FULTON VSRT Series - User Manual

Other manuals for FULTON VSRT Series

Installation And Operation Manual91 pages

Questions and Answers

J
James MccormickAug 25, 2025
Why does my FULTON Boiler have flame failure during normal run?
- L
  Leah FloresAug 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.
W
wrightvalerieAug 28, 2025
How to troubleshoot poor combustion in a FULTON VSRT Boiler?
- S
  Samantha RobertsonAug 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.
C
Christine SharpAug 30, 2025
What to do if my FULTON Boiler fails to start?
- M
  Marc AndersonAug 30, 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.
A
Anthony BerrySep 4, 2025
Why is my FULTON VSRT Boiler burner backfiring?
- J
  Julie HughesSep 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.
E
Edward BaileySep 6, 2025
What causes a FULTON VSRT to rumble and pulsate?
- M
  marissa94Sep 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.
T
Terry HansonSep 9, 2025
Why is my FULTON VSRT surging?
- S
  Shannon PhillipsSep 9, 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.
W
William SmithSep 12, 2025
What causes a FULTON VSRT to carry over water with steam?
- J
  Jacob SchneiderSep 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.
M
Melissa FosterSep 14, 2025
How to fix low fuel pressure in FULTON VSRT Boiler?
- M
  Micheal CruzSep 14, 2025
  To fix low fuel pressure in your FULTON Boiler, check and replace the gas pressure regulator.
P
peter49Nov 17, 2025
How to fix ignition failure in a FULTON VSRT Boiler?
- J
  Jeffrey JonesNov 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...
A
Andrea RobinsonNov 19, 2025
What to do if my FULTON VSRT burner cuts off?
- R
  Rebecca WilsonNov 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

Understanding Safety Information

Defines WARNINGS, CAUTIONS, and NOTES for safe operation.

General Hazard Warnings

Alerts to potential hazards of steam boilers, gas, and flue gas leaks.

Combustion Safety and Environmental Hazards

Warnings about incomplete combustion, CO, and air quality hazards.

Operational Safety and Equipment Warnings

Cautions on handling pressurized fluids, hot surfaces, and equipment limits.

Regulatory Compliance and Emergency Procedures

Outlines legal regulations and emergency actions for hazardous conditions.

Section 1 - Introduction

1.1 General

Explains pre-shipment inspections and the purpose of the manual.

1.2 Technical Data

Refers to Appendix A for specifications.

1.3 Product Overview

Describes the VSRT fuel fired steam boiler and its technology.

Section 2 - Installation

2.1 General

States installation must be by competent personnel according to regulations.

2.2 Pre-Installation

Lists considerations before boiler delivery, including planning and access.

2.2.1 Receiving Inspection

Customer should examine equipment for damage; installer ensures correct fitting.

2.2.2 Siting

Warnings about access for maintenance and safe siting requirements.

2.3 Ventilation

Importance of adequate fresh, clean air for combustion and ventilation requirements.

2.4 Connections

Details various connections to the boiler system.

2.4.1 Flue Outlet

Guidance on flue type, size, installation, material, condensate drain, and draft.

2.4.2 Blowdown Valves

Types of blowdown connections and requirements for blowdown receptacles.

2.4.3 Steam Safety Valve

Warnings about factory-set safety valves and discharge piping requirements.

2.4.4 Main Steam Valve

Recommendations for steam outlet piping rise, sizing, and condensate drainage.

2.4.5 Steam Pressure Gauge

Assembly of the steam pressure gauge and connection requirements.

2.5 Gas Supply

Warnings and cautions regarding gas supply, installation, and leak testing.

2.5.1 Gas Valve with Pilot Gas Line

Explains the gas valve bypass system and components.

2.5.2 Multi Bloc Gas Valves

Refers to manufacturer leaflets and illustrates gas valves and actuators.

2.6 Electrical Requirements

Cautions and warnings about electrical work, supply voltage, and wiring.

2.7 Water Supply

Cautions regarding water softeners, chemical treatment, and warranty.

2.12 Piping Specifications

Basic considerations for piping, including arrangement, material, and supports.

2.13 Insulation

Warnings about insulating hot pipework and vessels, and recommendations for covers.

Section 3 - Post Installation

3.1 Gas Purge

Warning about gas purging being for qualified persons only.

3.2 Pipework Leak;Pressure Tests

Procedures for soundness and leak detection fluid tests.

3.3 Electrical Installation Testing

Specifies earth bond test and terminal tightening.

3.4 Final Installation Inspection

Lists checks for ventilation, gas supply, flue system, and pipework.

Section 4 - Commissioning

4.1 Commissioning the Boiler

Emphasizes commissioning by qualified persons and outlines flue commissioning.

4.1.2 Boiler Inspection and Initial Firing Gas Burner

Steps for boiler inspection, water analysis, wiring, and feedwater pump checks.

4.1.3 Adjustment of the Yokogawa UT-32 A Operating Controller

Explains controller keys and procedures for adjusting set points and PID parameters.

