FULTON Reliance 500, Reliance 1000, Reliance 1500, Reliance 2000, Reliance 750 Installation And Operation Manual

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INSTALLATION AND

OPERATION MANUAL

Reliance (RLN)

High E ciency Hydronic Boilers

500,000 - 3,000,000 BTU/HR

Serial/ National Board Number

Model

Fulton Order

Sold To

Job Name

Date

RLN-IOM-2012-1205

RLN-IOM-2012-1205 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................1-2

Disclaimers and Local Codes ................................................................................1-2

Installation 2-1

Product Overview ................................................................................................. 2-2

Placement & Rigging ........................................................................................... 2-3

Clearances and Serviceability ..............................................................................2-3

Install Boiler Trim .................................................................................................2-5

Install Water Piping .............................................................................................. 2-6

LOW WATER CUT OFF .................................................................................................................210

Meet Water Chemistry Requirements ................................................................2-10

PREVENT FREEZING ...................................................................................................................211

PREVENT OXYGEN CONTAMINATION ........................................................................................211

ELIMINATE SYSTEM AIR ............................................................................................................212

Fill the Boiler With Water ...................................................................................2-12

Install Gas Piping ................................................................................................2-12

Install Condensate Drain (Optional) ................................................................... 2-13

Venting ............................................................................................................... 2-15

COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................216

COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........216

Exhaust Venting .................................................................................................2-17

STANDARD VENTING CONFIGURATION, CATEGORY IV .............................................................217

OPTIONAL VENTING CONFIGURATION, CATEGORY I ................................................................217

FOR BOTH VENTING CONFIGURATION OPTIONS ......................................................................218

COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS .................................218

Venting Terminations ......................................................................................... 2-19

WALL THIMBLE INSTALLATION .................................................................................................220

HORIZONTAL VENT TERMINATION ............................................................................................220

Electrical Connections ....................................................................................... 2-21

AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................222

INTAKE DUCT SIZING ................................................................................................................222

Operation 3-1

Test of High Back Pressure Switch ........................................................................3-5

Normal Operation of the Boiler ............................................................................ 3-5

CHANGING THE OPERATING SET POINT .....................................................................................36

SETTING COMBUSTION ................................................................................................................36

Shut Down Procedures .........................................................................................3-7

NORMAL SHUT OFF PROCEDURES .............................................................................................37

EMERGENCY SHUT OFF PROCEDURES .......................................................................................37

SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................37

STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................37

SOLA Control Features .......................................................................................... 3-7

FLAME DETECTION ......................................................................................................................37

CYCLE AND RUN HOURS MONITORING .......................................................................................38

SETPOINT CONFIGURATION.........................................................................................................38

SETTING THE CENTRAL HEAT SETPOINT .....................................................................................38

REVIEWING STATUS DETAIL ........................................................................................................38

LEAD/LAG OUTDOOR RESET FOR SINGLE BOILER APPLIC ATIONS ...........................................310

Maintenance 4-1

General ................................................................................................................. 4-2

Daily Maintenance and Inspection Schedule ......................................................4-2

Weekly Maintenance and Inspection Schedule .................................................. 4-2

Monthly Maintenance and Inspection Schedule .................................................4-2

Procedure for Cleaning the Air Inlet Filter ..........................................................4-3

Relief Valve Testing ............................................................................................... 4-3

Annual Maintenance and Inspection Schedule ................................................... 4-3

EXAMINE THE VENTING SYSTEM ................................................................................................44

INSPECT HEATING SYSTEM FOR OTHER PROBLEMS ..................................................................45

Procedure for Removing/Cleaning The Burner .................................................... 4-5

After All Repairs and Maintenance ...................................................................... 4-6

Troubleshooting ...................................................................................................4-6

Warranty & Parts 5-1

Standard Warranty for Fulton Reliance Boilers .................................................... 5-2

Parts ..................................................................................................................... 5-3

PARTS LISTING .............................................................................................................................54

Perform Pre-Start-Up Inspection .........................................................................3-2

Fill and Purge the System..................................................................................... 3-2

SOLA Control Program Presets .............................................................................3-3

Commission The Boiler ......................................................................................... 3-3

TEST OF IGNITION SAFETY SYSTEM ............................................................................................34

Perform Test of Low Water Cut O ....................................................................... 3-4

Perform Test of Limit Controls ............................................................................. 3-4

Perform Test of Low Gas Pressure Switch ............................................................ 3-5

Perform Test of High Gas Pressure Switch ............................................................ 3-5

Perform Test of Air Switch .................................................................................... 3-5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

0-1

TABLE OF CONTENTS RLN-IOM-2012-1205

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

1-1

INTRODUCTION RLN-IOM-2012-1205 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

§ Material inspections

§ Manufacturing process inspections

§ American Society of Mechanical Engineers (ASME)

welding inspection

§ ASME hydrostatic test inspection

§ Electrical components inspection

§ Operating test

§ Final engineering inspection

§ Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

§ 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 e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z223.1/NFPA 54 latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure and operating temperature of 160 psig and 210 F (121 C) respectively.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-1

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant 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 o ered by the CDC and OSHA for more information, including personal protective equipment recommendations.

Product Overview

Prior to the performance of installation, operation, or maintenance procedures, personnel should become familiar with the equipment (Table 1 and Figure 1) and its components.

The Fulton Reliance hot water boiler is an automatic, fuel- red, high-e ciency boiler. The boiler can either be of the sealed combustion/direct vent type or utilize conventional combustion air intake and  ue methods.

The boiler is capable of sidewall venting when the appropriate venting materials are used, and when permitted by local code requirements. It features low emission pre-mix combustion with pulse width modulation and fully automatic safety controls.

The Fulton Reliance boiler is constructed to ASME Section IV and certi ed to Underwriters Laboratories (UL) 795 Issue 2006/10/27 Edition 6 Standard for Safety Commercial-Industrial Gas Heating Equipment. All Reliance boilers are hydrostatically tested, test  red and shipped as a complete packaged unit.

This boiler is to be installed as part of a hydronic heating system. A quali ed engineer must be consulted for the selection of the equipment and components of the heating system. Various system conditions can result in incorrect heat distribution to users of the heating system.

Each Reliance Boiler is supplied with the following:

4 CAUTION

This boiler is certi ed for indoor installation only.

This boiler is not designed for use in systems where water is continuously replenished. The warranty is valid for closed loop systems only.

Fulton cannot be held responsible for the selection, engineering, installation, or sizing of any additional equipment or components of the hydronic heating system.

A quali ed engineer must be consulted for equipment selection and heating system components.

§ Outer cabinet utilizing an air gap as insulation

§ Integrated combustion supervision and temperature operating control

§ Operating and high temperature dual temperature probe

§ Low water  ow switch

§ Fully matched modulating premix combustion system including burner,

blower and fuel train controls.

§ ASME pressure relief valve

§ Instruction manual

§ Wiring diagram

§ Combustion Air Adapter

§ Temperature and pressure (T&P) gauge

The customer should examine the equipment for any damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are  tted in a correct and safe manner.

2-2

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Placement & Rigging

Proper placement of your Fulton product is essential. Attention paid to the following points will save a great deal of di culty in the future. Correct placement is the  rst step to trouble-free installation, operation, and maintenance.

Adhere to the following for placement and rigging:

1. Check building speci cations for permissible  oor loading. Use Table 1 for unit reference.

2. Conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction and/or the U.S. to the National Fuel Gas Code, latest edition. Authorities having jurisdiction should be consulted before installations are made. Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

3. Since an external electrical source is utilized, the boiler, when installed, must be electrically ground in accordance with the National Electric Code, American National Standards Institute (ANSI) National Fire Protection Association (NFPA) 70, latest edition.

4. This boiler is certi ed for indoor installation only. National Electrical Manufacturers Association (NEMA) 3R Con guration is available as an option from the factory, but an existing boiler cannot be retro tted for outdoor installation.

5. Install so that all system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service.

6. Install on a level, non-combustible surface in the vertical position. Concrete is strongly recommended.

7. Provide combustion and ventilation air in accordance with applicable provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section

5.3, Air for Combustion and Ventilation.

! WARNING

Competent personnel in accordance with all applicable local codes should carry out the installation of the Fulton equipment. All state and jurisdictional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classi cation, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.

The equipment must be installed on a non-combustible surface.

Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

8. Locate the boiler so that the air supply and exhaust piping between the boiler and outside wall/roof are within the maximum lengths for horizontal or vertical venting if sealed combustion will be used. See Clearances and Serviceability section of this manual.

Clearances and Serviceability

Adhere to the following for clearances and serviceability:

1. All local and national codes (NFPA, ANSI, UL, CSA, ASME) must be followed for proper clearances and serviceability for your boiler or heater. Authorities having jurisdiction should be consulted before installations are made.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4 CAUTION

Do not allow weight to bear on equipment components to prevent damage.

Boiler must be installed in such a way as to protect from water (including dripping,

misting, etc.) during boiler operation.

