FULTON VSRT-60 - User Manual

Other manuals for FULTON VSRT-60

Installation And Operation Manual91 pages

Questions and Answers

R
Robert OwenAug 26, 2025
Why does my FULTON VSRT-60 have flame failure during normal run?
- L
  Laura MolinaAug 26, 2025
  If your FULTON Boiler experiences flame failure during normal operation, consider these potential causes: * **Power Supply:** Check the fuse or circuit and reset or replace it as necessary. * **Gas Supply:** Verify the gas pressure entering the gas train. Contact the gas supplier if it's low, and adjust the gas valve regulator as needed. * **UV Detector:** Ensure the detector is correctly located and clean. * **Faulty Air Switch:** Check for a faulty air switch. * **Bad Combustion:** Check combustion readings.
E
erin73Aug 28, 2025
How to troubleshoot poor combustion in a FULTON VSRT-60 Boiler?
- A
  Adam CannonAug 28, 2025
  To troubleshoot poor combustion in your FULTON Boiler, consider the following: * **Main Air Adjustment:** Check air and gas servo motors and check CO2 and O2 combustion levels. * **Draft:** Check the draft with a gauge. It should be -.05 to -.10 mbar with the burner off, or -.10 to -.15 mbar when operating. A barometric damper may need to be installed. * **Dirty Flue:** Check that the draft complies with the minimum/maximum parameters. * **Negative Room Pressure:** Ensure there are no exhaust fans running in the boiler room. * **Dirty Fan:** Check the fan for obstructions and clean as required.
L
Laura MorrisAug 30, 2025
What to do if my FULTON VSRT-60 fails to start?
- S
  Steve WilliamsAug 31, 2025
  If your FULTON Boiler fails to start, check the following: * **No Power:** Check the fuse or circuit breaker. Reset or replace if necessary. * **Pressure Control:** Disconnect all power and wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point to check if the switch makes, then raise it to see if it breaks. Replace the controller if it operates improperly.
D
davidmccallSep 4, 2025
Why is my FULTON VSRT-60 burner backfiring?
- K
  Kendra PerezSep 4, 2025
  A FULTON Boiler burner backfiring can be attributed to: * **Ignition Electrodes:** Check for cracks, carbon buildup, and incorrect settings. Clean, adjust, or replace as needed. * **UV Detector:** Ensure it is correctly located and clean. * **Draft:** Check that the draft complies with the specified minimum/maximum parameters. * **Negative room pressure:** Ensure there are no exhaust fans running in the boiler room. * **Air Settings:** Check the air servo motor operation and setting. * **Gas Supply:** Check the gas pressure entering the gas train and adjust the gas valve regulator if necessary. Contact the gas supplier if the pressure is low. * **Dirty flue:** Check the flue for carbon buildup or obstructions.
P
Paul BaileySep 7, 2025
What causes a FULTON VSRT-60 to rumble and pulsate?
- C
  Curtis TerrySep 7, 2025
  If your FULTON Boiler is rumbling and pulsating, here are some potential causes: * **Poor Combustion:** Check combustion readings. * **Draft:** Check that the draft complies with the specified minimum/maximum parameters. * **Too much main air:** Adjust the air/gas ratio.
K
Kevin HarperSep 9, 2025
Why is my FULTON VSRT-60 Boiler surging?
- D
  Daniel StuartSep 10, 2025
