FULTON VSRT Series User manual

VSRT Series
Gas Fired Steam Boiler
This manual must be available to the boiler operator at all times. VSRT-IOMM-2019-1

Page II
VSRT-IOMM-2019-1
TABLE OF CONTENTS
Fulton Ltd
I Warnings & Cautions Explained IV
II Warnings & Cautions In Manual IV
III Regulations VII
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Technical Data 1
1.3 Product Overview 1
SECTION 2 - INSTALLATION
2.1 General 7
2.2 Pre-Installation 7
2.2.1 Receiving Inspection 8
2.2.2 Siting 9
2.3 Ventilation 9
2.4 Connections 11
2.4.1 Flue Outlet 11
2.4.2 Blowdown Valves 13
2.4.2.2 Water Level Gauge (sight glass) 13
2.4.3 Steam Safety Valve 13
2.4.4 Main Steam Valve 17
2.4.5 Steam Pressure Gauge 17
2.5 Gas Supply 18
2.5.1 Gas Valve with Pilot Gas line 19
2.5.2 Multi Bloc Gas Valves 20
2.6 Electrical Requirements 21
2.6.1 Electrical Customer Connections 21
2.7 Water Supply 24
2.7.1 Glossary of Water Supply Terms 25
2.12 Piping Specifications 26
2.13 Insulation 27
SECTION 3 - POST INSTALLATION
3.1 29
3.2 29
3.3
Gas Purge
Pipework Leak/Pressure Tests
Electrical Installation Testing
Final Installation Inspection
29
SECTION 4 - COMMISSIONING
4.1 Commissioning the Boiler 31
4.1.2 Boiler Inspection and Initial Firing - Gas Burner 31
SECTION 5 - OPERATION
5.1 General 46
5.2 Controls 46
5.2.1 Boiler Controls 46
5.2.2 Control Panel 47
5.2.3 Steam Pressure Controls 49
5.2.3.1 Setting Steam Pressure Controls 50
5.2.3.2 Testing Steam Pressure Controls 50
5.2.4 51
5.3 51
5.4 52
5.5
Water level control probes
Filling the Boiler - all models
Draining the Boiler
Boiler Start-Up (from cold) - all models 53
5.5.1 Boiler Start-Up Following Short Term Shut-Down 53
5.6 Boiler Shut-Down 54
5.6.1 Short Term Shut-Down (hours) 54
5.6.2 Medium Term Shut-Down (days) 54
5.6.3 Long Term Shut-Down (weeks) 54
SECTION 6 - MAINTENANCE
6.1 Boiler Platform (if fitted) 57
6.2 Visual Checks 57
6.3 Burner Flame Sensor Test 58
6.4 Water Level and Low Water Safety Control Procedures 59
6.4.1 Feedwater Pump Test 59
6.4.2 Low Water Level Check
6.4.3 Evaporation Check
6.5 Blowdown Procedures
6.5.1 Main Boiler Blowdown (Manual)
6.5.2 Water Level Gauge (Sight Glass) Blowdown
6.6 Boiler Internal Inspection
6.7 Fitting New Gaskets To Boiler Inspection Holes
6.7.1 Important Information
6.7.2 Fitting Procedure
6.8 Schedule of Operator Tests and Checks
6.8.1 Daily
6.8.2 Weekly-in addition
6.8.3 Monthly-in addition
6.8.4
6.8.5
Six Monthly - Gas Safe Engineer Only
6.8.6
Annually - Gas Safe Engineer Only
6.9
After All Repairs & Maintenance - In Addition
Maintenance Record Keeping
60
61
61
61
62
63
63
63
64
65
66
66
67
68
68
69
70
3.4 29
4.1.3 Adjustment of the Yokogawa UT-32A Operating
Controller 43

Page III
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Fulton Ltd TABLE OF CONTENTS
SECTION 7 - INSPECTION
7.1 Inspection 71
SECTION 8 - TROUBLESHOOTING
8.1 73
8.2 77
Troubleshooting - Gas Boiler
Troubleshooting - Feed Water Pump
APPENDIX A - TI SHEETS
VSRT Dimensions & Specification 79
Recommended Water Conditions 101
High Integrity Water Limiters 104
Auto TDS Blowdown Systems 107
109
Material & Workmanship Guarantee

