FULTON Endura+ Series, EDR+ 2500, EDR+ Series, EDR+ 3000, EDR+ 4000 Installation And Operation Manual

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INSTALLATION AND

OPERATION MANUAL

Endura+ (EDR+)

Condensing Hydronic Boilers

2,500,000 - 6,000,000 BTU/HR

Serial/ National Board Number

Model

Fulton Order

Owner

Site Name

Date

EDRP-IOM-2019-0212

EDRP-IOM-2019-0212 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................1-2

Disclaimers and Local Codes ................................................................................ 1-2

Installation 2-1

Product Overview ................................................................................................. 2-2

Massachusetts Installations ................................................................................. 2-2

Placement & Rigging ........................................................................................... 2-3

Clearances and Serviceability .............................................................................. 2-5

Install Boiler Trim ................................................................................................. 2-5

Install Water Piping ..............................................................................................2-6

VARIABLE PRIMARY PIPING ARRANGEMENT ............................................................................27

PRIMARYSECONDARY PIPING ARRANGEMENT ......................................................................210

Meet Water Chemistry Requirements ................................................................ 2-11

Fill the Boiler with Water .................................................................................... 2-12

Gas Supply Piping .............................................................................................. 2-12

PREVENT OXYGEN CONTAMINATION ........................................................................................212

ELIMINATE SYSTEM AIR ............................................................................................................212

INLET GAS PRESSURE ................................................................................................................212

LINE GAS PRESSURE REGULATION ............................................................................................213

GAS PIPING INSTALLATION .......................................................................................................213

COMPONENTS REQUIRING VENTILATION TO THE OUTDOORS .................................................216

Install Condensate Drain Trap .............................................................................2-16

SINGLE BOILER DRAIN TRAP .....................................................................................................216

MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP .........................................................219

Install pH Neutralization Kit ............................................................................... 2-21

Venting Requirements ....................................................................................... 2-21

Combustion Air Intake .......................................................................................2-22

COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................223

AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................224

Air Filter .............................................................................................................. 2-25

Flue Gas Exhaust Venting ................................................................................... 2-25

Common Venting Layouts for Endura+ ............................................................. 2-28

Venting Terminations ......................................................................................... 2-28

WALL THIMBLE INSTALLATION .................................................................................................232

ROOF VENT TERMINATION .........................................................................................................232

SIDE WALL VENT TERMINATION ................................................................................................232

Removing an Existing Boiler ............................................................................. 2-33

Assembly of Fulton Multi-Skid Systems............................................................. 2-34

Relocating the EDR+ 6000 Panel Box to Opposite Side ....................................2-35

Electrical Connections and Devices .................................................................... 2-36

JUNCTION BOX LOCATIONS FOR FIELD WIRING .......................................................................240

ELECTRICAL AND CONTROLS OPTIONS .....................................................................................240

Operation 3-1

Perform Pre-Start-Up Inspection ......................................................................... 3-2

Fill and Purge the System..................................................................................... 3-2

Commission The Boiler ......................................................................................... 3-3

SYSTEM DESIGN AND BOILER OPERATION .................................................................................33

TURNDOWN .................................................................................................................................34

Operation Modiers ........................................................................................... 3-4

Siemens LMV3 Control ......................................................................................... 3-4

BEFORE MODIFYING LMV PARAMETERS ....................................................................................36

STEPS TO ENTER PARAMETERS ...................................................................................................36

ADJUSTING FUEL/AIR CURVE .....................................................................................................36

MANUAL CONTROL MANUAL REQUEST FOR OUTPUT ............................................................38

PARAMETER BACKUP ..................................................................................................................39

PARAMETER RESTORE ...............................................................................................................310

Using the Endura+ PURE Control™ Interface .................................................... 3-12

NAVIGATION ...............................................................................................................................312

Endura+ PURE Control™ Menu Screen Functions ............................................. 3-14

BOILER CONTROL .......................................................................................................................314

LEAD/LAG ...................................................................................................................................316

PID CONTROL .............................................................................................................................317

SETPOINT ...................................................................................................................................319

SCHEDULING .............................................................................................................................320

TRENDING ..................................................................................................................................320

ADMIN ........................................................................................................................................320

Commissioning Mode ........................................................................................ 3-22

Perform Test of Limit Controls ........................................................................... 3-23

Perform Test of Low Gas Pressure Switch .......................................................... 3-23

Perform Test of High Gas Pressure Switch .......................................................... 3-23

General Operation of the Boiler ......................................................................... 3-23

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 ................................................. 4-3

Replacing the Combustion Air Inlet Filter .......................................................... 4-3

Replacing or Updating the Boiler Control ...........................................................4-3

Annual Maintenance and Inspection Schedule ................................................... 4-4

O Compensation Measurement .......................................................................... 4-4

Removing, Inspecting and Cleaning Burner ........................................................ 4-5

Inspecting the Pilot Ignition Assembly ................................................................ 4-7

After All Repairs and Maintenance ...................................................................... 4-7

Troubleshooting ................................................................................................. 4-10

Questions? Please Contact Your Local Manufacturer’s Representative

0-1

TABLE OF CONTENTS EDRP-IOM-2019-0212

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE

3 4

Questions? Please Contact Your Local Manufacturer’s Representative

1-1

INTRODUCTION EDRP-IOM-2019-0212 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 successfully completed Fulton Service School training specic to this product.

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 (99°C) respectively.

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.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE

3 4

Questions? Please Contact Your Local Manufacturer’s Representative

2-1

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

4 CAUTION

The standard conguration for 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.

Always verify gas type and pressure ratings for your boiler by viewing the boiler name plate.

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 Endura+ hot water boiler is an automatic, fuel-red, ultra higheciency boiler. The boiler can either have combustion air ducted directly from the outdoors 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.