2-3

INSTALLATION RLN-IOM-2012-1205 SECTION 2

TABLE 1A  OPERATING REQUIREMENTS

Reliance Model Size

Fuel Type Natural Gas or Propane*

Input BTU/Hr Max Min

Electrical Requirements (Amps) (120V/60/1) (240V/60/3)

Water Content Gal Liter

Dry Weight LB KG

500 750 1000 1500 2000 2500 3000

500,000 750,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000

100,000 150,000 200,000 300,000 400,000 500,000 600,000

2.7 3 3 7.3 7.3 11 11

10.2 11.4 11.4 27.6 27.6 41.6 41.6

675 700 700 1000 1000 1400 1400

306 318 318 454 454 635 635

<10

Operating Weight LB KG

Anchor Bolt Size IN MM

Dimensions • Reliance Hydronic Boiler

TABLE 1B  BOILER DIMENSIONS REFER TO FIGURE 1

700 725 725 1060 1060 1492 1492

317.5 329 329 481 481 676.75 676.75

.75 .75 .75 .75 .75 .75 .75

19 19 19 19 19 19 19

Reliance Model Size 500 750 & 1000 1500 & 2000 2500 & 3000

A. Boiler Width IN

B. Boiler Height IN

C. Boiler Depth IN

D. Boiler Depth with Trim IN

E. Air Inlet Diameter IN

F. Flue Outlet Diameter IN

G. Water Inlet/Outlet Size IN

H. Min Clearance to Walls IN

I. Min Clearance to Front and Rear IN

MM 914.4 914.4 914.4 914.4

J. Min Clearance to Ceiling

Notes:

Speci cations and dimensions are approximate. We reserve the right to change speci cations and dimensions without notice.

*The use of propane is allowable with concentration of up to 5% propylene, commonly referred to as HD5. The use of o -standard grades of propane,

such as propane HD10 (10% propylene) is not permitted unless a system is in place to reduce propylene concentration to less than 5% prior to

reaching any fuel delivery piping. This is the responsibility of the customer. Verify propylene concentration with supplier prior to commissioning and

operation of equipment.

IN 24 24 24 24

MM 609.6 609.6 609.6 609.6

24 24 32.125 34

610 609.6 815.9 863.6

45 50.7 67.9 72

1143 1287.8 1724.6 1828.8

29.3 29.3 34.3 42.2

744.2 744.2 871.2 1071.8

43.9 43.9 49.3 55.9

1115 1115 1115 1419.8

4 6 8 10

101.6 152.4 203.2 254

4 6 8 10

101.6 152.4 203.2 254

2 2 2.5 3

50.8 50.8 63.5 76.2

1 1 1 1

25.4 25.4 25.4 25.4

36 36 36 36

2-4

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Front View

Right Side View

2. Appropriate front, back, side and top clearances must be maintained (Figure 1). This will allow access around the equipment to facilitate maintenance and a safe work environment. An 1 inch (25.4 mm) side clearance is acceptable between boilers.

3. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

Install Boiler Trim

Each Reliance boiler is supplied with a safety relief valve sized in accordance with ASME requirements. Adhere to the following installation requirements:

1. The safety relief valve (Figure 2) must:

» Be connected to the coupling located in the

top rear outlet section of the boiler.

» Be installed in the vertical position.

» Be installed with a 4 inch (101.6 mm) nipple

between the boiler and the safety valve.

NOTE: ´ Safety relief valve size is determined by trim pressure

and is supplied in the trim kit along with appropriate bushing, inlet and outlet sizes.

The discharge pipe must:

» Not have a diameter less than the full area of the

valve outlet.

» Be as short and straight as possible and so

arranged as to avoid undue stress on the valve.

» Be supported by means other than the safety

valve itself.

» Be piped to avoid danger of scalding personnel.

NOTE: ´ Each boiler is equipped with a pressure-temperature

gauge to be installed in the outlet piping section of the boiler.

FIGURE 1 RELIANCE HYDRONIC BOILER CLEARANCES REFER TO TABLE 1B

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-5

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Ensure tank return line is not clogged. Obstructions in the line could cause damage to the pump seal.

The discharge from the safety relief valve must be arranged to ensure no danger of scalding personnel, or equipment damage.

Provisions must be made to properly pipe the safety relief discharge away from the boiler to the point of discharge.

No shuto of any kind shall be placed between the safety relief valve and the boiler, or in the discharge pipe between the valve and the atmosphere. Doing so may cause an explosion from overpressure.

The hydronic system should never be  ushed while the boiler is attached to the system since the debris could accumulate in the boiler and block water from passing through the heat exchanger.

Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Install Water Piping

All water supplies contain some solids, dissolved gases or dissolved minerals. These may promote corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly.

Adhere to the following for water piping installation (See Figure 3-5):

1. Boiler requires a minimum temperature di erential across the heat

exchanger at high  re, and has a minimum  ow requirement. Use Table 2 to identify ideal  ow rates for the Reliance boiler.

TABLE 2  IDEAL FLOW RATES/GALLONS PER MINUTE*

RLN Model

Min. GPM

Max. GPM

*The boiler warranty does not cover heat exchanger failure related to water  ow rates outside

of these parameters. The minimum return water temperature must be greater than 140 F

(60 C) at all times to avoid condensation in the heat exchanger. Warranty does not cover heat

exchanger failure due to condensation of products of combustion.

2. Ensure piping arrangements allow for heat-up times at or below

500 750 1000 1500 2000 2500 3000

23 45 45 75 90 130 140

43 63 83 130 150 200 210

30 seconds; this will reduce condensation which may contribute to equipment failure.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

4 CAUTION

Low  ow conditions will cause excessive cycling, damage and failure of equipment.

Ensure water piping arrangements allow for heat-up times at or below 30 seconds; this will reduce condensation which may contribute to equipment failure.

2-6

3. Pipe unions and isolation valves are recommended on both water connections for ease of service.

4. Install piping so that the boiler is not supporting any additional piping.

5. The top water connection on the back of the boiler is the hot water outlet and must be connected as the supply to the system. The bottom connection is the return/boiler inlet. See Figure 6.

6. Install a hot water circulator, remote mounted from boiler. Do not attach directly to the boiler. Refer to Figures 3 - 5 for proper location of circulators.

7. Install manual purging valves in all loops and zones. Install a pressure reducing (automatic  ll) valve in the cold water  ll line to the boiler system. Check that the proposed operation of zone valves, zone circulator(s) and diverting valves will not isolate air separator(s) and/ or expansion tank(s) from the boiler. Clearance from hot water pipes to combustibles must be at least 6 inch (152.4 mm).

8. The boiler, when used in conjunction with a refrigeration system, must

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Dedicated

Pump

Safety

Relief Valve

Heating

Loop

Return

12"

Strainer

Cold Water

Supply

Air

Separator

PRV

Expansion

Tank

Hot Water

Heating

Loop Supply

System

Pump

Air

Sep.

be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. If the boilers are connected to heating coils, located in air handling units where they may be exposed to refrigerated air circulation, such boiler piping systems shall be

equipped with  ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

9. The boiler is not provided with a drain valve directly on the boiler. A drain valve should be installed near the system return (water inlet) connection to the boiler and piped to a drain.

10. Before installing a Reliance boiler into a hydronic loop, be sure that the system piping and any other components of the system are clean and free of debris and any foreign matter. The hydronic system should be completely  ushed prior to installing the boiler itself.

FIGURE 2  SAFETY VALVE

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

FIGURE 3  SAMPLE PIPING LAYOUT: SINGLE BOILER WITH RETURN WATER TEMPERATURE >140 F 60 C

2-7

INSTALLATION RLN-IOM-2012-1205 SECTION 2

Dedicated

Pump

Safety

Relief

Valve

Heating

Loop

Return

12"

3-Way

Mixing

Valve

Strainer

Cold Water

Supply

Air

Separator

PRV

Expansion

Tank

Hot Water

Heating

Loop Supply

System

Pump

Air

Sep.

FIGURE 4  SAMPLE PIPING LAYOUT: SINGLE BOILER APPLICATION, WITH MIXING VALVE

2-8

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Dedicated

Pump

Safety

Relief

Valve

Safety

Relief

Valve

Dedicated

Pump

Safety

Relief

Valve

Dedicated

Pump

Cold Water

Supply

Air

Separator

PRV

Expansion

Tank

Hot Water

Heating

Loop Supply

Heating

Loop

Return

System

Pump

Strainer

FIGURE 5  SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, RETURN TEMPERATURE >140 F 60 C

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-9

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

The boiler must be disconnected at

the boiler shut o valve from the gas supply piping system during any pressure testing of the system.

4 CAUTION

Small levels of chlorides and/or sulfur presence in the combustion air or fuel will negatively impact the heat exchanger components. Any presence of these contaminants will void the warranty.

Install a strainer upstream of each boiler to ensure that no foreign matter will have the opportunity to get inside the heat exchanger.

¡ Low Water Cut Oﬀ

The Reliance boiler comes with an installed  ow-switch type low water cut-o (LWCO). The LWCO does not require  eld piping or wiring. If the  ow switch does not sense  ow, the boiler will shut down and an alarm condition will be annunciated on the SOLA color screen display.

Customer Electrical Connection

Rubber Air Inlet Coupling

Air Inlet

Water Outlet Connection (system supply)

Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly with clean water after leak check has been completed.

Exhaust Outlet Connection

Water Inlet Connection (system supply)

FIGURE 6  WATER INLET AND OUTLET CONNECTIONS

Meet Water Chemistry Requirements

System water chemistry requirements are as follows:

§ Maximum hardness of 8.5 grains (150 ppm)

2-10

§ Acceptable pH range of 7.5-10

§ Solids less than 2500 ppm

§ Alkalinity less than 500 ppm

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

§ Foreign matter: Oils, fats, grease, and other matter should be limited to 10

ppm.

Adhere to the following:

1. Refer to your water conditioning or chemical treatment supplier for analysis and recommendations for proper system conditions.

2. Follow a program with appropriate monitoring and maintenance of system water conditions as provided by your water conditioning or chemical treatment supplier.

3. Appropriate  ow rates and return water temperature may be achieved

through primary and secondary  ow loops. Please refer back to Figures 3 - 5 for example systems. Multiple pumps, valves and heating zones operating at a variety of conditions will cause system  ow to vary. System design professionals should consider the variety of conditions the heating system will experience.

