FULTON VSRT-60 - User Manual

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

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