  If your FULTON Boiler is surging (indicated by a widely fluctuating water level in the sight glass), consider these possible causes: * **Steam traps:** Check steam traps, clean or replace as required. * **Contamination:** Empty the boiler and feed tank, then flush and refill. If the system operates but progressively deteriorates, there is likely a leak. * **Scale build-up or lime deposits:** Consult Fulton or a water treatment specialist. * **Too much compound:** Dump the contents of the return tank and flush the system. Test the water. * **High Alkalinity:** Have a water treatment specialist test the water. * **Load exceeds boiler capacity:** Check the total system load against the boiler's output and decrease the load if necessary.
S
Shannon EsparzaSep 12, 2025
What causes a FULTON Boiler to carry over water with steam?
- J
  Jason ContrerasSep 12, 2025
  If your FULTON Boiler is carrying over water with the steam, consider these possible causes: * **Steam Traps:** Check steam traps, clean or replace as required. * **Too much compound:** Dump contents of the return tank and flush the system. Test the water. * **Contamination:** Empty boiler and feed tank. Flush out and refill, if system operates but progressively deteriorates, there is probably a leak somewhere in the system.
J
Jaime PayneSep 14, 2025
How to fix low fuel pressure in FULTON VSRT-60 Boiler?
- J
  James AndersonSep 14, 2025
  To fix low fuel pressure in your FULTON Boiler, check and replace the gas pressure regulator.
D
Dr. Laura Andrews DVMNov 17, 2025
How to fix ignition failure in a FULTON Boiler?
- H
  Heather TaylorNov 17, 2025
  If your FULTON Boiler is experiencing ignition failure, several factors could be the cause. Here's what you can check: * **Gas supply:** Check for proper gas pressure and any intermittent supply issues. * **Power Supply:** Check the fuse or circuit breaker, and reset or replace it if needed. * **Ignition Electrodes:** Inspect for cracks in the porcelain, clean any carbon buildup, and ensure the settings are correct. * **Transformer:** Verify the voltage between the transformer leads at the terminal block. * **UV Detector:** Look for any ignition interference. * **Burner Control:** Check the voltage between the ignition terminal and neutral before the control locks out. Replace the control if there's no power. * **Air Settings:** Check the operation and setting of the air ser...
S
smithandrewNov 19, 2025
What to do if my FULTON Boiler burner cuts off?
- M
  Melissa Mitchell DDSNov 19, 2025
  If your FULTON Boiler burner cuts off, consider the following potential causes and solutions: * **Gas supply:** Check the gas pressure entering the gas train and adjust the gas valve regulator if necessary. Contact the gas supplier if the pressure is low. * **Power Supply:** Check the fuse or circuit breaker, and reset or replace it if required. * **Ignition Electrodes:** Inspect for cracks, clean carbon buildup, and adjust settings. * **UV Detector:** Ensure it's correctly located and clean. * **Faulty Air Switch:** Check the air switch by jumpering the two air switch leads at the terminal block. Replace the air switch if the boiler starts and runs with the jumper in place. * **Faulty Level Control:** Check the level control relays are securely mounted and powered. Swap relay...