The Fulton Endura+ boiler is ETL-certied to Underwriters Laboratories (UL) Edition 7 UL Standard for Safety Commercial-Industrial Gas Heating Equipment, and bears the H stamp. The boiler heat exchanger is manufactured and stamped in accordance with American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure and temperature of 160 psi and 210°F (99°C) respectively. All Endura+ boilers are hydrostatically tested, test red and shipped as a complete packaged unit.

Fuel, water and electrical connections are similar to other boilers of this type.

Please be aware of which burner and control conguration has been designed specically for your application.

This Endura+ 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 Endura+ Boiler is supplied with the following:

 Integrated combustion supervision and temperature operating control

 Operating and high temperature probe(s) in pressure vessel

 Low water probe(s) in pressure vessel

2-2

 ASME safety relief valve

 Installation and Operation Manual

 Test re report

 Wiring diagram

 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.

Massachusetts Installations

Boilers installed in Massachusetts must have the following:

 A gas pressure regulator installed upstream of the gas train provided by

the manufacturer.

 Two safety shuto valves, in series, one of which is of the type

incorporating a valve seal overtravel interlock when the maximum ring rate per combustion chamber exceeds 5,000,000 BTU/hour.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

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. Standard Endura+ boilers are certied for indoor installation only, where room conditions do not expose the boiler to temperatures below 32°F (0°C) or exceeding 120°F (48.9°C).

5. Install so that all system components are protected from water (dripping, spraying, rain, etc.) and debris (dry wall dust, insulation particles, etc.) during boiler operation and service.

6. Install on a level, non-combustible surface. Concrete is strongly recommended. The surface must be elevated a minimum of 4” (102 mm) above the oor. The use of shims may be required to ensure the boiler is level. Do not install the boiler on springs.

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 draft pressure requirements for horizontal or vertical venting. See Clearances and Serviceability section of this manual.

! WARNING

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

Questions? Please Contact Your Local Manufacturer’s Representative

Do not allow weight to bear on equipment components to prevent damage.

Do not use to directly heat a swimming pool.

2-3

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS

Specications EDR+ 2500 3000 4000 5000 6000

Rated Input Capacity1 MBH 2,500 3,000 4,000 5,000 6,000 Minimum Input at Low Fire MBH 20 0 200 400 400 400 Output at BTS-2000 conditions MBH 2,420 2,889 3,784 4,725 5,75 4 Fuel Consumption at Capacity SCFH 2,475 2,970 3,960 4,950 5,941 Nat. Gas Pressure Required W.C. 4 - 14 4 - 14 4 - 28 8 - 28 8 - 28 Variable Water Flow GPM 25 - 350 25 - 350 75 - 700 75 - 700 75 - 700 Full Load Amps (460/3/60) AMP 15.0 15.0 15.0 2 3.0 23.0 Typical High Fire Amps (460/3/60) AMP 6.10 9. 75 9.0 10.0 15.6 Typical Low Fire Amps (460/3/60) AMP 0.75 0.75 1. 0 0.9 0.9 Water Content GAL 80 80 18 0 180 18 0 Dry Weight LBS 2,600 2,600 5,039 5,087 5, 092 Operating Weight LBS 3,267 3, 267 6,54 0 6,588 6,593

Dimensions EDR+ 2500 3000 4000 5000 6000

A. Boiler Width IN 30 30 34 34 34 B. Boiler Height IN 80 80 79 79 79 C. Boiler Depth IN 73 73 116. 2 116. 2 116. 2 D. Flue Gas Stack (dia) IN 8 8 12 14 14 E. Combustion Air Inlet (dia) IN 10 10 12 12 12 F. Water Inlet/Outlet (dia) IN 4 4 6 6 6

Minimum Clearance EDR+ 2500 3000 4000 5000 6000

G. Front IN 36 36 36 36 36 H. Rear IN 24 24 36 36 36 I. Top IN 18 18 18 18 18 J. Sides IN 1; 24 1; 2 4 1; 24 1; 24 1;24

Endura+ boilers may be operated up to 10,000 feet elevation, and up to 1,000 feet elevation at 80˚ F without de-rate. Consult your Fulton Representative for capacities at higher elevation. Applies to natural gas with a caloric value of 1,010 BTU per FT3. Standard natural gas congurations only. Alternate or custom congurations may have dierent requirements; always review the boiler nameplate before installation. Standard electrical congurations only. Alternate or custom congurations may have dierent requirements; always review the boiler nameplate before installation. An appliance adapter is required (optional factory trim; supplied only when ordered). 24-inch (610mm) clearance is required on one side to facilitate and expedite maintenance and any advanced troubleshooting. NOTE: Specications and dimensions are approximate and for reference only. Fulton practices continuous product improvement and reserves the right to change specications and/or dimensions without notice.

TOP VIEW

A C

FRONT VIEW SIDE VIEW

FIGURE 1  ENDURA+ HYDRONIC BOILER SERVICE CLEARANCE

2-4

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

DRAWING NUMBER

REV

DESCRIPTION:

DRAWN BY:

CHECKED BY:

B.O.M. REVIEW

MECH. ENG:

ELEC. ENG:

APPROVED BY:

JOB NUMBER:

PROJECT NAME:

PROJECT MANAGER:

This design and drawings

are proprietary and are the

exclusive property of

Fulton Group N.A., Inc.

The corporation does not

permit their use except

with prior written consent.

The items shown in this

drawing may be covered by

one or more patents of

Fulton Group N.A., Inc.

