Fulton Companies Gas Fired Steam Boiler VMP-60

Ceramic fiber burner tile removed

Burner tile bottom holding clips need replacement?

Scroll assembly carefully replaced without damaging the ceramic fiber burner tile

Sign off on the burner tile replacement

1. Have combustion (CO2, O2, CO) and input checked by responsible personnel

2. Dirty flues can cause air flow restrictions resulting in poor combustion and loss of efficiency. Clean flues as follows

a. Remove the outer flue cover plate

b. Remove inner plate and turbultors

c. Remove clean out plugs at lowest part of unit and clean the bottom of combustion chamber

d. Remove all soot from the top, and from the clean out plugs at the bottom with a vacuum cleaner

e. Replace clean out plugs carefully so as not to damage insulation and replace burner and flue cover plates

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;

NOTE: If it is determined that a servo motor needs to be replaced, the first step in this process is to verify the model number of the new servo motor is the same as the old servo motor

NOTE: The model number starts with the letters SQM and is displayed on a label on the side of the motor. Once the new motor has been verified to be correct, turn power to the boiler off

Turn off all electricity to the boiler

Remove the cover on the servo motor to be changed

Remove the green wiring plugs and the conduit termination point from the motor by pulling them towards you. A black grounding wire runs from the motor to the conduit termination point. Pull it off from the conduit termination point

Also note the location of the jumper on the left side of the motor

Loosen the allen screws on the motor end of the motor to valve coupling

Unbolt the motor from the mounting bracket and remove the motor

Turn the valve so it is in the closed position and can rotate clockwise to open

1. Cleaning the gas burner assembly

a. Disconnect the gas head from the burner by disconnecting the union. Remove the burner plate screws. Withdraw the burner assembly and clean the flame rod and ignition electrode

b. Check that the settings of the flame rod, if applicable, and ignition electrode correspond to those in the illustration below

c. Reassemble the burner assembly and check the flame rod setting or scanner setting

d. Check the combustion efficiency of the burner and adjust if necessary

e. Clean probe on top of boiler shell and probes in water column. There must be no pressure on the boiler during the removal of the probes

f. Check refractories for soot or breakage and inspect the stainless steel ring (50-100 HP only)

g. With the boiler under no more than 15 PSI pressure, check that the steam safety valve is operating by lifting the lever

2. Drain condensate tank and clean tank by flushing with hose. Check float valve operation

Remove the burner plate and top plate assembly up and out of the air to air heat exchanger

Remove the stainless steel combustion ring from the furnace

Remove the clean-out plugs from the bottom sides of the boiler

Break off the top holding clips that were used to keep the refractory in position during shipping

Break up the top and/or bottom refractories and remove the pieces from the boiler through the clean-out plugs

Round and bevel the outer edges of the new refractories

Lower the bottom refractory down the furnace with wire fastened around the refractory in three positions

Install the top refractory in the same manner as the bottom refractory

Seal the outer edges of the top refractory with insulcrete