FULTON Reliance 1000 Installation And Operation Manual Download Page 1

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INSTALLATION AND

OPERATION MANUAL

Reliance (RLN)

High Effi

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

Summary of Contents for Reliance 1000

Page 1: ...INSTALLATIONAND OPERATIONMANUAL Reliance RLN High Efficiency Hydronic Boilers 500 000 3 000 000 BTU HR Serial National Board Number Model Fulton Order SoldTo Job Name Date RLN IOM 2012 1205...

Page 2: ......

Page 3: ...eSystem 3 2 SOLAControlProgramPresets 3 3 CommissionTheBoiler 3 3 TESTOFIGNITIONSAFETYSYSTEM 3 4 PerformTestofLowWaterCutOff 3 4 PerformTestofLimitControls 3 4 PerformTestofLowGasPressureSwitch 3 5 Pe...

Page 4: ...TheFultonCompanies2012 TABLEOFCONTENTS RLN IOM 2012 1205 0 2...

Page 5: ...Questions Call 315 298 5121 orvisitusonlineat www fulton com 1 1 INTRODUCTION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 WARRANTY PARTS 5...

Page 6: ...his 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 protecti...

Page 7: ...Questions Call 315 298 5121 orvisitusonlineat www fulton com 2 1 INSTALLATION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 WARRANTY PARTS 5...

Page 8: ...ulton Reliance hot water boiler is an automatic fuel fired high efficiency boiler The boiler can either be of the sealed combustion direct vent type or utilize conventional combustion air intake and f...

Page 9: ...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 outsid...

Page 10: ...iler Depth IN 29 3 29 3 34 3 42 2 MM 744 2 744 2 871 2 1071 8 D Boiler Depth withTrim 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 O...

Page 11: ...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 Safe...

Page 12: ...mote 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...

Page 13: ...osed to refrigerated air circulation such boiler piping systems shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the coolin...

Page 14: ...8 FIGURE 4 SAMPLE PIPING LAYOUT SINGLE BOILER APPLICATION WITH MIXING VALVE Dedicated Pump T Safety Relief Valve Heating Loop Return 12 3 Way Mixing Valve Strainer Cold Water Supply Air Separator PRV...

Page 15: ...elief 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...

Page 16: ...the heat exchanger components Any presence of these contaminants will void the warranty Some soaps used for leak testing are corrosive to certain types of metals Rinse all piping thoroughly with clean...

Page 17: ...ions as provided by your water conditioning or chemical treatment supplier 3 Appropriate flow rates and return water temperature may be achieved through primary and secondary flow loops Please refer b...

Page 18: ...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 eliminat...

Page 19: ...lCondensateDrain Optional A condensate drain kit Figure 8 is intended for use with the Fulton Reliance boiler The Condensate Drain is Fulton Model Part Number 4 57 000440 Its recommended Operating Tem...

Page 20: ...upply maintains a water level in the drain kit to prevent the flue gas from entering the boiler room through the condensate connection 3 The 1 1 2 connection shall be piped to an appropriate drain for...

Page 21: ...n uninterruptible supply Fulton recommends connecting it before the Fast Fill valve to the boiler supply but after the back flow preventer to avoid contamination of a potable water supply Maximum allo...

Page 22: ...ss 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 flow of air to exhaust the hot air from the boil...

Page 23: ...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 th...

Page 24: ...rain piping see Figure 9 The pipe from the boiler directed to the drain should be installed at a slope of per foot 6 Ensure that condensate drain piping will not be exposed to temperatures where water...

Page 25: ...r 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 floors walls roofs or framed spaces...

Page 26: ...owing for installation see Figure 11 1 The thimble is inserted through the wall from the outside Secure the outside flange to the wall with nails or screws and seal with adhesive material 2 Install th...

Page 27: ...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...

Page 28: ...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 Contac...

Page 29: ...iately 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...

Page 30: ...ERENT 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 I...