1 OF 1

THIRD ANGLE PROJECTION

Fulton Group N.A., Inc

972 Centerville Road

Pulaski, New York USA 13142

UNLESS OTHERWISE NOTED

DIMENSIONS ARE IN INCHES

SHEET 1 OF 1

(1) PLACE DEC.

` 0.03

(2) PLACE DEC.

` 0.015

(3) PLACE DEC.

` 0.005

ANGLE

` 0.5 DEG

SURFACE FINISH

250 MICRO-INCHES

TOLERANCES

FRACTION &

WHOLE VALUE

`1/8

G-36-100018 -

ENDURA+ MULTIPLE BOILER COMMON EXHAUST

VENTING DIAGRAM

B. PALMER

K.D.B.

4/11/2016

4/19/2016

SEE NOTE 8

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.

2. Appropriate front, back, side and top clearances must be maintained (Figure 1) to allow access around the equipment to facilitate maintenance and a safe work environment, as follows:

» A 1-inch (25.4 mm) side clearance is acceptable

between a pair of boilers. Custom congurations may not allow 1-inch (25.4 mm) side clearance.

» 24-inch (610 mm) clearance is required on one

side to facilitate and expedite maintenance and any advanced troubleshooting.

3. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

4. Do not place or install any boiler room accessories, or other components, on the Endura+ cabinet panels.

Install Boiler Trim

Each Endura+ boiler is supplied with a safety relief valve sized in accordance with ASME requirements. Adhere to the following installation requirements:

TABLE 2 CONT.  SAFETY RELIEF VALVE INLET AND OUTLET SIZES

Model Trim Pressure

PSI (kPa)

EDR+ 4000

EDR+ 5000

EDR+ 6000

30 (206.84) 2 (50.8) 2 1/2 (63.5)

60 (413.69) 1 1/2 (38.1) 2 (50.8)

100 (689.48) 1 1/2 (38.1) 1 1/2 (38.1)

125 (861.84) 1 1/4 (31.8) 1 1/4 (31.8)

Inlet Size inch (mm)

Outlet Size inch (mm)

160 (1103.16) 1 (25.4) 1 1/4 (31.8)

2. The discharge pipe must:

» Not have a diameter less than the full area of the

valve outlet.

» Be as short and straight as possible and so

arranged as to avoid undue stress on the valve.

» Be supported by means other than the safety

valve itself.

» Be piped to avoid danger of scalding

personnel.

NOTE: Each boiler is supplied with a pressure-temperature

gauge to be installed in the outlet piping section of the boiler. Gauge must not be isolated from the boiler by any valve.

Note: Valve is shipped loose and must be

installed by the contractor.

1. The safety relief valve (Figure 2) must:

» Be connected to the coupling located in the top

of the boiler.

» Be installed in the upright vertical position.

NOTE: Safety relief valve size is determined by trim pressure

and is supplied in the trim kit. For inlet and outlet sizes, see Table 2.

TABLE 2  SAFETY RELIEF VALVE INLET AND OUTLET SIZES

Model Trim Pressure

PSI (kPa)

EDR+ 2500

EDR+ 3000

Questions? Please Contact Your Local Manufacturer’s Representative

30 (206.84) 1 1/2 (38.1) 2 (50.8)

60 (413.69) 1 1/4 (31.8) 1 1/2 (38.1)

100 (689.48) 1 (25.4) 1 1/4 (31.8)

125 (861.84) 1 (25.4) 1 1/4 (31.8)

160 (1103.16) 3/4 (19.1) 1 (25.4)

Inlet Size inch (mm)

Outlet Size inch (mm)

FIGURE 2  SAFETY VALVE INSTALLATION LOCATION

2-5

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

The discharge from the safety relief valve must be arranged to ensure no danger of scalding personnel, or equipment damage.

Provisions must be made to properly pipe the safety relief discharge away from the boiler to the point of discharge.

No shuto of any kind shall be placed between the safety relief valve and the boiler, or in the discharge pipe between the valve and the atmosphere. Doing so may cause an explosion from overpressure.

The hydronic system should never be ushed while the boiler is attached to the system since the debris could accumulate in the boiler and block water from passing through the heat exchanger.

For water-only systems, the water pressure at the boiler outlet must be 12 psi or greater at all times while the boiler is in operation. For systems using up to 50% glycol, a minimum of 30 psi is required at the boiler outlet.

Install Water Piping

All water supplies contain some solids, dissolved gases or dissolved minerals. These may cause corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler performance, valve operation and general pipe longevity, you must analyze and treat each installation uniquely.

Adhere to the following for water piping installation (see Figures 4  7):

 Manual isolation valves are recommended on both water connections for

ease of service.  Install piping such that the boiler is not supporting any piping load.  Install manual purging valves in all loops and zones.  Install a pressure-reducing (automatic ll) valve in the cold water ll line to

the boiler system.

NOT: For water-only systems, the water pressure at the boiler outlet must

be 12 psi or greater at all times while the boiler is in operation. For systems using up to 50% glycol, a minimum of 30 psi is required at the boiler outlet.

 To prevent scale and corrosion in boiler and associated piping, make

up water must be kept to a minimum. This is best achieved by ensuring

immediate repair of all leaks and that system pressure is maintained.

 Check that the proposed operation of zone valves, zone circulator(s) and

diverting valves will not isolate air separator(s) and/ or expansion tank(s)

from the boiler.

 Provide at least 6 inches (152 mm) clearance from hot water pipes to

combustibles.

 When used with a refrigeration system, install the boiler so that the chilled

medium is piped in parallel with the boiler with appropriate valves to

prevent the chilled medium from entering the boiler. If the boilers are

connected to heating coils (located in air handling units) where they may

be exposed to refrigerated air circulation, such boiler piping systems must

be equipped with ow control valves or other automatic means to prevent

gravity circulation of the boiler water during the cooling cycle.

