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FULTON Vantage VTG Series - User Manual

FULTON Vantage VTG Series
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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
Owner
Site Name
Date
VTG-IOM-2016-1214

Table of Contents

Questions and Answers

Summary

INTRODUCTION

Overview

Details manufacturing inspections and tests ensuring high standards for customers.

Warnings & Cautions

Emphasizes critical reading and adherence to all warnings and cautions for safety and equipment.

Disclaimers and Local Codes

Outlines installation conformity to national, state, and local codes and ASME standards.

INSTALLATION

Product Overview

Introduces the Vantage hot water boiler, its certifications, and supplied components.

Placement & Rigging

Provides essential guidelines for proper product placement and rigging for installation.

Clearances and Serviceability

Details required clearances for safe operation, maintenance, and serviceability.

Install Boiler Trim

Instructions for installing the safety relief valve and discharge piping.

Install Water Piping

Guidelines for water piping installation, including isolation valves and purging.

Variable Primary Piping Arrangement

Explains design for variable primary flow piping and adherence to arrangements.

Primary-Secondary Piping Arrangement

Discusses acceptable primary-secondary arrangements for decoupling boiler and system loops.

Meet Water Chemistry Requirements

Specifies system water chemistry requirements for pH, oxygen, iron, copper, and chloride.

Prevent Oxygen Contamination

Methods to prevent boiler water oxygen contamination by minimizing leaks and proper materials.

Eliminate System Air

Details on air elimination requirements, including air separators and vents.

Fill the Boiler With Water

Procedure for filling the boiler with water to prevent air-bound operation.

Install Gas Piping

Instructions for gas piping installation, including size, pressure, and leak testing.

Components Requiring Ventilation to the Outdoors

Guidelines for components needing outdoor ventilation, including vent limiter use.

Install Condensate Drain

Details on installing single and multiple boiler condensate drain traps.

Install pH Neutralization Kit

Instructions for installing the pH Neutralization Kit to adjust condensate pH.

Install #2 Fuel Oil Piping

Guidelines for installing #2 Fuel Oil piping for dual fuel gas/oil burners.

Oil Pump Priming

Steps for priming the oil pump to ensure proper fuel delivery.

Oil Filtration

Requirements for oil supply filtration and regular maintenance of the filter.

Venting

Requirements for exhaust and air intake venting, including pressure drops.

Combustion Air Supply From the Boiler Room

Guidelines for providing adequate combustion air and ventilation to the boiler room.

Air Piped From Outside Boiler Room

Instructions for piping combustion air directly to the boiler air inlet for sealed combustion.

Exhaust Venting

Requirements for exhaust venting, including material, slope, and support.

Common Venting Layouts for Vantage

Guidance on combining air intake and exhaust venting of multiple boilers.

Venting Terminations

Specifications for installing vent pipes and fittings with air space clearances.

Wall Thimble Installation

Steps for installing wall thimbles through combustible and non-combustible walls.

Removing an Existing Boiler

Procedures for removing an existing boiler from a common venting system.

Electrical Connections

Guidelines for making electrical connections, including voltage and frequency limits.

Assembly of Fulton Multi-Skid Systems

Instructions for assembling multi-skid engineered systems, including piping and alignment.

OPERATION

Perform Pre-Start-Up Inspection

Checklists for pre-start-up inspections, including gas leaks and system conditions.

Fill and Purge the System

Procedure for completely filling and purging the heating system with water.

Commission The Boiler

Steps for commissioning the boiler, including gas line verification and personnel familiarization.

System Design and Boiler Operation

Ensuring proper system design and boiler operation for efficiency and longevity.

Siemens LMV36 and LMV37 Control

Details on the Siemens LMV36/LMV37 control system and its operational parameters.

Operating Points on the Siemens LMV Control

Information on factory pre-programmed operating points and setup for commissioned boilers.

Steps to Enter Parameters

Guides users through the process of entering parameters using the Siemens AZL display.

Adjusting Fuel;Air Curve (Natural Gas or Propane or Modulating #2 Fuel Oil)

Instructions for adjusting fuel/air curve points using a flue gas analyzer.