4. Operate the boiler in a closed-loop system using water or water/glycol (not requiring a make-up water supply). A large amount of improperly treated make-up water can cause premature failure of the heat exchanger

resulting from scale build up. Scale build up will reduce the e ciency and useful life of the boiler.

! WARNING

If the water supply must be temporarily disconnected, the boilers must be turned o to prevent accidental  ue gas emission into the boiler room.

4 CAUTION

Care needs to be taken to eliminate oxygen from the water system, as excess oxygen in the system will reduce the life of any boiler. The boiler warranty does not cover heat exchanger replacement due to oxygen contamination of boiler water.

Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not covered under the warranty.

¡ Prevent Freezing

It is imperative to prevent freezing; adhere to the following:

§ If water/glycol is to be used in the system, a hazard analysis should be

performed to determine proper use and disposal. No greater than 40% glycol should be used.

§ Precautions for freeze protection are recommended for boiler installations

where freezing potential exists and for installations that will use sealed combustion with potential for outdoor air to fall below freezing point.

¡ Prevent Oxygen Contamination

There are several ways to prevent boiler water oxygen contamination:

§ Minimize system leaks to minimize make up water requirement

§ Do not use open tanks or  ttings

§ Do not use oxygen permeable materials anywhere in the water system

§ Repair leaks in the system quickly

§ Eliminate  ttings wherever possible

If the piping system attached to this unit will be chemically cleaned, the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler.

The hydronic system should never be

 ushed while the boiler is attached to the system since the debris could accumulate in the boiler and block water from passing through the heat exchanger. This will lead to premature boiler failure.

§ Use air elimination devices in system piping

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-11

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Do not use matches, candles,  ame or other sources of ignition to check for gas leaks.

DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact your Fulton representative prior to operation.

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

¡ Eliminate System Air

NOTE: ´ There are no built-in boiler air eliminating features.

Adhere to the following for air elimination:

1. The installation of an air separator and air eliminator (air vent) is required.

2. To prevent scale corrosion in boiler and associated piping, make up water must be kept to a minimum. This is best achieved by ensuring immediate repair of all leaks and that system pressure is maintained.

3. If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator.

4. If an air cushion type expansion tank is used, pipe tank directly into boiler supply.

5. On multi-zoned systems (or a system with both space and domestic water heating), air elimination must be provided either in the common piping or on every loop.

6. When the boiler is installed at a higher level than baseboard radiation (if used), air elimination must be provided directly above the unit.

Fill the Boiler With Water

To be sure that the boiler is not air-bound, open the pressure-relief valve located

at the rear of the boiler. Leave the relief valve open until a steady  ow of water is

observed. Close the valve and  nish  lling the system.

Install Gas Piping

The Reliance boiler is factory test  red and combustion is adjusted per the boiler data plate and test  re sheet.

The gas train (Figure 7) components are UL-795 certi ed to operate at speci c gas pressure requirements. If available gas pressure is greater than 14” W.C., a lock up style gas pressure regulator must be provided to reduce the provided pressure to the acceptable range of 3.5” W.C. to 14” W.C. for natural gas, and 7” W.C to 14” W.C. for propane.

Adhere to the following for gas piping installation:

1. See Table 3 for required natural gas pipe size, based on overall length of pipe from the meter plus equivalent length of all  ttings. Approximate sizing may be based on 1,020 BTU for 1 cubic foot of natural gas.

2-12

2. Piping must be installed such that no piping stresses are transmitted to the boiler. The boiler cannot be used as a pipe anchor.

3. The boiler and all gas piping connections must be pressure-tested and checked for leaks before being placed into service. Test with compressed air or inert gas if possible.

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Ball Valve

Gas Valve

Gas Inlet

installed upstream of the gas safety shut o valves.

8. Connect gas supply line to the open end of the tee on which the drip leg is installed.

9. When making gas-piping joints, use a sealing compound resistant to lique ed petroleum gases. Do

not use Te on tape on gas line threads.

10. After gas piping is completed and before wiring installation is started, carefully check all piping connections, (factory and  eld), for gas leaks. Use a soap and water solution.

Install Condensate Drain (Optional)

A condensate drain kit (Figure 8) is intended for use with the Fulton Reliance boiler.

FIGURE 7  TYPICAL GAS TRAIN

The Condensate Drain is Fulton Model Part Number 4-57-

000440. Its recommended Operating Temp. is 175 F max;

4. The boiler must be disconnected at the boiler manual

shuto valve (located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of

capacity is 4 QT; Inlet Size is 1inch; Outlet Size is 1 ½ inch; Water Supply is 100 psi max.; and Max. Btu’s input per drain kit is 12 MMBtu.

PH neutralization kits are available from the factory, if desired.

1/2 psig (14 inch W.C.).

Adhere to the following for installation:

5. Gas piping must be installed in accordance with National Fuel Gas Code, ANSI Z223.1 1991 or latest addenda and any other local codes, which may apply.

1. The 3/4” condensate drain on the Reliance unit must be connected to the drain of the “Boot Tee” that must be installed on the exhaust outlet of the boiler and

6. The pipe and the  ttings used must be new and free of dirt or other deposits.

7. Piping must be of the proper size to ensure adequate gas supply. A drip leg and union connection must be

TABLE 3  NOMINAL PIPE SIZE

Nominal Pipe Size

(“) (“) 90 Elb

1-1/4 1.380 3.45 6.9 950 ----- ----- ----- ----- ----- -----

1-1/2 1.610 4.02 8.04 1460 990 810 ----- ----- ----- -----

2 2.067 5.17 10.3 2750 1900 1520 1300 1150 950 800

2-1/2 2.469 6.16 12.3 4350 3000 2400 2050 1850 1500 1280

3 3.068 7.67 15.3 7700 5300 4300 3700 3250 2650 2280

4 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600

ID Equivalent Pipe

Length

(Feet)

Tee (Feet)

Max Capacity in ft3 of natural gas per hour. Pressure drop of

0.5”wc/Equivalent length of pipe (feet)

20 40 60 80 100 150 200

then tied together to the 1” inlet on the drain kit. One or more drain lines may be connected to this inlet (maximum of 12 MBH total per drain kit) through a common header.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-13

INSTALLATION RLN-IOM-2012-1205 SECTION 2

Detail A

(Condensate Drain Kit)

BACK VIEW

For multiple boiler installation, maintain a

minimum pipe size of 1” for the header piping.

(8boilers maximum per drain kit)

5 1/2”

Minimum

! WARNING

Do not store or use gasoline or other

 ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances. Cements for plastic pipe should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors.

An uninterruptible water supply is required and shall be connected to the ¼” compression  tting on the condensate drain. The water supply maintains a water level in the drain kit to prevent accidental  ue gas emission into the boiler room.

FIGURE 8  OPTIONAL CONDENSATE DRAIN KIT

2. An uninterruptible water supply is required and shall be connected to the

1/4” compression  tting on the drain  oat. The water supply maintains a water level in the drain kit to prevent the  ue gas from entering the boiler room through the condensate connection.

3. The 1 1/2” connection shall be piped to an appropriate drain for disposal. If the water supply must be temporarily disconnected, the boiler(s) must be turned o to prevent accidental  ue gas emission into the boiler room.

4. The cover should be kept on at all times, except during maintenance of the drain. This drain should be monitored and checked regularly in your Reliance maintenance schedule.

5. If the water supply must be temporarily disconnected, the boilers must be turned o to prevent accidental  ue gas emission into the boiler room.

6. The condensate drain cover must be kept on at all times, except during maintenance of the drain. This drain should be checked regularly in your boiler maintenance schedule.

2-14

7. A condensate collecting tank and condensate pump will be required if a  oor drain is not available to collect condensate (collecting tank and pump are not supplied with the boiler).

8. All piping (Figure 9) must be galvanized, or stainless steel and should be free of leaks. Copper, carbon steel/iron pipe, PVC or CPVC are not acceptable.

9. Connect 3/4” condensate drain(s) to the 1” header connected in a manifold as shown in Figure 10. The header must be at least 5 1/2” below the

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

Reliance

Boiler

AL294C Exhaust Pipe

4” Loop

Piped/Pitched to Appropriate Drain

Condensate Connection on Boiler

FIGURE 9  CONDENSATE DRAIN PIPING FOR RELIANCE BOILERS

condensate outlet of the individual boiler and must

remain  ooded by being at least 5 ½” below the outlet of the condensate drain trap.

10. Connect 1 1/2” drain outlet to an appropriate waste line following applicable codes. The 11/2” drain connection on the condensate drain must be the highest point prior to going to the drain. Failure to keep drain piping lower than this point will result in over ow of the condensate drain. Slope the drain pipe away at a minimum pitch of 1 inch (25.4 mm) for every 12 feet (3.65 m).

11. Attach a 1/4” water supply to the compression  tting on the  oat. The water line must be connected to an uninterruptible supply. Fulton recommends connecting it before the “Fast-Fill” valve to the boiler supply but after the back  ow preventer to avoid contamination of a potable water supply. Maximum allowable water pressure to the compression  tting is 100 PSI.

Venting

Adhere to the following venting requirements:

1. The boiler can be installed with either sealed combustion or a conventional venting arrangement. With either venting con guration, the di erence in pressure readings at the boiler exhaust connection and air intake connection cannot exceed +2.0” W.C. This equates to 70 feet (21.3 m) and 8 elbows when combining the distances on the air intake and exhaust with the piping diameters matching the standard connections.

2. The pressure at the boiler exhaust connection must not exceed 0.04” W.C. negative. This pressure must remain relatively constant throughout the operation of the boiler.