 Include the following in the mechanical equipment in the hydronic

heating system:

2-6

» An automatic pressure activated water make up valve with back ow

preventer. It must be set to maintain required 12 psi or greater at

boiler outlet, Net Positive Suction Head (NPSH) for re-circulating pumps, a positive system pressure at the highest point of at least 5-10 PSIG, and should be designed to add water to the system at the outlet of the boiler but should not be fed directly into the boiler.

» Air removal equipment, including an air separator and automatic

breather valves, along with a functioning expansion tank . Each must

be designed to system specications.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 100 200 300 40 0 500 600

Pressure Drop (PSI)

Water Flow Rate (GPM)

EDR+2500 EDR+3000

EDR+5000 EDR+6000

NOTE: The upper water connection on the back of the boiler is the outlet

connection. The lower water connection on the rear of the boiler is the inlet connection.

 Install ltration in the common loop or per boiler to remove particulates. A

#4 or ner mesh size is required.

 Install bypass chemical feeder for corrosion inhibitor maintenance if

required to comply with water chemistry requirements.

 Install corrosion coupon holder to assess corrosion inhibitor performance if

required to comply with water chemistry requirements.

 Before installing an Endura+ boiler into a hydronic loop, be sure that the

system piping and any other components of the system are clean and free of debris, ferrous oxide (magnetite), and any foreign matter. The hydronic system must be completely ushed prior to installing the boiler.

FIGURE 3  TYPICAL WATER SIDE PRESSURE DROP

6.0

5.0

EDR+2500 EDR+3000

EDR+4000 EDR+5000 EDR+6000

! WARNING

Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

4.0

3.0

Pressure Drop (PSI)

2.0

1.0

0.0 0 100 200 300 400 500 600

Water Flow Rate (GPM)

 Variable Primary Piping Arrangement

Endura+ boilers are designed for installation in variable primary ow piping arrangements (see Figures 4 and 5), sometimes referred to as full ow systems. This arrangement eliminates temperature mixing associated with primarysecondary piping, thereby delivering the lowest temperature water directly to the boiler return connections and increasing thermal eciency of the condensing boiler plant.

NOTE: Although it is acceptable to install Endura+ boilers in a primary-

secondary conguration, it is not required.

Adhere to the following for variable primary piping arrangements:

 Select pump(s) with sucient total dynamic head for the pressure drop of the

loop at design ow: See Figure 3 for the water side pressure drop through

the boiler. The Endura+ boiler will automatically perform a safe shutdown

Questions? Please Contact Your Local Manufacturer’s Representative

2-7

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

FULTON ENDURA+

CONDENSING BOILER

HEATING HOT

WATER RETURN

EXPANSION

TANK

AIR

REMOVAL

VARIABLE SPEED

SYSTEM PUMP

HEATING HOT

WATER SUPPLY

FULTON ENDURA+

CONDENSING BOILER

HEATING HOT

WATER RETURN

FIGURE 4  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; SINGLE BOILER

AIR

REMOVAL

RETURN WATER

TEMPERATURE SENSOR

TWO POSITION

MOTORIZED ISOLATION

VALVE

SUPPLY WATER

TEMPERATURE SENSOR

HEATING HOT

WATER SUPPLY

VARIABLE SPEED

SYSTEM PUMP

EXPANSION

TANK

FIGURE 5  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; MULTIPLE BOILERS

Note: Sample piping layout (P&ID) is a general representation of system installation. Good practice should be used in system design, including but not limited to adequate pipe/valve sizing and natural ow path for system water.

2-8

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

HEATING HOT

WATER RETURN

FULTON ENDURA+

CONDENSING BOILER

SUPPLY WATER

TEMPERATURE SENSOR

CLOSELY SPACED TEES

( <4 x DIAMETER)

DEDICATED BOILER

(PRIMARY) PUMP

SYSTEM

(SECONDARY)

PUMP

AIR

REMOVAL

HEATING HOT

WATER SUPPLY

EXPANSION

TANK

FIGURE 6  SAMPLE PIPING LAYOUT, PRIMARY  SECONDARY PIPING; SINGLE BOILER

FULTON ENDURA+

CONDENSING BOILER

HEATING HOT

WATER SUPPLY

SYSTEM (SECONDARY) PUMP

AIR REMOVAL

EXPANSION TANK

SUPPLY WATER TEMPERATURE

SENSOR

CLOSELY SPACED TEES

( <4 x DIAMETER)

HEATING HOT

WATER RETURN

RETURN WATER

TEMPERATURE SENSOR

REVERSE RETURN

DEDICATED BOILER

(PRIMARY) PUMP

FIGURE 7  SAMPLE PIPING LAYOUT, PRIMARY  SECONDARY PIPING; MULTIPLE BOILERS

Questions? Please Contact Your Local Manufacturer’s Representative

2-9

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

Do not use matches, candles, ame or other sources of ignition to check for gas leaks.

in the event of a low ow condition; however, proper design ow will be required to deliver heat to users and prevent nuisance high temperature limit trips.

 Use motorized isolation valves: Ensure system eectiveness by eliminating

ow through idle boilers in accordance with ASHRAE 90.1-2013 (6.5.4.3.2). Blending of unheated supply water may impact temperature control operation or cause manual reset high temperature lockouts. One motorized isolation valve should be installed per boiler; two-position type actuator, open or closed. It is acceptable to install the valve on either the inlet or the outlet piping of each boiler.

 Motorized isolation valve control: Ensure ow paths in the hydronic loop

and residual heat in the pressure vessel is adequately dispersed when the burner is disabled. The valve control system must be capable of leaving the lead boiler valve open at all times.