Section 5 - Operation

5.1 General

Instructions for competent operator use, safety, and understanding controls.

5.2 Controls

Overview of controls for efficient boiler operation.

5.2.1 Boiler Controls

Explains limiters, feedwater pump, high water controller, and burner programmer.

5.2.2 Control Panel

Explains indicator lights on the control panel and their meanings.

5.2.3 Steam Pressure Controls

Describes operating pressure transducer and high pressure limiter.

5.2.4 Water Level Control Probes

Describes types of water level probes for high integrity monitoring.

5.3 Filling the Boiler All Models

Step-by-step instructions for filling the boiler safely.

5.4 Draining the Boiler

Cautions regarding boiler water discharge and procedures for manual/automatic blowdown.

5.5 Boiler Start-Up (From Cold) All Models

Step-by-step guide for cold start-up, including safety checks and pressure build-up.

5.6 Boiler Shut-Down

Procedures for short, medium, and long-term boiler shutdown.

Section 6 - Maintenance

6.1 Boiler Platform (If Fitted)

Recommendations for mobile platforms for easy access and site risk assessment.

6.2 Visual Checks

Inspecting pipework, fittings, and handholes for leaks.

6.3 Burner Flame Sensor Test

Procedure to test the flame safeguard sensor's operation.

6.4 Water Level and Low Water Safety Control Procedures

Procedures to ensure correct functioning of water level and low water safety controls.

6.5 Blowdown Procedures

Importance of blowdown for removing sludge and scale.

6.5.1 Main Boiler Blowdown (Manual)

Step-by-step guide for manual boiler blowdown.

6.5.2 Water Level Gauge (Sight Glass) Blowdown

Procedure for blowdown of the water level gauge sight glass.

6.6 Boiler Internal Inspection

Procedure for inspecting the boiler interior for scale or sludge build-up.

6.7 Fitting New Gaskets to Boiler Inspection Holes

Important information regarding fitting new gaskets.

6.8 Schedule of Operator Tests and Checks

Advice on test frequencies, maintenance of gas parts, and fault reporting.

6.8.1 Daily

Daily inspection and checks for leakage, low water level, and blowdown.

6.8.2 Weekly in Addition

Weekly checks including safety valve security, pump test, evaporation check, flame failure.

6.8.3 Monthly in Addition

Monthly checks including internal water space inspection and feedwater line cleaning.

6.8.4 Six Monthly Gas Safe Engineer Only

Procedures for gas safe engineers including feedwater tank flush, flue test, combustion check.

6.8.5 Annually Gas Safe Engineer Only

Annual inspection of the pilot assembly.

6.8.6 After All Repairs & Maintenance - In Addition

Post-repair checks including safety checks, firing, and combustion analysis.

6.9 Maintenance Record Keeping

Importance of boiler log sheets for history and maintenance.

Section 7 - Inspection

7.1 Inspection

Requirement for annual inspection by a qualified boiler inspector.

Section 8 - Troubleshooting

8.1 Troubleshooting Gas Boiler

Lists common problems like ignition failure, flame failure, and poor combustion.

8.2 Troubleshooting Feedwater Pump

Lists problems with the feedwater pump not running, overload, capacity, or noise.

Appendix A

VSRT-10 Specifications and Features

Details VSRT-10 model features, controls, listings, and trim kit items.

VSRT-15 Specifications and Features

Details VSRT-15 model features, controls, listings, and trim kit items.

VSRT-20 Specifications and Features

Details VSRT-20 model features, controls, listings, and trim kit items.

VSRT-30 Specifications and Features

Details VSRT-30 model features, controls, listings, and trim kit items.

VSRT-40 Specifications and Features

Details VSRT-40 model features, controls, listings, and trim kit items.

VSRT-50 Specifications and Features

Details VSRT-50 model features, controls, listings, and trim kit items.

VSRT-60 Specifications and Features

Details VSRT-60 model features, controls, listings, and trim kit items.

Technical Information: Recommended Water Conditions

Recommended water quality parameters for feedwater and boiler water.

TI-149: High Integrity Water Limiters

Details on Guided Wave Radar, Vibrating Fork, and conductive water level limiters.

TI-30: Automatic TDS Blowdown Systems

Explains the operation and calibration of Automatic TDS control blowdown systems.

Material & Workmanship Guarantee

General Guarantee

Details the general guarantee terms for Fulton products.

On the Fulton Boiler Pressure Vessel

Specific guarantee terms for the boiler pressure vessel.

FULTON VSRT Series Specifications

General

Maximum Allowable Working Pressure (MAWP)	150 psi
Model Series	VSRT
Category	Boiler
Type	Vertical Tubeless
Fuel Type	Gas, Oil
Operating Pressure	Up to 150 psi (10.3 bar)
Burner Type	Forced Draft
Construction	ASME Code Construction
Control System	Microprocessor-Based Control System