3. The boiler should not be operated with a negative pressure in the boiler room (unless there is sealed combustion [intake piped outside]). Pay particular attention to other equipment installed in the boiler

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-15

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Do not use the boiler as support for ducted air piping. Ducted piping must be supported independently of the boiler.

Cements for plastic pipe are

 ammable liquids and should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors. Avoid contact of cement with skin and eyes.

room such as compressors and air handling units.

4. Consult your venting pipe supplier for assistance with sizing of vent materials and other potentially required accessories.

NOTE: ´ The installation of an air intake  lter is recommended for any Reliance

installation where particulate matter >50 microns could enter the boiler. An air intake  lter is available as an option from Fulton if required. The air intake  lter must be inspected and, if required, cleaned and/or replaced on a monthly basis at a minimum.

¡ Combustion Air Supply From the Boiler Room

Adhere to the following for installation:

1. Adequate combustion air and ventilation must be supplied to the boiler room in accordance with local codes and NFPA54/ANSI Z233.1, Section 5.3, Air for combustion and ventilation.

2. The boiler room must meet the NFPA criteria for a non-con ned space.

3. It is important to provide free access of air to the boiler. To burn fuel properly, it requires 0.4 square inch opening of fresh air for every 1,000 BTU input of fuel (2.58 cm2 for every 252Kcal).

4. Consistent proper ventilation of the boiler room is essential for good combustion. Install two fresh air openings, one at a low level, within 12

inches (305 mm) from the  oor but not less than 3 inches (76 mm), and one at a higher level within 12 inches (305 mm) of the ceiling but not less than 3” in the boiler room wall. This will provide a  ow of air to exhaust the hot air from the boiler room. Each opening must have a minimum of 1in2 per 1000 Btu/hr and be no less than 100in2.

5. Consider the blocking e ect of louvers and grills.

6. A combustion air supply damper (which can be shipped mounted to the boiler from the factory) is recommended for sealed combustion installations with high draft  ow. This is typical of installations with a total of 70 ft linear distance or greater of the combined distance of air intake and exhaust piping. In cold ambient conditions, high natural draft through an idle boiler can cause the water inside the heat exchanger to freeze.

¡ Combustion Air Piped From Outside Building Without Sealed

Combustion

Adhere to the following for installation:

1. If the boiler room is deemed a con ned space two permanent ducts

connected to the outdoors must be installed.

2-16

NOTE: ´ Assembly should be completed within 20 seconds after last application of

cement. Do not use a hammer to insert pipe.

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

2. After assembly, wipe excess cement from pipe at end of  tting socket. A properly made joint will show a bead around its entire perimeter. Any

gaps may indicate a defective assembly due to insu cient cement. Handle joints carefully until completely set. Galvanized steel joints should be sealed with adhesive aluminum tape.

Exhaust Venting

The Reliance boiler is equipped with a round vent connection (Figure 6) at the lower rear of the boiler.

¡ Standard Venting Conﬁ guration, Category IV

The Reliance boiler is standardly con gured as a Category IV appliance. The vent connection sizes are adequate for a Category IV arrangement. Venting material must be appropriate for condensing, positive pressure applications (condensing occurs in the stack).

Adhere to the following:

1. Venting material supplied for the Reliance boiler con gured as Category IV must be AL29-4C or 316L SS, listed and labeled to UL 1738, and guaranteed appropriate for the application by the manufacturer and supplier of the venting.

2. Do not utilize automatic vent dampers or barometric dampers with the Reliance boiler. Because the exhaust system operates at a positive pressure, utilizing dampers could result in  ue gases leaking into the boiler room.

3. The exhaust line must be sloped down toward a drain with a pitch of at least ¼” per foot. Failure to do so can result in a condensate pocket, which can result in an inoperative boiler. This must be no low spots in the exhaust pipe, as this can also result in a condensate pocket. A high spot is acceptable, provided the pitch from the high spot is maintained back to the drain.

! WARNING

Do not use the boiler/burner as support for ducted air piping. Ducted piping must be supported independently of the boiler.

Do not terminate venting into an enclosed area.

Never use open  ame or smoke from a cigarette, cigar, or pipe as a testing method during boiler installation, operation, or maintenance.

Foreign substances, such as combustible volatiles in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the boiler combustion air inlet must be piped to an outside location.

Regular maintenance of the

 lter is required (as per the  lter manufacturer’s recommendations) to maintain the warranty.

¡ Optional Venting Conﬁ guration, Category I

The Reliance boiler can be con gured as a Category I appliance. The boiler must be ordered this way from the factory. The operating controls will be con gured to limit the minimum modulation point to 50% of full input, thus preventing condensing from occurring in the stack.

Adhere to the following:

1. Shipped loose with the boiler will be a stack increaser  tting and a barometric draft regulator. These components must be used when venting the Reliance as a Category I appliance. The stack material must be 4” diameter larger than the stack connection on the boiler.

2. Venting material must be appropriate for non-condensing, negative pressure applications and should be B-Vent style material. This must be guaranteed appropriate for the application by the manufacturer and

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

Particulate matter or chemicals in the combustion air supply to the boiler will cause damage or failure to the burner and is not covered under warranty.

2-17

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Use of automatic vent dampers or barometric dampers with the Reliance boiler in positive pressure systems may result in exhaust leaking into the boiler room.

4 CAUTION

Failure to slope the exhaust line toward the drain with a pitch of at least 1/4” per foot may result in a condensate pocket, which can result in an inoperative boiler.

supplier of the venting.

3. Category I Installations, individual piping for each boiler: The pressure drop of the exhaust piping (not including the air intake piping) should be a negative during all possible operating conditions, between -0.02 and

-0.04”wc. Vertical rise in the exhaust pipe is typically required to achieve the desired negative pressure.

¡ For Both Venting Conﬁ guration Options

Adhere to the following:

1. The exhaust vent installer should be familiar with and adhere to the National Fuel Gas Code, ANSI A233.1, Part 10 or any other applicable provisions of local building codes.

2. The exhaust vent installer should follow the vent manufacturer’s instructions for proper installation procedures.

3. A tee/boot tee with a drain must be installed at the  rst elbow from the

boiler  ue outlet. There must be a minimum of 4” of water within a loop style trap (loop diameter 4”). The loop style trap can be high temperature silicone rated for 500 F (see Figure 9) and must be piped/pitched to drain freely.

4. The loop style trap must be  lled with water before connecting it to the

exhaust pipe. It is important that this trap is periodically checked and

veri ed that it remains  ooded during regular operation of the equipment. Failure to do this could result in  ue gases leaking into the boiler room.

5. The condensate connection on the boiler should be piped into the stack drain piping (see Figure 9). The pipe from the boiler directed to the drain should be installed at a slope of ¼” per foot.

6. Ensure that condensate drain piping will not be exposed to temperatures where water condensate will freeze in the lines.

¡ Common Air Intake and Exhaust Venting of Multiple Boilers

Combining multiple Reliance boilers into a common pipe for combustion air supply, exhaust, or both is only permitted on a case by case basis and must be accomplished with an engineered solution.

Adhere to the following:

1. The engineered solution must guarantee the prevention of  ue gases moving backwards through idle boilers. This is important to prevent  ue gases from entering the mechanical room (if sealed combustion is not being used) and also to prevent  ue gases from corroding the heat exchanger and/or other components in the upper cabinet of the boiler.

2-18

2. Reliance boilers should not be common vented with other types of equipment.

3. Fulton requires the use of a combustion air supply damper (which can be provided shipped mounted on the boiler by Fulton and incorporated into

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

control logic) for any common air intake/exhaust applications.

4. The pressure drop across an exhaust pipe shared by multiple boilers must have a negative pressure at all operating conditions up to -0.05” wc. A mechanical draft assist system, such as a variable speed fan, may be required to accomplish this.

5. Combustion air dampers and/or a variable speed exhaust fan may be required. Please contact your venting manufacturer for proper vent size and arrangement.

Venting Terminations

Adhere to the following for installation (see Figure 10):

1. All vent pipes and  ttings must be installed with appropriate air space

clearances to combustibles. These air space clearances apply to indoor or outdoor vents—whether they are open, enclosed, horizontal or vertical or

pass through  oors, walls, roofs, or framed spaces. The air space clearances should be observed to joists, studs, sub oors, plywood, drywall or plaster

enclosures, insulating sheathing, rafters, roo ng, and any other material classed as combustible.

! WARNING

Fulton cannot assume responsibility for an air intake or exhaust arrangement where Reliance boilers are common vented with any other type of equipment.

2. The required minimum air space clearances also apply to electrical wires and any kind of building insulation.

3. Adequate provision must be made to support the weight of the exhaust venting. It cannot be supported by the boiler exhaust connection.

4. Listed termination parts must be used.

5. Select the air intake point of penetration where a minimum of 1/4” per foot upward pitch can be maintained.

6. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain the pitch of the vent and provide sealing. Use adhesive material to seal around the vent on both sides of the wall. When penetrating a combustible wall, a wall thimble must be used. See Figure 11 for installation instructions. Minimum wall thickness through which vent system may be installed is 3.25 inches (82.5 mm). Maximum wall thickness through which vent system may be installed is 20 inches (508 mm).

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-19

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

The exhaust vent installer should be familiar with Federal Codes as well as local codes and regulations.

Fulton cannot assume responsibility for an air intake or exhaust arrangement where Reliance boilers are common vented with any other type of equipment.

4 CAUTION

To prevent the possible re-circulation of  ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building con gurations, etc. It is the responsibility of the installer to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions.

¡ Wall Thimble Installation

FIGURE 10  VENTING TERMINATIONS

Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.