 Use a reverse return header to properly balance ow across the boilers

for multiple boiler systems: Where reverse return cannot be used, it is

recommended to install a balancing valve per boiler.

 Do not install three-way mixing valves or minimum temperature protection:

The Endura+ boiler does not have a minimum return water temperature requirement.

 Primary-Secondary Piping Arrangement

It is acceptable to install the Endura+ boiler in a primary-secondary arrangement, although this arrangement is not required. See Figures 6 and 7. Primarysecondary arrangements are used to decouple the water ow of the primary (boiler) loop from the secondary (system) loop. Temperature mixing occurs in the shared piping region.

Adhere to the following for primary-secondary piping arrangements:

 Typical shared piping methods include closely spaced tees, a buer tank, or

a hydraulic separator.

 When using closely spaced tees as a decoupling method, the tees should

be separated by four pipe diameters or less.

 Install the dedicated boiler circulator on the inlet side of the Endura+

boiler, pumping into the return connection. Select pump(s) with sucient total dynamic head for the pressure drop of the loop at design ow. See Figure 3 for the water side pressure drop through the boiler.

 For multiple boiler systems:

» Use a single common supply connection and a single common return

connection into the secondary (system) piping. Do not use separate

connections for each boiler into the secondary piping.

2-10

» Use a reverse return primary header to properly balance ow across

the boilers. Where reverse return cannot be used, it is recommended to install a balancing valve per boiler.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

Meet Water Chemistry Requirements

System water chemistry requirements are as follows:

 pH: Range of 8.5 - 10.5

 Oxygen: Less than 250 ppb (operating condition)

 Total Iron/Copper: Less than 5 ppm

 Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2 mpy.

Due to changing environmental restrictions, a non-heavy metal ALL ORGANIC inhibitor is recommended which is designed for multi-metal systems including ferrous metals and yellow metals such as copper and brass.

 Chloride: Less than 200 ppm

 Hardness: Less than 3.5 grains per gallon (60 ppm) in make-up/ll water.

Calcium buildup on heating surfaces is not covered under warranty.

Adhere to the following:

1. Refer to your water conditioning or chemical treatment supplier for analysis and recommendations for proper system conditions.

2. Follow a program with appropriate monitoring and maintenance of system water conditions as provided by your water conditioning or chemical treatment supplier.

3. If RO/DI water is used as a source for hydronic loop water or makeup water, it must be neutralized to a pH of 8.5 - 10.5 prior to entering the boiler. Failure to neutralize the RO/DI water will void the pressure vessel warranty and may cause high general corrosion rates.

 The system must have an automatic pH controller to monitor and log

the levels. This must be independent of other chemical feed systems.

 Makeup water pH range must be 7.5 - 8.8; the boiler water must be

maintained within pH range of 8.5 - 10.5.

4. Operate the boiler in a pressurized closed-loop system using water or water/glycol solution. A large amount of improperly treated make-up water can cause premature failure of the heat exchanger resulting from scale build up. Scale build up will reduce the eciency and useful life of the boiler and is not covered under warranty.

5. For freeze protection, an inhibited propylene glycol is recommended. The maximum concentration is 50% glycol by volume. Only use mixtures formulated for hydronic systems. DOWFROST™ HD is recommended. Do not use automotive glycol.

! WARNING

If the water supply must be temporarily disconnected from the condensate drain trap, the boilers must be turned o to prevent accidental ue gas emission into the boiler room.

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

Care needs to be taken to eliminate oxygen from the water system, as excess oxygen in the system will reduce the life of any boiler. The boiler warranty does not cover heat exchanger replacement due to oxygen contamination of boiler water.

Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not covered under the warranty.

If the piping system attached to this unit will be chemically cleaned, the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler. If cleaning is desired, ush the boiler with clean domestic water only.

NOTE: For systems using up to 50% glycol, a minimum of 30 psi is required at the

boiler outlet.

6. At a minimum, the hydronic uid should be checked for glycol concentration and pH once a year, or per glycol manufacturer schedule. A refractometer is recommended.

Questions? Please Contact Your Local Manufacturer’s Representative

2-11

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

 Prevent Oxygen Contamination

There are several ways to prevent boiler water oxygen contamination:

 Minimize system leaks to minimize make up water

requirement

 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

 Eliminate System Air

NOTE: No built-in boiler air eliminating features exist.

Adhere to the following for air elimination:

1. The installation of an air separator and air eliminator (air vent) is required.

2. If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator on the suction side of the system circulator(s).

3. If an air cushion type expansion tank is used, pipe tank directly into boiler supply on the suction side of the system circulator(s).

4. 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.

The packaged gas train (see Figure 8) is congured to operate at specic gas pressure requirements. The standard requirements are detailed in Table 1. Do not modify the gas train.

NOTE: Alternate or custom congurations may have

dierent requirements; always review the boiler nameplate before installation.

The Endura+ boiler is factory test red and combustion is adjusted per the boiler nameplate and test re report.

 Inlet Gas Pressure

Adhere to the following:

 Static inlet gas pressure: Measure while boiler is idle.

Verify pressure is within allowable range.

 Dynamic inlet gas pressure: Measure while boiler is in

operation at maximum ring rate. Verify pressure is within allowable range.

 The gas delivery system must provide a stable and

consistent pressure across the entire turndown range, including light o and idle conditions.

 Maximum inlet gas pressure drop from static to

dynamic must not exceed 15%, or the maximum allowable by local code (CSA B149 clause 6.3.2 for

Canada). The stricter of the two shall apply.

GAS SERVO

FLUE TRAIN INLET

NOTE: INSTALL GAS

SHUT-OFF VALVE UPSTREAM

(NOT PROVIDED)

5. When the boiler is installed at a higher level than heating coils (e.g., a penthouse boiler room), air

elimination must be provided directly above the boiler.

