panel box, the electrical supply to the boiler must be
disconnected.
Assure all electrical connections are powered down
prior to attempting replacement or service of electrical
components or connections of the equipment.

SAFETY & WARNINGS  1
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VSRT_IOM_2018-1213
Label all wires prior to disconnecting when servicing
controls. Wiring errors can cause improper and
dangerous operation.
Operating the equipment beyond its design limits can
damage the equipment and can also be dangerous.
Do not operate the equipment outside its limits.
Do not try to upgrade the equipment performance
by unapproved modications. Unapproved
modications can cause injury and damage.
Contact your Fulton dealer before modifying the
equipment.
Defective equipment can injure you or others. Do
not operate equipment which is defective or has
missing parts. Make sure all repairs or maintenance
procedures are completed before using the
equipment. Do not attempt repairs or any other
maintenance work you do not understand.
Never attempt to operate equipment that has failed to
pass all the safety checks.
Please read these instructions and save for reference.
!WARNING
After checking controls by manual adjustment,
always ensure they are reset to their proper settings.
Follow proper lockout/tagout procedures for the
electrical, gas and water connections.
If any “Manual Reset” limit device trips, DO NOT
reset without determining and correcting the cause.
(Manual Reset Limits may include: ame safeguard,
high or low gas pressure, high temperature limit, high
pressure limit.)
Never tamper with low water (liquid level) cuto
sensors or circuitry.
Before commissioning the equipment, verify with
authorized personnel that gas lines have been purged.
Check daily that the equipment area is free and clear
of any combustible materials, including ammable
vapors & liquids.
WHAT TO DO IF YOU SMELL GAS:
Do not use matches, candles, ame or other sources
of ignition to check for gas leaks.
Do not try to light the appliance.
Do not touch any electrical switch; do not use any
phone in your building.
Immediately call your gas supplier from a safe
location.
Follow the gas supplier’s instructions. If you cannot
reach your gas supplier, call the re department.
A qualied installer, service agency or the gas supplier
must perform installation and service on the fuel
delivery system.
!WARNING
Do not store or use gasoline or other ammable
vapors and liquids or corrosive materials in the vicinity
of this or any other appliances. Cements for plastic
pipe should be kept away from all sources of ignition.
Proper ventilation should be maintained to reduce the
hazard and to minimize breathing of cement vapors.
No shuto of any kind shall be placed between
the safety relief valve and the equipment or in
the discharge pipe between such valve and the
atmosphere. Doing so can cause an accidental
explosion from overpressure.
The discharge from the safety relief valve shall be so
arranged that there will be no danger of scalding
personnel or damage to equipment. Provisions
should be made to properly drain safety relief valve
discharge piping.
Fluids under pressure may cause injury to personnel or
damage to equipment when released. Be sure to shut
o all incoming and outgoing uid shuto valves and

1  SAFETY & WARNINGS
© Fulton 2018
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VSRT_IOM_2018-1213
carefully decrease all trapped pressures to zero before
performing any maintenance.
Do not attempt to start the equipment for any
testing prior to lling and purging the vessel. A dry
re will seriously damage the equipment and may
result in property damage or personnel injury and
is not covered by warranty. In case of a dry ring
event, shut o the fuel supply and allow the
vessel to cool to room temperature before uid
is reintroduced to the pressure vessel. The boiler
should be inspected by a qualied individual prior
to commissioning the unit.
When opening any drains on the equipment or piping
system, steps should be taken to avoid scalding/
burning of personnel due to hot uids. 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.
!WARNING
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, American National Standards Institute
(ANSI) Z2231991 or latest addenda. In Canada, gas
installations must be in accordance with the current
CAN/Compressed Gas Association (CGA) B149.1 and 2
and/or local codes.
Hot surfaces (over 120 F [49 C]) should be insulated or
shielded for safety. See Installation section.
Use only your hand to turn valve handles. Never use
tools. If the handle will not turn by hand, don’t try to
repair. Forced or attempted repair may result in re or
explosion.
Should overheating occur or the gas supply fails to
shut o, manually shut o the gas supply external to
the equipment.
For reasons of safety, the hot exhaust gas duct and
chimney must be insulated or shielded within the
locality of the heater in compliance with local codes
and regulations.
Check daily that the boiler area is free and clear of
any combustible materials, including ammable
vapors and liquids.
Do not use matches, candles, ame or other sources of
ignition to check for gas leaks.
These instructions must not be considered as a
complete code of practice nor should they replace
existing codes or standards which may be applicable.
Commissioning/Start up by a non-Fulton authorized
person will void the product warranty.
To ensure that your Fulton equipment is operating
safely and eciently, follow the maintenance
procedures set forth in this manual.
!WARNING
SAFETY COMPONENTS: The end user of the boiler
must maintain all labels on the boiler in clean, legible
condition. All connections and safety devices, both
mechanical and electrical, must be kept clean, with
ease of access for inspection, use and maintenance.
!CAUTION
Maintenance procedures for this equipment should be
completed by trained personnel. Appropriate training
and instruction are available from the Fulton Service
Department at [phone] or your local Fulton
Representative.
When calculating ventilation requirements, heat
losses from the Fulton equipment (and other
equipment) should be considered.