Adhere to the following for installation (see Figure 11):

1. The thimble is inserted through the wall from the outside. Secure the

outside  ange to the wall with nails or screws, and seal with adhesive material.

2. Install the inside  ange to the inside wall, secure with nails or screws, and seal with adhesive material.

3. Pass the vent pipe through the thimble from the outside and join to the rest of the vent system.

4. Seal the pipe to the thimble  ange with adhesive material.

5. Install two pipe retaining clamps around the intake as well as vent pipes on both ends of the wall thimble (on the inside and outside of the wall) through which intake and vent pipes are passed. They will prevent the intake and vent pipes from being pushed or pulled.

¡ Horizontal Vent Termination

Adhere to the following for installation:

1. The vent termination is joined to the vent pipe outside the wall. Use the

same joining procedures for vent pipe and  ttings. The termination of the vent system must be at least 12 inches (304.8 mm) above the  nished grade, or at least 12 inches (304.8 mm) above normal snow accumulation

2-20

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

level (for applicable geographical areas). The termination of the vent system shall not be located in tra c areas such as walk ways, adjacent buildings, operable windows and building openings unless the venting system is at least 7 ft (21.3 m) above  nished grade, (National Fuel Gas Code, ANSI Z223.1). The vent terminations must be at least 4 feet (1.22 m) horizontally from electric meters, gas meters, regulators, and relief equipment. See Figure 12.

2. When installing inlet and exhaust terminations on the same wall, the exhaust outlet must be installed 3 ft (.914 m) minimum above and downwind from air supply inlet to prevent exhaust recirculation. Under

certain wind conditions, some building materials may be a ected by  ue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (such as an aluminum sheet) may be required to prevent staining or deterioration.

3. Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.

! WARNING

Cements for plastic pipe are

4. The minimum vent height should extend at least 3 ft (.914 m) above the roof, or at least 2 ft (.609 m) above the highest part of any structure within 10 ft (3.04 m) of the vent.

5. If the exhaust vent terminates within 10 ft (3.04 m) horizontally of the air inlet, the exhaust vent must be at least 4 ft (1.22 m) above the inlet. Dimensions listed above and those illustrated are minimum, and may or

may not be su cient for conditions at a speci c job site.

6. To prevent the possible re-circulation of  ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones,

building con gurations, etc. Fulton cannot be responsible for the e ects such adverse conditions may have on the operation of the boilers. It is important to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions.

Electrical Connections

Adhere to the following when installing electrical connections:

1. Install wiring and ground boiler in accordance with authority having jurisdiction, or in absence of such requirements utilize National Electrical Code, ANSI/NFPA 70.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the boiler.

2. This boiler requires an independent 120V 60Hz single phase connection. Connect power to the terminal strip as supplied on the inside cover of the panel box.

NOTE: ´ Connect a ground wire to green colored ground lug in electrical control

box.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-21

INSTALLATION RLN-IOM-2012-1205 SECTION 2

! WARNING

Do not use any dangerous source of  re or smoke (e.g., lighter, candle) to test equipment at any time.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the boiler.

4 CAUTION

Never install a barometric damper on  ue systems designed with positive pressure.

¡ Air Piped From Outside Boiler Room

Adhere to the following:

1. The combustion air supply can be piped directly to the air inlet of the boiler.

2. A rubber air intake coupling is recommended with boilers speci ed for

installation with ducted air supply. It must be used to connect the intake piping to the boiler air inlet. This rubber air inlet coupling is available from Fulton as an option. See Figure 6.

3. The air intake must be piped out of the building if the boiler room contains contaminated air.

¡ Intake Duct Sizing

1. Air intake ducting must be sized in conjunction with the exhaust venting to provide no greater than a +2.0” W.C. combined pressure drop. This equates to 70 feet and 8 elbows when combining the distances on the air intake and exhaust with the piping diameters matching the standard connections.

2. The installation of a recognized termination screen is required. Contact your local venting supplier for assistance in venting sizing.

3. Air Intake pipes and  ttings shall be Schedule 40 PVC pipe or galvanized steel. All Schedule 40 PVC pipe,  ttings, primer and cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM standards.)

4. Intake PVC piping must be assembled using cement. This will ensure that the intake is airtight and will not allow contaminates from the boiler room

into the boiler. The cement shall be free  owing and contain no lumps, un-dissolved particles or any foreign matter that adversely a ects the joint strength or chemical resistance of the cement. The cement shall not show

gelation, strati cation, or separation that cannot be removed by stirring.

} CEMENTING JOINTS

The following procedure for cementing joints (per ASTM D2855) should be adhered to:

1. Measure and cut PVC pipe to desired length.

2. Chamfer end of pipe, removing any ridges or rough edges. If end is not chamfered, the edge of the pipe may remove cement from the  tting socket and result in a leaking joint.

3. Clean and dry the surfaces to be joined.

4. Test  t joint and mark depth of  tting on pipe outside.

5. Uniformly apply a liberal coat of primer to inside socket surface of  tting and male end of pipe to depth of  tting socket.

2-22

SECTION 2 RLN-IOM-2012-1205 INSTALLATION

DIAMETER "C"

STAINLESS

3 1/2 IN. OR

4.35 CM

AIR GAP

ALL AROUND

THRU PIPE

VARIABLE

(3 1/4 IN. MIN.) - (20 IN. MAX.)

(8.255 CM MIN. - 50.8 CM MAX.)

DIAMETER "B"

ADJUSTABLE

WALL THUMBLE

WIDTH TO VARY WITH

WALL THICKNESS

DIAMETER "A"

COLLAR

END VIEW

SCREW OR BOLT EACH THUMBLE COLLAR

TO WALL (TYPICAL 4 PLACES) ORIENT

COLLAR AND CLAMPS AS REQUIRED

PIPE RETAINING CLAMP, TYPICAL EACH SIDE

6. Promptly apply solvent cement to end of pipe and

inside socket surface of  tting. Cement should be applied lightly—but uniformly—to inside of socket. Take care to keep excess cement out of socket. Apply second coat to pipe end

NOTE: ´ Time is critical at this stage. Do not allow primer to

dry before applying the cement.

7. Immediately after applying last coat of cement to pipe, while inside socket surface and end of pipe are wet with cement, insert end of pipe into socket, turn pipe 1/4 turn to distribute cement evenly, continue to insert pipe until it bottoms out.

FIGURE 11  WALL THIMBLE INSTALLATION

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-23

INSTALLATION RLN-IOM-2012-1205 SECTION 2

ROOF

SUPPORT

WIRES AND INSULATION

TO COMBUSTABLES,

AIR SPACE CLEARANCES

MAINTAIN MIN 9" / 22.86 CM

NOTE:

AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS.

4FT / 122 CM

FLASHING

ADJUSTABLE

4" PVC PIPE

FLASHING

ADJUSTABLE

ADHESIVE SEAL

STORM COLLAR

EXHAUST STACK IS DOWNWIND

OF AIR INTAKE OPENING

SCREENED INLET

MIN 4FT / 122 CM

ABOVE AIR INTAKE

PIPING

METAL PLATE

FIRE STOP

DO N OT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

TYPICAL ROOF PENETRATIONS

( SUGGESTED TERMINATION CONFIGURATIONS )

IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN. ) ABOVE THIS NORMALLY EXPECTED LEVEL.

FIGURE 12  ROOF PENETRATION DETAILS

2-24

OPERATION

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE WARRANTY & PARTS

4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-1

OPERATION RLN-IOM-2012-1205 SECTION 3

! 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. Failure to follow instructions may result in a  re or explosion, causing property damage, personal injury, or loss of life.

This boiler is equipped with an ignition device, which automatically lights the burner. Do not try to light the burner by hand.

Perform Pre-Start-Up Inspection

Prior to start-up, perform the following:

1. Smell all around the boiler area for gas. Be sure to smell next to the  oor, as

some gas is heavier than air and will settle. 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.

2. Ensure the boiler is located with the proper clearances as shown in the Clearances and Serviceability section of this manual.

3. Ensure that relief valves have been properly piped to  oor drains.

4. Ensure  ue gas from the boiler is properly vented.

5. Ensure the water system has been  ushed and is free of debris.

6. Ensure combustion air openings are not obstructed in any way and have adequate capacity.

7. Ensure there are no  ammable liquids, materials or hazardous fumes present in the environment.

8. Ensure nothing was damaged or knocked loose during installation and/or shipment.

9. Inspect the main gas train and trim assembly to be sure they were not damaged during shipment and/or installation.

Do not store or use gasoline or other  ammable vapors and liquids in the vicinity of this or any other appliances.

Use only your hand to turn the valve handle. Never use tools. If the knob will not turn by hand, don’t try to repair it. Call a quali ed service technician. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

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  re department. -A quali ed installer, service agency or the gas supplier, must perform installation and service.

3-2

Fill and Purge the System

Completely  ll and purge the heating system as follows:

1. Close combination shuto /purge valve in supply, all drain cocks, the

shuto valve for the pressure reducing ( ll) valve, and all manual air vents.

2. Open all other system shuto valves and one of the zone valves, the vent on the combination shuto / purge valve and the shuto valve to the pressure-reducing ( ll) valve.

3. Water will now begin to  ll the system. Air will escape through the vent on the combination shuto / purge valve. Continue  lling until a constant stream of water (no bubbling) is discharged from the vent.

4. Close the zone valve on the purged loop, and open the zone valve on the next loop to be purged. When all air has escaped and only water is discharged, close the zone valve. When all zones have been purged (one at a time), close the vent on the combination shuto /purge valve.