Summary

Safety Precautions

Manual Warnings & Cautions

General Safety Guidelines

Covers general safety warnings for repairs, electrical work, defective boilers, and lifting equipment.

Combustion & Electrical Safety

Details dangers of incomplete combustion, burner adjustment, electrical isolation, and ignition.

Pressure & Fluid Safety

Addresses safe discharge from safety relief valves and handling pressurized fluids.

Section 2 - Installation

2.1 Installation General

2.2 Pre-Installation Planning

2.2.2 Siting Requirements

2.3 Ventilation Requirements

Installation Safety Cautions

2.4 Pipe Connections

2.4.1 Flue Outlet Installation

Flue & Combustion Air Safety

2.4.3 Steam Safety Valve Installation

Explains safety valve function, pre-set nature, and discharge piping requirements.

Safety Valve Discharge Piping Guidelines

Lists guidelines for safety valve discharge pipe installation, ensuring cleanliness and proper termination.

2.4.4 Main Steam Valve Installation

2.5 Gas Supply Installation

Provides warnings about fuel changes and gas leak checks, and cautions about leak detection spray.

Gas Piping Installation Requirements

2.6 Electrical Requirements

2.7 Water Supply Requirements

Feedwater Pump Connection Details

2.12 Piping Specifications

2.13 Insulation Requirements

Section 3 - Post Installation

3.1 Gas Purge Procedure

3.2 Pipework Testing

3.3 Electrical Testing

3.4 Final Installation Inspection Checklist

Section 4 - Commissioning

4.1 Boiler Commissioning Overview

States commissioning should be done by qualified Fulton service engineers for safety and efficiency.

Flue Commissioning Checks

4.1.2 Boiler Inspection & Initial Firing

Details pre-firing checks like boiler wash-out, wiring, feedwater pump, and burner rotation.

Burner Control Unit Setup

Explains setting air pressure switches, gas pressure switches, and filling the boiler.

AZL2 Control Unit Operation

Describes navigating the AZL2 control unit, speed standardization, and burner pre-ignition phases.

Air & Fuel Damper Adjustment

Details adjusting air and fuel damper valve settings and setting air pressure switches.

Gas Pressure Setting & Burner Ignition

Explains setting the gas pressure switch and starting the burner ignition sequence.

Pilot Flame & Main Flame Setup

Details checking pilot flame stability, measuring pilot line gas pressure, and igniting the main flame.

PID Settings and Mode Control

Section 5 - Operation

5.2 Boiler Controls Overview

5.2.1 Boiler Control Components

Control Panel Components

5.2.3 Steam Pressure Controls

5.2.3.1 Setting Steam Pressure Controls

Guides on setting the boiler controller to the required system pressure.

5.2.3.2 Testing Steam Pressure Controls

Outlines the procedure for testing steam pressure controls, including setting limits and checking operation.

5.2.4 Water Level Control Probes

5.3 Filling the Boiler

Provides a step-by-step guide for filling the boiler, including valve positions and pump operation.

5.4 Draining the Boiler

Gives instructions for draining the boiler, with cautions regarding water temperature and regulations.

5.5 Boiler Start-Up (From Cold)

Details the procedure for starting the boiler from a cold state, including filling, gas train, and alarm reset.

5.5.1 Start-Up After Short Shutdown

5.6 Boiler Shut-Down Procedures

Section 6 - Maintenance

Maintenance Adherence Caution

Stresses the importance of following maintenance checks for boiler longevity.

6.2 Visual Checks

6.3 Burner Flame Sensor Test

Describes how to test the flame safeguard sensor's operation.

6.4 Water Level Safety Controls

6.4.1 Feedwater Pump Test Procedure

Provides steps to test the feedwater pump's operation under different boiler conditions.

6.4.2 Low Water Level Check Procedure

Details how to check the low water level safety controls and the feedwater pump's response.

6.4.3 Evaporation Check Procedure

6.5 Blowdown Procedures

6.5.1 Main Boiler Blowdown (Manual)

Describes the manual procedure for blowing down the main boiler.

6.5.2 Sight Glass Blowdown

Details the procedure for blowing down the water level gauge (sight glass).

6.6 Boiler Internal Inspection

Guides on inspecting the boiler interior after initial operation and subsequent regular intervals.

6.7 Fitting New Gaskets

Provides important information on fitting new gaskets, emphasizing their finite life and proper installation.

6.7.2 Gasket Fitting Procedure

Outlines the step-by-step procedure for fitting new Topog-E gaskets to inspection holes.

6.8 Operator Tests & Checks Schedule

Provides a schedule of recommended tests and checks for boiler operation and maintenance.

6.8.1 Daily Maintenance Checks

Lists daily visual inspections, low water level checks, and blowdown procedures.

6.8.2 Weekly Maintenance Checks

Details weekly checks including feedwater pump tests, evaporation checks, and flame failure checks.

6.8.3 Monthly Maintenance Checks

Lists monthly checks such as internal water space inspection and feedwater line cleaning.

6.8.4 Six Monthly Engineer Checks

Outlines six-monthly maintenance tasks for gas safe engineers, including flue testing and burner inspection.

6.8.5 Annual Engineer Checks

Details annual maintenance for gas safe engineers, focusing on pilot assembly inspection.