Page IV
VSRT-IOMM-2019-1
SAFETY PRECAUTIONS
Fulton Ltd
I WARNINGS & CAUTIONS EXPLAINED
For your safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
• 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 effectiveness.
• Notes: must be observed for essential and
effective operating procedures, conditions and
as a statement to be highlighted.
It is the responsibility and duty of all personnel involved
in the operation and maintenance of this equipment
to fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects
of safety and equipment prior to operation or
maintenance of the equipment.
II WARNINGS & CAUTIONS IN MANUAL
! WARNING
Steam boilers are a potential hazard, possibly fatal if not properly maintained.
! CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry
out the routine maintenance checks could result in a drastic reduction in the life expectancy of the
system and increase the possibility of fire, explosion, property damage, personal injury or loss of life.
Escaping gas can lead to explosions which may result in serious injury.
WHAT TO DO IF YOU SMELL GAS:
• Do not use matches, candles, flame 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 fire department.
Flue Gas can lead to life threatening poisoning.
WHAT TO DO IF YOU HAVE A FLUE GAS LEAK:
• Shut down the heating system.
• Ventilate the boiler room.
• Close all doors leading to the space.
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the boiler and serious personal injury.

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SAFETY PRECAUTIONS
Fulton Ltd
! WARNING
Do not try to do repairs or any other maintenance work
you do not understand. Obtain a service manual from
Fulton Ltd or call a Fulton service engineer.
It is the responsibility of the installer to ensure all parts
supplied with the boiler are fitted in a correct and safe
manner.
Understand the electrical circuit before connecting
or disconnecting an electrical component. A
wrong connection can cause injury and or
damage.
A defective boiler can injure you or others. Do not
operate a boiler which is defective or has missing
parts. Make sure that all maintenance procedures are
completed before using the boiler.
Do not change the boiler fuel without consulting the
boiler manufacturer.
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local
regulations and is suitable for the job. You can be
injured if you use faulty lifting equipment. Make sure the
lifting equipment is in good condition.
Operating the boiler beyond its design limits can
damage the boiler, it can also be dangerous. Do
not operate the boiler outside its limits. Do not try
to upgrade the boiler performance by unapproved
modifications.
Non-approved modifications can cause injury and
damage. Contact your Fulton dealer before modifying
the boiler.
Only qualified persons should be allowed to
operate and maintain the boiler and its equipment.
The installation of gas appliances including the flue
system should only be carried out by Gas Safe
registered engineers.
Steam boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent and
qualified personnel should work on or in the locality
of a steam boiler and ancillary equipment. Always
ensure the working area and floor are clear of potential
hazards, work slowly and methodically.
Do NOT store flammable materials near the boiler.
The importance of correct boiler water and feedwater
cannot be over emphasized, see the relevant section in
this manual.
! WARNING
DANGER FROM INCOMPLETE COMBUSTION
The importance of correct burner adjustment to achieve
low emissions, safe, clean and efficient combustion
is paramount. Poor combustion, where unburnt gas
forms carbon monoxide is both a health hazard, and
the potential risk to the boiler from overheating, caused
by re-burning of the unburnt gas in the secondary flue
passes.
Prior to the commencement of any work requiring the
removal of cover plates and the opening of control
panel box, the electrical supply to the boiler must be
isolated.
Boilers should always be drained through an approved
blowdown vessel.
This boiler is equipped with an ignition device, which
automatically lights the burner. Do not try to light the
burner by hand.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation.
Never attempt to operate equipment that has failed to
pass all the safety checks.
Follow proper lockout 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: flame safeguard, high or low
gas pressure, high pressure limit.)
Never tamper with low water (liquid level) cut-off
sensors or circuitry.
Before commissioning the equipment, verify with
authorized personnel that gas lines have been purged
and certified.
Check daily that the equipment area is free and clear
of any combustible materials, including flammable
vapours & liquids.
Do not store or use gasoline or other flammable
vapours 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 vapours.
No shut-off 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.