Adjusting Fuel;Air Curve (Multistage #2 Fuel Oil - VTG-2000 DF to VTG-4000 DF)

Procedure for adjusting fuel/air curve points for multistage #2 Fuel Oil operation.

Viewing Flame Signal Intensity

How to view flame signal intensity using the Siemens AZL display.

Manual Control (Manual Request for Output)

Steps for manually controlling boiler output via the Siemens AZL display.

Viewing Total Burner Start-ups

How to view the total number of burner start-ups from the Siemens AZL display.

Viewing Total Burner Hours

How to view the total number of burner operating hours from the Siemens AZL display.

Changing Modbus Address

Procedure for changing the Modbus address of the boiler controller.

Viewing Lockout History

How to access and view the boiler's lockout history and error codes.

Parameter Backup

Procedure for backing up the ModSync controller's program and settings.

Parameter Restore

Procedure for restoring the ModSync controller's program and settings.

Operating Temperatures and Fuel Selection

Table detailing minimum return water temperatures for different fuels.

Temperature Controller Instructions

Instructions for configuring temperature controllers like SC-500 and Yokogawa UT 32A.

SC-500 Temperature Controller Basic Programming

Basic programming steps for the SC-500 Temperature Controller.

Yokogawa UT 32 A Basic Programming

Basic programming steps for the Yokogawa UT 32A temperature controller.

Access to Variable Speed Drive Blower Motor

Information on accessing the Variable Frequency Drive (VFD) for blower motor control.

Perform Test of Ignition Safety System

Procedure for testing the ignition system safety shutoff functionality.

Perform Test of Low Water Cut Off

Procedure for testing the boiler's low water cut-off safety feature.

Perform Test of Limit Controls

Tests for high temperature limit, low gas pressure, and high gas pressure switches.

General Operation of the Boiler

Guidelines for boiler operation to ensure longevity and prevent excessive cycling.

MAINTENANCE

General

Overview of recommended maintenance practices for ensuring boiler safety and efficiency.

Daily Maintenance and Inspection Schedule

Daily tasks for observing temperatures, air flow, and ensuring a clean environment.

Weekly Maintenance and Inspection Schedule

Weekly tasks, including observing the main flame and checking air adjustment.

Monthly Maintenance and Inspection Schedule

Monthly tasks, including testing high-limit control and operating temperature controls.

Procedure for Cleaning the Air Inlet Filter (Low Emissions Burners)

Steps to clean or replace the air inlet filter for Low Emissions burners.

Annual Maintenance and Inspection Schedule

Annual tasks, performed by factory trained technicians, for fuel train, burner, controls, and venting.

Annual Removal and Inspection of LE Bekaert Burner

Procedure for removing and inspecting the LE Bekaert burner.

Verification of Torque Settings on Fireside Access Doors

Instructions for verifying torque settings on fireside access doors for specific models.

Inspecting;Cleaning the Flue Passages

Procedure for inspecting and cleaning flue passages, especially for oil-fired boilers.

Ignition Pilot Adjustment - Dual Fuel Burners

Ensuring pilot and electrode are positioned and adjusted correctly for dual fuel burners.

After All Repairs and Maintenance

Steps to follow after completing repairs, including pre-start checks and combustion checks.

Troubleshooting

Using tables to guide troubleshooting for common boiler issues.

WARRANTY & PARTS

Standard Warranty for Fulton Vantage Hydronic Boilers

Details lifetime thermal shock, 5-year pressure vessel, and parts warranties.

Parts

Information on ordering spare and replacement parts through local representatives or Fulton Companies.

INTRODUCTION

ModSync

Overview of the ModSync Sequencing System for hydronic boiler installations.

ModSync Features

Details features like Lead/Lag, Outdoor Reset, Setback Schedule, and Modbus Communication.

INSTALLATION

Location

Guidelines for locating the ModSync enclosure in a clean, dry environment near boilers.

Power Supply

Requirements for the ModSync's 120VAC/60Hz/1PH electrical supply and circuit breaker.

Hydronic Boiler Interface

Describes how hydronic boilers provide status feedback via contacts or analog signals.

Temperature Sensors

Details PT100 RTD sensors for Outdoor Air and Hydronic Loop temperature monitoring.