5. At this point, the system has been initially  lled. However, air pockets may still remain at high points in the system and in heating loops above

SECTION 3 RLN-IOM-2012-1205 OPERATION

the level of the combination shut/o purge valve. It is quite possible, depending on the particular system that all piping above the combination shuto /purge valve still contains air. If manual vents are installed on the system high points, these should be opened to vent these locations. When only water is discharged from all vents, the initial purging is complete.

6. Open the combination shuto / purge valve (keep the vent closed). With the gas shuto valve closed, turn on power to the boiler and operate the circulator. Circulate the system water for approximately 30 minutes to move all air to the automatic air separation point.

7. Again, open manual air vents at high points of heating loop until a constant stream of water is discharged from the vent. Close the vent and make sure it’s watertight. Repeat procedure for all high points and for every zone.

8. Check temperature/pressure indicator reading, which should equal the pressure-reducing ( ll) valve set pressure. No more water should be entering the system. Close the shuto valve on the cold-water  ll line.

9. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system, repair leaks and re ll/purge the system. If no pressure drop is detected for a period of two hours under pressure, the system may be considered watertight.

10. When purging is completed, make sure the following are open— combination shut-o /purge valve, shuto valve to pressure reducing ( ll valve), shuto valve in cold water  ll line, and shuto valve in return line.

! WARNING

Do not attempt to start the boiler for any testing before  lling and purging the boiler. A dry  re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty.

Before commissioning the boiler, verify with authorized personnel that the gas lines have been purged.

Never attempt to operate a boiler that has failed to pass all the safety checks.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage could occur.

Check daily that the equipment area is free and clear of any combustible

materials, including  ammable vapors and liquids.

11. Make sure the following are closed - all drain cocks, the vent on the combination shuto -purge valve, & all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler.

12. Open fuel shuto valve, allowing fuel to  ow to boiler.

SOLA Control Program Presets

The SOLA control (Figures 13 - 19) has been factory-programmed and requires no alteration of program presets. Only factory-trained personnel should attempt to alter password protected preset values.

Commission The Boiler

Adhere to the following when commissioning the boiler:

1. Verify with authorized personnel that the gas lines have been purged. Do not proceed without veri cation.

2. Familiarize all personnel on all aspects of boiler use, safety, and contents of this manual. This includes, but is not limited to, the use of the controls, lighting, and shutdown procedures.

4 CAUTION

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately

call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

Commissioning/Start up by a nonFulton authorized person will void the product warranty.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

3. Review the unit-speci c control schematics, and follow appropriate instructions.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-3

OPERATION RLN-IOM-2012-1205 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

After checking controls by manual adjustment, make sure they are always reset to their proper settings.

¡ Test of Ignition Safety System

Test the ignition system safety shuto as follows:

1. Remove the black plug/connector from the main gas valve (it is held on with a central screw).

2. With the main gas cock (inlet manual gas valve) open, the burner should

be cycled on. After all the safety limits such as gas pressure, water  ow and

temperature are satis ed, the blower will run and pre-purge the boiler.

3. Once the purge is complete (15-30 seconds), the ignition transformer will be energized. There will be a 4 second trial for ignition period.

4. The main gas valve will not open because there is no power to the valve

due to the disconnected wires. Hence, no  ame will be established and the  ame safeguard will not receive a  ame signal from the UV scanner.

5. After 4 seconds, the  ame safeguard programmer will assume a “Flame Failure” condition and go to a “lockout” mode. Lockout will require manual reset of the  ame safeguard. The control will allow one retry before locking out.

6. After completing this test, turn o the boiler and reconnect the wires to the main gas valve.

Perform Test of Low Water Cut Oﬀ

This boiler is equipped with a  ow switch type low water cut-o in the outlet nozzle. Once the boiler is full of water the following test can be accomplished:

1. Turn the boiler o .

2. Turn system pump o .

3. Turn the boiler back on. The “Hold 63 LCI O ” will annunciate, after a call for heat from the Temperature Control. The boiler should not start until the pump is started.

4. Perform appropriate test for any external or factory-installed probe-type low water cut-o .

Perform Test of Limit Controls

Fire the boiler and test the high limit control as follows:

1. Access the High Limit screen of the SOLA control.

2. Alter high temperature limit to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the boiler locks out. This condition has to be manually reset. Alter the high limit cut o temperature to normal level, typically 10-20 degrees above set point.

3-4

SECTION 3 RLN-IOM-2012-1205 OPERATION

Perform Test of Low Gas Pressure Switch

Test the low gas pressure switch as follows:

1. With the boiler running increase the low gas pressure setpoint until a lock out is annunciated.

2. Reset the switch to normal level, re-start the boiler.

Perform Test of High Gas Pressure Switch

Test the high gas pressure switch as follows:

1. Close the downstream main gas cock and start the boiler.

2. Once the trial for ignition period is reached, the main gas valve will open, pressurizing the line. This will trip the high gas pressure switch.

3. Manually reset the high gas pressure switch after it trips.

Perform Test of Air Switch

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

When making changes to the controls

pro le, a combustion analyzer is required.

Fire the boiler and test the air switch as follows:

1. At low  re turn the adjustment on the switch clockwise until the switch

trips and the boiler shuts down.

2. Back out the adjustment to previous position.

Test of High Back Pressure Switch

Fire the boiler and test the high back pressure switch as follows:

1. At high  re turn the adjustment on the switch counter clockwise until it opens and the boiler shuts down.

2. Turn the adjustment in two turns.

Normal Operation of the Boiler

Under normal operating circumstances, this boiler functions as a fully automatic appliance. The automatic control senses the water outlet temperature and  res the boiler when heat is needed by the system. Additionally this boiler may function as part of an integrated building management system.

Outlet water temperature, fan speed and set point are displayed on the SOLA touch screen display on the front of the boiler. Figure 13 shows a sample screen display on the SOLA control.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-5

OPERATION RLN-IOM-2012-1205 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

This boiler is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand.

¡ CHANGING THE OPERATING SET POINT

From the main screen do the following:

1. Tap “Con gure”

2. Tap “Central Heat Con guration”

3. Tap “CH Set Point”

4. Tap “Clear”

5. Enter New Set Point

6. Tap “OK”

7. Tap the escape arrow in top right hand corner

¡ SETTING COMBUSTION

To Set Combustion, perform the following:

1. Obtain the following tools: Calibrated combustion analyze, manometer to measure inlet gas pressure

2. From home screen tap “Operation.”

3. Tap the yellow background “rpm” box next to  ring rate.

4. Under “Firing Rate Control” tap “Manual in Run.” Refer to Figure 16.

5. Using test  re sheet enter the light o rpm’s in the “Manual Firing Rate” box.

6. Once the rpm’s are entered tap “OK”, then return to the home screen.

7. Turn the local/o /remote switch to the local position.

8. Once burner has started and you have veri ed  ame signal return to the

“Manual Firing Rate” box.

9. Increase the  ring rate in 500 rpm increments until you reach the high  re rpm’s from the factory test  re sheet.

10. At each point check combustion. CO2/CO should remain constant throughout  ring range.

11. Monitor inlet gas pressure during combustion.

12. Once the high  re rpm setting is reached make  ne tuning adjustments on the gas ratio valve “ ow rate” to match factory test  re settings. The “ ow rate” adjustment requires a 3mm hex wrench.

NOTE: ´ Turning the screw counterclockwise increases gas  ow, clockwise

decreases gas  ow.

3-6

NOTE: ´ Combustion changes are made at high and low  re only, as the gas ratio

valve has a 1:1 ratio.

SECTION 3 RLN-IOM-2012-1205 OPERATION

13. Manually decrease the  ring rate by 500 rpm increments observing combustion down to the low  re rpm setting (minimum) on the factory test  re sheet. If required low  re combustion may be altered by adjusting the o set adjustment screw with either a Torx®T40 or a 5mm hex wrench.

NOTE: ´ Turning the screw counterclockwise decreases gas  ow, clockwise

increases gas  ow.

14. Before leaving the “Firing Rate” screen, tap “Automatic”  ring rate control. Do not leave the unit in the “Manual in Run” mode.

Shut Down Procedures

¡ Normal Shut Oﬀ Procedures

1. Place the local/o /remote switch in the o position.

2. Close all manual gas valves.

3. Turn o electrical power.

! WARNING

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

¡ Emergency Shut Oﬀ Procedures

The main gas cock should be closed immediately. If overheating occurs or the gas supply fails to shut o , do not turn o or disconnect the electrical supply to the pump. Instead, shut o the gas supply at a location external to the boiler.

¡ Shutting the Boiler Down for an Extended Period of Time

If the boiler is to be shut o for a period greater than 3 months:

1. Perform normal shut down procedure

2. Isolate water supply and  ow circuit from boiler

3. Drain boiler

4. Disconnect electrical supply

¡ Starting Boiler After Prolonged Shutdown

Perform initial start up procedures as described in this manual.

SOLA Control Features

¡ Flame Detection

The  ame signal can be viewed from the Main Screen and the Status Detail screen on the Control. See Figure 13.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-7

OPERATION RLN-IOM-2012-1205 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

¡ Cycle and Run Hours Monitoring

Burner cycles, burner run time, and pump cycles can be viewed from the

Statistics Con guration screen on the Control. See Figure 14.

FIGURE 13  MAIN/HOME SCREEN

3-8

FIGURE 14  CYCLE AND RUN HOURS MONITORING

¡ Setpoint Conﬁ guration

Refer to Figure 15 for Setpoint Con guration data.

¡ Setting the Central Heat Setpoint

Refer to Figures 15 -17 for CH Con guration and Operation details.

¡ Reviewing Status Detail

Refer to Figure 18 for  ame signal status detail.

