Manual Caldera Fulton

Installation Operation And Fulton VMP
Maintenance Manual (Vertical Multi-Port)

VMP-STEAM-GAS_IOM_2016-1007-REV1 Gas Fired Steam Boilers
Serial # : ___________________________
40-150 HP
Model # : ___________________________
Fulton Order # : ___________________________
Sold To : ___________________________
Job Name : ___________________________
Date : ___________________________
ProductBulletin
Date: January 22, 2010
Subject: Water Chemistry Requirements for Fulton Steam Products
Products: ICS/ICX, FB-A, FB-F, FB-S, VMP, PVLP, PHP, Electric Steam
Boilers and Unfired Steam Generators
Please note that the water chemistry is different for carbon steel vs. stainless steel
pressure vessels and vertical vs. horizontal orientation.
Effective immediately, please use the limits below. Should you have any questions,
please do not hesitate to contact Fulton at 315-298-5121.
Water Chemistry Requirements for Fulton Steam Products (to 300 psig MAWP)
Carbon Steel Stainless Steel

Feedwater Vertical Horizontal Feedwater Vertical Horizontal
Boiler/Steam Boiler/Steam Boiler/Steam Boiler/Steam
Parameter Pac Water Pac Water Pac Water Pac Water
pH 7.5-9.5 8.5-10.5 8.5-10.5 6.0-9.5 8.5-10.5 8.5-10.5
Feedwater 140F* --- --- 140F* --- ---
Temperature
Hardness as <2ppm <10 ppm <15 ppm <2 ppm <10 ppm <15 ppm
CaCO3
Chlorides --- --- --- --- 50 ppm 50 ppm
Total --- <300 ppm <500 ppm --- <300 ppm <500 ppm
Alkalinity
Total --- <2000 ppm <3000 ppm --- <2000 ppm <3000 ppm
Dissolved
Solids
Suspended No visual No visual No visual No visual No visual No visual
Solids turbidity** turbidity** turbidity** turbidity** turbidity** turbidity**
Total Organic No sheen No sheen No sheen No sheen No sheen No sheen
Carbon No foam+ No foam+ No foam+ No foam+ No foam+ No foam+
Iron Colorless Colorless Colorless Colorless Colorless Colorless
liquid++ liquid++ liquid++ liquid++ liquid++ liquid++
Dissolved <1ppm* ND ND <5ppm ND ND
Oxygen
Visual Oil ND ND ND ND ND ND
Conducivity --- <2985 <4477 --- <2985 <4477
(uS/cm)
NOTES:
*This is a minimum temperature. Feedwater temperatures below 200F will require an oxygen scavenger.
** Suspended solids: Take a water sample. After the sample sits for 10 minutes, no solids should be visible.
+ Total Organic Carbon: Take a water sample. Shake vigorously for 30 seconds. No sheen or foam should be visible.
++ Iron: Take a water sample. Hold the sample against a white background. The water should have no visible yellow, red or
orange tinge.
ND: None Detected.
Product Bulletin
2010-001PB
The Fulton Companies
972 Centerville Road
Pulaski, N.Y. 13142
Contents
1
Section Safety Warnings
and Precautions
PAGE 3
2
Installation
PAGE 9
3
Operation
PAGE 17
4
Maintenance
PAGE 31
5
Parts and
Warranty
PAGE 35
VMP IOM 1
2 VMP IOM
1
Section Safety Warnings
and Precautions
2
3
4
5
VMP IOM 3
4 VMP IOM
Safety Warnings and Precautions
This manual is provided as a guide to the correct operation and The customer should examine the boiler for any damage, especially
maintenance of your Fulton Gas Fired Steam Boiler, and should be the refractories. It is the responsibility of the installer to ensure
permanently available to the staff responsible for the operation of all parts supplied with the boiler are fitted in a correct and safe
the gas fired boiler. manner.
These instructions must not be considered as a complete code of NOTE

practice, nor should they replace existing codes or standards which The installation of the Fulton Gas Fired Steam Boiler should
may be applicable. be carried out by competent personnel in accordance with the
standards of the National Fire Protection Association, National
The requirements and instructions contained in this section or Canadian Electrical Code. All state and jurisdictional codes
generally relate to the standard Fulton Gas Fired Steam Boiler. beyond the scope of the applicable ASME Boiler and Pressure
When installing a packaged unit, this entire section should be read Vessel Codes, for its corresponding classification, should be
to ensure that the installation work is carried out correctly. followed in all cases. Jurisdictional authorities must be
consulted prior to installation.
Prior to shipment the following tests are made to assure the
customer the highest standards of manufacturing: WARNING
Operating the boiler beyond its design limits can damage the
a) Material inspections. boiler and can also be dangerous. Do not operate the boiler
b) Manufacturing process inspections. outside its limits. Do not try to upgrade the boiler performance
c) ASME welding inspections. by unapproved modifications. Unapproved modifications can
d) ASME hydrostatic test inspection. cause injury and damage. Contact your Fulton dealer before
e) Electrical components inspection. modifying the boiler.
f) Operating test.
g) Final Engineering Inspection
h) Crating inspection. WARNING
A defective boiler can injure you or others. Do not operate a
All units are crated for fork lift transport. Once uncrated, all units can boiler which is defective or has missing parts. Make sure that
be transported with a forklift. Under no circumstances should weight all maintenance procedures are completed before using the
be allowed to bear on the jacket, control panel, or fan housing of any boiler. Do not attempt repairs or any other maintenance work
Fulton Boiler. you do not understand. Obtain a Service Manual from Fulton
or call a Fulton Service Engineer.
Rigging your boiler into position should be handled by a competent
rigger experienced in handling heavy equipment.
WARNING: If the information in this manual is not followed exactly, a fire or

explosion may result causing property damage, personal injury or loss of life.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliances.
- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas
supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
- Installation and service must be performed by a qualified installer, service agency

or the gas supplier.
VMP IOM 5
For Your Safety
The following WARNINGS, CAUTIONS, and NOTES appear in various sections of this manual.
They are repeated on these safety summary pages as an example and for emphasis.
WARNINGS must be observed to prevent serious injury, or death to personnel.
CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness.
NOTES must be observed for essential and effective operating procedures, conditions, and as a statement to be highlighted.
It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the
WARNINGS, CAUTIONS, and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all
aspects of safety and equipment prior to operation or maintenance of the equipment.
WARNING NOTE
Care should be taken to ensure that the blow off receptacle After installation is complete and prior to operation the
used meets the regulations covering such vessels. A means to pressure vessel should be cleaned or boiled out per
cool boiler blowdown water to <140o F prior to discharging to instructions included in this manual.
floor drains is required for personnel and equipment
protection. NOTE
a) The fused disconnect switch that controls the feed water
WARNING pump should be kept in the “on” position at all times during
Only properly trained personnel should install and maintain the boiler operation as well as during the non-operating
water gauge glass and connections. Wear safety glasses period of the boiler.
during installation. Before installing, make sure all parts are
free of chips and debris. Gauge glass valves must be fully b) This switch should be turned “off” only when repairs or
open to prevent boiler water damage if a gauge glass breaks. adjustments should be made.
WARNING NOTE
Prior to the commencement of any work requiring the removal The feedwater pump will continue to operate until the water
of cover plates and the opening of the control panel box, the reaches the correct level in the boiler. This level is
electrical supply to the boiler must be disconnected. approximately the center of the water gauge glass.
WARNING NOTE
DO NOT TAMPER WITH THE SAFETY FEATURES OF THE To ensure that your Fulton Steam Boiler is kept operating
LOW WATER SAFETY CUT OFF. safely and efficiently, follow the maintenance procedures set
forth in Section 4 of this manual.
WARNING
When shutting down the boiler for any extensive repairs, shut NOTE
off main disconnect switches on both the boiler and the feed If only the top refractory is to be changed, the bottom
water pump. refractory need not be removed.
WARNING
Do not clean the gauge glass while pressurized. Ensure gauge NOTE
glass valves are fully shut prior to glass removal. The boiler blow off operation should be done once during the
day when the boiler is at 10 PSIG or less.
WARNING
Do not allow anyone to operate, service or repair this NOTE
equipment unless they fully understand all applicable sections After a new Fulton Boiler has been in operation for several
of this manual. months, pieces of burned metal will be found in the space at
the bottom of the boiler. These pieces of metal are the remains
CAUTION of a light gauge metal form which was used during
To prevent corrosion fatigue at the feedwater nozzle or manufacture for forming the boiler insulation. This is a normal
cold end corrosion, boiler feed water must be at least condition and does not affect the efficiency or the life of the
140o F prior to entry into the boiler. boiler in any way.
CAUTION
A temperature exceeding 100oF in the boiler room may
cause premature failure of electrical components in the
boiler control panel.
CAUTION
The water chemistry in the boiler must be kept within
limits outlined in this manual. Failure to do so will likely
cause premature boiler pressure vessel failure and poor
steam quality.
6 VMP IOM
VMP IOM 7
8 VMP IOM
1
2
Section Installation
3
4
5
VMP IOM 9
Installation
Burner Alignment
Gas Train Assembly Tabs
Burner Plate Assembly Transformer
Top Plate Assembly
Secondary Air Damper

Scroll
Burner Motor
Flue Cover Plate
To
O.P.C.* Steam Gauge
Lifting Hook(s) Assembly
To
H.P.C.*
Gauge Glass
Stainless Steel Ring Valve
Gauge Glass and

Protector Rods
Flue Outlet
Gauge Glass
Valve
Water Column
Top Refractory
Turbulator Control Box
Fiberglass Insulation
Bottom Refractory
Outside Jacket
Feedwater Inlet
Blowdown Outlet
Handhole
Blowdown Outlet
Castable Refractory Insulation
Clean Out Opening
* O.P.C. = Operating Pressure Control

* H.P.C. = High Pressure Control
Artwork Revision 2017-0927
10 VMP IOM
Fulton Vertical
Product Data Submittal MultiPort
Fulton Models: VMP40, VMP49.5, VMP50, VMP60,
VMP80, VMP100, VMP130 and Steam Boilers
VMP150
(Standard Burners)
Dimensions
Models VMP 40 49.5 50 60 80 100 130 150
Unit Size: BHP 40 49.5 50 60 80 100 130 150
A. Boiler Diameter IN 50.5 55 55 55 63 69 76.5 76.5
MM 1283 1397 1397 1397 1600 1753 1943 1943
B. Boiler Height IN 84 91 91 97 100 100 115 115
MM 2133 2312 2312 2464 2540 2540 2921 2921
C. Boiler Depth IN 90 100 100 100 114 119 128 130
MM 2286 2540 2540 2540 2896 3022 3251 3302
D. Boiler Height w/trim IN 107 112 112 118 124 126 135 141
MM 2718 2832 2832 2984 3150 3200 3429 3582
E. Overall Boiler Width IN 56 62 62 62 68 74 84.5 84.5
MM 1422 1575 1575 1575 1727 1880 2146 2146
F. Flue Outlet Diameter IN 12 12 12 12 14 14 14 16
MM 305 305 305 305 356 356 356 407
G. To Center of Flue Outlet IN 79 86 86 92 95 95 107 107
MM 2006 2184 2184 2237 2413 2413 2718 2718
H. Feedwater Inlet IN 35 35 35 35 35 35 39 39
MM 889 889 889 889 889 889 991 991
J. Blowdown Outlet IN 17 18 18 18 18 18 22 22
MM 432 457 457 457 457 457 559 559
K. Height to Steam Outlet1 IN 73 77 77 84 89 89 102 102
MM 1854 4956 4956 2134 2260 2260 2591 2591
L. Min. Clearance to Ceiling IN 110 115 115 125 130 132 145 145
MM 2794 2921 2921 3175 3302 3353 3683 3683
Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions.
NOTE: Minimum clearance is 24” to the side and back and 36” in front of unit.
1. The boiler may be fitted with a 90o elbow spool piece making the steam outlet connection higher.
F Minimum Clearance
For Burner Removal
SteamOutlet
G
C D
K
B
A
H
J
E
Top View Side View Front View
11 VMP IOM
Specifications
Models VMP 40 49.5 50 60 80 100 130 150
Unit Horsepower 40 49.5 50 60 80 100 130 150
Boiler Connections
Steam Outlet 15 PSI - 150# Flanged IN 4 4 4 4 6 6 *6 *6
MM 101 101 101 101 152 152 203 203
Steam Outlet 150 PSI IN NPT 3 3 3 3 3 3 4 4
MM 76 76 76 76 76 76 101
Feedwater Inlet IN NPT 1 1 1 1 1 1.25 1.25 1.25
MM 25 25 25 25 25 31 32 32
Blowdown Outlet (2) IN NPT 1.5 1.5 1.5 1.5 1.5 2 2 2
MM 38 38 38 38 38 51 51 51
Water Column Blowdown IN NPT 1 1 1 1 1 1 1 1
MM 25 25 25 25 25 25 25 25
Surface Blowdown IN NPT .75 .75 .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19 19 19
Safety Valve 150 PSI Inlet IN NPT .75 1 1 1 1.25 1.25 1.5 1.5
MM 19 25 25 25 31 31 38 38
Safety Valve 150 PSIOutlet IN NPT 1 1.25 1.25 1.25 1.5 1.5 2 2
MM 25 31 31 31 38 38 51 51
Safety Valve 15 PSI Inlet (2) IN NPT 1.25 1.25 1.25 1.25 1.5 1.5 2 2
MM 31 31 31 31 38 38 51 51
Safety Valve 15 PSI Outlet IN NPT 1.5 1.5 1.5 1.5 2 2 2 2
MM 38 38 38 38 51 51 51 51
Natural Gas Connection IN 1.5 1.5 1.5 2 2 2 2 2
MM 38 38 38 51 51 51 51 51
Light Oil Connection IN .25 .25 .25 .25 .25 .25 .375 .375
MM 6 6 6 6 6 6 9.5 9.5
Burner Motor (Gas) HP 1.5 1.5 1.5 1.5 3 3 10 10
KW 1.1 1.1 1.1 1.1 2.2 2.2 7.5 7.5
Burner Motor (Oil/Combo) HP 2 2 2 2 3 3 10 10
KW 1.5 1.5 1.5 1.5 2.2 2.2 7.5 7.5
Approximate Weights
Shipping Weights (approx.) LB 5775 6550 6575 7370 8000 9500 12350 12350
KG 2620 2972 2980 3340 3630 4310 5600 5600
Operating Weight (approx.) LB 6720 8850 8209 9227 11760 14525 20135 20135
KG 3050 4015 3720 4190 5330 6590 9130 9130
**Ratings Sea Level to 3000 FT. (914 M)
Output 1000 BTU/HR 1340 1656 1673 2009 2678 3347 4353 5022
1000 KCAL/HR 338 417 422 506 675 843 1097 1266
Steam Output LBS/HR 1380 1708 1725 2070 2760 3450 4485 5175
KG/HR 626 775 783 939 1252 1565 2035 2348
Water Content GAL 172 274 242 270 383 518 810 810
LITERS 651 1038 916 1022 1450 1960 3066 3066
Approximate Fuel Consumption at Rated Capacity+
Natural Gas FT3/HR 1595 1972 1992 2392 3188 3985 5200 5978
M3/HR 45 56 56 68 90 113 147 169
LP Gas FT3/HR 638 788 797 957 1275 1594 2080 2391
M3/HR 18 22 23 27 36 45 59 68
Light Oil GPH 11.0 13.9 14.0 17.0 22.8 28.0 37.0 42.0
LPH 41.6 52.6 53 64.3 87 106 140 159
Gas Pressure Required
Standard Burners Min. IN W.C. 7 7 7 7 9 9 40 40
Gas Pressure Required
Standard Gas Train Max. IN W.C. 13 13 13 13 27 27 5 psig 5 psig
Electrical Requirements/Amps for Burner Motors
208V, 50/60 CY, 3 Phase (Gas/Oil) 6.6/7.5 6.6/7.5 6.6/7.5 6.6/7.5 10.6 10.6 30.8 30.8
230V, 50/60 CY, 3 Phase (Gas/Oil) 6.0/6.8 6.0/6.8 6.0/6.8 6.0/6.8 9.6 9.6 28 28
460V, 50/60 CY, 3 Phase (Gas/Oil) 3.0/3.4 3.0/3.4 3.0/3.4 3.0/3.4 4.8 4.8 14 14
* Steam separator or dual steam nozzle design required.
**Ratings - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2 and at 100 Degrees C +Consumption based on natural gas 1000 BTU/FT3;
Propane 2500, and Light Oil 140,000 BTU/GAL.
NOTE: 7” - 11” wc gas pressure is required during run for 40-60 HP boilers with standard burners. 9”-11” wc gas pressure is required during run for 80-100 HP boilers with
standard CSD-1 burners, 40” W.C. is required for 130-150 HP
Specifications & dimensions are approximate. We reserve the right to change without notice.