Fill the Boiler with Water

To be sure that the boiler is not air-bound, open the pressurerelief valve located at the rear of the boiler. Leave the relief valve open until a steady ow of water is observed. Close the valve and nish lling the system.

Gas Supply Piping

The Endura+ is a gas red fully modulating boiler that requires delivery of gas at a relatively constant pressure and caloric content. This ensures ecient and reliable combustion.

2-12

SHUTOFF VALVE WITH TEST PORT

NOTE: MEASURE MAIN

GAS VALVE DOWNSTREAM

PRESSURE HERE

FIGURE 8  TYPICAL GAS TRAIN VARIES BY SIZE/MODEL

SHUTOFF VALVE WITH TEST PORT

NOTE: MEASURE INLET

GAS PRESSURE HERE

MAIN GAS VALVE

WITH HIGH AND LOW

GAS PRESSURE SWITCHES

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

 Line Gas Pressure Regulation

When inlet gas pressure exceeds the maximum on the boiler name plate, a line gas pressure regulator is required to step the gas pressure down to an acceptable pressure. See Figure 9.

Proper selection and installation of a gas pressure regulator is essential in providing ideal conditions for ecient and reliable combustion. Adhere to the following guidelines when selecting and installing a gas pressure regulator:

 A sediment trap is recommended prior to the inlet of

the regulator.

 If the level of pipe system cleanliness is unacceptable

or unknown, install a gas lter prior to the regulator.

 On the outlet of the regulator: Install a straight and

uninterrupted section of pipe matching regulator connection size with a minimum length of 10 pipe diameters prior to any valves or ttings.

 When installed in close proximity to an appliance,

some regulators may experience oscillation (hunting) or an outlet pressure spike when demand ends. Provide adequate volume by locating the regulator a minimum of 10 total linear feet of pipe from boiler fuel train inlet. Consult the regulator manufacturer for installation requirements.

 The body size should never be larger than the pipe

size. However, a properly sized regulator may be smaller than the pipeline.

 The inlet pressure used for sizing should be measured

directly at the regulator inlet. Measurements taken at any other point may be subject to losses associated with upstream piping.

 Consult the regulator manufacturer for orice selection.

 If two or more springs are available for a particular

outlet pressure in the desired range use the spring with the lower range for better accuracy.

NOTE: Regulators are not intended for use as “shut o”

devices. As per ANSI Z21.80/CSA 6.22 lock-up is dened as an outlet pressure not more than 150% or 5” W.C., whichever is greater, above the setpoint after a downstream safety shuto valve closes within 2 seconds.

 Appliance regulators must not be used as line gas

pressure regulators to step down the gas pressure. For additional information regarding gas regulator selection and installation consult your regulator manufacturer, any applicable local codes or ordinances, the standard for line pressure regulators ANSI Z21.80/ CSA 6.22, and The National Fuel Gas Code NFPA 54/ANSI Z223.1.

 Gas Piping Installation

Adhere to the following for gas piping installation:

1. See Table 3 for required natural gas pipe size, based on overall length of pipe from the meter plus equivalent length of all ttings. Approximate sizing may be based on 1,020 BTU for 1 cubic foot of natural gas. See Figures 6 and 7 for piping arrangements.

2. Install a manual gas shuto valve prior to the boiler.

3. Piping must be installed such that no piping stresses are transmitted to the boiler. The boiler cannot be used as a pipe anchor.

TABLE 3  SCH 40 PIPE NATURAL GAS CAPACITY

Nominal Pipe Size

Inch (mm) Inch (mm) 90 Elb

1-1/4 (31.75) 1.380 (35.05) 3.45 (1.05) 6.9 (2.10) 950 ----- ----- ----- ----- ----- ----1-1/2 (38.1) 1.610 (40.89) 4.02 (1.22) 8.04 (2.45) 1460 990 810 ----- ----- ----- ----2 (50.8) 2.067 (52.50) 5.17 (1.57) 10.3 (3.13) 2750 1900 1520 1300 1150 950 800 2-1/2 (63.5) 2.469 (62.71) 6.16 (1.87) 12.3 (3.74) 4350 3000 2400 2050 1850 1500 1280 3 (76.2) 3.068 (77.92) 7.67 (2.33) 15.3 (4.66) 7700 5300 4300 3700 3250 2650 2280 4 (101.6) 4.026 (102.26) 10.10 (3.07) 20.2 (6.15) 15800 10900 8800 7500 6700 5500 4600 6 (152.4) 6.07 (154.17) 10.10 (3.07) 23.60 (7.19) ----- ----- ----- ----- 20200 16503 12766 8 (203.2) 7.98 (202.69) 13.30 (4.05) 29.10 (8.86) ----- ----- ----- ----- 41200 33660 29128

Questions? Please Contact Your Local Manufacturer’s Representative

ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour at 14" WC pressure.

Pressure drop of 0.5" WC. Equivalent length of pipe (feet)

Feet (meter)

Tee Feet (meter)

20 40 60 80 100 150 200

2-13

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

4. The boiler and all gas piping connections must be pressure-tested and checked for leaks before being placed into service. Test with compressed air or inert gas if possible.

5. The boiler must be disconnected at the boiler manual shuto valve (located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of

2.0 psig (55 inch W.C.).

6. Gas Piping must be installed in accordance with National Fuel Gas Code, ANSI Z223.1 1991 or latest addenda and any other local codes, which may apply.

7. The pipe and the ttings used must be new and free of dirt or other deposits.

8. Piping must be of the proper size to ensure adequate gas supply. A drip leg and union connection must be installed upstream of the gas safety shut o valves and must be a 5 inch (127 mm) minimum length.

