Attachment A OandM Manual.pdf

Questions? Please Contact Your Local Manufacturer’s Representative 4-1

MAINTENANCE

INTRODUCTION 1

INSTALLATION 2

OPERATION 3

MAINTENANCE 4

WARRANTY & PARTS 5

Specification Section 235233-Page 116 of 132

© The Fulton Companies 20164-2

MAINTENANCE VTG-IOM-2016-1214 SECTION 4

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected.

Label all wires prior to disconnection;

wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

What to do if you smell gas:

Do not try to light the appliance.

Do not touch any electrical switch.

Do not use any phone in the building.

Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the fire department.

After initial start-up by qualified personnel, linkage, control settings, and fuel pressures should not be readjusted.

4 CAUTION

All maintenance procedures should be completed by trained personnel.

Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Heating Solutions Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

General Your Vantage boiler has been designed to provide years of trouble free performance. To ensure continued safety and efficiency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

Daily, Weekly and Monthly Maintenance and Inspection (Fulton considers the following to be good practice for any boiler, and is applicable to the full line of Vantage boilers). It is also good practice for any boiler installation to perform a thorough review of the overall system on a regular basis, and after any maintenance procedures. Any potential issues should be noted and followed up on to ensure safety and reliability of all relevant equipment. System review items may include:

� Looking for discoloration of any painted equipment, boiler jacket panels, and/or insulation used in system piping

� Looking for evidence of leaks including the air intake/exhaust systems, boilers, hydronic system piping, pumps, valves and other system components

� Once boilers are running, making sure there are no flue gases around the boilers, or in the boiler room

Daily Maintenance and Inspection Schedule Daily maintenance and inspection must include the following:

1. Observe operating temperature and general conditions.

2. Make sure that the flow of combustion and ventilating air to the boiler is not obstructed.

3. Boiler area is free and clear of any combustible materials, including flammable vapors and liquids.

Weekly Maintenance and Inspection Schedule Weekly maintenance and inspection must include the following:

1. Observe the conditions of the main flame. Correct air adjustment is essential for the efficient operation of this boiler. If an adjustment to the combustion is necessary, the flue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions.

Monthly Maintenance and Inspection Schedule Monthly maintenance and inspection must include the following:

1. Test high-limit control by reducing setting below the operating temperature. Burner should shut off. After readjusting the thermostat, press the button to reset the switch.

Specification Section 235233-Page 117 of 132

Questions? Please Contact Your Local Manufacturer’s Representative 4-3

SECTION 4 VTG-IOM-2016-1214 MAINTENANCE

! WARNING

Crystalline silica may be present in components of this equipment.

Exposure to crystalline silica may pose significant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines offered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Never use open flame or other sources of ignition to check for gas leaks.

4 CAUTION

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

Do not allow oil leaks, dust, or dirt to accumulate around the boiler.

2. Test operating temperature control by reducing temperature setting as necessary to check burner operation.

3. Check flue gas temperature at outlet. If there is a temperature increase over previous readings, the probable cause is soot or water-scale build-up on the tubes. Consult Fulton Heating Solutions immediately if there is a concern.

4. Test low gas pressure switch and high gas pressure switch utilizing the procedure in operation section.

5. For Low Emissions model boilers, inspect the air inlet filter. If any dust, lint or debris has accumulated, clean or replace the filter.

� Procedure for Cleaning the Air Inlet Filter (Low Emissions Burners)

Proceed as follows:

1. Remove the filter. The filter sits in a custom slot on the air inlet connection to the boiler.

2. Remove all debris and dirt from the filter using a non-corrosive soap and water. If debris is not readily removeable from the filter, replace the filter.

It is imperative that the same type/style/size filter is used (available from Fulton).

3. Dry filter and return the filter to its original position in the slot.

4. If filters have extreme amount of debris, investigate the source of combustion air to ensure proper quality before running the boiler.

Annual Maintenance and Inspection Schedule Annual maintenance and inspection must be performed prior to each heating season, and includes but is not limited to the following tasks, which must be done by a factory trained technician:

1. Inspect the fuel train, burner and control panel to be sure components are free of debris and are properly attached to the boiler.

NOTE:� There is no need to disassemble the fuel train, burner or control panel unless the technician suspects damage or malfunction.

2. Examine the venting system (air intake and exhaust piping).

� Check all joints and pipe connections for tightness.

� Check piping for corrosion or deterioration.

� Check that the piping is clear of debris.

� Check that the condensate drain system is functioning.

3. Inspect the hydronic heating system for other problems.

Specification Section 235233-Page 118 of 132

© The Fulton Companies 20164-4

4 CAUTION

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

All maintenance procedures should be completed by trained personnel.

Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Heating Solutions Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4. Test all safety devices for proper operation.

5. Perform combustion analysis and adjust if necessary.

6. Leak test the gas valves.

7. Test relief valve per manufacturer instructions by lifting the lever for 5 seconds and allowing the valve to snap shut. Please see the manufacturer’s recommendations on the relief valve tag.

� Annual Removal and Inspection of LE Bekaert Burner

1. Disconnect power.

2. Shut off gas supply.

3. Disconnect the gas union and properly support the gas train. It may be possible to remove just the gas actuator from the valve body to gain access to the burner.

4. Remove 8 bolts from the burner plate. This will allow the removal of the burner plate and the gas injector in one piece.

5. Remove 8 nuts and washers from the burner mounting flange and remove the burner. When removing the burner be careful to not scrape burner against the refractory.

6. Check burner and wipe off (do not scrub or use wire brush) any soot or foreign material that may have accumulated. Use compressed air to clear the burner.

7. Replace burner gaskets.

8. Reinstall burner and components. Torque specifications are 23 ft/lbs.

Verification of Torque Settings on Fireside Access Doors

NOTE:� This section applies to Models VTG-2000 and VTG-3000 with National Board #s of 8275 and higher, or ship dates after July 10, 2013. It also applies to all VTG-4000 and VTG-5000 units starting with National Board # 7603 and higher, or ship dates after June 14, 2012, and all VTG-6000 units. This includes ALL configurations: Standard, DF, and LE; in all model sizes. Please read carefully.

There are two access doors to the fireside of the heat exchanger of the above referenced Vantage models. There are a series of nuts on each door that must be checked for torque every 2,500 operating hours, or once per heating season (whichever is more frequent). Complete procedures while boiler is NOT operational/powered on.

Proceed as follows:

1. Remove the boiler jacket panels (upper and lower) on the front of the boiler.

Specification Section 235233-Page 119 of 132

Questions? Please Contact Your Local Manufacturer’s Representative 4-5

4 CAUTION

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

All maintenance procedures should be completed by trained personnel.

Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Heating Solutions Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

2. Verify settings of the upper door. The upper door is retained by (4) 1-1/8” nuts. Tools required for upper door setting verification:

� 1-13/16” socket and ¾ x ½” adapter (U.S. only; these were provided from the factory and should be stored in a safe place in the boiler room). If these components have been misplaced, please contact Fulton to purchase replacement components.

Upper Door

Lower Door

Tighten nuts in criss-cross pattern

1st

3rd

4th

2nd

FIGURE 24 - VERIFYING TORQUE SETTINGS (FRONT VIEW, PANELS REMOVED)

VTG-2000 THROUGH VTG-5000

Upper Outer Doors (QTY 4)

FIGURE 25 - VERIFYING TORQUE SETTINGS (FRONT VIEW, PANELS REMOVED)

VTG-6000

Lower Door

Tighten nuts in numbered pattern

Specification Section 235233-Page 120 of 132

© The Fulton Companies 20164-6

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

4 CAUTION

All maintenance procedures should be completed by trained personnel.

Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Heating Solutions Representative.

The VTG-2000 through VTG-5000 Fulton part numbers are 2-22-000570 (socket) and 2-22-000571 (adapter). For VTG-6000, the socket part number is is 2-22-000572. It is a 1 1/16” Deep Well Socket that does not require an adapter like the VTG-2000 through VTG-5000 model sizes.

� ½” drive torque wrench and extension (U.S. only; provided by service technician)

NOTE:� Do not loosen or remove the upper doors without guidance from the factory with regards to proper procedures for accessing the fireside of the heat exchanger.

3. Proceed as follows based on model size:

VTG-2000

through

VTG-5000

Sizes Only:

Evenly tighten all 4 nuts on the upper door in five stages, in a criss-cross pattern: top left, bottom right, bottom left, top right (see Figure 24), in the following order:

� 20 ft/lbs (27.1 NM)

� 35 ft/lbs (47.4 NM)

� 50 ft/lbs (67.8 NM)

� 100 ft/lbs (135.5 NM)

� 130 ft/lbs (176.2 NM)

Recheck all nuts in a circular pattern, and proceed to step 4.

VTG-6000

Size Only:

See Figure 25. Evenly tighten all 5/8 numbered nuts (1-20) as follows, in the sequence illustrated:

� 25 ft/lbs (33.9 NM)

� 50 ft/lbs (67.8 NM)

� 75 ft/lbs (101.6 NM)

� 100 ft/lbs (135.5 NM)

Recheck all at 100 ft/lbs (135.5 NM), and proceed to step 4.