Pulaski, New York 13142 vmpstd-pds-2010-1008
Call 315-298.5121
Fax 315-298.6390
www.fulton.com
11a VMP IOM
Fulton Vertical
Fulton Models: VMP40, VMP49.5, VMP50, VMP60, Steam Boilers
VMP80, and VMP100 (Low Emissions Burners)
(<20 PPM NOx)
Dimensions
Models VMP 40 49.5 50 60 80 100
Unit Size: BHP 40 49.5 50 60 80 100
A. Boiler Diameter IN 49 55 55 55 63 69
MM 1245 1397 1397 1397 1600 1753
B. Boiler Height IN 84 91 91 97 100 100
MM 2133 2312 2312 2464 2540 2540
C. Boiler Depth IN 90 100 100 100 114 119
MM 2286 2540 2540 2540 2896 3022
D. Boiler Height w/trim IN 107 112 112 118 124 126
MM 2718 2832 2832 2984 3150 3200
E. Overall Boiler Width IN 56 62 62 62 68 74
MM 1422 1575 1575 1575 1727 1880
F. Flue Outlet Diameter IN 12 12 12 12 14 14
MM 305 305 305 305 356 356
G. To Center of Flue Outlet IN 79 86 86 92 95 95
MM 2006 2184 2184 2237 2413 2413
H. Feedwater Inlet IN 35 35 35 35 35 35
MM 889 89 889 889 889 889
J. Blowdown Outlet IN 17 18 18 18 18 182
MM 432 457 457 457 457 457
K. Height to Steam Outlet1 IN 73 77 77 84 89 89
MM 1854 4956 4956 2134 2260 2260
L. Min. Clearance to Ceiling IN 123 135 135 144 147 147
for Burner Removal MM 3124 3429 3429 3658 3734 3734
Specifications and Dimensions are approximate. We reserve the right to change specifications and/or dimensions.
NOTE: Minimum clearance is 24” to the side and back and 36” in front of the unit.
1. The boiler may be fitted with a 90o elbow spool piece making the steam outlet connection higher.
C
D L
G B K
E
A
Top View Side View Front View
12 VMP IOM
Specifications
Models VMP 40 49.5 50 60 80 100

Unit Horsepower 40 49.5 50 60 80 100
Boiler Connections
Steam Outlet 15 PSI IN 4 4 4 4 6 6
150# Flanged MM 101 101 101 101 152 152
Steam Outlet 150 PSI IN NPT 3 3 3 3 3 3
150# Flanged MM 76 76 76 76 76 76
Feedwater Inlet IN NPT 1 1 1 1 1 1.25
MM 25 25 25 25 25 31
Blowdown Outlet IN NPT 1.5 1.5 1.5 1.5 1.5 2
MM 38 38 38 38 38 51
Water Column Blowdown IN NPT 1 1 1 1 1 1
MM 25 25 25 25 25 25
Surface Blowdown IN NPT .75 .75 .75 .75 .75 .75
MM 19 19 19 19 19 19
Safety Valve 150 PSI Inlet IN NPT .75 1 1 1 1.25 1.25
MM 19 25 25 25 31 31
Safety Valve 150 PSIOutlet IN NPT 1 1.25 1.25 1.25 1.5 1.5
MM 25 31 31 31 38 38
Safety Valve 15 PSI Inlet (2)@ IN NPT 1.25 1.25 1.25 1.25 1.5 1.5
MM 31 31 31 31 38 38
Safety Valve 15 PSI Outlet (2) IN NPT 1.5 1.5 1.5 1.5 2 2
MM 38 38 38 38 51 51
Natural Gas Connection IN 1.5 1.5 1.5 2 2 2
MM 38 38 38 51 51 51
Burner Motor HP 5 5 5 5 5 7.5
KW 3.7 3.7 3.7 3.7 3.7 5.6
Approximate Weights
Shipping Weights (approx.) LB 6575 7375 7375 8170 8800 10300
KG 2982 3345 3345 3706 3992 4672
Operating Weight (approx.) LB 8659 9684 9684 10671 12051 14700
KG 3928 4393 4393 4840 5466 6668
Ratings Sea Level to
3000 FT. (914 M)
Output 1000 BTU/HR 1340 1656 1673 2009 2678 3347
1000 KCAL/HR 338 417 422 506 675 843
Steam Output** LBS/HR 1380 1708 1725 2070 2760 3450
KG/HR 626 775 783 939 1252 1565
Water Content GAL 172 274 242 270 383 518
LITERS 651 1038 916 1022 1450 1960
Natural Gas FT3/HR 1595 1972 1992 2392 3188 3985
M3/HR 45 56 56 68 90 112
Gas Pressure Required Min. IN W.C. 30 30 30 40 40 40
Gas Pressure Required Max. PSIG. 5 5 5 5 5 5
208V, 60 CY, 3 Phase 16.7 16.7 16.7 16.7 16.7 24.2
230V, 60 CY, 3 Phase 15.2 15.2 15.2 15.2 15.2 22.0
460V, 60 CY, 3 Phase 7.6 7.6 7.6 7.6 7.6 11.0
* Steam separator or dual steam nozzle design required. Consult factory for availability.
**Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2 and at 100 Degrees C
3
+Consumption based on natural gas 1000 BTU/FT and 20 ppm NOx @ 3% CO2 burner.

Pulaski, New York 13142
Call 315-298.5121
Fax 315-298.6390 vmp40-100le-pds-2010-1008
www.fulton.com
12a VMP IOM

Fulton Vertical
Fulton Models: VMP130 and VMP150 Steam Boilers
(Low Emissions Burners)
(<30 PPM NOx)
Dimensions
Models VMP 130 150
Unit Size: BHP 130 150
A. Boiler Diameter IN 76.5 76.5
MM 1943 1943
B. Boiler Height IN 115 115
MM 2921 2921
C. Boiler Depth IN 128 130
MM 3251 3302
D. Boiler Height w/trim IN 135 149
MM 3429 3785
E. Overall Boiler Width IN 84.5 84.5
MM 2146 2146
F. Flue Outlet Diameter IN 14 16
MM 356 407
G. To Center of Flue Outlet IN 107 107
MM 2718 2718
H. Feedwater Inlet IN 39 39
MM 991 991
J. Blowdown Outlet IN 22 22
MM 559 559
K. Height to Steam Outlet1 IN 102 102
MM 2591 2591
L. Min. Clearance to Ceiling IN 155 155
for Burner Removal MM 3937 3937
M. Height to top of FGR Loop IN 121 121
MM 3073 3073
Specifications and Dimensions are approximate. We reserve the right to change
specifications and/or dimensions.
NOTE: Minimum clearance is 24” to the side and back and 36” in front of unit.
1. The boiler may be fitted with a 90o elbow spool piece making the steam outlet
connection higher.
M
C
D G B K L
J
E
A
13 VMP IOM
Specifications
Models VMP 130 150

Unit Horsepower 130 150
Boiler Connections
Steam Outlet 15 PSI - 150# Flanged IN *6 *6
MM 152 152
Steam Outlet 150 PSI IN NPT 6 6
150# Flanged MM 152 152
Feedwater Inlet IN NPT 1.25 1.25
MM 32 32
Blowdown Outlet IN NPT 2 2
MM 51 51
Water Column Blowdown IN NPT 1 1
MM 25 25
Surface Blowdown IN NPT .75 .75
MM 19 19
Safety Valve 150 PSI Inlet IN NPT 1.5 1.5
MM 38 38
Safety Valve 150 PSIOutlet IN NPT 2 2
MM 51 51
Safety Valve 15 PSI Inlet (2)@ IN NPT 2 2
MM 51 51
Safety Valve 15 PSI Outlet (2) IN NPT 2 2
MM 51 51
Natural Gas Connection IN 2.5 2.5
MM 63 63
Burner Motor HP 10 10
KW 7.4 7.4
Approximate Weights
Shipping Weights (approx.) LB 12800 12800
KG 5806 5806
Operating Weight (approx.) LB 20585 20585
KG 9337 9337
Ratings Sea Level to
3000 FT. (914 M)
Output 1000 BTU/HR 4353 5022
1000 KCAL/HR 1097 1266
Steam Output** LBS/HR 4485 5175
KG/HR 2035 2348
Water Content GAL 810 810
LITERS 3066 3066
Natural Gas FT3/HR 5182 5978
M3/HR 146 169
Gas Pressure Required Min. IN W.C. 21 21
Gas Pressure Required Max. PSIG 5 5
208V, 60 CY, 3 Phase 30.8 30.8
230V, 60 CY, 3 Phase 28 28
460V, 60 CY, 3 Phase 14 14
* Steam separator or dual steam nozzle design required. Consult factory for availability.
**Steam Output LB/HR - From 0 PSIG and at 212 Degrees F and KG/HR - From 0 KG/CM2 and at 100 Degrees C
3
+Consumption based on natural gas 1000 BTU/FT and 20 ppm NOx @ 3% O2 burner.

Pulaski, New York 13142
vmp130-150le-pds-2010-1008
Call 315-298.5121
Fax 315-298.6390
www.fulton.com
13a VMP IOM

Installation
Locating the Boiler The Gas Supply g. When making gas piping joints, use a
sealing compound resistant to the action
a. The boiler should be located in dry a. Gas Piping should be installed in of liquefied petroleum gases. Do not use
surroundings on a level base, making accordance with National Fuel Gas teflon tape on gas line threads.
sure that there is sufficient room around Code, ANSI-Z223-1-1984 or latest
the boiler to enable the operator and/or addenda and any other local codes h. The main and the pilot gas pressure
the maintenance engineer to gain which may apply. In Canada gas regulators must be vented to the
access to all parts of the boiler. Check installations must be in accordance with atmosphere.
location for ease of water supply and the current CAN/CGA B149.1 and .2
electrical connections. and/or local codes. i. After gas piping is completed carefully
check all piping connections, (factory
b. Place the boiler on a non combustible b. Install a dirt trap ahead of all of the gas and field), for gas leaks. Use a soap and
floor with clearances to unprotected valves. water solution.
combustible materials, including plaster
or combustible supports. c. The pipe and the fittings used must be CAUTION
new and free of dirt or other deposits. Some soaps used for leak testing are
c. It is necessary to have the following corrosive to certain types of metals.
vertical clearance from the floor to the d. The piping must be of the proper size to Rinse all piping thoroughly with clean
ceiling for removal of the burner for ensure adequate gas supply to the gas water after leak check has been
servicing: head assembly. Consult your gas completed.
company for specific recommendations.
Minimum Vertical Clearances
BHP IN MM j. The boiler must be disconnected at the
e. 7” - 11” wc gas pressure is required boiler shut off valve from the gas supply
40 110 2794 during run for 40-60 HP boilers with piping system during any pressure
50 115 2921 standard burners. 9”-11” wc gas testing of the system at pressure in
60 125 3175 pressure is required during run for 80 excess of 1/2 PSIG-14" W.C.
80 130 3302 100 HP boilers with standard CSD-1
100 130 3302 burners, 11”-13” wc gas pressure is k. The boiler must be isolated from the gas
130 145 3683 required for 80-100 HP IRI boilers. 40” supply piping system by closing the
150 145 3683 W.C. is required for 130-150 HP shut-off cock during any pressure
testing of the gas supply piping system
f. For propane or butane gas: see “e” at pressures equal to or less than 1/2
above. Propane not available for LoNOx PSIG--14" W.C.
boilers.
14 VMP IOM
Installation
The Gas Supply Basic Boiler, Condensate 3. Vent pipe should not be down-sized
(this may cause pressure build up in
For LE Models Tank, and Blow-Down the condensate tank).
A minimum of 40” w.c. gas pressure is Separator 4. Return pipes must not be insulated.
required at the inlet of the gas train while This can cause overheating the
operating for the 40-100HP; 60” w.c. for NOTE
Where a condensate return tank is to be return system, causing a vapor lock
the 130-150HP boiler. in the pump.
fitted:
WARNING 1. This should be vented to a safe 5. See Return System Instruction
For units equipped with Flue Gas location. Manual for detailed instructions.
Recirculation (FGR), the ducting must
be insulated. 2. This should have a capacity sufficient NOTE
to satisfy boiler consumption as well Care should be taken to ensure that the
blow-down receptacle used meets the
CAUTION as maintain proper return tank
temperature. regulations covering such vessels. If in
Do not exceed the rated pressure of doubt consult a Fulton Representative
the fuel train. for advice.
VMP IOM 15
Installation
a. Make sure two check valves are
installed between the boiler and pump
(one check valve is supplied with the
unit).
b. In a closed system an end of the line

trap should be installed.
c. There are four blow-down valves on the

boiler: Two main bottom blow-down
valves, the gauge glass blow-down
valve, and the water column blow-down
valve. All blow-down connections must
be piped to blow-down seperator.
All these procedures should be done in

accordance with state and/or local codes.
The water column blow-down valve and the
gauge glass blow-down valve should be
connected to the main blow-down line.
Steam Supply
Pipe the steam supply line from the top right
side of the boiler.
Steam Safety Valve

1. Before installing, be sure that all pipes
and connections have been blown
clean. Pipe compound or dope is used
on external threads only. Be sure inlet of
valve is free of any foreign material.
5. Since the purpose of this safety valve is Steam Pressure Gauge

to protect against an overpressure
situation, it will loudly discharge hot Assembly
steam in doing so. Therefore, it is The gauge should be facing front towards
recommended that a discharge pipe be the panel box and/or operator of the boiler.
securely installed and run to a safe point
of disposal. Except as noted, each assembly or any of
its component parts may be oriented, other
2. Do not use a pipe wrench! When 6. When a discharge pipe is used, it must than as shown to provide improved
making installation, use proper type and be of a pipe size equal to or greater than operating clearances and/or view of gauge.
size wrench. that of the valve outlet. Use schedule 40 Before installing steam gauge on the
discharge pipe only. Do not use siphon, add a small amount of water to the
3. The valve should be installed in a schedule 80, extra strong or double siphon to create a water seal to buffer the
vertical upright position in the extra strong discharge pipe or gauge element. This must be done to
connection provided on the top left side connections. It must be as short and prevent inaccurate pressure readings and
of the boiler with no unnecessary straight as possible and so arranged as /or premature failure of the gauge. Install
intervening pipe. Under no to avoid undue stress on the valve. It the steam gauge into the siphon on the
circumstances should there be a shut off must have an ample provision for water column.
valve or restriction of any kind between draining condensate at or near the valve
the safety valve and the connection outlet. It must terminate freely to
provided. atmosphere with no intervening valve of
any description and it must be securely
4. Do not cap or plug drain hole in the side anchored and supported.
of valve body.
16 VMP IOM
Installation
Blow-Down Valve Water Column
There are four blow-down valves on the Install the piping from the water column and
boiler: Two main bottom blow-down valves, water gauge glass to a safe blow-down point.
the gauge glass blow-down valve, and the
water column blow-down valve. All blow-
down connections must be piped to blow-
down seperator.
Feed Water Piping

1. Provisions must be made for adequate
water supply and properly sized piping.
Piping must be done in compliance with
all local codes. The following chart may
be used as a guideline for sizing.
BHP Minimum Water