GAS SHUTOFF VALVE

(NOT PROVIDED)

MINIMUM 10 LINEAR FEET OF

PIPE BETWEEN REGULATOR

9. Connect gas supply line to the open end of the tee on which the drip leg is installed.

10. When making gas-piping joints, use a sealing compound resistant to liqueed petroleum gases. Do not use Teon tape on gas line threads.

11. After gas piping is completed and before wiring installation is started, carefully check all piping connections (factory and eld) for gas leaks. Use a soap and water solution or combustible gas detector. A GASMate® 0119 or equivalent is recommended.

12. The boiler must be disconnected at the boiler shut o valve from the gas.

LINE GAS PRESSURE REGULATOR

AND BOILER

NOTE: REQUIRED FOR INSTALLATIONS

WHERE SUPPLY GAS PRESSURE EXCEEDS

MAXIMUM ON BOILER NAME PLATE.

(NOT PROVIDED)

GAS SHUTOFF VALVE

(NOT PROVIDED)

GAS SUPPLY

2-14

FIGURE 9  ENDURA+ SINGLE BOILER GAS SUPPLY PIPING

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

LINE GAS PRESSURE REGULATOR

` MULTIPLE BOILER INSTALLATION

When gas supply pressure exceeds the maximum on the boiler name plate, a line gas pressure regulator is required. It is recommended that an individual regulator be used at each boiler. See Figure 10.

When a single regulator is used for multiple boilers, the regulator must be appropriate for the entire gas delivery ow (CFH) turndown range. This includes all boilers on at full re to one boiler on at low re.

GAS SHUTOFF VALVE

(NOT PROVIDED)

MINIMUM 10 LINEAR FEET OF

PIPE BETWEEN REGULATOR

AND BOILER

NOTE: REQUIRED FOR INSTALLATIONS

WHERE SUPPLY GAS PRESSURE EXCEEDS

MAXIMUM ON BOILER NAME PLATE.

(NOT PROVIDED)

GAS SHUTOFF VALVE

(NOT PROVIDED)

GAS SUPPLY

FIGURE 10  ENDURA+ MULTIPLE BOILER GAS SUPPLY PIPING

Questions? Please Contact Your Local Manufacturer’s Representative

2-15

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

 Components Requiring Ventilation to the

Outdoors

NOTE: The port marked “AIR” on the SKP25 actuator cannot

be used as as gas vent connection. Connecting a vent line to this port may cause operational issues.

The following do not require ventilation to the outdoors, as there is a vent limiter in use:

 Regulator on the pilot line (not applicable to all sizes).

An authority having jurisdiction (AHJ) may not permit the use of a vent limiter on some or all components. If venting is required, use the following general guidelines:

 Drill an appropriately sized penetration for each vent

line of the boiler cabinet. Do not install any vent lines through removable latching panels. Properly seal around the pipe with sensor safe silicone.

 Each component must have a separate vent line to

the outdoors. Vent lines must not be manifolded or combined with any other vent or exhaust systems.

 Start with the vent connection size and as soon as it is

practical, increase the pipe size one diameter. For every ten feet of vent, increase the pipe size one diameter. Never reduce the vent size.

 Protect the vent termination from debris, dust and

insects. Install the vent termination above the snow line and point down to prevent ingress of water. The termination must be a minium of 3 ft (0.9 m) from a source of ignition.

Install Condensate Drain Trap

A condensate drain trap is intended for use with the Fulton Endura+ boiler.

 Single Boiler Drain Trap

The single boiler condensate drain trap is Fulton Part Number 4-57-005500. The drain trap must be congured one per boiler, with a maximum of 4.0 MMBH total. (See Figures 11 and 13).

Adhere to the following for installation:

1. A exible condensate drain hose must be installed between the boiler and any piping anchored to the oor. Ensure that there are no low spots.

2. The 1 inch (25.4 mm) boiler condensate drain outlet will be reduced and connected to the 3/4 inch (19.05 mm) inlet on the top of the drain trap.

3. A condensate collecting tank and condensate pump will be required if a oor drain is not available to collect condensate (collecting tank and pump are not supplied with the boiler).

4. All piping (Figure 11) must be CPVC, high temperature silicone tubing, galvanized, or stainless steel, and be free of leaks. Copper, carbon steel/iron pipe, or PVC are not acceptable.

5. The 3/4 inch (19.05 mm) drain trap outlet must remain below the 1 inch (25.4 mm) boiler condensate drain.

6. Connect the 3/4 inch (19.05 mm) trap outlet to an appropriate waste line following applicable codes. The 3/4 inch (19.05 mm) drain connection on the drain tank must be the highest point prior to going to the drain. Failure to keep drain piping lower than this point will result in overow of the drain tank. Slope the drain pipe away at a minimum pitch of 1 inch (25.4 mm) for every 12 feet (3.65 m).

2-16

7. Ensure condensate drain piping will not be exposed to freezing temperatures.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

(NOT PROVIDED)

Figure Notes:

1. Pipe must be level or slightly pitched toward the drain.

2. Pipe material must be CPVC, high-temperature silicone tubing, galvanized steel, or stainless steel.

3. The condensate drain trap outlet must be below the condensate outlet of the boiler.

4. The maximum capacity to attach per condensate drain kit is 4 MMBH total.

SIDE VIEW

HOUSEKEEPING PAD

MINIMUM 4-INCH (102 MM)

FLEXIBLE DRAIN HOSE

(SUPPLIED, REQUIRED)

REDUCING BUSHING

BACK VIEW

FIGURE 11  CONDENSATE DRAIN PIPING FOR INDIVIDUAL ENDURA+ BOILER

Questions? Please Contact Your Local Manufacturer’s Representative

2-17

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

BACK VIEW

HOUSEKEEPING PAD

MINIMUM 4-INCH (102 MM)

FLEXIBLE, DRAIN HOSE (SUPPLIED, REQUIRED)

Figure Notes:

1. Header must be level or slightly pitched toward the drain.

2. Header material must be CPVC, high-temperature silicone tubing, galvanized steel, or stainless steel.

3. Header should be taken to the lowest point possible and maintain a minimum 2-inch (51 mm) drop from the boiler condensate drain outlet.