SAFETY & WARNINGS  1
Questions? Call [phone], or visit us online at www.fulton.com 1-5
VSRT_IOM_2018-1213
The stack arrangement and draft conditions should
be in accordance with the information in this manual
for proper performance of the equipment.
A competent rigger experienced in handling heavy
equipment should handle rigging your equipment
into position.
Competent personnel in accordance with all
applicable local codes should carry out the
installation of the Fulton equipment. “Factory-Trained
Personnel” refers to someone who has attended a
Fulton Service School specically for the equipment
covered in this manual.
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.
The equipment must be installed on a non-
combustible surface.
!CAUTION
Some soap used for leak testing is corrosive to certain
types of metals. Clean all piping thoroughly after
completing the leak check.
A temperature exceeding 120°F (49°C)* in the boiler
room may cause premature failure of electrical
components. Provisions should be made to maintain
an ambient temperature of 120°F (49°C)* or less (the
panel box interior should not exceed 125°F [52°C]*).
*Pumps, Programmable Logic Controllers (PLC)
or ModSync panels may require lower ambient
temperatures or additional cooling.
Particulate matter or chemicals (example:
perchlorethylene, chlorine, or halogenated
compounds) in the combustion air supply to the boiler
will cause damage or failure to the burner and is not
covered under warranty. Airborne materials from
construction and maintenance activities constitute a
high-risk situation.
An exhaust fan may draw products of combustion
into the work environment creating a possible hazard
to personnel.
Never leave an opened manual air vent unattended.
In the event an opened vent is left unattended, water
or uid damage could occur. The exception to this
warning is a feed water deaerator manual vent
cracked open may be left unattended.
Do not use this equipment if any part has been
under water (or subjected to heavy rains/water if
the equipment does not have National Electrical
Manufacturers Association (NEMA) 4 wiring, controls
and instrumentation). Immediately call a qualied
service technician to inspect the equipment and to
replace any part of the control system and/or gas
control(s) which have been under water.
For all systems containing boilers or unred steam
generators, the water chemistry in the boiler must be
kept within the limits outlined in this manual. Failure
to do so may cause premature pressure vessel failure
and poor steam quality and will void the warranty.
!CAUTION
Do not use the equipment as support for ducted
air piping. Ducted piping must be supported
independently of the equipment.
Do not run the pump dry. Irreparable damage to the
seal can result. Prime the pump in accordance with
the manufacturer’s instructions. Never operate the
pump with a closed discharge valve.
After adjustingcomponents in the fuel or air
delivery system combustion/emissions must be
veried throughout the ring range. If emissions
are improper, adjust combustion following the
appropriate procedure in this manual.
Should you suspect that the boilers ue passage ways
have become blocked, contact your authorized Fulton
representative.

1  SAFETY & WARNINGS
© Fulton 2018
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VSRT_IOM_2018-1213
Steam Boiler Systems
Warnings and Cautions
The following WARNINGS and CAUTIONS are specic
to Steam Boiler Systems and may also appear in
various chapters of this manual. It is critical that all
personnel read and adhere to all information contained
in WARNINGS and CAUTIONS throughout this manual.
In addition, there are bolded Notes throughout the
manual, which are included as additional information
for essential and eective operation and conditions.
!WARNING
Boiler blowdown water must be cooled to <140˚F
(60˚C) prior to discharge to a drain, or as required per
local jurisdictional codes. Failure to use an approved
blow o vessel with adequate cooling could cause
personnel/equipment damage.
Improper installation or maintenance of gauge glass
and connections can cause immediate or delayed
breakage resulting in bodily injury and/or property
damage. Only properly trained personnel should
install and maintain gauge glass connections. Wear
safety glasses during installation. Be sure all parts are
free of chips and debris.
!CAUTION
Where an atmospheric feedwater tank is to be
installed, this should: 1) be vented to a safe location; 2)
have capacity sucient to satisfy boiler consumption,
as well as maintain proper return tank temperature; 3)
Vent pipe should not be downsized, as it may caused
pressure build up in the tank; 4) Return pipes must
not be insulated as this can cause overheating in the
feedwater tank and potential vapor lock in the pump.
Return pipes should be shielded to prevent burn
hazard.
Gauge glass valves need to be fully open during boiler
operation to prevent boiler damage in case of gauge
glass failure.
After installation is complete and prior to operation,
the pressure vessel should be cleaned or boiled out per
instructions in this manual.