Supply Piping Size
IN MM
40 1 25
50 1 25
60 1 25
80 1 25
100 1.25 31.7
130 1.25 31.7
150 1.25 31.7
2. When feeding the boiler using a return

system, the city water pressure should
not exceed 40 PSI. A pressure reducing
valve should be installed a head of the
return tank when above this pressure.
3. It is important that all piping be lined up

and not forced into place. It is
recommended that you begin piping at
the pump. If the lines are ended at the
pump, particularly if the last piece is cut
too short or long, the pump will be forced
to meet the pipe and strain or distortion
will result.
4. Do not use the pump as a piping

support. It is critical that the pipe be
independently supported near the pump
so no strain will be transmitted to the
unit.
5. Connect the feed water stop valve to the

feed water pipe at the rear of the boiler
and pipe it to the return system.
VMP IOM 17
Installation
Water Gauge and Gauge 10.Hand tighten both glass packing nuts, WARNING
then tighten 1/2 turn more by wrench. Improper installation or maintenance of
Glass Installation Tighten only enough to prevent leakage. gauge glass and connections can cause
Instructions DO NOT OVER TIGHTEN! If any immediate or delayed breakage resulting
leakage should occur, tighten slightly, a in bodily injury and/or property damage.
NOTE quarter turn at a time, checking for
Only properly trained personnel should leakage after each turn.
install and maintain water gauge glass
and connections. Wear safety glasses 11. Install the protective guard, and utilize
during installation. Before installing, automatic ball checks where necessary
make sure all parts are free of chips and to help prevent injury in case of glass
debris. breakage.
NOTE
Keep gauge glass in original packaging
until ready to install.
1. Verify the proper gauge has been

supplied.
2. Examine the gauge glass and packings

carefully for damage before installation.
Do not use the glass if it contains any
scratches, chips, or any other visible
signs of damage.
3. Do not subject the gauge glass to

bending or torsional stresses.
4. Apply teflon tape or pipe dope to pipe

threads. Install top gauge fitting (fitting
without a drain valve) into the
uppermost tapping. Wrench tighten the
fitting until it is snug and the glass outlet
is pointing at five o’clock (about 1/8 turn
from its final downward vertical
position).
5. Install the bottom gauge fitting (the fitting

with a drain valve) until it is snug and the
glass outlet is pointing directly upward.
Verify top and bottom fittings are
threaded into the tappings the same
number of turns (distance A=distance
B).
6. Remove glass packing nut, friction

washer and glass packing from the
fittings, and place them, in the same
order, on to both ends of the gauge
glass. Push both packings about an inch
up the gauge glass.
7. Gently insert one end of the glass into

the top gauge fitting. Keeping the glass
inside the top fitting, gently rotate the top
gauge fitting clockwise until vertically
aligned with the bottom gauge fitting,
then inset glass into bottom fitting until
glass bottoms out on the shoulder inside
the bottom fitting.
8. Carefully raise glass about 1/16” and

slide lower glass packing down until the
glass packing contacts the lower gauge
fitting. DO NOT allow the glass to
remain in contact with any metal!
9. Carefully slide upper glass packing up

as far as possible.
18 VMP IOM
Installation
Water Supply Boiler Water: carbonates, break down to form carbon
dioxide in steam, which is a major factor in
Feed water contains solids and dissolved Alkalinity ........................less than 300 ppm in the
the corrosion on condensate lines. High
gases. These may promote formation of form of CACO3
alkalinity also causes foaming and carry
scale; foaming, priming, surging, and solids Chloride.........................less than 500 ppm
over in boilers.
in steam; corrosion and pitting; or caustic pH Value .......................9 to 11 (tested at room
embrittlement. To prevent this, feedwater temperature)
Both foaming and carry over cause erratic
must be studied individually and treated Total Dissolved Solids..... 2,000 ppm maximum
boiler operation. When foaming occurs an
accordingly by reputable professionals Hardness.......................less than 50.0 ppm
anti-foam should be added or increased.
specializing in this field. It is strongly Dissolved Oxygen ........none
The reason for the high alkalinity should be
recommended that a competent water Suspended Solids.........40 ppm
determined. It may result from lack of
treatment company be consulted prior to ppm = parts per million; CACO3=Calcium sufficient blow-down. Pretreated makeup
the installation of the boiler. Carbonate; PO4=Phosphate; SiO2=silicon water and condensate should also be
dioxide; * 1 Grain Hardness = 17.118 ppm checked. quite often the source of alkalinity
The purpose of this treatment should be to Therefore: 70 ppm = 4.10 grains hardness is an overdose of alkaline internal water
provide quality feedwater to the boiler such treatment chemical.
that corrosion and deposition in the boiler b. It is critical that the boiler pH be alkaline
will be minimized. Dissolved oxygen, high (9-11) whenever water is in the boiler. pH
TDS levels and low pH can all be major Solids that enter in with the feed water pH is a measure of the degree of acid or
causes of corrosion. Untreated hardness is concentrate in the boiler. Daily boiler base of solution. Neutral pH ranges of 6.5-
the major cause of scale deposits. Poor blow down is recommended to prevent 7.5 will have negative influence on the
quality feedwater will require increased corrosion and/or deposits from forming. corrosion rate of carbon steel. A low pH can
blow-down and increased chemical result in corrosion of metals, while a high
treatment costs to prevent boiler corrosion pH can result in scale formation. Optimal
and scaling. Glossary of Water Supply boiler pH is 9-11, slightly alkaline
One way to lower the amount of dissolved

Corrosives and Inhibitors
In order to control boilers and equipment
oxygen in the boiler feed water is the DISSOLVED OXYGEN used for the external treatment of make up
feedwater preheating option. This option Oxygen that is dissolved in the feedwater water, it is essential that frequent reliable
injects live steam into the feedwater to will cause the steel in the boiler and the pH measurements be made.
increase the water temperature to at least feedwater system to be attacked by the
180 degrees F (82 degrees C) which water in a manner described as “pitting”.
removes oxygen from the water. The pits that are produced can vary from
tiny depressions to holes large enough to
TDS can be controlled by increasing the penetrate the boiler metal and are usually
number and/or duration of blow downs per covered with tubercles of iron oxide. Once
day from one to four. pitting starts, it may be extremely hard to
arrest. Pitting can proceed at a surprisingly
The Fulton Warranty does not cover rapid rate and can occur not only in the
damage or failure that can be attributed boiler proper, but also in pre-boiler
to corrosion, scale or sludge equipment such as economizers, feedwater
accumulations. Oxygen is corrosive. See heaters, and feedwater lines.
the Warranty Section of this manual for full
details. SUSPENDED SOLIDS
Suspended solids are the undissolved
matter in water, including dirt, silt, rust and
Recommended Water any other insoluble matter. Normally
Treatment suspended solids are expressed in terms of
turbidity.The presence of suspended solids
a. Following are recommendations for feed in cooling water can increase impingement
water and boiler water. Contact your local type corrosion. Suspended solids may also
water treatment professional for testing deposit in low velocity areas and create
and treatment recommendations. It is differential aeration cells. Pitting can result.
very important that a strict water The most common cause of high
treatment program be followed. suspended solids is high hardness
feedwater piping corrosion and inadequate
Feedwater: blow-down rate.
Dissolved Oxygen..............less than 0.05 ppm
pH Value.............................9-11 (tested at room In line filters, or various types of
temperature) pretreatment can be used to lower the
*Hardness ..........................less than 25 ppm suspended solids level. Various polymers
in the form of CACO3 assist in holding solids in suspension. Boiler
Oil........................................none blow-down is the best way to control
Suspended Solids..............none suspended solids.
Organic Matter ...................less than 5.0 ppm
Total Dissolved Solids .......less than 300ppm ALKALINITY
Alkalinity is the capacity of a water to
neutralize acids. Common water alkalinities
consist of bicarbonate, carbonates,
hydroxide, phosphate, and silicate. These
alkalinities, especially bicarbonates and
VMP IOM 19
Installation
CHLORIDES/CHLORINE Often oil in boiler water will originate in the WATER HARDNESS
Chlorides are generally considered condensate. This contaminated condensate Water hardness is the measure of
detrimental in stainless steel systems only. should be directed to the sewer until the calcium and magnesium content as
Stress corrosion cracking can occur from source of the oil is determined and corrective calcium carbonate equivalents. Water
high chlorides. steps taken. Boiler and boiler system piping hardness is a primary source of scale in
boil out procedure are designed to rid a boiler equipment. Hardness is removed
High chlorine levels can cause severe system of oil contamination. by water softeners or RO/DI systems. It
corrosion. Corrosion from chlorine can be can also be treated with various
controlled by removal via carbon filtration. IRON (OXIDES) chemical treatments (i.e. Phosphates).
City water can contain high levels of Iron in any of its oxide or complex forms is
chlorine. undesirable in boiler water. It is very difficult FEEDWATER
to disperse so that it can be removed the Feedwater is the combination of fresh
OIL bottom blow-down lines. makeup and returning condensate that is
Oil is not a natural constituent of boiler pumped to the boiler. Hot (>180°F)
water; still it can frequently enter a system Iron in its various forms can originate in the feedwater, free of hardness, solids and
through leaks in a condenser or other heat raw water makeup, condensate return water, oxygen will yield the most protection to a
exchanger. Oil can also enter a system or form directly in the boiler as a result of boiler.
through the lubrication of steam driven corrosion. Most iron oxide originates outside
reciprocating equipment. Whatever the the boiler. It concentrates in the boiler and it CONDENSATE
source, the presence of oil in boiler water is tends to collect in stagnant areas. If a boiler Condensate is condensed steam that is
undesirable. is using raw water makeup, iron is almost normally low in dissolved solids. Hence, it
certain to be a major component of does not contribute to the dissolved solid
Foaming is one indication of oil in boiler developing scale or sludge deposits. content of the feedwater. In addition,
water. Its presence can also be confirmed condensate is very expensive to waste. It's
by first shaking a bottle containing boiler been chemically treated, heated, pumped,
water. If oil is present foam will result. To converted to steam, and condensed. This
ensure the foaming is being caused by oil, costs money and when condensate is
add a small amount of powdered activated returned to the boiler, money is saved.
carbon to the bottle containing the boiler
water and shake. Little or no foam will
appear if the foaming is caused by oil.
20 VMP IOM
Installation
Electrical Requirements
1. Connect wiring as shown in the wiring
diagram which is furnished inside the
electrical control panel box.
2. Be sure to install a separate disconnect

for each piece of equipment. The
disconnects should be installed in
compliance with the NEC (National
Electric Code) and all local codes.
3. Connections for an optional audible

alarm are provided in the control panel
and are clearly indicated on the diagram.
Fresh Air Supply

for Boiler
It is most important to provide free access of
air to the boiler. To burn fuel properly, it
requires one square inch opening of fresh air
for every 3,000 BTU input of fuel. (6.4cm2 for
every 756 Kcal).
Proper ventilation of the boiler room is

essential for good combustion. Install two
fresh air openings, one at a low level 24”
(610 mm) from floor and one at a higher
level in the boiler room wall.This will provide
a flow of air to exhaust the hot air from the
boiler room. Boiler room temp not to
exceed 100°F.
The following openings are recommended for

each size boiler: Adequate provision must be made for the
Conventional Venting support of the weight of the chimney and
Make Up Air Openings The stack should rise continuously to the stack to avoid having too great a load
connection with the chimney, and should imparted to the flue outlet connection of the
BHP FT2 M2
contain no more than two bends at 45° boiler.
40 5 .46
angles or less. If required as the result of
50 5 .46
space limitations, one 90° elbow can be The proper flue size and draft control is
60 7.5 .69
fitted at the back of the boiler. There should most important for proper burner operation.
80 12.5 1.11
be two feet of straight, horizontal flue before The flue must be
100 16 1.49
any bends or turns. Any alternative stack as large or larger than the outlet on the
130 21 1.95
arrangement must supply a negative .02 - boiler. Avoid flue piping and elbows by
150 24 2.23
.04” W.C. pressure (0.508 to 1.016 mm) placing the boiler as close as possible to the
with the burner off. chimney.
Be sure total BHP = proper make up air
opening size.
The run in the total distance of stack ducting, A mechanical draft regulator should be
as measured in a straight line from the outlet installed in the flue outlet. Do not install the
These measurements are subject to state
of the boiler to the outlet of the stack, should draft regu-lator prior to the first turn of the
and local regulations. The installation of
not exceed 70% of the rise. With the flue.
exhaust fans in a boiler room is not
exception of a duct run described in Item a,
recommended.
horizontal sections of ducting must be BHP Boiler Flue Size
avoided, and should not exceed four feet of IN MM
An exhaust fan, or similar equipment can
total run. 40, 50, 60 12 305
create down draft in the stack or restrict the
burner’s air supply which will result In poor 80, 100, 130 14 356
The stack and chimney must be 150 16 406
combustion. It is essential that only fresh air
constructed from material that is rated for
is allowed to enter the combustion air
1000°F operating temperature. Check all The installer should check the draft with a
system. Foreign substances, such as
local codes for exact requirements. meter at negative .02 -.04” W.C. pressure
combustible volatiles and lint, in the
combustion system can create hazardous (0.508 to 1.016 mm) with the burner off.
conditions.
VMP IOM 21
Installation
Corrosion of flue pipe When the next cold start-up occurs, the Installation Check Points
process repeats except that more and more
In the case of a combustion flue pipe, acid chloride collects and concentrates along 1. Make sure all piping connections are
may develop over a long period of time per the flue. As the quantity of chloride complete and tight.
the following process. Chlorine containing increases it does not dehydrate completely
gases, such as halocarbon refrigerants, as the flue heats up and a corrosive poultice 2. Make sure the pressure controls are
carbon tetrachloride, trichloroethylene, or develops which attacks the steel and will adjusted properly.
perchloroethylene, when drawn into also attack the boiler.
combustion air are broken down into 3. Make sure all electrical connections in
elemental chlorine gas which exits up the Concentration levels of only a the control panel box, the water column,
flue pipe. If the flue pipe is cold, as it would few ppm of chlorine containing compounds and elsewhere are secure.
be if the combustion process had been off in combustion air can produce serious
for some time, the water vapor condenses corrosion over long periods of time. High 4. Make sure the door in the boiler room is
in the flue pipe during the first few minutes chlorine containing compounds such as closed. Combustion air contaminates
of ignition and the chlorine in the carbon tetrachloride or perchloroethylene can cause damage to the boiler jacket
combustion gas dissolves in the water would be prime suspects. and stack.
forming hydrochloric acid. As the
combustion system flue line increases in In addition, normal combustion creates NOTE
temperature, the water vapor no longer carbon dioxide which may condense in a After installation is complete and prior
condenses because the flue temperature is cold flue to form carbonic acid. to operation the pressure vessel should
above the dew point of the combustion gas. be cleaned.
The combustion gas then dries out
(dehydrates) the hydrochloric acid solution
leaving behind dry chloride salt.
Gas Train Available with Optional Ignition

High-Low-Off, or Modulation Pressure Switch Electrode
Primary steam outlet
(Valve not shown)
Gas Valve
UV Scanner
Exhaust stack
Gas Regulator Safety Valve(s) adapter
Lifting Lug
Modulation
Motor
Ignition
Scroll Transformer
Blower
Air Gate
Control circuit
transformer
Electric
Control
Panel
22 VMP IOM
Cleaning (Boil out) the
Pressure Vessel
After the boiler has been installed and
before it is placed in service it is advisable
to purge the pressure vessel of any oil
film,dirt, or other impurities. Clean the
pressure vessel as follows:
1. Isolate the boiler from the system by

shutting off the main steam valve.
2. Remove the steam safety valve.
3. Mix washing soda with water in a one-

gallon container and pour it into the
boiler through the steam safety valve
opening.
4. The mixture of washing soda to water is

as follows:
Boiler Size Soda

40, 50, 60 4 lb (1,814g)
80 5 lb (2270g)
100 7 lb (3178g)
130 9 lb (4080g)
150 10.5 lb (4760g)
5. Replace the steam safety valve.
6. Fill the boiler with water. Water level is

about center in the water gauge glass.
7. Generate 15 PSI (1.054 kg/cm2) of

steam and shut off the boiler. Allow this
hot solution to remain in the boiler for 10
minutes.
8. Drain and flush the boiler twice with

fresh water.
9. To remove all the oil and dirt from the

main steam and the condensate return
lines, allow the returns to go into a floor
drain or a safe discharge point for the
first week of operation.
CAUTION
Do not store halogenated hydrocarbons
in or near the boiler room. In general,
ensure that the boiler area is in
conformance with established boiler
room requirements. Review national
and local codes.
We cannot emphasize enough the
importance of proper water treatment:
Water analysis should be made by a
competent water treatment concern and
their recommendations should be
followed.
VMP IOM 23
24 VMP IOM
1
2
3
Section Operation
4
5
VMP IOM 25
Operation
Starting the
Gas Fired Boiler
STOP! Make sure you have read and
followed all previous safety information.
Check with local authorities where

approval for start-up is required. In
some localities, final inspection of
services may be required.
In general, ensure that the boiler area is

in conformance with established boiler
room requirements. Review national
and local codes.
Carry out the following procedure on the 4. Open the water feed valve on the boiler.
initial start up of the boiler and on every
subsequent occasion when restarting the
boiler after a shut down.
7. Activate the boiler power on switch,

located on the side of the panel box.
8. With the unit full of water the low water

safety relay(s) will be in a lock-out
mode. Press the low water safety relay
5. Open valves on makeup water line to manual reset button located on the side
return if return system is used. of the control panel box.
1. Close the blow-down valves.
Gas Burner Set Up
1. Open the manual gas cocks on the pilot
and main lines of the gas head.
2. Switch on the main power to the burner.