SECTION 3 RLN-IOM-2012-1205 OPERATION

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

FIGURE 15  SETPOINT CONFIGURATION

FIGURE 16 EDITING THE MANUAL FIRING RATE

FIGURE 17  CENTRAL HEAT CONFIGURATION SCREEN

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-9

OPERATION RLN-IOM-2012-1205 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

FIGURE 18  FLAME SIGNAL STATUS DETAIL

¡ Lead/Lag Outdoor Reset for Single Boiler Applications

Refer to Figure 19.

§ Maximum Outdoor Temperature – highest outdoor temperature in the

outdoor reset curve. This outdoor temperature correlates to the Low Water Temperature

§ Minimum Outdoor Temperature – lowest outdoor temperature in the

outdoor reset curve. This correlates to the Central Heat Con guration (Setpoint)

§ Low Water Temperature – lowest water temperature the boiler will try to

maintain in relation to the corresponding Maximum Outdoor Temperature

§ Minimum Boiler Water Temperature – Limits the boiler temperature.

This will “cut the curve o ” and not allow the boiler to go below this temperature.

3-10

FIGURE 19  LEAD/LAG OUTDOOR RESET FOR SINGLE BOILER APPLICATIONS

SECTION 3 RLN-IOM-2012-1205 OPERATION

§ Central Heat Con guration (Setpoint) – (See Figure 20) The highest water

temperature the boiler will try to maintain in relation to the to the Minimum Outdoor Temperature

§ Time of Day Setpoint – Forces the Outdoor Reset line to parallel shift down

to a lower setpoint, also known as a night time setback. A contact closure is required on connector J10 terminals (2&3) to utilize Time of Day setpoint.

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

FIGURE 20  CENTRAL HEAT CONFIGURATION SETPOINT

Example (See Figure 21): If the outdoor temperature is at 20 degrees Fahrenheit the boiler temperature will be 172 degrees Fahrenheit. The boiler will modulate to maintain this temperature and shutdown at 172 plus o Hysteresis, which from the above Central Heat Con guration Screen is 10, so the unit would shut down at 172F +10 (O Hysteresis) = 182 degrees. The boiler will get a call for heat at 172F+/- 10 (On Hysteresis) = 162.

FIGURE 21  EXAMPLE SCREEN

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-11

OPERATION RLN-IOM-2012-1205 SECTION 3

3-12

MAINTENANCE

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE

WARRANTY & PARTS

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-1

MAINTENANCE RLN-IOM-2012-1205 SECTION 4

! WARNING

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  re department.

General

Your Reliance boiler has been designed to provide years of trouble free

performance. To ensure continued safety and e ciency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

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  ow of combustion and ventilating air to the boiler is not obstructed.

3. Assure that boiler area is free and clear of any combustible materials, including  ammable vapors and liquids.

Weekly Maintenance and Inspection Schedule

Weekly maintenance and inspection must include the following:

1. Observe the conditions of the main  ame. A normal high  re  ame shows an orange screen with a blue halo. In Low  re the burner should display a reddish orange glow.

2. Correct air adjustment is essential for the e cient operation of this boiler. If an adjustment to the combustion is necessary, the  ue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions.

After initial start-up by quali ed personnel, 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 Representative.

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

4-2

Monthly Maintenance and Inspection Schedule

Monthly maintenance and inspection must include the following:

1. View  ame detection strength via the SOLA Control. See Operation section of this manual for screen details.

1. Test high-limit control by reducing setting below the operating temperature. Burner should shut o . Return high limit to previous setting.

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

3. Check  ue 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.

SECTION 4 RLN-IOM-2012-1205 MAINTENANCE

5. Test the water  ow switch by trying to restart boiler with system pump o . The boiler should not operate.

6. If an air inlet  lter is included with the boiler, inspect and clean  lter of any dust or lint. See Procedure for Cleaning the Air Inlet Filter.

7. Verify the water loop style traps in the exhaust venting system are  ooded.

Procedure for Cleaning the Air Inlet Filter

The air  lter is an optional part and does not come with every boiler.

Proceed as follows:

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

2. Remove all debris and dirt from the  lter using a non-corrosive soap and water.

3. Return the  lter to its original position in the slot.

Relief Valve Testing

The relief valve should be tested as per manufacturer instructions or every two months 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 Maintenance and Inspection Schedule

! WARNING

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

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may

pose signi cant 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 o ered by the CDC and OSHA for more information, including personal protective equipment recommendations.

Annual maintenance and inspection must be performed prior to each heating season, and includes the following tasks which must be done by a factory trained technician.

Observe the general operation of the unit to verify the following:

1. Stack temperature readings are in line with factory test  re and regular maintenance reports.

2. Boiler is lighting o reliably and quietly.

3. There are no unusual sounds coming from the burner or blower assembly.

4. It is considered good practice to remove and inspect the burner and ignition assembly on an annual basis. Follow Procedure for Removing/ Cleaning Burner in this manual if there is evidence of foreign matter built up on the burner or ignition assembly. See Figure 22.

5. It is considered good practice to inspect the copper  nned tubes in the heat exchanger on an annual basis. This can be done from the inside of the heat exchanger while the burner is removed, or by removing the front outer jacket panel.

§ To remove the outer jacket panel, open the front lower door of the outer

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.

Hazard analysis should be performed by end user to ensure safety of employees/personnel.

Any damage to the burner or any other aspect of the boiler because of

an air  lter that was not cleaned and maintained regularly will void the warranty on the Reliance boiler.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-3

MAINTENANCE RLN-IOM-2012-1205 SECTION 4

! WARNING

Follow proper lockout / tag out procedures for the electrical, gas and water connections. Use caution when lifting heavy parts.

4 CAUTION

jacket. Remove the two vertical rails and the upper and lower bands. Now the front third of the inner jacket may be removed.

§ If soot or other debris is present, the heat exchanger must be cleaned.

If cleaning is necessary, remove the burner/blower assembly prior to

washing the copper  nned tubes with water and non-corrosive soap.

§ Examine the gaskets and note signs of deterioration, replace if necessary.

§ Green scale on the copper tubes indicates that the boiler is or has

been experiencing  ue gas condensation in the heat exchanger; this is

detrimental to the life of any copper  nned tube heat exchanger. This may be the result or an improperly designed system operating at low water temperatures, or substantial cold start-up periods. Copper  nned tube heat exchangers are susceptible to failure if there are system return water temperatures below 140 F present. Inspect for the presence of leaking or failed tubes. A replacement heat exchanger may be necessary.

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

FIGURE 22  BURNER WITH IGNITION ASSEMBLY MOUNTED

¡ Examine the Venting System

1. Check all joints and pipe connections for tightness.

4-4

2. Check vent for corrosion or deterioration. If any venting needs replacing, do so immediately.

3. Perform any recommended maintenance as required by the vent material manufacturer.

SECTION 4 RLN-IOM-2012-1205 MAINTENANCE

4. Check to ensure loop traps are  ooded.

¡ Inspect Heating System for Other Problems

1. Perform combustion analysis and adjust if necessary.

2. Leak test gas valves. Leak Test must be performed only by quali ed

personnel, who have been trained in this procedure in a Fulton Service School.

Procedure for Removing/Cleaning The Burner

Perform the following to remove/clean the burner:

1. Remove top and side panels from the boiler outer jacket.

2. Disconnect both wire plug connectors to the pre-mix blower.

3. Disconnect the UV scanner/ ame rod, ignition wire and ground wire block.

4. Disconnect air sensing tubing from Venturi mixing unit, carefully swing the tubing away.

5. Disconnect air switch sensing tubing between switch and Venturi mixing unit inlet.

4 CAUTION

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

6. Disconnect high backpressure sensing tubing between switch and ignition assembly connection point.

7. Disconnect the four bolts between the Venturi mixing unit  ange and the gas train  ange. Verify the gas train is properly supported prior to removing the above-mentioned four bolts, also verify supply gas is isolated. Inspect gasket located between these two  anges for signs of deterioration.

8. Undo four nuts holding pre-mix blower to the burner/blower mounting plate. Use care, the pre-mix blower/venturi-mixing unit is heavy. Inspect gasket for signs of deterioration.

9. Undo four nuts holding burner/blower-mounting plate to the outlet water header.

10. Remove burner, being careful not to scrape burner on heat exchanger or outlet water header. Inspect gasket for signs of deterioration.

11. Inspect burner and wipe o (do not scrub or use wire brush) any soot or foreign material that may have accumulated. If available, use compressed air to clear the burner. Wipe out the inside of the burner with a clean cloth.

12. Check that the gap between the electrode and the ground rod. Gap should be 1/8-inch (3mm) +/- 1/16,-0. For Liquid Propane, the gap should be exactly 1/8-inch (3mm).

13. Check the horizontal gap between the point of ignition and the exterior of the mesh burner. The required gap is 5/16-3/8-inch (8-10 mm).

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-5

MAINTENANCE RLN-IOM-2012-1205 SECTION 4

! WARNING

If any manual reset limit device trips, do not reset without determining and correcting the cause. These include

 ame safeguard, high or low gas pressure, and high temperature limit.

4 CAUTION

14. To inspect the gasket between burner/blower mounting plate and mesh burner undo the 4 bolts.

15. Check for cracking of the electrode insulator. Do not over tighten the electrode.

16. Use a soft, clean cloth to remove accumulated contaminants from the UV detector/scanner glass envelope.

17. Use a soft, clean cloth to remove accumulated contaminants from the sight glass.

18. Before re-installing the burner, check the cleanliness of the heat exchanger and the condition of the combustion chamber. If corrosion or leaks are noticed, contact Fulton Heating Solutions.

19. Reverse removal steps for reinstallation of the burner assembly.

20. Reinstall side and top jacket panels.

21. Test  re the boiler and use a combustion analyzer to ensure that the fuel/

air ratio is set correctly throughout the range. Refer to the Fulton Heating Solutions factory test  re report for combustion settings.

