Fulton Reliance (RLN) High Efficiency Cooper Fin Boiler - Manual (Page 3)

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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 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 3-1
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 Off ....................................................................... 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
Test of High Back Pressure Switch ........................................................................ 3-5
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
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 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 ................................................................................................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 5-1
Standard Warranty for Fulton Reliance Boilers .................................................... 5-2
Parts ..................................................................................................................... 5-3
PARTS LISTING .............................................................................................................................5-4