Fulton Vantage (VTG) Fully Condensing Hydronic Boiler - Manual (Page 3)

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VTG-IOM-2013-0815
TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Product Overview ................................................................................................. 2-2
Placement & Rigging ........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-4
Install Boiler Trim ................................................................................................. 2-6
Install Water Piping .............................................................................................. 2-6
Meet Water Chemistry Requirements .................................................................. 2-9
PREVENT OXYGEN CONTAMINATION ..........................................................................................2-9
ELIMINATE SYSTEM AIR ............................................................................................................2-10
Fill the Boiler With Water ................................................................................... 2-10
Install Gas Piping ................................................................................................ 2-10
COMPONENTS REQUIRING VENTILATION TO THE OUTDOORS .................................................2-13
Install Condensate Drain .................................................................................... 2-14
Install pH Neutralization Kit ............................................................................... 2-15
Install Oil Piping ................................................................................................. 2-15
OIL PIPING (FOR DUAL FUEL BOILERS WITH THE RIELLO BURNER) .......................................2-15
Hydraulic Connections ....................................................................................... 2-18
Oil Pump Priming .............................................................................................. 2-18
Oil Filtration ........................................................................................................ 2-18
Venting ............................................................................................................... 2-18
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................2-21
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................2-21
Exhaust Venting ................................................................................................. 2-22
COMMON VENTING LAYOUTS FOR VANTAGE ............................................................................2-22
VENTING TERMINATIONS ..........................................................................................................2-25
WALL THIMBLE INSTALLATION .................................................................................................2-26
HORIZONTAL VENT TERMINATION ............................................................................................2-27
Removing an Existing Boiler ............................................................................. 2-27
Electrical Connections ....................................................................................... 2-28
Assembly of Fulton Multi-Skid Systems............................................................. 2-28
Operation 3-1
Perform Pre-Start-Up Inspection ......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
Commission The Boiler ......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION .................................................................................3-3
Siemens LMV36 and LMV37 Control .................................................................... 3-4
OPERATING POINTS ON THE SIEMENS LMV CONTROL ...............................................................3-4
NORMAL OPERATION ..................................................................................................................3-4
INITIAL PROGRAMMING .............................................................................................................3-4
COMMISSIONING THE UNIT .........................................................................................................3-5
Siemens LMV51 Control ....................................................................................... 3-6
OPERATING POINTS ON THE SIEMENS LMV CONTROL ...............................................................3-6
NORMAL OPERATION ..................................................................................................................3-6
PRE-IGNITION .............................................................................................................................3-6
SETTING PILOT (FOR BOILERS EQUIPPED WITH A PILOT) ..........................................................3-7
SETTING MAIN BURNER IGNITION ..............................................................................................3-8
RESETTING THE ALARM ...............................................................................................................3-8
SETTING MODULATION ...............................................................................................................3-9
SETTING LOW FIRE .......................................................................................................................3-9
SETTING THE COMPLETE TURNDOWN RANGE .........................................................................3-10
Operating Temperatures and Fuel Selection ...................................................... 3-11
Temperature Controller Instructions .................................................................. 3-11
SC-500 TEMPERATURE CONTROLLER BASIC PROGRAMMING ................................................3-11
YOKOGAWA UT 32A BASIC PROGRAMMING: ...........................................................................3-12
SIEMENS RWF40 BASIC PROGRAMMING .................................................................................3-13
Access to Variable Speed Drive Blower Motor .................................................. 3-14
TEST OF IGNITION SAFETY SYSTEM ..........................................................................................3-15
Perform Test of Low Water Cut Off ..................................................................... 3-15
Perform Test of Limit Controls ........................................................................... 3-15
Perform Test of Low Gas Pressure Switch .......................................................... 3-16
Perform Test of High Gas Pressure Switch .......................................................... 3-16
General Operation of the Boiler ......................................................................... 3-16
Maintenance 4-1
General ................................................................................................................. 4-2
Daily Maintenance and Inspection Schedule ...................................................... 4-2
Weekly Maintenance and Inspection Schedule .................................................. 4-2
Monthly Maintenance and Inspection Schedule ................................................. 4-2
PROCEDURE FOR CLEANING THE AIR INLET FILTER (LOW EMISSIONS BURNERS) ..................4-3
Annual Maintenance and Inspection Schedule ................................................... 4-3
ANNUAL REMOVAL AND INSPECTION OF LE BEKAERT BURNER ...............................................4-4
Verifi cation of Torque Settings on Fireside Access Doors ..................................... 4-4
Inspecting/Cleaning the Flue Passages ............................................................... 4-7
BOILERS FIRING ON #2 OIL, B100 BIO-DIESEL, DIGESTER GASES OR ANY OTHER SUBSTANCE
BESIDES NATURAL GAS OR PROPANE .........................................................................................4-7
PROCEDURE FOR ACCESSING THE DUPLEX STAINLESS STEEL FLUE PASSAGES ........................4-7
Replacing a Servomotor and Related Components ............................................. 4-7
Ignition Pilot Adjustment - Dual Fuel Burners ..................................................... 4-8
FOR UNITS WITH RIELLO RLS-100-130E BURNER ......................................................................4-8
FOR UNITS WITH RIELLO RLS-160E BURNER ............................................................................4-8
After All Repairs and Maintenance ...................................................................... 4-8
Troubleshooting ................................................................................................... 4-8