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VSRT-IOMM-2019-1
SAFETY PRECAUTIONS
Fulton Ltd
! WARNING
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
off all incoming and outgoing fluid shut-off valves and
carefully decrease all trapped pressures to zero before
performing any maintenance.
Do not attempt to start the equipment for any testing
prior to filling and purging the vessel. A dry fire 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 firing event, shut off
the fuel supply and allow the vessel to cool to room
temperature before fluid is reintroduced to the pressure
vessel. The boiler should be inspected by a qualified
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 fluids. Whenever
possible, the system should be cooled prior to opening
any drains.
Hot surfaces (over 49 °C) should be insulated or
shielded for safety where practicable. See
installation section.
Should overheating occur or the gas supply fails to shut
off, manually shut off the gas supply external to the
equipment.
Improper installation or maintenance of gauge glass
and connections can cause immediate or delayed
breakage resulting in bodily injury and/or property
damage. Only trained personnel should install and
maintain gauge glass connections. Wear suitable
safety eye-wear during installation. Be sure all parts
are free of chips and debris.
! CAUTION
WATER SOFTENER, SALT & CHEMICAL TREATMENT
The chemicals required to operate the water softeners
and chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
It is the responsibility of the operator to ensure
adequate supplies of chemical are available at all times
(including commissioning). Costly repairs could be
required should the plant operate without chemicals or
the wrong dosage of chemicals.
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and
is normally only required by engineering surveyors /
inspectors. In order to ensure the material/ pressure
vessel does not suffer from brittle fracture, hydraulic
testing should not be carried out below 7 °C.
The stack arrangement and draft conditions should be
in accordance with the information in this manual for
proper performance of the equipment.
Use appropriate leak-detection fluid. Clean all piping
thoroughly after completing the leak check.
A temperature exceeding 32 °C* in the boiler room
may cause premature failure of electrical components.
Provisions should be made to maintain an ambient
temperature of 32 °C* or less (the panel box interior
should not exceed 32 °C*.
*Pumps, Programmable Logic Controllers (PLC)
or sequence panels may require lower ambient
temperatures or additional cooling.
Particulate matter or chemicals (example: per
chloroethylene, 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. High-risk situations for particulate
matter to be in the air include construction and
maintenance activities.
For all systems containing boilers or unfired 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.
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.
Should you suspect that the boiler’s flue passage
ways have become blocked, stop the boiler
immediately and contact the Fulton office.
! CAUTION
Obey all laws and local regulations which affect you
and your boiler.
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary preheat the
feedwater. If in doubt consult Fulton Ltd.

Page VII
VSRT-IOMM-2019-1
SAFETY PRECAUTIONS
Fulton Ltd
III REGULATIONS
Observe the following when working on this system:
• Work on gas equipment must only be carried out by a qualified gas engineer.
• Work on electrical equipment must only be carried out by a qualified electrician.
• All legal instructions regarding the prevention of accidents,
• All legal instructions regarding environmental protection,
• The Code of Practice of relevant trade associations,
• All current safety regulations as defined by PED, DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable
standards,
• Gas Safety (Installation & Use) Regulations
- The appropriate Building Regulation either the Building regulations, the Building Regulation (Scotland) or
Building Regulations (Northern Ireland).
- The Water Fittings Regulation or Water Bylaws in Scotland,
- The current I.E.T. Wiring Regulations.
! CAUTION
In case of emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous
conditions.
If such a condition should occur during commissioning or during subsequent operation of this product,
whatever the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been
investigated by a competent person and rectified.
The Pressure System Safety Regulations 2000
Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.
For further information contact:
(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) Health and Safety Executive local office.
(c) Your Competent Person.