4. Verify settings of the lower door. The lower door is retained by (16) 3/8” bolts. Tools required for lower door setting verification:

� 9/16” socket and 3/8” drive wrench (U.S. only; provided by service technician)

5. Evenly tighten all nuts on the lower door to 23 ft/lbs (31.2 NM) in a criss-cross pattern. See Figure 24 and Figure 25. Do not over torque, as this can result in damaging of the door seal.

Specification Section 235233-Page 121 of 132

Questions? Please Contact Your Local Manufacturer’s Representative

4-7

6. Do not replace any of the bolts, nuts, washers, gaskets or other boiler components without consulting the factory.

Any replacement components must be to factory specifications.

7. Once all bolts are tightened to proper torque, replace the boiler jacket panels.

8. To confirm proper seal on the door after this procedure has been conducted, ensure there are no flue gases present around the boiler once unit is running.

Inspecting/Cleaning the Flue Passages For boilers firing on Natural Gas or Propane, there is no need to inspect the flue passages of the boiler unless the technician suspects damage or malfunction.

� Boilers Firing on #2 Oil, B100 Bio-Diesel, Digester Gases or Any Other Substance Besides Natural Gas or Propane

Inspect the duplex stainless steel flue passages every 4,000 hours of operation (not including hours operating on Natural Gas or Propane). This is the bottom section of the heat exchanger and will not require removal of the burner or fuel train.

� Procedure for Accessing the Duplex Stainless Steel Flue Passages (all models)

1. Lock out the power supply to the boiler and isolate the fuels supplied to the unit.

2. Remove the front lower jacket panel from the boiler.

3. Remove the flue passage cover and turbulators.

4. If deemed necessary, clean the flue passages with the proper equipment, such as round wire brushes and a wet/dry shop vacuum or soot vacuum system.

5. Insert the turbulators back into position.

6. The flue passage cover gasket must be replaced. Do not reuse the gasket.

7. Reinstall the flue passage cover. Confirm torque to 23 ft/ lbs (31.2 NM) on all bolts. Do not replace any bolts, nuts, washers or other components without consulting the factory.

8. Restore power to the unit and restore fuel to the unit.

9. Fire the boiler and set combustion to proper levels.

10. To confirm proper seal on the door after this procedure has been conducted, ensure there are no flue gases present around the boiler once unit is running.

11. If evidence of extensive soot, scaling or corrosion is present in the duplex stainless steel flue passages, this may indicate that removal of the burner and cleaning of the furnace and upper flue passages is required.

Please contact Fulton’s service department for more information and instructions, as requirements vary by model and burner selection.

Ignition Pilot Adjustment - Dual Fuel Burners

� For Units With Riello RLS-100-130E Burner Ensure pilot and electrode are positioned and adjusted as shown in Figures 26 and 27.

� For Units With Riello RLS-160E Burner Ensure pilot and electrode are positioned and adjusted as show in Figures 28, 29, and 30.

After All Repairs and Maintenance

1. Follow “Pre-Start Check List” provided with the unit, and all Safety Checks.

2. Fire the Boiler and perform combustion check.

3. Make any necessary adjustments.

Troubleshooting Use the tables on the following pages as a guide to troubleshooting your boiler.

Specification Section 235233-Page 122 of 132

© The Fulton Companies 2016

4-8

1 3/8”

Electrode

Ignition Pilot

FIGURE 30 - RLS-160 BURNER ELECTRODE POSITION FOR OIL

OPERATION

FIGURE 26 - RLS-100-130E BURNER ELECTRODE POSITION FOR OIL OPERATION

FIGURE 27- RLS-100-130E BURNER ELECTRODE POSITION FOR GAS

OPERATION

FIGURE 28 - RLS-160 BURNER ELECTRODE AND IGNITION PILOT

LOCATIONS

FIGURE 29 - RLS-160 BURNER ELECTRODE POSITION FOR GAS

OPERATION

1 3/8”

Model Nozzle A Nozzle B

VTG-

2000DF

5 GPH

60° B

5 GPH

45° B

VTG-

3000DF

7.5 GPH

45° W

7.5 GPH

45° W

VTG-

4000DF

11 GPH

60° B

11 GPH

60° B

A B

Specification Section 235233-Page 123 of 132

4-9

TROUBLESHOOTING

PROBLEM CAUSE CHECK

Control does not illuminate Power supply Check fuse or circuit breaker. Reset or replace as necessary.