The water level relay is equipped with a
manual reset. Depress the button on the
box.
3 The flame programmer is the

main control in the panel box. The
programmer in conjunction with a sensing
device, either a flame rod or a UV
scanner, "supervises" the ignition
sequence - proves the flame is
satisfactory, and finally"monitors" the
established flame. Should any fault occur,
2. Close the water gauge drain valve. 6. Place feedwater pump fused switch in either during the ignition sequence or
the "on" position. during normal running, the programmer
3. Open main steam stop valve at the top will immediately go to "lock-out" and the
of the boiler. burner will shut down.
NOTE
IMPORTANT:
IMPORTANT The pump will continue to operate until NOTE
the water reaches the correct level in the To reset the boiler burner after a “Lock
When commissioning this boiler, firing rate boiler. This level is approximately the out” signal, push the reset button on the
must remain at low fire during first center of the water gauge glass. control.
4 hours of operation. The output may then
be increased 7% to 10% per hour, until a
firing rate of 75% is reached. The 75% firing IM
rate should be maintained for 3 to 4 hours.
26 VMP IOM
Operation
c. The flame programmer is the main 3. Mount the gas train on the pipe nipple of
control in the panel box. The programmer the burner plate with the gas train inlet
in conjunction with a UV scanner directly facing over the panel box.
“supervises” the ignition sequence - Reconnect the linkage from the butterfly
proves the flame is satisfactory, and valve to the modulation motor.
finally “monitors” the established flame.
Should any fault occur, either during the 4. The end of the linkage arm that attaches
ignition sequence or during normal to the butterfly valve will have a notch on
running, the programmer will immediately both sides of it, where the swivel collar
go to “lock-out” and the burner will shut should be centered. This setting was
down. based on factory test fire conditions.
d. When the pilot flame is established, 5. Combustion analysis should be done at

ultra-violet scanner senses the flame. the installation to make any changes to
4. When the pilot flame is established, the This signal is transmitted back to the insure proper combustion characteristics.
flame rod (or ultra-violet scanner) flame programmer which opens the
senses the voltage which is created in main gas valve giving a main flame. 6. The modulating burner will have a
the flame between the flame rod and the modulation lock switch to enable you to
gas nozzle (ground). This signal is e. If the installation is new or the burner lock the firing sequence anywhere along
transmitted back to the flame has been disassembled, the burner may the firing rate from low to high.
programmer which opens the main gas not fire at the first attempt due to air
valve giving a main flame. which must be purged from the gas 7. Depending on the combustion
lines. This will result in the burner flame characteristics, it may be necessary
5. All Fulton propane or butane boilers and programmer going to lockout. Repeat to adjust both linkage arms. To adjust
Fulton natural gas boilers 50 HP and the procedure for starting the burner. the linkages, unscrew the swivel
above are standardly furnished with UV collar and move the linkage rod in the
Scanners. f. The main gas valve will remain open as appropriate direction.
long as there is a demand for heat and
a. If the installation is new or the burner the flame is carrying a sufficient signal to 8. Standard modulating burners will have a
has been disassembled, the burner the flame programmer. proportioning pressure control in
may not fire at the first attempt due to addition to the standard operating
air which must be purged from the gas g. If the flame is not established at the pressure control that will send a 0-135
lines. This will result in the burner flame start, the safety switch in the flame ohm signal to the modulation motor to
programmer going to lockout. Repeat programmer control will open the adjust the firing rate. Both operating
the procedure for starting the burner. contacts and shut off the burner. pressure controls should have the same
setting.
b. The main gas valve will remain open h. Push the reset button on the control to
as long as there is a demand for heat reset. If trouble persists, it may be 9. NEMA 4 units will use a digital pressure
and the flame is carrying a sufficient necessary to check the UV scanner. controller with transducer as the
signal to the flame programmer. See Maintenance Section for procedure operating pressure control which sends
to check UV Scanner. a 0ma signal to the modulation motor to
c. If the flame is not established at the control firing rate.
start, the safety switch in the flame WARNING
programmer control will open the Prior to the commencement of any work
contacts and shut off the burner. requiring the removal of cover plates Gas Burner Set Up For
d. Push the reset button on the control
and the opening of the control panel Boilers Equipped with
box, the electrical supply to the boiler High-Low-Off
to reset. If trouble persists, it may be must be disconnected.
necessary to check the flame rod 1. A gas fired burner equipped for high-
setting or the UV scanner. See low-off firing is available as an option on
Maintenance Section 4 for procedure Gas Burner Set Up For Fulton gas fired steam boilers for 40 -
to check flame rod setting or UV
Scanner. Boilers Equipped with 150 HP units.
Modulation 2. Boilers that have a high-low-off firing
rate will have a linkage between the
Gas Burner Set Up 1. Modulation is available as an option on
Fulton gas fired steam boilers for 40 - high-low gas valve and the primary air
For LE Models 150 HP units. gate. This valve is equipped with a
WARNING spring return.
For units equipped with Flue Gas 2. Boilers equipped with modulation will
Recirculation (FGR), the ducting must 3. The linkage will be disconnected from
be insulated. have the linkage rod disconnected
between the modulation motor and the the gas valve for shipment.
a. Open the manual gas cocks on the pilot gas butterfly valve for shipment.
and main lines of the gas head. 4. Mount the gas train on the pipe nipple of
NOTE the burner plate with the gas train inlet
b. Switch on the main power to the burner. directly facing over the panel box.
If Seiman linkageless modulation is
The water level relay is equipped with a Reconnect the linkage from the primary
ordered, no mechanical linkage rod is
manual reset. Depress the button on the air gate to the high-low gas valve.
required, thus none provided.
box.
VMP IOM 27
Operation
5. The end of the linkage arm that goes to
the gas valve will have a notch on both Primary Air Adjustment
sides of where the swivel collar should is located at the fan
be centered. This setting was based on housing face.
factory test fire conditions.
6. Combustion analysis should be done at

the installation to make any changes to
insure proper combustion characteristics.
7. To adjust the linkage, unscrew the

swivel collar and move the linkage rod in
the appropriate direction. The high-low-
off configuration comes with two
operating pressure controls.
8. Set the low operating pressure control to

approximately 60% of your desired set
point and the main operating pressure
control to your desired set point.
WARNING
Prior to the commencement of any work
requiring the removal of cover plates
and the opening of the control panel
box, the electrical supply to the boiler
must be disconnected.
pulling the damper open more air is
forced down the blast tube and less on
Primary Air Adjustment the outside wall of the deflector face and
for Fulton Gas Fired fire chamber.
Steam Boilers 2. It is important in the combustion process

1. The primary air adjustment or main air to maintain proper air mixtures between
control is located at the fan housing the outer surface and center of the blast
face. This control is used to supply the tube area. On most boilers the damper
burner with excess air needed to is locked in a wide open position.
facilitate good combustion. Too much or However, if it is necessary to close the
too little air will result in poor damper, care should be taken to close
combustion. It is important to make sure the damper slowly and no more than 1/4
the lowest level of excess oxygen is of the distance of the swing of the
present while still maintaining a high damper assembly.
level of carbon dioxide and negligible Secondary Air Adjustment
carbon monoxide. Using a CO2 or O2 3. A visual examination down the blast
tester it is possible to determine the tube should reveal that no heat, flames
percent of excess air in the combustion or fumes are backing up through the
mixture. burner plate area. If they are, the
secondary damper must be opened up
2. It is a good policy on a gas fired unit to once again. Failure to remove the flame
have between 3.5% and 4% oxygen or gases from the blast tube area can
present in the combustion. This will give cause a backfire as well as cause
you 10.5% to 9.5% carbon dioxide. The premature failure of electrodes, flame
carbon monoxide level should always rods, and other burner components.
be less than 400 PPM.
4. A visual inspection down the burner
view port should also show the fire
Secondary Air Adjustment completely covering the furnace walls. If
Procedure for Fulton Gas the fire is tunneling down or is not to the
outside wall of the furnace, the efficiency
Fired Steam Boilers will drop off. Close the secondary air
1. The secondary air control adjustment is damper until tunneling stops.
located on the top, right-hand side of the
burner assembly. This damper type air IMPORTANT
controller is used to introduce air to and When commissioning this boiler, firing rate
through the blast tube of the burner. The must remain at low fire during first
purpose of the secondary air adjustment 4 hours of operation. The output may then
is to proportionately divide the air to the Burner
center or outer fire chamber. By moving be increased 7% to 10% per hour, until a Viewing Port
the damper closed, the air is forced to firing rate of 75% is reached. The 75% firing
the outside of the fire chamber with less rate should be maintained for 3 to 4 hours. Blast Tube
air going down the blast tube area. By Viewing Port
28 VMP IOM
Operation
Boiler Controls c. Pressure Relief Valve
Limits the maximum operating pressure
of the boiler.
f. High Limit Pressure Control

Located in the control panel box and
a. Flame safeguard burner control connected to the water column
This is the main control in the panel box. assembly by means of a copper tube.
The programmer in conjunction with a d. Operating Steam Pressure Control The pressure is usually set 10 to 15 PSI
sensing device, either a flame rod or an Located in the control panel box and (.703 - 1.054 kg/cm2) above the
ultra violet scanner, "supervises" the connected to the steam pressure gauge operating pressure, but below the
ignition sequence - proves the flame is assembly by means of a copper tube. maximum pressure of the pressure
satisfactory - and finally "monitors" the The pressure control regulates the relief valve. If the pressure exceeds the
established flame. Should any fault on/off cycle of the burner, shutting the high limit pressure control setting, the
occur, either during the ignition burner off when maximum pressure is boiler will automatically shut off. The
sequence or during normal running, the reached and switching on when the high limit pressure control must be
programmer will immediately go to steam pressure falls below a manually reset by depressing the
"lock-out" and the burner will shut down. predetermined level. plunger located on top of the control.
b. Low Water Cut-Off - Probe Type e. Sight Glass Isolation Valves g. Air Pressure Switch
Cuts off the unit when water level is too The brass sight glass isolation valves Mounted on the burner scroll, this switch
low after a 3 second time delay to avoid are equipped with an internal ball check. is operated by the pressure of air
nuisance shut downs. As a standard In the event that a sight glass should entering the burner through the throat of
feature, Fulton boilers are equipped with break, the ball will seat, preventing the the scroll. Absence of air, or insufficient
ASME CSD-1 Code controls which discharge of steam and water. The pressure, will prevent the switch
include a manual reset feature on the brass valve stem must be opened fully completing the circuit, thus preventing
burner low water cut off relay and ASME to enable this feature. If the valve is in the burner from operating.
CSD-1 Code controls also feature an any other position than full open, the ball
independent second low water cut off will not seat. For added safety all Fulton WARNING
relay. Press the low water reset button boilers are equipped with gauge glass When stopping the boiler for any
and the boiler will start. protectors. extensive repairs, shut off main
disconnect switches on both the boiler
CAUTION side as well as the feed water side.
Do not tamper with the safety features of
the low water safety cut out. NOTE
To ensure that your Fulton Steam Boiler
is kept operating safely and efficiently,
follow the maintenance procedures set
forth in Section 4 of this manual.
VMP IOM 29
Operation
Air and Gas Adjustment If at any time the burner control locks out on The full list of program stops are:
a fault condition and the red flame failure 24:Air damper in the prepurge position
for LE Models light illuminates: 32:Traveling to the FGR position (if the unit
The low emission burner can be best is equipped with FGR)
• Read the diagnostic feedback on the AZL
described as a fuel staged, multi-radial 36:Ignition position (before pilot ignition)
display, address the fault if possible.
injection type. Two air/gas ratio electro 44:Ignition position (after pilot ignition)
servo actuators control the fuel supplied to • Press escape on the AZL once. 52:Ignition position (after main burner ignition)
this burner. A radial blade type fan supplies 72:Air damper in the postpurge position
• Press enter on the AZL to reset the
the air. A direct-coupled reversing actuator 76:Traveling to the FGR position (if the unit
control. The red light should go out.
modulates the air which in turn regulates is equipped with FGR)
the fuel input. No mechanical linkage is If the fault persists contact Fulton.
utilized with this system. As a safety device, 5. Press Escape 4 times to get back to the
a thermocouple is placed in the small partial If the boiler has a dual fuel burner, the main menu.
premix area of the burner to monitor burner setup procedures on the following
temperature. It is used in conjunction with a pages must be performed for each fuel. 6. Under ManualOperation > Setload,
temperature limit that should be set change the load to 0% by using the
between 600° and 700°F. LMV Control arrow keys. Press enter and verify the
0% has been acknowledged in the
for LE Models “curr” field.
Commissioning/Start Up NOTE 7. Press Escape once to get back to the
for LE Models The following procedure must be
ManualOperation menu.
repeated for each fuel the boiler is
WARNING equipped to operate on.
Commissioning/Start Up by a non- 8. Under Auto/Manual/Off, change the
Fulton authorized person will void the operation to Burner On by using the
PRE-IGNITION STEPS arrow keys. Press enter and verify that
product warranty.
1. Verify the main burner switch is in the “Burner On” is acknowledged in the
Before commissioning the boiler, verify with OFF position. If the boiler has dual fuels, current field.
authorized personnel that the gas lines verify the fuel selector switch is turned to
have been purged. the correct fuel. 9. Press Escape twice to get back to the
main menu.
SIEMENS LMV LINKAGELESS BURNER 2. Supply power to the boiler. The AZL will
MANAGEMENT SYSTEM display “system test” and then move to 10.Increase the setpoint on the temperature
(If Equipped) the main menu. controller to create a heat demand.
The Siemens LMV system is a fully 3. Select PWLogin, press Enter. Select 11. Turn the main burner switch to the
packaged burner management system, AccessServ. Press Enter. (This type of Local or On position.
linkageless control and first out annunciator. step will be shown as PWLogin >
AccessServ for the remainder of this NOTE
When operating the Siemens LMV section. Enter the service passwords If the burner loses flame while driving to
systems, all changes are made through the using the arrow key. The password is a point then:
Siemens AZL display. The left and right case sensitive. The case of a letter can
be changed by pressing the other arrow • Turn the main ON/OFF switch to OFF.
arrow keys are used for scrolling through
key. (For example, if you used the right Reset the loss of flame fault. Press
the menu and changing controller
arrow key to get to the letter A, press the Escape on the AZL once. Press Enter
parameters. Enter accepts the menu and
left arrow key to get a). After you have on the AZL to reset the control The
parameter changes.
pressed Enter on the last character of red light on the panel box door
the password, press Enter once more should go out.
to accept the password. If you do not • Adjust the air and gas servos for that
have the password, contact your Fulton point while the burner is off. Follow
Authorized Representative to perform steps 28-29.
the changes.
• Turn the main ON/OFF switch to ON.
4. Select Params&Display. Press Enter.
Select RatioControl. Press Enter. Select 23.Under Params&Display > RatioControl
ProgramStop. Press Enter. Change ProgramStop, change the program stop
the Program Stop to 44 Interv1 by using to deactivated by using the arrow keys.
the arrow keys. Confirm the change by Confirm that ‘deactivated’ is acknowledged
pressing Enter. This will set the burner in the current field.
management system to a ‘pilot hold’
setting. 24.This change will allow the burner to
modulate. The burner will now drive to
Verify that the current value “curr” changes low fire. Remember, it is only important
to 44 Interv 1. at this stage to set low fire to be stable
and with clean combustion. Exact
It is possible to return to the main menu at
IMPORTANT setting is to be performed once high fire
any time by repeatedly pressing Escape.
When commissioning this boiler, firing rate is confirmed.
When running the boiler, the status of the
burner is to be monitored with the Siemens must remain at low fire during first
25.Press Escape 5 times to get back to the
AZL display. 4 hours of operation. The output may then
main menu.
be increased 7% to 10% per hour, until a
firing rate of 75% is reached. The 75% firing
rate should be maintained for 3 to 4 hours.
30 VMP IOM
Operation
26. You can observe the status of the 30.If operating on gas, adjust the incoming BEFORE LEAVING THE INSTALLATION
burner by going to OperationalStat > gas pressure at the main gas regulator
NormalOperation. to match the test fire report. Adjust the Check all controls to insure they are
gas servo motor to change the last operating properly. Cycle the boiler several
27. Verify the flame signal on the display, elbow pressure to match the test fire times. Make sure the installation complies
measure input if fuel meter is available. report. Adjust the air servo motor to with all applicable codes.
If not, match last elbow pressures and adjust the emissions as needed. If
combustion from test fire sheet. Adjust operating on oil, adjust the oil pump and NOTE
the burner as needed. To adjust the air pressure regulator to match the Decreasing the primary will typically
servo position, follow steps 28-29. pressures on the test fire sheet. Adjust decrease the NOx levels. If the primary
the oil servo until the oil flow rate is decreased too much, stability may be
SETTING LOW FIRE matches the test fire sheet. Adjust the compromised.
air servo to match the test fire sheet.
NOTE a. Start the boiler and check for stable
As soon as a servo position is altered, 31.Repeat step 28 but start at the high fire combustion at low fire. Refer to the test
the servo will move to that position. point number. Continually decrease the fire sheet for acceptable parameters.
Only change servo settings by a point number after combustion has
maximum of 0.5° at a time before been verified at each point. b. Adjust secondary servo air/gas if
verifying combustion. needed to bring combustion into an
32.Once all the points have been verified, acceptable range. Adjust carefully as
28.Go to Params&Display > RatioControl > press Escape until you are back to the this is the main fuel adjustment.
GasSettings (or Oil Settings, depending main menu.
on the current fuel) > CurveParams. c. After a stable flame is achieved and the
33.You can observe the status of the burner combustion is within the test fire sheet
29.Wait for the spinning line on the left to by going to OperationalStat > parameters, manually and slowly drive
disappear. Press Enter. The number 1 NormalOperation. the servo’s motor to high fire insuring
should appear to the right of the cursor, that the combustion readings stay within
this is the Point Number. 34.Turn the main ON/OFF switch to OFF. the given parameters. Adjust secondary
The control will now postpurge. servo as needed.
Press Enter once. Select ChangePoint by
pressing the arrow keys to highlight and then 35.Follow steps 3-20 again to verify ignition d. If the last elbow pressure is above or
press Enter to select. This will cause the with the new gas pressures. below the stated requirement on the test
servo motors to move to this low fire point. fire sheet, adjust the combustion air
36.Turn the main burner switch to OFF. damper to bring the last elbow pressure
Check combustion and adjust the servo The control will now post purge. inline. The gas pressure is directly
motors as required. To adjust a servo proportional to the air pressure and
motor, arrow to it and press Enter. Then 37. Change the operation to Automatic under therefore, increasing the air pressure to
adjust the setting as required and press ManualOperation > Auto/Manual/Off the burner will increase the gas input
Enter. You can now adjust another servo and press Enter and confirm Automatic is proportionally.
motor if needed. entered in the current field.
e. Manually drive the unit back to low fire
When combustion is properly set for that 38.Press Escape twice to get back to the and check combustion.
point, press Escape once more. If it asks main menu.
you to store the point, press Enter. Note the f. If the combustion is outside of the test
AZL will only ask to save if either servo 39. Under Updating > ParamBackup, fire parameters for the servo, adjust the
value has been altered. select LMV51 - AZL. This will store all of secondary.
the adjustments that have been made in
Low fire is now set and stored. the LMV base module to the display. If g. After the unit is brought back into range,
the base module were to fail, the display manually drive the unit back to high fire.
SETTING THE COMPLETE RANGE can be used to download all of the
a. Remember it is only necessary to parameters into a new base module. h. Adjust secondary air/gas ratio slightly if
approximate the setting through the needed.
modulation range until high fire 40.Press Escape 4 times. Select PW
conditions are established. Logout, the password is now logged out. i. Repeat this procedure 2 or 3 times until
you obtain consistency in high and low
b. Press Enter once more to have access 41.Press Escape twice. Select fire combustion.
to the point number field. Increase the OperationalStat > NormalOperation.
point number by one and press Enter. The control is now on the normal j. In most cases, the primary gas should
Select ChangePoint and press Enter. operational display screen. only be adjusted if the unit is unstabe at
The servos will now move to that point. low fire and/or NOx are not acceptable
42.The boiler is now ready to run. Adjust at low fire.
c. Verify combustion is satisfactory. your setpoint on the temperature control
to the desired temperature and turn the
d. Measure input or monitor last elbow main ON/OFF switch to ON for the
pressure. Verify that these points are in burner to operate.
general correspondence with the test
fire sheet. Repeat step b. until the point
position has a load value of 100%. You
are now at high fire. Verify combustion is
per test fire sheet.
VMP IOM 31
Operation
CAUTION IMPORTANT
During startup insure that adequate gas When commissioning this boiler, firing rate
pressure is supplied to the main valves.
The indicator on the actuator should must remain at low fire during first
never reach the bottom of the indicator
window. In the event that this happens, 4 hours of operation. The output may then
adjustability will be lost. See minimum be increased 7% to 10% per hour, until a
incoming gas pressure requirement on
the test fire sheet. The SKP10 actuator firing rate of 75% is reached. The 75% firing
functions only as on/off. When
activated, the indicator will reach the rate should be maintained for 3 to 4 hours.
bottom of the indication window. The
main gas pressure regulator is only
used to comply with standard
regulations and therefore uses a high
outlet pressure spring that is set at the
max. The SKP70 fuel valves have a built
in regulator function.
Glossary of Terms
PRIMARY GAS
The smaller gas line injects fuel at the
burner head.
SECONDARY GAS
The main gas line inject fuel prior to the
burner head.
REVERSING ACTUATOR
Used for positioning control inlet damper,
combustion air.
AIR/GAS RATIO CONTROLLING