Page VIII
VSRT-IOMM-2019-1
Fulton Ltd

INTRODUCTION - 1
Fulton Ltd
1.1 GENERAL
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
• Hydrostatic test inspection
• Electrical components inspection
• Documented Fire and Test (FaT)
• Packing, inspection and final check
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 staff
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,
qualified 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 qualified and fully understand all requirements and procedures.
1.2 TECHNICAL DATA
For a specification, refer to Appendix A - VSRT Data Sheets
1.3 PRODUCT OVERVIEW
The VSRT fuel fired steam boiler is a vertical two-pass boiler of efficient design and construction.
The VSRT uses Fulton’s PURE technology to achieve higher efficiency and lower NOx levels with
a smaller footprint than its Fulton J series equivalent.
VSRT connections and specifications are listed in Tables 1 and 2 and shown in Figures 1, 2, 3
and 4.
CONTINUED ON NEXT PAGE
VSRT-IOMM-2019-1
Page 1

INTRODUCTION - 1
Fulton Ltd
Table 1 – VSRT Customer Connections (See Figs. 1-4)
Table 2 – VSRT Specifications
Unit Size (BHP)
10
15
20
30
40
50
60
Maximum allowable working pressure (barg)
10.34 barg
10.34 barg
10.34 barg
10.34 barg
10.34 barg
10.34 barg
10.34 barg
Boiler input
120 kw
179 kw
239 kw
359 kw
478 kw
598 kw
718 kw
Boiler input (Natural gas); m3/hour
10.7 m3/hr
16.1 m3/hr
21.5 m3/hr
32.3 m3/hr
43 m3/hr
53.9 m3/hr
64.7 m3/hr
Boiler input (Propane); m3/hour
4.6 m3/hr
6.9 m3/hr
9.2 m3/hr
13.8 m3/hr
18.3 m3/hr
23 m3/hr
27.6 m3/hr
RATINGS* (Sea level to 914.4m)
Boiler Output
98 kw
147 kw
196 kw
294 kw
392 kw
490 kw
589 kw
Steam Output - Minimum Service Capacity; kg/hr
156 kg/hr
235 kg/hr
313 kg/hr
470 kg/hr
626 kg/hr
782 kg/hr
939 kg/hr
Net Effective Heating Service (m2)
5.06 m2
5.06 m2
6.04 m2
6.04 m2
10.77 m2
10.77 m2
10.77 m2
Water Capacity (Operating)
356 litres
356 litres
424 litres
424 litres
1,306 litres
1,306 litres
1,306 litres
Burner Turndown
4:1
6:1
4:1
6:1
6:1
8:1
10:1
Minimum Draft Requirement
-0.25” W.C.
-0.25” W.C.
-0.25” W.C.
-0.25” W.C.
-0.25” W.C.
-0.25” W.C.
-0.25” W.C.
Minimum Incoming Gas Pressure
19 mbar
19 mbar
19 mbar
19 mbar
19 mbar
19 mbar
19 mbar
Weights (Approximate)
Dry Weight; kg
876 kg
876 kg
1,284 kg
1,284 kg
2,654 kg
2,654 kg
2,654 kg
Operating Weight; kg
1,232 kg
1,232 kg
1,707 kg
1,707 kg
3,959 kg
3,959 kg
3,959 kg
Shipping Weight; kg
1,134 kg
1,134 kg
1,542 kg
1,542 kg
2,800 kg
2,800 kg
2,800 kg
Flooded Weight; kg
1,364 kg
1,364 kg
1,841 kg
1,841 kg
4,228 kg
4,228 kg
4,228 kg
Electric Power Requirements
Voltage
400/50/3
400/50/3
400/50/3
400/50/3
400/50/3
400/50/3
400/50/3
Operating FLA (refers to boilers rated draw at high fire)
14.8 AMPS
14.8 AMPS
14.8 AMPS
21.6 AMPS
21.6 AMPS
21.6 AMPS
21.6 AMPS
10/15BPH
20/30 BPH
40/50/60 BPH
Description
Size
Type
Size
Type
Size
Type
A.
Feed Water Inlet
1”
B.S.P.T.
1”
B.S.P.T.
1”
B.S.P.T.
B.
Blowdown Outlet
1¼”
B.S.P.T.
1¼”
B.S.P.T.
1½”
B.S.P.T.
C.
Steam Outlet
1¼”
DN32
1½”
DN32
2”
B.S.P.T.
D.
Flue
152.4
------
202
------
254
------
E.
Auxiliary Water Column
1”
B.S.P.T.
1”
N.P.T.
1”
N.P.T.
F.
Fuel Inlet
1”
B.S.P.T.
1¼”
B.S.P.T.
1½”
B.S.P.T.
G.
Water Column
1”
B.S.P.T.
1”
B.S.P.T.
1”
B.S.P.T.
H.
Surface Blowdown
¾”
B.S.P.T.
¾”
B.S.P.T.
¾”
B.S.P.T.
J.
Combustion Air Inlet
101.6
-----
152.4
------
152.4
------
K.
Safety Relief Valve
¾”
B.S.P.T.
¾”
B.S.P.T.
1”
B.S.P.T.
L.
Steam Gauge Port
¼”
B.S.P.T.
¼”
B.S.P.T.
1/42
B.S.P.T.
M.
Inspection Port
-----
-----
-----
-----
82.55
150#
N. Inspection Opening
-----
-----
-----
-----
50.8
N.P.T.
VSRT-IOMM-2019-1
Page 2

