Table Of Contents - FULTON Reliance 500 Installation And Operation Manual

RLN-IOM-2012-1205
Introduction
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation
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
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
Test of High Back Pressure Switch ........................................................................ 3-5
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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
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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 APPLICATIONS ...........................................3 10
Maintenance
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
Standard Warranty for Fulton Reliance Boilers .................................................... 5-2
Parts ..................................................................................................................... 5-3
PARTS LISTING .............................................................................................................................5 4
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