ACTUATOR
Regulates gas flow according to air
pressure.
32 VMP IOM
1
2
Section
3
4
Maintenance
5
VMP IOM 33
Maintenance
Burner Alignment
Tabs
Gas Train Assembly
Burner Plate Assembly Transformer
Top Plate Assembly
Secondary Air Damper

Scroll
Burner Motor
Flue Cover Plate
To
O.P.C.* Steam Gauge
Lifting Hook(s) Assembly
To
H.P.C.* Gauge Glass
Stainless Steel Ring Valve
Gauge Glass
and Protector
Flue Outlet
Gauge Glass
Valve
Water Column
Top Refractory
Turbulator Control Box
Fiberglas Insulation
Bottom Refractory
Outside Jacket
Feedwater Inlet
Blowdown Outlet
Handhole
Blowdown Outlets
Castable Refractory Insulation
Clean Out Opening
* O.P.C. = Operating Pressure Control

* H.P.C. = High Pressure Control
Artwork Revision 2017-0927
34 VMP IOM
Maintenance
NOTE
To ensure the continued safety and
efficiency of the boiler, the schedule of
maintenance outlined in this section
should be adhered to.
WARNING
Prior to the commencement of any work
requiring the removal of cover plates
and the opening of the control panel
box, the electrical supply to the boiler
must be disconnected.
Procedure for Cleaning

Water Probes
Clean probe on top of boiler shell and
probes in water column. Make sure there is
no pressure on the boiler during the
removal of the probes. Remove one probe,
clean with very fine emory cloth and replace
it before removing another to assure no
probe mix ups that would change the
control functions.
A B C D
For replacement purposes, installed probe

lengths are indicated in the chart below. For
a universally adaptable plug and probe
which can be cut to length in the field to fit
all boilers, order Part No. 2-20-017.
A= 7 1/4 IN / 184 mm
B= 9 1/4 IN / 235 mm
C= 11 1/4 IN / 286 mm
D= 4 IN / 102 mm
“D” is located in the boiler pressure

vessel.
VMP IOM 35
Maintenance
Gas Train Assembly
Blast Tube Viewing Port
Burner Plate
Burner Alignment Tab
Scanner Location
Ignition Electrode
Gas Orifice Assembly
Burner Viewing Port Top Plate
Blast Tube
Deflector
Flame Scanner 5. Adjustments to establish a good signal

may include the following items:
Adjustments for Fulton
a. Primary and secondary air adjustments.
Gas Fired Steam Boilers
b. Increasing the pilot gas through the
1. Flame scanner adjustments are made pilot gas regulator.
with the detectors installed and the
burner running. It is essential to obtain
optimum flame signal detection for safe Checking the Stainless
and continual operation of the control
relay.
Steel Combustion Ring
on Fulton Gas Fired
2. If a scanner is inoperable, it may prove
the detector is working and only an
Steam Boilers
adjustment to the pilot flame is needed 1. The stainless steel combustion
to improve the signal. ring in Fulton gas fired boilers are
designed to bring quick and effective
3. If the scanner is found to be flame transfer to the fire wall. The ring
defective, replace. should fit securely and tight against the
furnace wall for best results.
NOTE
The scanner is located on the outside 2. The ring should be inspected for
edge of the burner top plate for 40, 80, distortion in the event of poor
and 100 HP. combustion which could result in flame
failures.
4. For the RM7800 Series use a keyboard Stainless Steel
display module or volt meter. The flame Combustion
safeguard will require a 1.25 VDC Ring (40-100)
signal to pull in the main flame. Then a
maximum signal should be obtained on
main flame (5.0 VDC).
36 VMP IOM
Maintenance
Furnace Refractory Gas Train Assembly
Replacement Procedure
1. Remove the burner plate and top plate
assembly up and out of the air to air
heat exchanger.
2. Remove the stainless steel combustion

ring from the furnace .
Air Deflector
3. Remove the clean-out plugs from the
bottom sides of the boiler. The boiler has
two clean out plugs, one is located at the
bottom of the boiler to the right hand
side of the panel box. The second one is
180 degrees on the opposite side of the
boiler.
4. Break off the top holding clips that were

used to keep the refractory in position Stainless Steel
during shipping. The boiler has welded Combustion
Chamber Ring
flat bars beneath the top refractory.
These bars will have to be cut to change
the lower refractory. Rewelding of the
bars will be required prior to installation
of the top refractory. For the lower
refractory you will also need to break off
the top holding clips that were used to
keep the refractory in position during
shipment.
Top Castable
5. Break up the top and/or bottom Refractory
refractories and remove the pieces from
the boiler through the clean-out plugs.
Turbulator
NOTE
If only the top refractory is to be
changed, the bottom refractory need not Bottom
be broken. Castable
Refractory
6. Round and bevel the outer edges of the
new refractories.
Handhole
7. The bottom refractory has the largest
hole, while the top refractory has the
smallest.
8. Lower the bottom refractory down

the furnace with wire fastened around
the refractory in three positions. When
the refractory is close to position, it can
be tipped by maneuvering the wire to
drop it flat on the holding clips. If the
refractory will not tip, it may have to be
removed and again rounded and
beveled.
9. Install the top refractory in the same

manner as the bottom refractory. When Artwork Revision 2017-0927
installed the outer edges must be

sealed with insulcrete - a castable
refractory mix available from the Fulton
factory. It is not necessary to reinstall the
shipping clips.
9. Install the stainless steel combustion ring,

burner assembly, and clean out plug.
10.Normal operation can be resumed

immediately.
VMP IOM 37
Pilot Adjustment for 4. Also note the location of the jumper on Recommended Daily
the left side of the motor.
Fulton LoNOx Burner. Maintenance Schedule
1. Close downstream shut off valve. 5. Loosen the allen screws on the motor The following procedures should be carried
end of the motor to valve coupling. out daily. They are designed to prevent the
2. Start boiler and check flame signal on build up of scale, silt, or sludge in the bottom
6. Unbolt the motor from the mounting
pilot, lock programmer into pilot hold. of the boiler and in the pipes leading to the
bracket and remove the motor.
water gauge. In addition to these procedures,
3. Adjust air and gas regulator as needed the advice of a water treatment supplier
7. Turn the valve so it is in the closed
to obtain a strong pilot signal. should be sought and followed. An ASME
position and can rotate clockwise to open.
Section VIII blow-down receptacle must be
4. Slowly open downstream shut off valves provided for the appropriate pressure.
8. Mark the coupling or valve shaft if
and take the flame programmer off of hold.
needed so the position of the valve can
1. Blow down the boiler each morning by
be determined when the servo motor is
starting the boiler and generating not
Main Flame Adjustment installed.
more than 10 PSI (.703 kg/cm2) of
For LE Models 9. Bolt the new servo motor on to the
steam. Turn on tap water to blow-down
separator, then open the boiler blow-
1. Place a combustion analyzer in the mounting bracket with the motor shaft
down valves for approximately 10
exhaust of the boiler. inserted into the coupling.
seconds, then close the valve. Shut off
tap water to blow-down separator.
2. Do not adjust main gas regulator. To 10.Rotate the valve shaft/coupling assembly
increase fuel to the burner, the servos closed as stated above.
that control modulating gas valves
require adjustment. 11. While holding the valve closed, tighten
the allen screws on the coupling.
Burner Tile Replacement 12. Install the wired green wiring plugs and the
For LE Models conduit termination point on the new motor.
Connect the black grounding wire from the
1. Remove scroll assembly. motor to the conduit termination point.
2. Break off top holding clips. 13.Verify the jumper on the motor is located
on the same pins as the motor that was
3. Remove ceramic fiber burner tile. replaced.
4. Replace burner tile bottom holding clips 14.Turn power to the boiler on.
if needed.
15.The screen will display ‘system test’.
5. Replace with new burner tile. The fault “Fault Feedback Air Actuator’
Blow Down Boiler Daily. Shown is the
will be displayed. DO NOT RESET
6. Carefully replace scroll assembly so that blow down "Y" valve.
THIS FAULT YET. Press Escape twice
the ceramic fiber burner tile is not to clear the fault from the screen.
damaged. NOTE
16. Press Escape to get to the main menu. If the boiler is being operated
Under Params&Display > Actuators > automatically on a time clock, the blow-
Servo Motor Replacement Addressing, select either the gas actuator down operation may be done once
For LE Models or air actuator depending upon which was during the working day and once at the
replaced. The control will run an actuator end of the day when at 10 PSIG or less.
If it is determined that a servo motor needs to check then display ‘Start Address
be replaced, the first step in this process is to Assignment with ENTER’. Press Enter. 2. Blow down water column each morning
verify the model number of the new servo The display will then have you press the when boiler is at 10 PSI (.703 kg/cm2) by
motor is the same as the old servo motor. addressing button on the actuator. This is opening the water column and the water
the red button on the actuator. The screen gauge blow-down valves for approximately
The model number starts with the letters SQM will then display ‘Actuator Address 5 seconds, then close the valves.
and is displayed on a label on the side of the Assignment Successful’.
motor. Once the new motor has been verified
to be correct, turn power to the boiler off. 17.Press Escape until the main menu is
reached. Under OperationalStat >
1. Turn off all electricity to the boiler. Status/Reset, reset the fault.
2. Remove the cover on the servo motor to
be changed. CAUTION
The boiler emissions may not be correct
3. Remove the green wiring plugs and the after changing the servo motor. Verify the
conduit termination point from the motor emissions throughout the range of
by pulling them towards you. A black modulation. If emissions are off, the
grounding wire runs from the motor to servo motor can be adjusted by following
the conduit termination point. Pull it off the procedure in the Commissioning the
from the conduit termination point. Boiler section of this manual.
18. Attach cover to servo motor.
38 VMP IOM
3. If the feed water is being treated by 2. Clean water pump strainers. f. Check refractories for soot or
compounds, make sure that this breakage and inspect the stainless
treatment is carried out carefully and 3. Check scanner or flame rod and ignition steel ring (50-100 HP only).
according to the manufacturer's electrodes.
instructions. g. With the boiler under no more than 15
4. Check starter contacts. Burned or pitted PSI pressure, check that the steam
NOTE contacts should be replaced. Do not use safety valve is operating by lifting the
Fulton recommends that the feedwater sand paper or file to clean. lever.
treatment should be added between the
pump and the boiler. 5. Clean water traps and strainers in fuel 2. Drain condensate tank and clean tank
lines. by flushing with hose. Check float valve
4. When first starting the boiler each day, operation.
make sure ignition and burner are 6. Check operation of all steam traps on
working properly. condensate return system. 3. Check electrical controls and motors for
correct operation.
5. Check water level in sight glass. 7. Remove brass pipe plug at the cross
connection below water column and 4. Check water pump for correct operation.
6. Check to be sure feed water pump is clean nipple into boiler. Boiler must be
working. cold and water level below pipe. 5. Shut off the boiler completely and drain.
7. For float type water level control, blow 6. Remove the hand holes and inspect the
down float chamber. interior of the vessel for scale or sludge
deposits. The amount of deposits will
indicate the efficiency of the water
Recommended Weekly treatment being used. The frequency of
the inspection will depend on the
Maintenance Schedule condition of the water side of the boiler.
Check that the low water cut-off relay is
operating correctly in the following manner:
1. Make sure that the boiler is cool with
little or no pressure showing on the
steam pressure gauge.
2. With the burner operating, open the

boiler blow-down valves. When the
water drops below the required level
(note the level in the water gauge glass)
the burner should shut off; this is when Recommended Semi-
the water level falls below the low water Annual Maintenance
electrode in the water column assembly
and/or the boiler shell. Manual reset of Schedule
the low water relay is required. 1. Cleaning the gas burner assembly:
a. Disconnect the gas head from the
Recommended Monthly burner by disconnecting the union.
7. Replace hand hole gaskets using the
Maintenance Schedule Remove the burner plate screws.
following procedure:
WARNING Withdraw the burner assembly and a. Remove the hand hole assembly
Make sure main power switch is off clean the flame rod and ignition using a 1 1/4 " tee handle wrench or 1
before starting work. electrode. 1/4 " drive socket wrench.
1. Cleaning the water gauge glass: b. Check that the settings of the flame
rod, if applicable, and ignition
CAUTION electrode correspond to those in the
Do not clean the gauge or gauge glass illustration below.
while pressurized or in operation.
c. Reassemble the burner assembly
a. Clean the water gauge glass using a and check the flame rod setting or
commercial non-abrasive glass scanner setting.
cleaner. Use diluted acids such as
hydrochloric (muriatic) acid when d. Check the combustion efficiency of
regular cleaners do not seem to work. the burner and adjust if necessary.
Do not use wire brushes or any other
abrasive materials which could e. Clean probe on top of boiler shell and
scratch the glass. If any leakage is probes in water column. There must
evident, replace the gaskets. be no pressure on the boiler during
the removal of the probes.
b. Always replace the high impact
plastic gauge glass protector which is
standard on all Fulton Boilers.
VMP IOM 39
Maintenance
b. Remove the old gasket and Recommended Annual e. Replace clean out plugs carefully so
thoroughly clean the surface on the as not to damage insulation and
boiler and the plate. Maintenance Schedule replace burner and flue cover plates.
1. Have combustion (CO2, O2, CO) and
c. Fit the hand hole assembly as follows: input checked by responsible personnel.
i. Place the gasket on the hand hole
plate and ensure that it is seating 2. Dirty flues can cause air flow restrictions
correctly. Do not use any grease, resulting in poor combustion and loss of
lubricant, or adhesive. efficiency. Clean flues as follows:
ii. Position the plate in the boiler. Set a. Remove the outer flue cover plate.
the yoke and tighten the securing nut
sufficiently enough to provide a snug
fit. Verify the position of the plate in
the boiler, then make it hand tight and
then snug with wrench about 1/4 turn.
Do not compress excessively.
3. Flush boiler out if necessary. See