INTRODUCTION - 1
Fulton Ltd
Figure 1 – Model VSRT-60 Dimensions – Front View
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Figure 2 – Model VSRT-60 Dimensions
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INTRODUCTION - 1
Fulton Ltd
Figure 3 – Model VSRT-60 Dimensions – Top Side View
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Figure 4 – Model VSRT-60 Dimensions – Rear Side View
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INSTALLATION - 2
Fulton Ltd
2.1 GENERAL
The installation of a VSRT fuel fired steam boiler should be carried out by competent personnel in
accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that
these regulations are complied with.
2.2 PRE-INSTALLATION
Prior to delivery of the boiler, consideration should be given to the following:
(Planning regulations may call for more consents than those listed below, always check with your
Local Planning Authority).
A. Local Planning consents where appropriate.
B. Consideration given to access for delivery and positioning of the boiler.
C. Preparation of a suitable non-combustible base, which must be able to support the total
weight of the system under operating conditions.
The locations of services to the site required for the system, under operating conditions.
D. Electricity supply, check the loading required/available.
E. Drainage system, check the suitability of the drainage system.
F. Local regulations for discharge into existing drains.
G. Suitable access for delivery and off-loading.
H. Safe access to the plant when installation is complete.
Appropriate front, back, side and top clearances must be maintained (see Table 3). This will allow
access around the equipment to facilitate maintenance and a safe work environment.
Table3 - Minimum Clearance Around Boiler
Unit Size (BHP
Front of Panel (mm)
Rear/Sides of
Boiler (mm)
Vertical Clearance from
Floor to Ceiling (mm)
10
915
610
2,502
15
915
610
2,502
20
915
610
2,800
30
915
610
2,800
40-60
915
610
3,315
Note: The vertical clearance from the floor to the ceiling is necessary for removal of the
burner for servicing.
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INSTALLATION - 2
Fulton Ltd
2.2.1 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 fitted in a correct and safe manner.
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INSTALLATION - 2
Fulton Ltd
2.2.2 SITING
!WARNING
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.
(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1
Communication 1676, and in particular to Section 5, Location of Appliances).
The boiler house should be sufficiently sized to allow easy and safe access to all parts of the
boiler for operational and maintenance purposes.
Reference should be made to Appendix A - VSRT Tech Data Sheets and data product
submittals to ascertain the relevant dimensions and weights, special note should be taken
of the required vertical clearance required for maintenance.
!WARNING
Maintenance on the burner assembly requires the area directly above and to one side of the boiler must not be
obstructed with pipework or equipment which would interfere with the removal of the complete burner unit. Care should be
taken on installation of the boiler to ensure this area remains clear of obstructions.
The flooring must be level, laid in a non-combustible material and be of sufficient strength to
support the boiler.
2.3 VENTILATION
Adequate fresh, clean air is necessary for safe and efficient combustion, and as a minimum
should be provided at high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part
1 Communication 1676.
This product is capable of being connected as either room sealed or non-room sealed. There are
different requirements for each type of system.
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INSTALLATION - 2
Fulton Ltd
It is essential that only fresh air be allowed to enter the combustion air system. Foreign
substances in the combustion system can create hazardous conditions. Particulate matter like
lint, combustible volatiles, dust, smog or chemicals (example, perchloroethylene, halogenated
compounds) in the combustion air supply to the equipment will cause damage or failure of the
burner and is not covered under warranty.
Eliminate potential for high risk situations for particulate matter to be in the air supply (e.g.,