6.8.6 Post Repair Maintenance Checks

Specifies post-repair and maintenance checks, including safety checks and combustion analysis.

Section 7 - Inspection

7.1 Annual Inspection Requirement

Section 8 - Troubleshooting

8.1 Gas Boiler Troubleshooting

Lists common problems with gas boilers, their causes, and remedies for ignition and flame failure.

Flame Failure Issues

Addresses flame failure causes like power supply, gas supply, UV detector, and combustion.

Boiler Start-Up Failures

Lists causes for the boiler failing to start, including no power and pressure control issues.

Burner Cut-Off Causes

Poor Combustion & Backfires

Pressure & Surging Issues

8.2 Feedwater Pump Troubleshooting

Feedwater Pump Noise & Intermittent Operation

FULTON VSRT-60 Specifications

General

Brand	FULTON
Model	VSRT-60
Category	Boiler
Language	English

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FULTON VSRT-60 - User Manual

Table of Contents

Other manuals for FULTON VSRT-60

Questions and Answers

Summary

Safety Precautions

Manual Warnings & Cautions

General Safety Guidelines

Combustion & Electrical Safety

Pressure & Fluid Safety

Section 2 - Installation

2.1 Installation General

2.2 Pre-Installation Planning

2.2.2 Siting Requirements

2.3 Ventilation Requirements

Installation Safety Cautions

2.4 Pipe Connections

2.4.1 Flue Outlet Installation

Flue & Combustion Air Safety

2.4.3 Steam Safety Valve Installation

Safety Valve Discharge Piping Guidelines

2.4.4 Main Steam Valve Installation

2.5 Gas Supply Installation

Gas Piping Installation Requirements

2.6 Electrical Requirements

2.7 Water Supply Requirements

Feedwater Pump Connection Details

2.12 Piping Specifications

2.13 Insulation Requirements

Section 3 - Post Installation

3.1 Gas Purge Procedure

3.2 Pipework Testing

3.3 Electrical Testing

3.4 Final Installation Inspection Checklist

Section 4 - Commissioning

4.1 Boiler Commissioning Overview

Flue Commissioning Checks

4.1.2 Boiler Inspection & Initial Firing

Burner Control Unit Setup

AZL2 Control Unit Operation

Air & Fuel Damper Adjustment

Gas Pressure Setting & Burner Ignition

Pilot Flame & Main Flame Setup

PID Settings and Mode Control

Section 5 - Operation

5.2 Boiler Controls Overview

5.2.1 Boiler Control Components

Control Panel Components

5.2.3 Steam Pressure Controls

5.2.3.1 Setting Steam Pressure Controls

5.2.3.2 Testing Steam Pressure Controls

5.2.4 Water Level Control Probes

5.3 Filling the Boiler

5.4 Draining the Boiler

5.5 Boiler Start-Up (From Cold)

5.5.1 Start-Up After Short Shutdown

5.6 Boiler Shut-Down Procedures

Section 6 - Maintenance

Maintenance Adherence Caution

6.2 Visual Checks

6.3 Burner Flame Sensor Test

6.4 Water Level Safety Controls

6.4.1 Feedwater Pump Test Procedure

6.4.2 Low Water Level Check Procedure

6.4.3 Evaporation Check Procedure

6.5 Blowdown Procedures

6.5.1 Main Boiler Blowdown (Manual)

6.5.2 Sight Glass Blowdown

6.6 Boiler Internal Inspection

6.7 Fitting New Gaskets

6.7.2 Gasket Fitting Procedure

6.8 Operator Tests & Checks Schedule

6.8.1 Daily Maintenance Checks

6.8.2 Weekly Maintenance Checks

6.8.3 Monthly Maintenance Checks

6.8.4 Six Monthly Engineer Checks

6.8.5 Annual Engineer Checks

6.8.6 Post Repair Maintenance Checks

Section 7 - Inspection

7.1 Annual Inspection Requirement