Section 2 for proper procedure for
"Cleaning the Pressure Vessel."
4. Provide annual inspection by a qualified

ASME Boiler inspector.
Illustration shows correct pressure on Troubleshooting

gasket. b. Remove inner plate and turbultors.
The following trouble shooting guide will
iii. If the gasket leaks while pressure assist in the diagnosis and the correction of
is being built up, tighten only enough minor field problems. It contains instructions
to stop leakage. Never tighten more and information necessary to locate and
than necessary to prevent leakage. isolate possible troubles which occur during
Excessive tightening may shorten the normal operation. It should be used in
life of the gasket. conjunction with the unit wiring diagram and
the component literature provided in
Section 7 of this manual.
The following lists cover the most common

troubles that may occur on the Fulton gas
fired boilers. Refer to left hand column of
the chart to locate the problem. Determine
which cause, listed in the center column,
that represents the problem by performing
the corrective action as listed in the right
hand column titled “REMEDY”.
Illustration shows over-compressed c. Remove clean out plugs at lowest
gasket. part of unit and clean the bottom of
combustion chamber.
d. Refill the boiler with fresh water.
d. Remove all soot from the top, and
NOTE from the clean out plugs at the bottom
After a new Fulton Boiler has been in with a vacuum cleaner.
operation for several months, pieces of
burned metal will be found in the space
at the bottom of the boiler. These pieces
of metal are the remains of a light gauge
metal form which was used during
manufacture for forming the boiler
insulation. This is a normal condition
and does not affect the efficiency or the
life of the boiler in any way.
40 VMP IOM
Boiler Safety Testing – Fulton Vertical Steam Boilers
High Pressure Limit Switch:
 With the burner on and the boiler under pressure, lower the set pressure on the switch until it
trips and shuts down the burner. Ensure the pressure that the switch trips at is the same as the
boiler operating pressure.
 To test the manual reset button, wait until the boiler has fully completed the post purge phase.
Once the boiler is in the standby position, reset the switch to the original set point.
 Press the manual reset switch on the pressuretrol. This will ensure that the manual reset switch is
functioning correctly. The burner should not start until the reset button is pressed.
Operating Pressure Limit Switch:
 With the boiler under pressure, lower the set pressure on the switch until it trips and shuts down
the burner. Be sure that the pressure that the switch trips at is the same as the boiler operating
pressure.
 This switch is an auto reset.
 Reset the switch to the original set point. The burner should turn back on automatically.
Flame Scanner:
 Verify that the flame scanner is observing flame with the burner running.
 Turn boiler to the off position.
 NOTE
o Do not shut off gas supply with boiler operation. This can lead to a potentially dangerous
situation.
 Close both the main gas supply isolation valve and gas pilot line isolation valve.
 Turn the boiler to the on position. The boiler will proceed through the ignition sequence. Once
burner control completes the ignition sequence, the burner control should display fault code for
pilot flame failure.
 During the pilot sequence, burner control should not display any flame signal during scanner test
with gas valves turned to the off position. If flame signal is present, troubleshooting will be
required to identify cause of the spark pickup.
 Turn the boiler to the off position and open the gas pilot line isolation valve while leaving the
main gas isolation valve in the closed position. This will allow for the burner to cycle through
the pilot sequence and test main flame failure. The burner control should display fault code for
main flame failure. Turn the boiler off after this test is complete.
o Typically on boilers 30 HP and below, the pilot flame will be sufficient to allow the
boiler to cycle through the main flame test. If this occurs, slowly shut the pilot line
isolation valve. This will cause the boiler to fail on main flame.
 Once the boiler has completed the post purge cycle, turn the boiler to the off position. Open the
main gas supply valve, turn the boiler to the on position and resume normal operation.
Low Water Cutoffs:
Definition: Each cutoff device shall be installed to prevent startup and to cut off the boiler fuel or
energy supply automatically, prior to the fall of the water level below the lowest visible part of the
gauge glass.
Standard low water cutoff is Fulton level probes. Alternate cutoffs are MM-63, MM-150, MM-157,
MM-193-7b, etc. All cutoffs are tested in the same manner as described below.
When testing the low water cutoff devices, it is important that the boiler feed pump is turned off to
allow for proper draining. Remember to turn the pumps back on when level cutoff testing is
complete.
Testing of Low Water Cutoff Controls:
Your Fulton steam boiler is equipped with two automatic Low-Water Cut-Off (LWCO) controls. Each
LWCO will prevent startup and cut off the boiler fuel or energy supply automatically when the surface
of the water falls to a level not lower than the lowest visible part of the gage glass. One control is set to
function ahead of the other. The standard Fulton LWCO control utilizes a water level probe and
incorporates a 3 seconds time delay to prevent short cycling. Optional float type LWCO controls may
also be used on the boiler.
The LWCO controls can be tested by lowering the water in the boiler. The test should be done with zero
steam pressure in the boiler, or not more than 10 PSI.
Shut off the make-up water supply to the boiler.
Open the blow-down valve at the back of the boiler to allow the water level to slowly drop until ¾” and
1” of water level is visible sight glass and close the blow down valve. The first LWCO control will drop
out within 3 seconds and cut off the boiler fuel or energy supply. This LWCO control is typically
configured to automatically reset when the adequate water level in the boiler is restored. Some local
jurisdictions require this LWCO control to be a manual reset.
Open the blow-down valve at the back of the boiler to allow the water level to slowly drop until 1/8” to
1/4” of water level is visible sight glass and close the blow down valve. The second LWCO control will
drop out within 3 seconds and cut off the boiler fuel or energy supply. This LWCO control is
configured for manual reset. When the adequate water level in the boiler is restored you have to
momentarily press the LWCO manual reset button to enable operation of the boiler.
Air Switch:
 To test the air switch, first turn the boiler to the off position.
 Once the boiler is off, remove the air supply from the air switch and turn on the boiler. Once the
boiler is in the purge process, the safety interlock should appear and shut down the burner.
 Turn the burner off and reattach the air switch air supply.
 Reset the flame programmer.
 Cycle the boiler multiple times to be sure that no nuisance faults occur.
Low Gas Pressure Switch:
 Bring boiler to high fire (100% firing rate)

 Increase the dial on the low gas pressure switch until it trips and locks out the boiler
 Make note of the pressure that the burner shuts down at
 Once the gas switch trips, set the pressure switch to 50% lower than the value that the switch
tripped at – Example: gas switch trips at 10 in. w.c., set the switch to 5 in. w.c.
 Reset the switch and flame programmer
 Cycle the burner and observe for proper operation
High Gas Pressure Switch:
 Bring boiler to low fire (0% firing rate)

 Decrease the dial on the high gas pressure switch until it trips and locks out the boiler
 Make note of the pressure that the burner shuts down at
 Once the switch trips, set the pressure switch to 50% higher than the value that the switch tripped
at – Example: gas switch trips at 10 in. w.c., set the switch to 15 in. w.c.
 Reset the switch and flame programmer
Proof of Closure:
 Disconnect power to the boiler

 While the boiler is off, remove the common wire to the proof of closure switch and install a wire
nut on the end of switch or wrap in tape to properly protect the wire.
 Turn power to the boiler back on
 The boiler should immediately lock out on alarm due to the POC being disconnected.
 Disconnect power and reconnect the POC wire
 Turn power to the boiler back on and reset any flame programmer faults
Flashback Protection:
 Locate the flashback protection device and change the setting to the lowest setting. This is
typically 32 deg. F.
o To change the setting, the “Set/Reset” button must be pressed as the wheel is rotated
 The device will generate an alarm
 Reset the device to the factory temperature setting. This is typically 750 deg. F for standard
steam units.
 Try to turn on the burner. It should not work as the reset button on the control has not yet been
pressed.
 Press the reset button on the controller. The boiler should now operate correctly.
Maintenance
Troubleshooting Gas-Fired Boilers
PROBLEM CAUSE REMEDY
Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.
2. Ignition Electrodes Check electrodes for carbon buildup and clean if necessary.
Check for proper adjustment. Readjust if necessary.
Check for cracks in porcelain. If found,replace.
3. Transformer Check voltage between transformer leads at terminal block to be sure
transformer is being powered.
4. Flame Safeguard Control Check voltage between ignition terminal and neutral.
Check must be made before control locks out on safety.
If no power, replace control.
5. Faulty Air Switch Check for bad air switch by jumpering the two air switch leads at the
terminal block. If the boiler starts and runs with these terminals
jumpered, the air switch should be replaced.
6. Gas Valve Sticking (Pilot) Check for dirt in valve or orifice and clean if necessary.
Check for faulty actuator or valve and replace if necessary.
7. Gas Supply Check for gas pressure and for intermittent supply problems.
Gas pressure for natural gas should be 3-1/2" W.C. plus fan pressure
at the elbow to the burner and 7" to 11" W.C. at the head of the train.
8. Loose wire connection Check connections to all components.
Flame Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.
Gas pressure for natural gas should be 3-1/2" W.C. plus fan pressure
at the elbow to the burner and 7" to 11" W.C. at the head of the train.
Check for cracks in porcelain; if found, replace.
4. Primary Air Adjustment Check air adjustment.
5. UV Scanner Adjustment Check for dirt on flame scanner and clean.
Check for proper location of detector.
6. Flame Safeguard Control Check voltage at terminal leading to main gas valve. If no power,
replace the control.
7. Loose wire at fuel valve circuit Tighten wiring connections.
8. Contact open on air Adjust to proper setting.
safety switch
9. Scanner wiring reversed Change to correct terminals.
at panel box.
Burner Cut-Off 1. Power Supply Check fuse or circuit; reset or replace, as necessary.
2. Gas Supply Check to be sure main gas cock is not closed.
Check coil in gas valve with OHM meter. Replace if faulty.
Check gas regulator setting and readjust as necessary.
Check inlet gas pressure and increase or decrease as necessary.
Check for proper adjustment Readjust if necessary.
Check for cracks in porcelain; if found replace.
4. Air Switch Check for bad air switch by jumpering the two air switch leads at the
6. Weak Amplifier Replace.
7. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator.
8. Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight
glass shows the proper water level. If there is no power at this terminal,
the control is bad and must be replaced.
9. Dirty or defective UV Scanner Clean or replace.
VMP IOM 41
Maintenance
Poor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in
pieces. Clean or replace as necessary.
2. S.S. Ring Check to be sure ring is present and fits tight against the furnace wall.
3. Primary Air Adjustment Check air adjustment. Air/fuel mixture may be off. Open primary air so
fire is to outside wall of furnace.
4. Secondary Air Adjustment Check main air adjustment to see if it is loosened up. Adjust as
necessary and tighten plate in position.
Check CO2 and O2 levels.
5. Draft Check draft with a gauge. Draft should be a -.02 " to -.04" W.C. with
burner off or -.04" to -.06" when operating. May need to install a
barometric damper.
6. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.
7. Negative Room Pressure Make sure no exhaust fans are running in the boiler room.
Burner back fires 1. Refractories Check refractories to see if they are plugged with soot or broken in
pieces. Replace as necessary.
2. Ignition Electrodes Check electrodes for carbon buildup and clean if
necessary. Check for proper adjustment Readjust if
necessary. Check for cracks in porcelain; if found replace.
3. Draft Check draft with a gauge. Draft should be a -.02 " to -.04"
W.C. with burner off or -.04" to -.06" when operating. May
need to install a barometric damper.
Boiler will not 1. Gas Supply Check gas pressure coming into gas train. If low, contact gas company.
maintain pressure Check coil in gas valve with AMP meter. Replace if bad.
3. Pressuretrol Disconnect all power to the controller. Disconnect the wires from the
controller. Put an OHM meter between the switch terminals. Lower the
set point of the controller. Switch should make. Raise the set point and
recheck with OHM meter. Switch should break. If the controller
operates improperly, replace it.
4. Scale Built up in boiler Refer to Section 2 “Pressure Vessel Cleaning”.
5. Refractories Check refractories to see if they are cracked or broken in pieces.
Replace as necessary.
6. Steam traps blowing through Check traps to see if they are clean or replace as necessary.
7. Boiler size. Boiler may be undersized.
Boiler is Surging 1. Steam traps blowing through Check traps to see if they are clean or replace as necessary.
2. High organic in boiler Drain and clean boiler with washing soda per instruction manual.
(i.e. Perc or oil)
3. High boiler TDS Drain boiler and flush system. Refill and increase blow-down
rate/frequency.
4. Too much water akalinity Have water tested by water treatment company, lower boiler alkalinity
(high PH) to recommended level.
5. High sudden steam load Check total equipment horsepower required against horsepower of
boiler being used. Decrease amount of equipment being used at one
time, or reduce the steam flow by partially closing the steam stop valve.
6. High level of water Consult water treatment expert and adjust levels to boiler
treatment chemicals recommended levels.
Boiler Rumbles and 1. Draft problem Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with
Pulsates burner off or -.04” to -.06” when operating. May need to install a
barometric damper.
Boiler pushing water 1. Steam Traps Check traps. Clean or replace as necessary.
with the steam (carryover) 2. High boiler TDS Drain boiler and flush system. Refill and increase blow-down
rate/frequency.
3. High level of water Consult water treatment expert and adjust to boiler recommended levels.
treatment chemicals
42 VMP IOM
Maintenance
Pump will not cut off 1. Dirty Probes Clean or replace as necessary.
2. Relay failed Make sure relay is plugged in tightly. If so, replace water level relay.
3. Ground Connection Check for tightness and clean.
4. Probes not sensitive enough Replace probes and relays with extra sensitive ones.
(RO/DI Water)
Pump runs but does 1. Vapor locking of pump Allow system to cool down, check steam traps and check to be sure
not put water into boiler return lines are not insulated. Check return tank temp. If it is above
180°F (82°C) vapor locking of pump may occur. Inspect check valves.
Clean and replace as needed. Replace pump with multistage
centrifugal good for 250°F (121°C).
2. Impeller Adjustment Check for impeller wear and adjust per component information in
instruction manual (Burks only).
3. Pump suction plugged Remove/clean inlet strainer.
4. Plugged feed water nipple Check and clean or replace as necessary.
5. Pump undersized/worn Replace with appropriate pump.
3. Back pressure on pump Need to install repair kit on pump.
Water pump will not 1. Scale on probes. Check and clean or replace as necessary.
come on at times 2. Bad Pump Contactor Check to see if contactor is being powered.
Check to see if contactor coil is pulling in. Replace if necessary.
3. Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power.
If power is present but motor does not run, replace it.
Low Fuel pressure 1. Gas pressure regulator Check and replace.
Boiler Flooding 1. Pump does not shut off Dirty Probes. Clean or replace as necessary.
4. Vacuum created with boiler off As the boiler cools off, it pulls water from the system piping. To prevent
this, add a 1/4" check valve on the steam gauge assembly piping,
which closes under pressure and opens under vacuum.
Troubleshooting Gas-Fired Boilers - LE Models

Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.
Check for proper adjustments. Readjust if necessary.
Check for cracks in porcelain. If found, replace.
3. Transformer Check voltage between transformer leads at terminal block to be sure
transformer is being powered.
4. Flame Safeguard Control Check voltage between ignition terminal and neutral.
Check must be made before control locks out on safety. If no power,
replace control.
5. Faulty Air Switch Check for bad air switch by jum pering the two air switch leads at the
7. Gas Supply Check for gas pressure and for intermittent supply problems. See test
fire sheet for last elbow.
8. Loose wire connection Check connections to all components.
Main Flame Fails 1. Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report.
Adjust gas servo setting.
2. Air Servo Motor not set properly Verify the over burner pressure matches the start up report.
Adjust the air servo motor.
Boiler Fails while 1. Gas Servo Motor not set properly Verify the last elbow gas pressure matches the start up report.
Modulating adjust gas servo setting.
2. Air Servo Motor not set properly Verify the over burner pressure matches the start up report.
Adjust air servo setting.
VMP IOM 43
Maintenance
Flame Failure 1. Power Supply Check fuse or circuit breaker. Reset or replace, as necessary.
4. Primary Air Adjustment Check air adjustment. Air may be blowing flame away from burner head.
5. Scanner Check for dirt on flame scanner and clean. Check for proper location
of detector.
6. Flame Safeguard Control Check voltage at terminal leading to main gas valve. If no power,
replace the control.
7. Loose wire at fuel valve circuit Tighten wiring connections.
8. Contact open on air safety switch Adjust to proper setting.
9. Scanner wiring reversed Change to correct terminals.
at panel box
Burner Cut-Off 1. Power Supply Check fuse or circuit; reset or replace, as necessary.
2. Gas Supply Check to be sure main gas cock is not closed.
Check coil in gas valve with OHM meter. Replace if faulty.
Check inlet gas pressure and increase or decrease as necessary.
4. Scanner Check for dirt on flame scanner and clean.
5. Air Switch Check for bad air switch by jumpering the two air switch leads as the
7. Weak Amplifier Replace.
8. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator.
9. Faulty Liquid Level Control Check to see if there is power to terminal number 10 when the sight
glass shows the proper water level. If there is no power at this terminal,
the control is bad and must be replaced.
10. Dirty or defective UV Scanner Clean or replace.
Poor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in
pieces. Clean or replace as necessary.
2. Air Adjustment Check CO2 and O2 levels. Adjust Gas/Air Ratio.
3. Draft Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with
burner off or -.04” to -.06” when operating. May need to install a
barometric damper.
6. Gas Servo Malset Adjust gas servo setting.
7. Air Servo Malset Adjust air servo setting.
Burner back fires 1. Refractories Check refractories to see if they are plugged with soot or broken in
pieces. Replace as necessary.
Check for cracks i nporcelain; if found, replace.
3. UV Scanner Check for dirt on flame scanner and clean.
4. Draft Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with
burner off or -.04” to -.06” when operating. May need to install a
barometric damper.
44 VMP IOM
Maintenance
Boiler will not 1. Gas Supply Check gas pressure coming into gas train. If low, contact gas company.
maintain pressure 2. Dirty Flue Check flue for carbon buildup or blockage. Clean flue passages with brush.
3. Pressuretrol Disconnect all power to the controller. Disconnect the wires from the
controller. Put an OHM meter between the switch terminals. Lower the
set point and recheck with OHM meter. Switch should break. If the
controller operates improperly, replace it.
4. Scale Built up in boiler Refer to Section 2 “Pressure Vessel Cleaning”.
5. Refractories Check refractories to see if they are cracked or broken in pieces.
Replace as necessary.
6. Steam traps blowing through Check traps to see if they are clean or replace as necessary.
7. Boiler size Boiler may be undersized.
Boiler is Surging 1. Steam traps blowing through Check traps to see if they are clean or replace as necessary.
2. High organic in boiler Drain and clean boiler with washing soda per instruction manual.
(i.e. Perc or oil)
3. High boiler TDS Drain boiler and flush system. Refill and increase blow-down
rate/frequency.
4. Too much water akalinity Have water tested by water treatment company, lower boiler alkalinity
(high PH) to recommended level.
5. High sudden steam load Check total equipment horsepower required against horsepower of
boiler being used. Decrease amount of equipment being used at one
time, or reduce the steam flow by partially closing the steam stop valve.
6. High level of water Consult water treatment expert and adjust levels to boiler
Boiler Rumbles and 1. Draft problem Check draft with a gauge. Draft should be a -.02” to -.04” W.C. with
Pulsates burner off or -.04” to -.06” when operating. May need to install a
barometric damper.
Boiler pushing water 1. Steam Traps Check traps. Clean or replace as necessary.
with the steam 2. High boiler TDS Drain boiler and flush system. Refill and increase blow-down
(carryover) rate/frequency.
3. High level of water Consult water treatment expert and adjust to boiler
Pump will not cut off 1. Dirty Probes Clean or replace as necessary.
4. Probes not sensitive enough Replace probes and relays with extra sensitive ones.
(RO/DI Water)
Pump runs but does 1. Vapor locking of pump Allow system to cool down, check steam traps and check temp. If it is
not put water into boiler to be sure return lines are not insulated.
Check return tank above 180°F (82°C) vapor locking of pump may occur.
Inspect check valves. Clean and replace as needed.
Replace pump with multistage centrifugal good for 250°F (121°C).
2. Impeller Adjustment Check for impeller wear and adjust per component information in
instruction manual (Burks only).
3. Pump suction plugged Remove/clean inlet strainer.
4. Plugged feed water nipple Check and clean or replace as necessary.
5. Pump undersized/worn Replace with appropriate pump.
Water pump will not 1. Scale on probes Check and clean or replace as necessary.
come on at times 2. Bad Pump Contactor Check to see if contactor is being powered.
Check to see if contactor coil is pulling in. Replace if necessary.
3. Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power.
If power is present but motor does not run, replace it.
Low Fuel pressure 1. Gas pressure regulator Check and replace.
Boiler Flooding 1. Pump does not shut off Dirty probes. Clean or replace as necessary.
4. Vacuum created with boiler off As the boiler cools off, it pulls water from the system piping. To prevent
this, add a 1/4” check valve on the steam gauge assembly piping,
which closes under pressure and opens under vacuum.
VMP IOM 45
46 VMP IOM
1
2
3
4
5
Section Parts and
Warranty
VMP IOM 47
Parts and Warranty
It is important that the correct replacement
part is fitted to your Fulton Gas Fired Steam
Boiler.
When ordering replacement or spare parts,

make sure that the full information given in
the Parts List is supplied, together with the
following details as shown on your boiler
identification plate:
1. Boiler Number
2. Boiler Type
3. Electrical Specifications
NOTE
The policy of Fulton Boiler Works, Inc. is
one of continuous improvement, and
therefore, we reserve the right to change
prices, specifications, and equipment
without notice.
Part No. Description Approx. Net Weight

(lbs) (kgs)
5-60-100 Instruction Manual, Fuel-Fired 2 0.91
5-60-165 Certification Papers
Boiler Shell Parts

5-12-017 Furnace Refractory 30" OD x 91/2" ID (80 HP Top) 225 102.27
5-12-018 Furnace Refractory 30" OD x 10" ID (100 HP Top) 225 102.27
5-12-019 Furnace Refractory 30" OD x 13"D (80 & 100 HP Bottom) 225 102.27
5-12-015 Furnace Refractory 24" OD x 8" ID (40 - 60 HP Top) 125 56.82
5-12-016 Furnace Refractory 24" OD X 10" ID (40- 60 HP Bottom) 125 56.82
2-12-000 Furnace Cement- 2 Ib. can 2 0.91
2-12-001 Furnace Cement - 8 Ib. can 8 3.64
2-12-002 Furnace Cement - 15 Ib. can 15 6.82
Misc Flue Cover 40-60 HP (10)
5-10-11034 Flue Cover Plate - 80 HP (10) 64 29.09
5-10-11024 Flue Cover Ring -100 HP (10) 75 34.09
5-12-003 Square Cleanout Plug 15 6.82
2-12-064 Flexitalic (HHG) Extra Heavy High Pressure 0.5 0.23
2-12-088 Blue Max HHG 0.05 0.02
5-10-804 Handhole Welding Patch 60-100 HP 1.1 0.5
2-12-004 Handhole Gasket 60-100 HP 0.05 0.02
2-11-TIL105 HandholeYoke 1.5 0.68
2-11-TIL104 3 x 4 Handhole Cover 40-100 HP (Blue) 2 0.91
4-11-028 40 -100 HP Handhole Assembly (Blue) 7 3.18
2-12-504 Blanket Insulation (Sq. ft.) 0.5 0.23
5-21-306 Steel Jacket 40-60 HP - No Holes Cut 125 56.82
5-21-308 Steel Jacket 80 HP - No Holes Cut 180 81.82
5-21-309 Steel Jacket 100 HP - No Holes Cut 205 93.18
5-21-375 Exhaust Transition (40-60 HP)
5-21-374 Exhaust Transition (80 HP) 8.5 3.86
5-21-373 Exhaust Transition (100 HP)
2-12-502 Kast Set - per Ib. (10 Ibs. minimum) - Use for making refractories
2-21-015 Buckeye Stamping for Bottom Handhole 60-100 HP 1 0.45
2-21-093 Buckeye Stamping for Upper Handhole 60-100 HP 1 0.45
2-23-171 Touch Up Paint - MICA Spray (10 oz.) 1 0.45
4-23-014 Mica Paint - Quart 2 0.91
4-23-044 Mica Paint - Gallon 7.8 3.55
2-12-504 TIW Filler Insulation per sq ft
48 VMP IOM
Parts and Warranty
(lbs) (kgs)
Burner Assembly - Parts (Common)
2-40-613 1.5 HP 115/230/60/1 Burner Motor 3450 RPM 40 18.18
2-40-615 1.5 HP 230/460/60/3 Burner Motor 2850/3450 RPM 31 14.09
2-40-621 3.0 HP 230/460/50/60/3 Burner Motor 2850/3450 RPM 43 19.55
2-12-014 Pyrex Plate Glass 1 " - 4 -100 HP 0.1 0.05
2-45-025 Bakelite Terminal 90° for Electrode 0.05 0.02
2-45-026 Bakelite Terminal Straight for Electrode 0.05 0.02
2-45-017 Ignition Wire - per foot 0.01 0
2-11-080 Burner Scroll Casting - 80 & 100 HP 65 29.55
5-20-061 Burner Scroll Casting - 40, 50 & 60 HP 50 22.73
Burner Fans: Size HP Applicable Fuel Hz.

2-30-421 8-3/8 x 2-1/2 x 1 40-50 Propane or nat. Gas 50/60 3.00 1.36
60 Propane or nat. Gas 50/60 3.00 1.36
2-30-826 9-15/16 x 3-1/2 x LO75 80
2-30-559 9-15/16 x 3 x LO75 100
*When ordering burner fans, check for the correct part number on the back of the fan plate.
Burner Assembly - Gas

2-40-082 Ignition Transformer - Gas 115/60 9.5 4.32
2-45-026 Straight Bakelite Terminal 0.03 0.01
4-45-010 Ignition Cable with 90° Bakelite Terminal 0.5 0.23
2-20-033 Ignition Electrode 0.4 0.18
2-30-118 Air Switch 80-100 HP 0.72 0.33
5-20-018 Burner Plate Gas - 30-60 HP 1 0.45
5-10-398 Burner Plate Gas - 80 HP 1 0.45
5-10-399 Burner Plate Gas -100 HP 1 0.45
7-20-094 Air Deflector - Gas 80 & 100 HP 65 29.55
7-20-092 Air Deflector - Gas 40 - 60 HP 45 20.45
2-40-533 Gas Pressure Switch High-Low 3.25 1.48
2-30-298 1/2" Pilot Gas Valve (80-100 HP) 1.5 0.68
2-30-312 1-1/2" Gas Valve V5055A (40-60 HP) 10.7 4.86
2-30-313 2" Gas Valve V5055A (80-100 HP) 9.85 4.48
2-30-3003 Modulating Butterfly Valve (40-60 HP)
2-30-3020 Modulating Butterfly Valve (80-100 HP)
2-30-303 1-1/2" Main Gas Valve - V48A 4.5 2.05
2-40-253 Gas Valve Body - P.O.C V5055C (40-60 HP) 11.5 5.23
2-40-254 Gas Valve Body - P.O.C V5055C (80-100 HP) 10.5 4.77
2-40- High-Low-Off Gas Valve Body 80 HP
2-40- HIgh-Low-Off Gas Valve Body 100 HP
2-40-214 Actuator Valve Body 13.70 6.23
2-40-220 Actuator Valve Body w/Proof of Closure Switch 12.8 5.82
2-30-583 High-Low-Off Gas Valve Actuator 80 and 100 HP
2-30-402 1-1/4" Vent Valve - 120V Normally Open 4.7 2.14
2-30-401 1" Vent Valve - 120V Normally Open 4.3 1.95
2-30-198 1/8" Gas Cock (Pet Cock) 0.25 0.11
2-30-111 1/2" Pilot Gas Cock 0.6 0.27
2-30-115 1-1/2 " Main Gas Cock 4.8 2.18
2-30-110 2" Main Gas Cock 16.8 7.64
2-30-102 1/2" Gas Pressure Regulator RV 48 0.7 0.32
2-30-107 1-1/2"Gas Pressure Regulator - RV 81 4.8 2.18
2-30-108 2" Gas Pressure Regulator - RV 91 8.5 3.86
7-20-298 Natural Gas Orifice - 40 HP 4 1.81
7-20-093 Natural Gas Orifice - 80 HP 4.5 2.04
7-20-302 Natural Gas Orifice - 100 HP 4.5 2.04
7-20-275 Propane Orifice - 40 HP 4 1.81
Misc. Propane Orifice - 50 hP 4 1.81
VMP IOM 49
Parts and Warranty
(lbs) (kgs)
7-20-322 Propane Orifice - 60 HP 4 1.81
7-20-094 Propane Orifice - 80 HP 4.5 2.04
7-20-095 Propane Orifice - 100 HP 4.5 2.04
2-30-180 Propane Spring RV81 .05 0.23
2-30-181 Propane Spring RV91 .05 0.23
7-30-006 Top Plate Assembly - 40, 50 & 60 HP - Natural or Propane Gas 65 29.55
7-30-000079 Top Plate - 80 HP - NG/LP 100 45.4
7-30-000081 Top Plate - 80 HP - Combo 100 45.4
7-30-000110 Top Plate - 100 HP - NG/LP 100 45.4
7-30-000112 Top Plate - 100 HP - Combo 100 45.4
7-30-000031 Burner Plate Assembly - 40, 50 HP - Natural Gas 12 5.45
7-30-000073 Burner Plate Assembly - 80 HP - Natural Gas 12 5.45
7-30-000075 Burner Plate Assembly - 80 HP - Combo 12 5.45
7-30-000173 Burner Plate Assembly - 80 HP -Propane 12 5.45
7-30-000174 Burner Plate Assembly - 80 HP - Town Gas 12 5.45
7-30-000175 Burner Plate Assembly - 80 HP - Butane 12 5.45
7-30-000115 Burner Plate - 100 HP - Gas 1 .454
7-30-000117 Burner Plate - 100 HP - Combo 1 .454
7-30-000176 Burner Plate - 100 HP -Propane 1 .454
7-30-000177 Burner Plate - 100 HP - Town Gas 1 .454
7-30-000178 Burner Plate - 100 HP - Butane 1 .454
7-54-1006 Gas Train Assembly - 40 - 50 HP - Natural Gas 70 31.82
7-54-5158 Gas Train Assembly - 80 HP - Natural Gas On/Off 100 45.45
7-54-5159 Gas Train Assembly -100 HP - Natural Gas On/Off 100 45.45
7-54-6158 Gas Train Assembly - 80 HP - Propane Gas On/Off 100 45.45
7-54-6159 Gas Train Assembly -100 HP - Propane Gas On/Off 100 45.45
7-54-8488 Gas Train Assembly 80 HP - Natural Gas High/Low/Off 100 45.45
7-54-8489 Gas Train Assembly 100 HP - Natural Gas High/Low/Off 100 45.45
7-54-7758 Gas Train Assembly 80 HP Natural Gas Modulation 100 45.45
7-54-7759 Gas Train Assembly 100 HP Natural Gas Modulation 100 45.45
7-54-8498 Gas Train Assembly 80 HP - Propane Gas High/Low/Off 100 45.45
7-54-8499 Gas Train Assembly 100 HP -Propane Gas High/Low/Off 100 45.45
7-54-8409 Gas Train Assembly 80 HP Propane Gas Modulation 100 45.45
7-54-8410 Gas Train Assembly 100 HP Propane Gas Modulation 100 45.45
Water Column
5-20-022 Fulton Water Column Bottle Casting -4-100 HP 20 9.09
2-30-151 MM 150 Pump Control 25 11.36
2-30-193 MM 150 - M/R Control 25 11.36
2-30-152 MM 150 HD Assembly 25 11.36
2-30-192 MM 150-M-HD M/R Head 25 11.36
2-12-125 MM 150-14 Gasket 0.05 0.02
2-30-136 MM 157 Pump Control and Low Water Cutoff 39.7 18.05
2-30-137 MM 53-2 Boiler Feeder and Low Water Cutoff 38.5 17.5
2-45-144 MM Mercury Switch - 2 Wire 1 0.45
2-45-143 MM Mercury Switch - 3 Wire 1 0.45
2-30-149 Water Gauge Glass Valves w/Ball Checks 1.5 0.68
2-30-047 Try Cocks 0.4 0.18
2-12-065 8-5/8" Extra Heavy Gauge Glass 0.05 0.02
2-12-008 9-1/4 Water Gauge Glass - standard 0.05 0.02
2-12-007 9-1/4" Extra Heavy Gauge Glass 0.1 0.05
2-12-017 9-1/4" Water Gauge Glass -Corning 0.05 0.02
2-12-018 10" Water Gauge Glass- MM 0.06 0.03
2-12-020 Brass Water Gauge Glass Gasket 0.0018 0
2-12-019 Rubber Water Gauge Glass Gasket 0.004 0
2-12-080 Teflon Water Gauge Gaskets 0.01 0
2-35-514 Brass Packing Nut for Gauge Glass Valve 0.1 0.05
2-30-330 Gauge Glass Protector Rods 0.04 0.02
2-12-022 Lucite Gauge Glass Guard for 9-1/4" Glass 0.4 0.18
50 VMP IOM
Parts and Warranty
(lbs) (kgs)
2-12-024 Lucite Gauge Glass Guard for 10" Glass 0.5 0.23
4-21-010 Water Column Electrode Basket & Cover 0.5 0.23
4-30-052 Set of four (4) Water Level Probes & Plugs - 80-100 HP 1.3 0.59
4-30-042 Set of 3 Water Column Probes 0.8 0.36
2-20-010 Pump Off Probe - 7-1/4 " 0.2 0.09
2-20-011 Pump On Probe - 9-1/4" 0.2 0.09
2-20-012 Low Water Probe in Water Column -11-1/4” 0.3 0.14
2-20-017 Low Water Probe in Boiler- 17-1/2” 0.5 0.23
2-21-012 Probe Cover - 2" 1 0.45
2-21-013 Probe Cover - 4" 1 0.45
2-30-398 1/4"Male-Female Ball Valve for Water Column 0.6 0.27
2-40-021 Probe Basket 0.05 0.02
Panel Box Parts