Fan will not start High temperature is tripped 1. Reset switch

2. Replace switch

Low gas is tripped 1. Reset switch

2. Replace switch

High gas is tripped 1. Reset switch

2. Replace switch

UT32A incorrectly set/no heat Adjust UT32A

Flame detector has detected light/scanner 1. Identify light source, remove

2. Replace flame detector

Air switch is made when fan is not on 1. Reset switch

2. Replace switch

Blower contactor made when fan not on Replace motor contactor

Gas valve proof of closure defective Replace valve

Loose wire connection Check wiring

Pilot Fails Insufficient gas supply 1. Verify the manuals shut off valves are open allowing gas flow to the pilot tube.

2. Adjust incoming gas pressure to match the start up report.

3. Adjust pilot gas pressure regulator to match the start up report.

Pilot valve fails to open 1. Check pilot gas pressure at the burner.

2. Verify operation of the valve. If pressure does not increase when the valve is supposed to open, replace valve.

Air in pilot gas line Have the boiler attempt to light up to three times. If the boiler fails to light, call Fulton.

Ignitor failure 1. Check the gap between the top of the electrode and the pilot tube wall. The gap should be 1/16” (1.59 mm). Adjust the gap.

1. Check for cracked porcelain. Replace electrode.

Combustion air not sufficient 1. Verify the over burner pressure matches the start up report. Adjust the servo setting.

2. Verify there is enough make up air in the room.

3. (For direct vent only) Verify venting is not obstructed.

Flame Detector Defective 1. Visually verify the flame through the site glass.

2. Remove flame detector and visually verify flame through the scanner tube.

3. Verify the flame detector eye is not dirty.

4. Replace flame detector.

Specification Section 235233-Page 124 of 132

© The Fulton Companies 2016

4-10

PROBLEM CAUSE CHECK

Main flame fails Gas actuator not set properly 1. Verify the last elbow gas pressure matches the start up report.

2. Adjust actuator setting.

Air actuator not set properly 1. Verify the over burner pressure matches the start up report.

2. Adjust actuator motor.

Flame detector failure 1. Visually verify the flame through the sight glass.

2. Remove flame detector and visually verify the flame through the scanner tube.

3. Verify the flame detector eye is not dirty.

4. Replace scanner.

Insufficient Gas Supply 1. Verify the manual shut down valves are open, allowing gas flow through the gas train.

2. Adjust incoming gas pressure to match the start up report.

Air supply blocked (direct vent only) Verify venting is not obstructed.

Boiler fails while modulating

Gas actuator not set properly 1. Verify the last elbow matches the start up report.

2. Adjust actuator setting.

Air actuator not set properly 1. Verify the over burner pressure matches the start up report.

2. Adjust actuator setting.

Air supply blocked (direct vent only) Verify venting is not obstructed.

Poor combustion Gas actuator not set properly Adjust actuator setting.

Air actuator not set properly Adjust actuator setting.

Manual Reset limit device trips

Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit

DO NOT reset without determining and correcting the cause.

Power outage to the boiler room

Entire boiler system is disabled and de-energized. When power has returned, the boiler will have to be manually reset, as it will be in the lockout position

Gas Pressure alarm is annunciated

Insufficient gas pressure for safe and proper operation of the boiler. This shuts down the burner.

When gas pressure is restored, the annunciated alarm will remain on and the boiler will remain locked out until the gas pressure switch is manually reset.

Locate cause and correct. Qualified service personnel must correct the problem before restarting the boiler.

High water temp alarm is annunciated

Boiler water has exceeded both the operating and high-limit temperature. When the water temperature falls below the high-limit temperature, the boiler will remain locked out until the controller is manually reset.

Locate cause and correct. Once the control is reset, the sequence returns to normal operation provided that the other limits are satisfied.

Specification Section 235233-Page 125 of 132

4-11

PROBLEM CAUSE CHECK

Low Air Flow Supply indi-cated on low air switch

Low Air is annunciated if the airflow switch detects low airflow through the boiler.

The air switch has been factory set and should not be adjusted in the field.

An extended low air indication does not mean that the low air switch is defective.

Check that blower is power and feedback plugs are clipped into the blower.

Check that the burner is clean by observing through the venturi. Check the blower purge speed and low fire speed is correctly displayed on the touch screen.

Check for obstructions in the vent.

Check for obstructions in the air inlet.

Main flame failure during firing period

Main gas control valve is de-energized and the con-trol goes into “lockout” mode. Flame failure occurs and the indicator is illuminated.

The programmer must be manually reset.

Ignition Failure If UV scanner/flame rod does not detect the flame during the 4-second trial-for-ignition period, the gas valve and spark ignition are de-energized. At this time a safety lockout occurs.

Identify and correct.

Specification Section 235233-Page 126 of 132