Page 31: ...Questions Call 315 298 5121 orvisitusonlineat www fulton com 3 1 OPERATION INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 WARRANTY PARTS 5...

Page 32: ...r 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 shutoff purge valve 5 At this point the system has been...

Page 33: ...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 poin...

Page 34: ...e signal from the UV scanner 5 After 4 seconds the flame safeguard programmer will assume a Flame Failure condition and go to a lockout mode Lockout will require manual reset of the flame safeguard Th...

Page 35: ...e high gas pressure switch 3 Manually reset the high gas pressure switch after it trips PerformTestofAirSwitch Fire the boiler and test the air switch as follows 1 At low fire turn the adjustment on t...

Page 36: ...next to firing rate 4 Under Firing Rate Control tap Manual in Run Refer to Figure 16 5 Using test fire sheet enter the light off rpm s in the Manual Firing Rate box 6 Once the rpm s are entered tap OK...

Page 37: ...ly If overheating occurs or the gas supply fails to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the boiler Shutti...

Page 38: ...er password protected Control preset values CycleandRunHoursMonitoring Burner cycles burner run time and pump cycles can be viewed from the Statistics Configuration screen on the Control See Figure 14...

Page 39: ...nce 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 passw...

Page 40: ...to Figure 19 Maximum OutdoorTemperature highest outdoor temperature in the outdoor reset curve This outdoor temperature correlates to the Low Water Temperature Minimum OutdoorTemperature lowest outdoo...

Page 41: ...rature 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 off Hysteresis which from the ab...

Page 42: ...TheFultonCompanies2012 OPERATION RLN IOM 2012 1205 SECTION3 3 12...

Page 43: ...Questions Call 315 298 5121 orvisitusonlineat www fulton com 4 1 MAINTENANCE INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 WARRANTY PARTS 5...

Page 44: ...ntenance and inspection directions outlined in this section of the manual DailyMaintenanceandInspectionSchedule Daily maintenance and inspection must include the following 1 Observe operating temperat...

Page 45: ...lint See Procedure for Cleaning the Air Inlet Filter 7 Verify the water loop style traps in the exhaust venting system are flooded ProcedureforCleaningtheAirInletFilter The air filter is an optional p...

Page 46: ...at exchanger must be cleaned If cleaning is necessary remove the burner blower assembly prior to washing the copper finned tubes with water and non corrosive soap Examine the gaskets and note signs of...

Page 47: ...Venturi mixing unit carefully swing the tubing away 5 Disconnect air switch sensing tubing between switch and Venturi mixing unit inlet 6 Disconnect high backpressure sensing tubing between switch an...

Page 48: ...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...

Page 49: ...control is reset the sequence returns to normal operation provided that the other limits are satisfied Insufficient flow of heat transfer medium causes lock out Boiler requires minimum flow when requi...

Page 50: ...TheFultonCompanies2012 MAINTENANCE RLN IOM 2012 1205 SECTION4 4 8...

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Page 53: ...Questions Call 315 298 5121 orvisitusonlineat www fulton com 5 1 WARRANTY PARTS INTRODUCTION 1 INSTALLATION 2 OPERATION 3 MAINTENANCE 4 WARRANTY PARTS 5...

Page 54: ...y 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 a...

Page 55: ...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...

Page 56: ...ulator Gas Valve Propane X X 2 30 000114 1 Ball Valve lever handle X X 2 30 000113 1 Ball Valve lever handle X X 2 30 000957 1 Ball Valve Tee handle X X 1 Ball Valve Tee handle X X 2 40 000907 Sola Co...

Page 57: ...alve 30psi 1 X X 2 30 000951 Safety Relief Valve 60psi 1 X X 2 30 000221 Safety Relief Valve 30psi 1 X 2 22 001013 Bonding Screws X X X X 2 45 001015 Terminal Block X X X X 2 45 000916 Tyco Connector...

Page 58: ...r 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 4...

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Page 60: ...nstallation Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies Fulton BoilerWorks Inc Fulton Heating Solutions Inc F...

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