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Summary of Contents for FULTON Reliance 500
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Page 1: Operation 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... -
Page 3: Table Of Contents
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... - Page 4 TABLE OF CONTENTS RLN-IOM-2012-1205 © The Fulton Companies 2012...
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Page 5: Introduction
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 6: Overview
Code ANSI Z223.1/NFPA 54 latest edition, and the speci c should it replace existing codes or standards which may be instructions in this manual. Authorities having jurisdiction applicable. Fulton reserves the right to change any part of should be consulted prior to installation. this installation, operation and maintenance manual. -
Page 7: Installation
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 8: Product Overview
Per The Fulton Reliance boiler is constructed to ASME Section IV and certi ed to the Centers for Disease Control and Underwriters Laboratories (UL) 795 Issue 2006/10/27 Edition 6 Standard for Prevention (CDC) and Occupational Safety Commercial-Industrial Gas Heating Equipment. -
Page 9: Placement & Rigging
Placement & Rigging All information in this manual is for Proper placement of your Fulton product is essential. Attention paid to reference and guidance purposes, the following points will save a great deal of di culty in the future. Correct... - Page 10 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. © The Fulton Companies 2012...
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Page 11: Install Boiler Trim
» Be installed in the vertical position. gauge to be installed in the outlet piping section of the boiler. Front View Right Side View FIGURE 1 RELIANCE HYDRONIC BOILER CLEARANCES REFER TO TABLE 1B Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 12: Install Water Piping
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... - Page 13 Loop Supply System Pump Safety Relief Expansion Valve Tank 12" Strainer Dedicated Pump Heating Loop Return FIGURE 3 SAMPLE PIPING LAYOUT: SINGLE BOILER WITH RETURN WATER TEMPERATURE >140 F 60 C Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 14 INSTALLATION SECTION 2 RLN-IOM-2012-1205 FIGURE 4 SAMPLE PIPING LAYOUT: SINGLE BOILER APPLICATION, WITH MIXING VALVE © The Fulton Companies 2012...
- Page 15 INSTALLATION SECTION 2 RLN-IOM-2012-1205 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...
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Page 16: Low Water Cut Off
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) Acceptable pH range of 7.5-10 Solids less than 2500 ppm Alkalinity less than 500 ppm 2-10 © The Fulton Companies 2012... -
Page 17: Prevent Freezing
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 Use air elimination devices in system piping 2-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 18: Eliminate System Air
DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in 4. If an air cushion type expansion tank is used, pipe tank directly into boiler doubt, contact your Fulton representative supply. prior to operation. 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. -
Page 19: Install Condensate Drain (Optional)
6.16 12.3 4350 3000 2400 2050 1850 1500 1280 3.068 7.67 15.3 7700 5300 4300 3700 3250 2650 2280 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600 2-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 20 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 2-14 © The Fulton Companies 2012...
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Page 21: Venting
(unless there is sealed pressure to the compression tting is 100 PSI. combustion [intake piped outside]). Pay particular attention to other equipment installed in the boiler 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 22: Combustion Air Supply From The Boiler Room
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 Cements for plastic pipe are... -
Page 23: Exhaust Venting
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 2-17 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 24: For Both Venting Configuration Options
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 2-18... -
Page 25: Venting Terminations
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). 2-19 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 26: Wall Thimble Installation
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 © The Fulton Companies 2012... -
Page 27: Electrical Connections
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. -
Page 28: Air Piped From Outside Boiler Room
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. Do not use any dangerous source of re or smoke (e.g., lighter, candle) to... - Page 29 1/4 turn to distribute cement evenly, continue to insert pipe until it bottoms out. 2-23 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 30 4" PVC PIPE DO N OT PLACE INSULATION IN REQUIRED AIR METAL PLATE SPACE CLEARANCE FIRE STOP MAINTAIN MIN 9" / 22.86 CM AIR SPACE CLEARANCES TO COMBUSTABLES, WIRES AND INSULATION FIGURE 12 ROOF PENETRATION DETAILS 2-24 © The Fulton Companies 2012...