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. Analyze combustion throughout the range and verify proper operation of safety devices.

3. Make any necessary adjustments.

Troubleshooting

Use the following table as a guide to troubleshooting your boiler.

4-6

SECTION 4 RLN-IOM-2012-1205 MAINTENANCE

PROBLEM CAUSE CHECK/SOLUTION

Manual Reset limit device

trips

Power outage to the boiler

room

Gas Pressure alarm is

annunciated

Manual Reset Limits include: Flame safeguard, high

or low gas pressure, high temperature limit

Entire boiler system is disabled and de-energized. When power has returned, the boiler will restart

Either insu cient gas pressure or the gas pressure

to the manifold is too high 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.

DO NOT reset without determining and correcting

the cause.

unless it was in lockout position at time of outage.

Locate cause and correct. In the event of a high

gas manifold pressure condition, quali ed service

personnel must correct the problem before

restarting the boiler.

High water temp alarm is

annunciated

Insu cient  ow of heat

transfer medium causes

lock out

Low Air Flow Supply Low Air is annunciated if the air ow switch detects

High Back Pressure Switch trip/boiler shutdown

Main ﬂ ame failure during ﬁ ring period

Igni" on Failure If UV scanner does not detect the ﬂ ame during the

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.

Boiler requires minimum  ow; when required  ow is

resumed, boiler will resume operation.

low air ow through the boiler.

Excessive Vent Pressure This condi" on will automa" cally recycle, so

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

4-second trial-for-igni" on period, the gas valve and spark igni" on are de-energized. At this " me a safety lockout occurs.

Locate cause and correct. Once the SOLA control

is reset, the sequence returns to normal operation

provided that the other limits are satis ed.

Identify and correct.

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

An extended low air indica" on does not mean that the low air switch is defec" ve.

Check that blower is powered 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 ﬁ re speed is correctly displayed on the touch screen.

Check for obstruc" ons in the vent.

Check for obstruc" ons in the air inlet.

the boiler will try to relight. The vent and heat exchanger should be checked for obstruc" ons and cleaned.

The programmer must be manually reset.

Iden" fy and correct; reset via the SOLA Control.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-7

MAINTENANCE RLN-IOM-2012-1205 SECTION 4

4-8

WARRANTY & PARTS

INTRODUCTION

INSTALLATION

1 2

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-1

WARRANTY & PARTS RLN-IOM-2012-1205 SECTION 5

Standard Warranty for Fulton Reliance Boilers

Warranty Valid for Models RLN

Ten (10) Year Thermal Shock Warranty

Fulton Heating Solutions guarantees the Reliance heat exchanger against thermal shock for a period of ten (10) years when the boiler is installed as a closed loop hot water boiler and is operated per the Installation and Operation Manual. This guarantee will cover damage due to thermal shock, such as leaks in the heat exchanger. This guarantee does not cover damage due to corrosion, scaling, sooting or improper installation or operation. The ﬂ ow rate through the boiler must be consistent with the requirements in the equipment manual.

The guarantee is limited solely to the repair or replacement of the components listed above. An inspection must be performed by Fulton or their Representative to determine the cause of the damage. The warranty does not cover labor or freight.

Five (5) Year (60 Month) Material and Workmanship Warranty

The pressure vessel is covered against defective material or workmanship for a period of ﬁ ve (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 deﬁ ned 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 be installed in a closed loop 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 notiﬁ ed 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 ofﬁ cer 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 ﬁ tness 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 proﬁ ts 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.

Excessive cycling will reduce the life of ANY boiler. Verify that your system is properly designed and check cycling rate according to maintenance procedures listed in this manual.

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.

9/25/2009

5-2

SECTION 5 RLN-IOM-2012-1205 PARTS & WARRANTY

Parts

Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherence with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

! WARNING

Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty.

Figure 21 Legend

A. Premix Blower Assembly

B. Sight Glass & High Back Pressure Switch

Connection Assembly

C. UV Scanner Assembly

D. Ignition Assembly (includes spark plug,

 ame rod, mounting plate, ground)

E. Heat Exchangers (Cast Headers, Copper

Finned Tubes, Tube Sheets, Stainless Steel

Outer Jacket)

F. Fiber Mesh Burner

G. Ignition Ground Wire

H. Burner/Blower Mounting Plate

I. Venturi Air Gas Mixing Unit

FIGURE 21  GENERAL PARTS DESCRIPTION OF THE RELIANCE BOILER

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-3

WARRANTY & PARTS RLN-IOM-2012-1205 SECTION 5

¡ Parts Listing

Part Number Description RLN-750 RLN-1000 RLN-1500 RLN-2000

7-57-CHR102

2-20-000014

2-20-000015

2-30-001639

2-30-001614

2-30-001642

2-30-001637

2-30-001641

2-30-000949

2-30-000974

2-30-000975

2-30-000939

2-30-000975

2-30-000114

2-30-000113

2-30-000957

2-40-000907 Sola Control X X X X

2-40-000917 Sola Display X X X X

2-45-000915 12VDC Power Supply (comes with display) X X X X

2-45-000914 Sola Wire Plug Sets X X X X

2-30-000765 Clips (set of 12) X X X X

2-30-000799

2-30-000798 Door Latch, Small, for electrical door X X X X

4-12-002000

2-12-000702

2-12-000703

2-12-000704

2-12-000210

2-12-000559

2-12-000049

Heat Exchanger

Ignition Assemblies

Bekaert Burner

EBM Blower

Venturi Gas / Air Mixing

Gas / Air Servo Regulator Gas Valve Nat Gas

Gas / Air Servo Regulator Gas Valve Propane

1 ¼” Ball Valve lever handle

1” Ball Valve lever handle

1 ¼” Ball Valve Tee handle

1” Ball Valve Tee handle

Door Latch, Large, for Heat Exchanger Door

Gasket Kit for Heat Exchanger / Burner (no o-rings) includes below 8 items

Burner Plate to Header Gasket

Ignition Plate to Burner Plate Gasket

Blower to Burner Plate Gasket

Fiberglass Rope Gasket for Rails

Tadpole Gasket (Head to Outside Chamber)

Fiberglass gasket for Inner S.S. jacket

X X

X X X X

X X

5-4

SECTION 5 RLN-IOM-2012-1205 WARRANTY & PARTS

Part Number Description RLN-750 RLN-1000 RLN-1500 RLN-2000

2-12-001031

2-12-000565

2-40-000906 Low Gas Pressure Switch X X X X

2-30-001139 High Gas Pressure Switch X X X X

2-40-000908 Honeywell Sensor w/ 42” Lead X X X X

2-40-000161 UV Scanner X X X X

2-30-000270 Fan Switch, Dwyer X X X X

2-30-000498 McDonnell Miller Flow Switch X X X X

2-30-001009 Temp / Pressure Gauge X X X X

2-30-000120

2-30-000121

2-30-000145 Safety Relief Valve 100psi ¾” X X X X

2-30-000166 Safety Relief Valve 160psi ¾” X X X X

2-30-000851

2-30-000951

2-30-000221

2-22-001013 Bonding Screws X X X X

2-45-001015 Terminal Block X X X X

2-45-000916

2-45-001029

2-45-000917

2-45-001012

2-35-001953 1/8” npt female x 1/4” tubing ﬁ tting Polytite X X X X

2-45-001025

2-45-001026

2-30-000739

2-30-000973 Seismic Anchor Kit X X X X

2-30-000797

2-30-000834

2-30-000972

2-30-000983

Venturi Flange Gasket

Burner to mounting plate Gasket

Burner Plate to Header Gasket

Ignition Plate to Burner Plate Gasket

Blower to Burner Plate Gasket

Safety Relief Valve 30psi ¾”

Safety Relief Valve 60psi ¾”

Safety Relief Valve 30psi 1”

Safety Relief Valve 60psi 1”

Safety Relief Valve 30psi 1 ¼”

Tyco Connector for EBM blower power connection

Tyco Female terminal - EBM blower power connection

Molex connector for EBM blower PWM connection

Molex female terminal - EBM blower PWM connection

Honeywell Ignition cable 500Ω per foot / 24” long

Ignition cap terminal, washer for transformer

Air Inlet Filter Kit

Dedicated Circulator Pump 15 ft/hd, 130 GPM, single phase

Dedicated Circulator Pump at 16 ft/hd, 65gpm, single phase

Thermostatic 3-way Mixing Valve, 2 ½”, 125 psi, FF ﬂ ange, 180F

Thermostatic 3-way Mixing Valve, 150psi, 2” NPT, 180F

High Exhaust Temp Switch (H.E.T.) X X X X

X X

X X X

X X

X X X X

X X

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-5

WARRANTY & PARTS RLN-IOM-2012-1205 SECTION 5

Part Number Description RLN-750 RLN-1000 RLN-1500 RLN-2000

2-60-000118 Adhesive Spray X X X X

2-40-000625 24VAC Power Supply X X X X

2-45-000339 3-position switch X X X X

2-45-000411 Red Alarm Light X X X X

2-40-000795 Black Push Button

2-45-000412 Green Call For Heat Light X X X X

X X X X

5-6

No part of this Installation, Operation, and Maintenance manual

may be reproduced in any form or by any means without

permission in writing from the Fulton Companies.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of the Fulton Group of Companies, a global manufacturer

of steam, hot water and thermal  uid heat transfer systems.

The heat transfer innovators.

The Fulton Companies

972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

RLN-IOM-2012-1205

FULTON Reliance 500, Reliance 1000, Reliance 1500, Reliance 2000, Reliance 750 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual