FULTON Reliance 500 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

Questions? Call(315)298-5121,or visit us online at www.fulton.com
RLN-IOM-2012-1205 TABLE OF CONTENTS
0-1
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 BoilerTrim ................................................................................................. 2-5
InstallWater Piping.............................................................................................. 2-6
LOWWATER CUT OFF.................................................................................................................210
MeetWater Chemistry Requirements................................................................ 2-10
PREVENT FREEZING...................................................................................................................211
PREVENT OXYGEN CONTAMINATION........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................212
Fill the BoilerWithWater ................................................................................... 2-12
Install Gas Piping................................................................................................ 2-12
Install Condensate Drain (Optional)................................................................... 2-13
Venting............................................................................................................... 2-15
COMBUSTION AIR SUPPLY FROMTHE BOILER ROOM..............................................................216
COMBUSTION AIR PIPED FROM OUTSIDE BUILDINGWITHOUT SEALED COMBUSTION........216
ExhaustVenting ................................................................................................. 2-17
STANDARD VENTING CONFIGURATION, CATEGORY IV.............................................................217
OPTIONALVENTING CONFIGURATION, CATEGORY I ................................................................217
FOR BOTHVENTING CONFIGURATION OPTIONS ......................................................................218
COMMON AIR INTAKE AND EXHAUSTVENTING OF MULTIPLE BOILERS.................................218
VentingTerminations......................................................................................... 2-19
WALL THIMBLE INSTALLATION.................................................................................................220
HORIZONTALVENTTERMINATION............................................................................................220
Electrical Connections ....................................................................................... 2-21
AIR PIPED FROM OUTSIDE BOILER ROOM................................................................................222
INTAKE DUCT SIZING ................................................................................................................222
Operation 3-1
Perform Pre-Start-Up Inspection......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
SOLA Control Program Presets............................................................................. 3-3
CommissionThe Boiler......................................................................................... 3-3
TEST OF IGNITION SAFETY SYSTEM ............................................................................................34
PerformTest of LowWater Cut O ....................................................................... 3-4
PerformTest of Limit Controls ............................................................................. 3-4
PerformTest of Low Gas Pressure Switch ............................................................ 3-5
PerformTest of High Gas Pressure Switch............................................................ 3-5
PerformTest of Air Switch.................................................................................... 3-5
Test of High Back Pressure Switch........................................................................ 3-5
Normal Operation of the Boiler............................................................................ 3-5
CHANGINGTHE 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
SHUTTINGTHE 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
SETTINGTHE CENTRAL HEAT SETPOINT.....................................................................................38
REVIEWING STATUS DETAIL........................................................................................................38
LEAD/LAG OUTDOOR RESET FOR SINGLE BOILER APPLICATIONS...........................................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
ReliefValveTesting............................................................................................... 4-3
Annual Maintenance and Inspection Schedule................................................... 4-3
EXAMINETHE VENTING SYSTEM ................................................................................................44
INSPECT HEATING SYSTEM FOR OTHER PROBLEMS..................................................................45
Procedure for Removing/CleaningThe 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

© The Fulton Companies 2012
TABLE OF CONTENTS RLN-IOM-2012-1205
0-2

Questions? Call(315)298-5121,or visit usonlineat www.fulton.com 1-1
INTRODUCTION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
1-2
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.
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.
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.

Questions? Call(315)298-5121,or visit usonlineat www.fulton.com 2-1
INSTALLATION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
INSTALLATION RLN-IOM-2012-1205 SECTION 2
2-2
! 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.
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.
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:
§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.

Questions? Call(315)298-5121,or visit usonlineat www.fulton.com
SECTION 2 RLN-IOM-2012-1205 INSTALLATION
2-3
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.
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.
! 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.
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.

© The Fulton Companies 2012
INSTALLATION RLN-IOM-2012-1205 SECTION 2
2-4
TABLE 1A  OPERATING REQUIREMENTS
Reliance Model Size 500 750 1000 1500 2000 2500 3000
Fuel Type Natural Gas or Propane*
Input BTU/Hr Max
Min
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
Electrical Requirements (Amps) (120V/60/1)
(240V/60/3)
<3
NA
<3
NA
<3
NA
<6
NA
<6
NA
NA
<10
NA
<10
Water Content Gal
Liter
2.7 3 3 7.3 7.3 11 11
10.2 11.4 11.4 27.6 27.6 41.6 41.6
Dry Weight LB
KG
675 700 700 1000 1000 1400 1400
306 318 318 454 454 635 635
Operating Weight LB
KG
700 725 725 1060 1060 1492 1492
317.5 329 329 481 481 676.75 676.75
Anchor Bolt Size IN
MM
.75 .75 .75 .75 .75 .75 .75
19 19 19 19 19 19 19
Dimensions • Reliance Hydronic Boiler
Reliance Model Size 500 750 & 1000 1500 & 2000 2500 & 3000
A. Boiler Width IN 24 24 32.125 34
MM 610 609.6 815.9 863.6
B. Boiler Height IN 45 50.7 67.9 72
MM 1143 1287.8 1724.6 1828.8
C. Boiler Depth IN 29.3 29.3 34.3 42.2
MM 744.2 744.2 871.2 1071.8
D. Boiler Depth with Trim IN 43.9 43.9 49.3 55.9
MM 1115 1115 1115 1419.8
E. Air Inlet Diameter IN 4 6 8 10
MM 101.6 152.4 203.2 254
F. Flue Outlet Diameter IN 4 6 8 10
MM 101.6 152.4 203.2 254
G. Water Inlet/Outlet Size IN 2 2 2.5 3
MM 50.8 50.8 63.5 76.2
H. Min Clearance to Walls IN 1 1 1 1
MM 25.4 25.4 25.4 25.4
I. Min Clearance to Front and Rear IN 36 36 36 36
MM 914.4 914.4 914.4 914.4
J. Min Clearance to Ceiling IN 24 24 24 24
MM 609.6 609.6 609.6 609.6
TABLE 1B  BOILER DIMENSIONS REFER TO FIGURE 1
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.