OPERATION

Sequence of Operations

Details the ModSync's sequential staging and modulation of boilers for efficiency.

Screen Descriptions

Overview of the ModSync's screen interfaces for access and configuration.

Main Menu Screen

Describes the main menu touchscreen interface for selecting other screens.

System Status Screen

Displays current temperature, setpoint, control variable, and boiler status.

Hydronic “Boiler Config” Configuration Screens

Screens for independently setting up each hydronic boiler and manual control options.

System Configuration Menu

Access to values for initial configuration of the ModSync system.

System and Scaling Screen 1

Configuration of rotation priority, manual priority, remote setpoint, and system settings.

System and Scaling Screen 2

Configuration for oil operation, outlet scaling, and outlet monitoring.

System and Scaling Screen 3

Access to optional features like outdoor reset, return sensor, and isolation valves.

Password and Screen Saver

Configuration for user password, bypass timer, saving/loading settings, and screen saver.

Maintenance Configuration Screen 1

Shows current boiler cycles and hours, with manual adjustment capability.

Maintenance Configuration Screen 2

Optional run hour monitor for preventive maintenance tracking and reset.

Sensor Configuration

Selection of temperature reading sources and update frequency.

BMS Configuration

Configuration of communication settings to the Building Management System.

Alarm Configuration

Setting up boiler alarms, sensor delays, and monitor alarm retry.

Setback Schedule

Setting up setpoint curves based on time of day and day of week.

Setpoint Configuration without Outdoor Reset

Configuration of loop setpoints without utilizing outdoor reset functionality.

Setpoint Configuration with Outdoor Reset

Configuration of loop setpoints using outdoor reset based on outdoor temperature.

Outdoor Reset Configuration

Setup of loop setpoint based on outdoor reset when enabled in ModSync mode.

Alarm Status

Text display of existing alarm conditions and last monitored alarm history.

Trending

Allows comparison and charting of Loop, Setpoint, and Outdoor Temperatures.

Lead; Lag Configuration 1

Configuration of rotation schedule for lead boiler and PID settings.

Lead; Lag Configuration 2

Configuration of lag boiler start/stop delays and lead boiler start/stop deviations.

Lead; Lag Configuration 3

Defines firing rates for consecutive stages and additional lag enabled CV.

Lead; Lag Configuration 4

Configuration of PID parameters: Proportional Band, Integral Time, Derivative Time.

NETWORK

Network Parameter Configuration and Address Listings

Details communication parameters and ModSync addresses for BMS integration.

Port 2 Wiring Diagram (Slave) RJ-11 Type Serial Port

Wiring diagram for ModSync port 2 serial communication.

Boiler Modbus Network (Port 3)

Configuration for Modbus communication to boilers, including wiring and addressing.

Fulton Endura Boiler

Configuration of SOLA display for Modbus communication with ModSync SE.

Procedure (SOLA Settings)

Steps for configuring SOLA settings for Modbus communication with ModSync.

Fulton Vantage Boiler

Setup for Fulton Vantage Boiler communication with ModSync via LMV3 controller.

Setup at the LMV3 Controller (AZL)

Steps for configuring the LMV3 controller for Modbus communication.

MAINTENANCE

ModSync Alarms

Explanation and recommended actions for various ModSync alarm messages.

Backing up the Program

Procedure to back up ModSync program and settings for data retention.

Battery Replacement

Recommendation and procedure for replacing the ModSync screen's backup battery.

Common Troubleshooting Issues

Table of common issues and their possible resolutions for ModSync controlled boilers.

PARTS AND WARRANTY

ModSync Limited Warranty

Details the warranty terms for Synex ModSync components and parts.

Specifications

Provides mechanical, environmental, electrical, and wiring specifications for the ModSync.

FULTON Vantage VTG Series Specifications

General IconGeneral
ModelVantage VTG Series
CategoryBoiler
ManufacturerFULTON
FuelNatural Gas, Propane
Hot Water OutputVaries by model
Operating Pressure (Steam)15 psi
Input Range2, 000, 000 - 6, 000, 000 BTU/hr
Heat ExchangerStainless Steel
TypeVertical Tubeless Gas-Fired Boiler

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