as the result of construction or maintenance activities). If foreign substances can enter the
air
stream, the combustion air inlet must be piped to an outside location. Failure to do so will void the
warranty.
Note: Ensure that there is adequate ventilation in the boiler room to correct standards. Lack of
ventilation will create a high temperature and cause control lockout. There is a minimum ventilation
requirement to supply the air for combustion.
Note: Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the
necessary boiler draught forced vent interlocks.
Note: see Appendix A - VSRT Data Sheets for low and high level values.
!CAUTION
Do not store chemicals such as perchloroethylene in the boiler house, the fumes may damage the boiler and
flue and cause the burner to lock out on flame failure.
!CAUTION
A temperature exceeding 49 C in the boiler room may cause premature failure of electrical
components. Provisions should be made to maintain an ambient temperature of 49 C or less (the
panel box interior should not exceed 52 C).
!CAUTION
Recommended boiler HSE temperatures should not exceed:
•Floor Level (0-100mm): 25 C
•Mid Level (1.5m above floor): 32 C
•Ceiling Level (0-100mm from ceiling): 40 C
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INSTALLATION - 2
Fulton Ltd
2.4 CONNECTIONS
2.4.1 FLUE OUTLET
The height and type of flue will be subject to local planning regulations and approvals.
The following information is only intended to provide assistance for the installation of a simple
flue. Where multi-boiler flues or difficulties are experienced, specialist advice should be obtained.
An appropriately sized flue should be connected to the flue gas outlet at the boiler. A 45° Boot
Tee termination from the back of the boiler is recommended. The correct flue size and draft
control is most important for correct burner operation. The flue must be as large as or larger than
the outlet on the vessel. Avoid flue piping and elbows by placing the equipment as close as
possible to the chimney.”
The flue should rise continuously to the connection at the chimney and should contain no more
than two bends at 45 degree angles or less.
There should be min 0.6m of straight, horizontal flue before any change in direction, fitting or
draft regulator. This is to prevent potential pilot or main flame failures due to back pressure
build-up during ignition.
The run in the total distance of flue ducting, as measured in a straight line from the outlet of the
boiler to the outlet of the flue, should not exceed 70% of the rise. With the exception of the duct
run previously described, horizontal sections of ducting must be avoided and should not exceed
1.5 metre total.
The flue, chimney, and any components must be constructed from material that is rated for a
300 °C operating temperature and sized for 280 °C operating temperature – Twin Wall
construction, 316 Stainless Steel.
The flue and chimney material shall comply with all applicable codes.
A condensate drain should be included at low point.
Adequate provision must be made for the support of the weight of the chimney and stack to avoid
having a load imparted to the outlet connection of the equipment.
The installation of a draft regulator by the client/contractor will help maintain the required draft.
Where a chimney cowl is fitted, care should be taken to ensure that the distance between the
lowest point of the cowl and the top of the flue is 1.5 x the diameter of the flue and that it is of the
terminal stub type.
The VSRT requires a flue design that generates draft conditions of -0.25”W.C. – 1.5”W.C draft of
the boiler.
Note: Ensure all flue pipes from the boiler to the main flue have a rising pitch.
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INSTALLATION - 2
Fulton Ltd
!WARNING
To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the
section of the chimney duct within the building should be insulated.
!CAUTION
Concentration levels of only a few ppm of chlorine containing compounds in combustion air can
produce serious corrosion of the flue over long periods of time. High chlorine containing compounds
such as carbon tetrachloride or perchloroethylene would be prime suspects.
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