Fulton Reliance High Efficiency Cooper Fin Boiler User Manual
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 .................................................................................................................210
Meet Water Chemistry Requirements ................................................................2-10
PREVENT FREEZING ...................................................................................................................211
PREVENT OXYGEN CONTAMINATION ........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................212
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 ..............................................................216
COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........216
Exhaust Venting .................................................................................................2-17
STANDARD VENTING CONFIGURATION, CATEGORY IV .............................................................217
OPTIONAL VENTING CONFIGURATION, CATEGORY I ................................................................217
FOR BOTH VENTING CONFIGURATION OPTIONS ......................................................................218
COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS .................................218
Venting Terminations ......................................................................................... 2-19
WALL THIMBLE INSTALLATION .................................................................................................220
HORIZONTAL VENT TERMINATION ............................................................................................220
Electrical Connections ....................................................................................... 2-21
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................222
INTAKE DUCT SIZING ................................................................................................................222
Operation 3-1
Test of High Back Pressure Switch ........................................................................3-5
Normal Operation of the Boiler ............................................................................ 3-5
CHANGING THE OPERATING SET POINT .....................................................................................36
SETTING COMBUSTION ................................................................................................................36
Shut Down Procedures .........................................................................................3-7
NORMAL SHUT OFF PROCEDURES .............................................................................................37
EMERGENCY SHUT OFF PROCEDURES .......................................................................................37
SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................37
STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................37
SOLA Control Features .......................................................................................... 3-7
FLAME DETECTION ......................................................................................................................37
CYCLE AND RUN HOURS MONITORING .......................................................................................38
SETPOINT CONFIGURATION.........................................................................................................38
SETTING THE CENTRAL HEAT SETPOINT .....................................................................................38
REVIEWING STATUS DETAIL ........................................................................................................38
LEAD/LAG OUTDOOR RESET FOR SINGLE BOILER APPLIC ATIONS ...........................................310
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 ................................................................................................44
INSPECT HEATING SYSTEM FOR OTHER PROBLEMS ..................................................................45
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 .............................................................................................................................54
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 ............................................................................................34
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
© The Fulton Companies 2012
INTRODUCTION
INTRODUCTION
INSTALLATION
1
2
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
© The Fulton Companies 2012
INSTALLATION
INTRODUCTION
INSTALLATION
1
2
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
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.
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
© The Fulton Companies 2012
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
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.
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
<3
NA
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
<3
NA
<3
NA
<6
NA
<6
NA
NA
<10
NA
<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
MM
B. Boiler Height IN
MM
C. Boiler Depth IN
MM
D. Boiler Depth with Trim IN
MM
E. Air Inlet Diameter IN
MM
F. Flue Outlet Diameter IN
MM
G. Water Inlet/Outlet Size IN
MM
H. Min Clearance to Walls IN
MM
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
© The Fulton Companies 2012
SECTION 2 RLN-IOM-2012-1205 INSTALLATION
A
B
D
J
H
I
C
Front View
Right Side View
F
E
G
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
© The Fulton Companies 2012
SECTION 2 RLN-IOM-2012-1205 INSTALLATION
Dedicated
Pump
T
Safety
Relief
Valve
Heating
Loop
Return
12"
Strainer
Cold Water
Supply
Air
Separator
PRV
P
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
T
Safety
Relief
Valve
Heating
Loop
Return
12"
3-Way
Mixing
Valve
Strainer
Cold Water
Supply
Air
Separator
PRV
P
Expansion
Tank
Hot Water
Heating
Loop Supply
System
Pump
Air
Sep.
2-8
FIGURE 4 SAMPLE PIPING LAYOUT: SINGLE BOILER APPLICATION, WITH MIXING VALVE
© The Fulton Companies 2012
SECTION 2 RLN-IOM-2012-1205 INSTALLATION
Dedicated
Pump
T
Safety
Relief
Valve
T
Safety
Relief
Valve
Dedicated
Pump
T
Safety
Relief
Valve
Dedicated
Pump
Cold Water
Supply
Air
Separator
PRV
P
Expansion
Tank
Hot Water
Heating
Loop Supply
Heating
Loop
Return
System
Pump
Strainer
Strainer
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
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.
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
© The Fulton Companies 2012
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
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.
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.
© The Fulton Companies 2012
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