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Page 31: Operation
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 32: Perform Pre-Start-Up Inspection
5. At this point, the system has been initially lled. However, air pockets service agency or the gas supplier, must may still remain at high points in the system and in heating loops above perform installation and service. © The Fulton Companies 2012... -
Page 33: Sola Control Program Presets
This includes, but is not limited to, the use of the controls, lighting, and shutdown procedures. 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... -
Page 34: Test Of Ignition Safety System
WARNING Test of Ignition Safety System Test the ignition system safety shuto as follows: Non-Fulton product information is for reference purposes only. No Fulton 1. Remove the black plug/connector from the main gas valve (it is held on document should substitute for full with a central screw). -
Page 35: Perform Test Of Low Gas Pressure Switch
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... -
Page 36: Changing The Operating Set Point
SECTION 3 RLN-IOM-2012-1205 WARNING CHANGING THE OPERATING SET POINT From the main screen do the following: Non-Fulton product information is for reference purposes only. No Fulton 1. Tap “Con gure” document should substitute for full review of documentation available 2. Tap “Central Heat Con guration”... -
Page 37: Shut Down Procedures
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... -
Page 38: Cycle And Run Hours Monitoring
RLN-IOM-2012-1205 WARNING Cycle and Run Hours Monitoring Non-Fulton product information is for Burner cycles, burner run time, and pump cycles can be viewed from the reference purposes only. No Fulton Statistics Con guration screen on the Control. See Figure 14. - Page 39 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...
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Page 40: Lead/Lag Outdoor Reset For Single Boiler Applications
OPERATION SECTION 3 RLN-IOM-2012-1205 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. CAUTION Only factory-trained personnel should attempt to alter password protected Control preset values. - Page 41 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 3-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 42 OPERATION SECTION 3 RLN-IOM-2012-1205 3-12 © The Fulton Companies 2012...
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Page 43: Maintenance
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 44: General
3. Check ue gas temperature at outlet. If there is a temperature increase local Fulton Representative. 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 In order to meet warranty conditions, concern. -
Page 45: Procedure For Cleaning The Air Inlet Filter
To remove the outer jacket panel, open the front lower door of the outer Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 46: Examine The Venting System
A replacement heat exchanger may be necessary. regulations. All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative. In order to meet warranty conditions, ensure all appropriate maintenance activities are performed. -
Page 47: Inspect Heating System For Other Problems
2. Leak test gas valves. Leak Test must be performed only by quali ed jurisdictional/professional codes and personnel, who have been trained in this procedure in a Fulton Service regulations. School. All maintenance procedures should Procedure for Removing/Cleaning The Burner be completed by trained personnel. -
Page 48: After All Repairs And Maintenance
21. Test re the boiler and use a combustion analyzer to ensure that the fuel/ All maintenance procedures should air ratio is set correctly throughout the range. Refer to the Fulton Heating be completed by trained personnel. Solutions factory test re report for combustion settings. - Page 49 If UV scanner does not detect the fl ame during the Iden fy and correct; reset via the SOLA Control. 4-second trial-for-igni on period, the gas valve and spark igni on are de-energized. At this me a safety lockout occurs. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 50 MAINTENANCE SECTION 4 RLN-IOM-2012-1205 © The Fulton Companies 2012...
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Page 53: Warranty & Parts
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 54: Standard Warranty For Fulton Reliance Boilers
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. -
Page 55: Parts
Fulton Companies. When ordering replacement parts, please have for this equipment. Use of non-factory the model number and serial number of your Fulton boiler ready. Factory-direct authorized parts may jeopardize safety replacement parts must be used to ensure proper equipment operation and and system performance, and voids the adherence with warranty requirements. -
Page 56: Parts Listing
Burner Plate to Header Gasket 2-12-000703 Ignition Plate to Burner Plate Gasket 2-12-000704 Blower to Burner Plate Gasket 2-12-000210 Fiberglass Rope Gasket for Rails Tadpole Gasket (Head to Outside Cham- 2-12-000559 ber) 2-12-000049 Fiberglass gasket for Inner S.S. jacket © The Fulton Companies 2012... - Page 57 65gpm, single phase Thermostatic 3-way Mixing Valve, 2 ½”, 2-30-000972 125 psi, FF fl ange, 180F Thermostatic 3-way Mixing Valve, 150psi, 2-30-000983 2” NPT, 180F High Exhaust Temp Switch (H.E.T.) Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 58 WARRANTY & PARTS SECTION 5 RLN-IOM-2012-1205 Part Number Description RLN-750 RLN-1000 RLN-1500 RLN-2000 2-60-000118 Adhesive Spray 2-40-000625 24VAC Power Supply 2-45-000339 3-position switch 2-45-000411 Red Alarm Light 2-40-000795 Black Push Button 2-45-000412 Green Call For Heat Light © The Fulton Companies 2012...
- Page 60 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.
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