2-40-420 Fulton Pump Relay-120V 0.5 0.23
2-40-421 Fulton Burner Relay - 120V 0.5 0.23
2-40-422 Base for Fulton Pump Relay 0.25 0.11
2-40-423 Base for Fulton Burner Relay 0.25 0.11
2-12-090 Spring Retainer for burner/pump relay 0.001 0
2-40-131 General Purpose Relay (Ice Cube) - AB 0.8 0.36
2-40-096 Base for Ice Cube Relay 0.1 0.05
2-45-091 On/Off Switch 0.05 0.02
2-45-092 Manual Reset Switch 0.05 0.02
2-45-090 Night Switch for two (2) Pressuretrols 0.05 0.02
2-40-552 4" Alarm Bell 1 0.45
2-40-551 120V Transformer for Bell 1 0.45
2-45-412 AB Green Panel Light 120 V - NEMA 4 0.02 0.01
2-45-413 AB Amber Panel Light 120 V - NEMA 4 0.02 0.01
2-45-411 AB Red Panel Light 120 V - NEMA 4 0.02 0.01
2-45-410 AB White Panel Light 120 V - NEMA 4 0.02 0.01
2-40-567 Motor Contactor - AB - 100 - 3RT1015-1AK6 0.8 0.36
2-40-642 3 Phase Motor Contactor - 3RT1017-1AK6 0.8 0.36
2-40-648 Overload - AB - BSB 16 3RB1015-2PBO 0.45 0.2
Overload - AB - BSB 15 0.45 0.2
Overload - AB - BSC 10 0.45 0.2
2-40-573 Overload - 60 3RB1015-2SBO 0.45 0.2
2-40-566 Overload - 3RB1015-2NBO 0.45 0.2
2-40-651 Overload - 3RB1025-2OBO
4-40-050 Night Heating Pressuretrol Set Up 3.5 1.59
2-40-227 Pressuretrol L404A - 2-15 PSI 1.7 0.77
2-40-228 Pressuretrol L404A - 5-50 PSI 2 0.91
2-40-229 Pressuretrol L404A - 10-150 PSI 2 0.91
2-40-230 Pressuretrol L404A - 20-300PSI 2.7 1.23
2-40-231 Pressuretrol L404C - 2-15 PSI 2 0.91
2-40-234 Pressuretrol L404C - 20-300 PSI 2.7 1.23
2-40-161 Flame Scanner (Mini-Peeper) 0.5 0.23
2-40-262 RM7800M Programmer 40-100 HP - 120 V 2.5 1.14
2-40-265 7 Second Prepurge Timer 0.1 0.05
2-40-269 RM7800 Amplifier - For UV Amp 0.2 0.09
2-40-161 Mini Peeper For All 7800 0.5 0.23
VMP IOM 51
Parts and Warranty
(lbs) (kgs)
2-40-270 Base For All 7800 0.5 0.23
2-40-272 Display Module for 7800 Controls English (Also Available in Spanish) 0.5 0.23
2-40-247 Remote Mounting Bracket for 7800 0.65 0.3
2-40-248 Extension Cable
Boiler Trim
2-30-396 1" Spring Loaded Check Valve - 200# 2.55 1.16
2-30-397 1-1/4" Spring Loaded Check Valve - 200# 3.8 1.73
2-30-019 1/4" Ball Valve - 200# 0.6 0.27
2-30-008 1/2" BallValve-200# 0.7 0.32
2-30-027 3/4" BallValve-200# 1.4 0.64
2-30-026 1" Ball Valve - 200# 1.75 0.8
2-30-001 1" MxF Ball Valve 200# 2 0.91
2-30-017 1-1/4" Ball Valve - 200# 3.1 1.41
2-30-018 1-1/2" Ball Valve - 200# 4.7 2.14
2-30-025 2" Ball Valve - 200# 6.35 2.89
2-30-208 3" Ball Valve - 200# 18 8.18
2-30-393 1-1/2" Y Type Blowdown Valve - 200# 8.4 3.82
2-30-394 2" Y Type Blowdown Valve-200# 13.5 6.14
2-30-023 1-1/2" Quick Action Blowdown Valve 23 10.45
2-30-024 2" Quick Action Blowdown Valve 28 12.73
2-40-133 Timer for Automatic Blowdown System 0.8 0.36
2-30-403 1-1/2" Motorized Valve for Automatic Blowoff 12.6 5.73
2-30-389 2" Motorized Valve for Automatic Blowoff 13.7 6.23
2-30-1066 1/2" Steam Solenoid Valve - 120V 2.3 1.05
2-30-122 3/4" Steam Solenoid Valve - 120V 2.5 1.14
2-30-146 1" Steam Solenoid Valve - 120V 4.5 2.05
2-30-147 1-1/4 " Steam Solenoid Valve - 120V 4.9 2.23
2-30-148 1-1/2" Steam Solenoid Valve - 120V 6.3 2.86
2-30-016 1-1/2" 15# Series 19 V-Stamped Safety Valve 2 0.91
2-30-217 2" 15# Series 19 V-Stamped Safety Valve 2.5 1.14
2-30-085 1-1/4"-150# Safety Valve 6.8 3.09
2-30-086 1-1/2"-15# Safety Valve 2 0.91
2-30-087 1-1/2"-100# Safety Valve 12.4 5.64
2-30-088 1-1/2"-125# Safety Valve 10.9 4.95
2-30-089 1-1/2"-150# Safety Valve 12.3 5.59
2-35-518 1/4" Steel Pigtail Syphon for Steam Gauge Assembly- Long 0.6 0.27
2-30-326 0-30 PSI Steam Pressure Gauge 0.5 0.23
2-30-327 0-600 PSl Steam Pressure Gauge 0.5 0.23
2-12-027 Teflon Disc for 1-1/2" Y Valve 0.2 0.09
2-11-017 Brass Seat for 1-1/2" Y Valve 0.1 0.05
2-12-028 Teflon Disc for 2" Y Valve 0.2 0.09
2-11-018 Brass Seat for 2" Y Valve 0.1 0.05
Test Equipment/Tools
2-40-090 Test Leads 0.6 0.27
2-40-215 Microampmeter - W136 2 0.91
2-60-100 Jr. Amprobe - Y25 1 0.45
2-60-102 Pocket Draft Meter 1 0.45
2-60-103 All Purpose Draft Meter 3 1.36
2-60-104 CO Tester-Gas 15 6.82
2-60-105 CO Tubes 0.25 0.11
2-60-106 StackThermometer 4 1.82
2-60-108 SmokeTester-Oil 2 0.91
2-60-110 Fisher Gauge - 50 PZ 1 0.45
2-60-247 Flue Brush - Pipe Type - 2-1/2" - 100 HP 1 0.45
52 VMP IOM
Parts and Warranty
(lbs) (kgs)
2-60-248 Flue Brush - Pipe Type - 2" - 40 and 80 HP 1 0.45
5-10-397 Tee Handle Wrench 2.7 1.23
2-20-110 Fan Puller - 5/8" Hub 2 0.91
Barometric Controls
2-30-099 14" M&MG2 80 - 100 HP - Oil, Gas, Comb. 16 7.27
2-30-0415 16" M&MG2 25 11.36
Spare Parts Kits

2-12-517 Burner Plate Gasket 40, 80 and 100 HP Gas 0.06 0.03
2-12-023 Screws (11) 0.001 0.00
5-12-046 Bottom Cleanout Gasket Only 0.5 0.23
2-12-550 Combination Gasket 0.05 0.02
4-12-114 Flue Cover Plate Gasket - Strip & Stick - Box of 3 3 1.36
1/4" Braided Rope Gasket 80-100 HP - price per foot 0.25 0.11
2-12-077 Handhole Funnel Gasket 80-100 HP Top 0.05 0.02
2-12-079 Handhole Funnel Gasket 80-100 HP Bottom 0.05 0.02
2-12-531 Scroll Gasket- 40-60 HP 1 0.45
Scroll Gasket- 80-100 HP 1 0.45
Stack Extension Gasket 14" 80-100 HP 1 0.45
2-12-521 Top Plate Gasket - 40-60 HP 1 0.45
2-12-522 Top Plate Gasket - 80-100 HP 1 0.45
4-12-516 Gas, Oil, & Comb Gasket Kit 15 6.82
4-12-520 80-100 HP Gas, Oil, & Comb Gasket Kit 10 4.55
See the component assembly drawings to assist with parts identification.
VMP IOM 53
Parts and Warranty
54 VMP IOM
Parts and Warranty
Standard Warranty for Fulton Boilers

(Warranty Valid for Models ICS, ICX, ICW, ICXW, VMP, VMPW, FB-A, FB-F, FB-L, FB-S, FB-W)
Five (5) Year (60 Months) Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of five (5) years
from the date of shipment from the factory. Fulton will repair or replace F.O.B. factory any part of the
equipment, as defined above, provided this equipment has been installed, operated and maintained by the
buyer in accordance with approved practices and recommendations made by Fulton. The commissioning
agency must also successfully complete and return the equipment Installation and Operation Checklists to
Fulton’s Quality Assurance department. This warranty covers any failure caused defective material or
workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the
boiler water management and chemistry be maintained as outlined in the Installation and Operation
Manual.
Parts Warranty
Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be
defective in workmanship or material within one (1) year of shipment from the factory provided this
equipment has been installed, operated and maintained by the buyer in accordance with approved
practices and recommendations made by both Fulton and the component manufacturers and the
commissioning agency has successfully completed and returned the equipment Installation and Operation
Checklists to Fulton’s Quality Assurance department.
General
Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include
freight, handling or labor charges of any kind.
These warranties are contingent upon the proper sizing, installation, operation and maintenance of the
boiler and peripheral components and equipment. Warranties valid only if installed, operated, and
maintained as outlined in the Fulton Installation and Operation Manual.
No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the
company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing,
by the Fulton Quality Manager.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited
to the implied warranties of merchantability and fitness for a particular purpose. Fulton shall in no event be
liable for any consequential or incidental damages arising in any way, including but not limited to any loss
of profits or business, even if the Fulton Companies has been advised of the possibility of such damages.
Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective.
To activate the warranty for this product, the appropriate commissioning sheets must be completed and
returned to the Fulton Quality Assurance department for review and approval.
9/9/09
VMP IOM 55
Parts and Warranty
Extended Warranty for Fulton Boilers

(Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S)
Ten (10) Year Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of ten (10) years from the date of shipment from the factory. Fulton
will repair or replace at our option, F.O.B. factory any part of the equipment, as defined above, provided this equipment has been installed, operated and
maintained in accordance with the Installation, Operation and Maintenance Manual. The commissioning agency must also successfully complete and return
the equipment Installation and Operation Checklist to Fulton’s Service Department. This warranty covers any failure caused by defective material or
workmanship, however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler water management and chemistry be
maintained as outlined in the Installation, Operation and Maintenance Manual.
The extended warranty is valid only for steam boilers that are purchased as part of a skid mounted boiler system. Generally, this system MUST include ALL
of the following equipment in order for the warranty to apply.
1. Fulton boiler with model number as listed above.
2. Fulton DA or condensate return system with preheat kit.
3. Fulton blowdown tank/separator
4. Water softener
5. Chemical feed system
6. Automatic surface or bottom blowdown, which must operate to maintain TDS levels as specified in the Installation, Operation and Maintenance Manual.
Any deviation or additional equipment specified by Fulton Engineering must be used and maintained per the Installation, Operation and Maintenance Manual
There is a $1,000 labor allowance for any failed pressure vessel that is covered under the above warranty.
Parts Warranty
Fulton will repair or replace FOB factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within twelve
(12) months of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved
practices and recommendations made by both Fulton and the component manufacturers.
General
Fulton shall be notified in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind.
No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority. Fulton will not pay
any charges unless they were pre-approved, in writing, by the Fulton Quality Manager.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and
fitness for a particular purpose. Fulton shall in no event by liable for any consequential or incidental damages arising in any way, including but not limited to
any loss of profits or business, even if Fulton has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for
the original equipment found to be defective.
Conditions of Warranty
Warranties are only valid if the boiler is installed, operated and maintained as outlined in the Installation, Operation and Maintenance Manual. Fulton shall
accept no responsibility if the equipment has been improperly installed, operated or maintained or if the buyer has permitted any unauthorized modification,
adjustment, and/or repairs to the equipment. The use of replacement parts not manufactured or authorized by Fulton will void any warranty express or
implied.
Warranty coverage for all components and equipment in said warranty are not valid unless the boiler is started up by a factory certified technician. The
commissioning agency must successfully complete and return the equipment Installation and Operation Checklist to Fulton’s Service department.
The boiler must be maintained in accordance with the product manual and annual combustion and maintenance reports must be produced for warranty
consideration.
The warranty is valid for the original installation only in the U.S.A and Canada.
08/20/10
VMP IOM 57
No part of this Installation, Operation, and Maintenance
972 Centerville Road manual may be reproduced in any form or by any means without
Pulaski, New York USA 13142 permission in writing from the Fulton Companies.
Call 315-298.5121 VMP-STEAM-GAS-IOM_2016-1007-REV1
Fax 315-298.6390 Fulton Heating Solutions, Inc., Fulton Boiler Works, Inc. & Fulton Thermal Corporation are part of the
www.fulton.com Fulton Group of Companies, manufacturers of high grade industrial/commercial heat transfer products.

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Installation Operation And Fulton VMP

Maintenance Manual (Vertical Multi-Port)

Fulton Order # : ___________________________

Job Name : ___________________________

Subject: Water Chemistry Requirements for Fulton Steam Products

Carbon Steel Stainless Steel

ND: None Detected.

These instructions must not be considered as a complete code of NOTE

WARNING: If the information in this manual is not followed exactly, a fire or

- WHAT TO DO IF YOU SMELL GAS

- Installation and service must be performed by a qualified installer, service agency

Burner Plate Assembly Transformer

Top Plate Assembly

Secondary Air Damper

Flue Cover Plate

Gauge Glass and

Turbulator Control Box

Castable Refractory Insulation

Clean Out Opening

* O.P.C. = Operating Pressure Control

The Fulton Companies

Top View Side View Front View

Models VMP 40 49.5 50 60 80 100

The Fulton Companies

12a VMP IOM

Models VMP 130 150

The Fulton Companies

13a VMP IOM

b. In a closed system an end of the line

c. There are four blow-down valves on the

All these procedures should be done in

Steam Safety Valve

5. Since the purpose of this safety valve is Steam Pressure Gauge

Feed Water Piping

BHP Minimum Water

2. When feeding the boiler using a return

3. It is important that all piping be lined up

4. Do not use the pump as a piping

5. Connect the feed water stop valve to the

1. Verify the proper gauge has been

2. Examine the gauge glass and packings

3. Do not subject the gauge glass to

4. Apply teflon tape or pipe dope to pipe

5. Install the bottom gauge fitting (the fitting

6. Remove glass packing nut, friction

7. Gently insert one end of the glass into

8. Carefully raise glass about 1/16” and

9. Carefully slide upper glass packing up

One way to lower the amount of dissolved

2. Be sure to install a separate disconnect

3. Connections for an optional audible

Fresh Air Supply

Proper ventilation of the boiler room is

The following openings are recommended for

Gas Train Available with Optional Ignition

1. Isolate the boiler from the system by

2. Remove the steam safety valve.

3. Mix washing soda with water in a one-

4. The mixture of washing soda to water is