4. The condensate drain trap outlet must be below the condensate outlet of the boiler.

5. For multiple boiler installation, maintain minimum pipe size of one inch (25.4 mm) for the header piping.

Note: A ¼" fresh water makeup line is required.

HEADER MUST BE AT

FLOOR (NOT PAD) HEIGHT

¼" TAPPING PROVIDED

FOR FRESH WATER

CONNECTION

≥2"

SIDE VIEW

6. The maximum capacity to attach per multiple boiler condensate drain trap is 12 MMBH total.

FIGURE 12  CONDENSATE DRAIN PIPING FOR MULTIPLE ENDURA+ BOILERS

2-18

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

RIGHT SIDE VIEW

1 1/2

1 3/8

7 3/4

10 11/16

10 1/8

6 1/2

7 5/8

FRONT VIEWTOP VIEW

(COVER NOT SHOWN)

5/8

3/8" (TYP.)

1/4" WATER SUPPLY

CONNECTION

6 1/2

5 1/8

 Multiple Boilers Sharing A Common Drain Trap

The multiple boiler condensate drain trap is Fulton Part Number 4-57-000440. The maximum capacity to attach per condensate drain trap is 12 MMBH total. (See Figures 12 and 14).

Adhere to the following for installation:

1. A exible condensate drain hose must be installed between the boiler and any piping anchored to the oor. Ensure there are no low spots.

2. The Fulton Endura+ boiler 1 inch (25.4 mm) condensate drain outlet will be connected to the 1 inch (25.4 mm) inlet on the drain trap. One or more drain lines may be connected to this inlet (max of 12 MM BTU per drain) using a common header pipe.

3. If the water supply must be temporarily disconnected, the boilers must be turned o to prevent accidental ue gas emission into the boiler room.

4. The condensate drain cover must be kept on at all times, except during maintenance of the drain. This drain should be checked regularly in your boiler maintenance schedule.

5. A condensate collecting tank and condensate pump will be required if a oor drain is not available to collect condensate (collecting tank and pump are not supplied with the boiler.)

6. All piping (Figure 12) must be CPVC, high-temperature silicone tubing, galvanized, or stainless steel, and be free of leaks. Copper, carbon steel/iron pipe or PVC are not acceptable.

7. Connect 1 inch (25.4 mm) condensate drain(s) (at the rear of the boiler), to the 1 inch (25.4 mm) inlet at the base of the drain tank. The header must be at least 5.5 inches (14.2 cm) below the condensate outlet of the individual boiler, and must remain ooded - achieved by ensuring it is at least 5.5 inches (14.2 cm) below the outlet of the condensate drain trap.

8. Connect the 1.5 inch (38.1 mm) drain outlet to an appropriate waste line following applicable codes. The

1.5 inch (38.1 mm) drain connection on the drain tank must be the highest point prior to going to the drain. Failure to keep drain piping lower than this point will result in overow of the drain tank. Slope the drain pipe away at a minimum pitch of 1 inch (25.4 mm) for every 12 feet (3.65 m).

9. Attach a ¼” water supply to the compression tting on the oat. The water line must be connected to an uninterruptible supply. Install before the “fast ll” valve to the boiler supply—but after the back ow preventer—to avoid contamination of a potable water supply. Maximum allowable water pressure to the compression tting is 100 PSI (689.5 kPa).

10. Ensure condensate drain piping will not be exposed to freezing temperatures.

3/4" NPT

FRONT VIEW BACK VIEW TOP VIEW

FIGURE 13 SINGLE BOILER CONDENSATE DRAIN TRAP

Questions? Please Contact Your Local Manufacturer’s Representative

FIGURE 14  MULTIPLE BOILER CONDENSATE DRAIN TRAP

4 13/16

3/4" NPT

11/16

2-19

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

TOP VIEW

TANK COVER REMOVED FOR CLARITY

ISOMETRIC VI EW

FRONT VI EW

TOP VIEW

ISOMETRIC VI EW

FRONT VI EW

TOP VIEW

ISOMETRIC VIEW

LEFT VIEW

MULTIPLE BOILER

ASSEMBLY

½"

1½" N.P. T.

OUTLET

12½"

11⅜"

1½" N.P.T.

6½"

INLET

2¾"

FRONT VIEW

RIGHT VIEW

2¾"

FIGURE 15  FULTON PH NEUTRALIZING KIT

SINGLE BOILER

ASSEMBLY

2-20

ISOMETRIC VI EW

Multiple Boilers Individual Boiler

(A) pH Kit Outlet 1 1/2” 1 1/2” (B) Condensate Drain Trap 4-57-000440 4-57-005500 (C) Drain Outlet 1 1/2” 3/4” (D) pH Kit Inlet 1 1/2” 1 1/2” (E) pH Neutralization Kit 4-50-000008 4-50-000008 (F) Drain Inlet 1” 3/4” Neutralizing Media 2-30-001580 2-30-001580

FIGURE 16  FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK

ISOMETRIC VI EW

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

! WARNING

Install pH Neutralization Kit

The pH Neutralization Kit uses a consumable medium to bring the pH level of the boiler’s condensate to a more neutral level. It is not a replacement or alternative for the Condensate Drain Trap. See Figures 15 and 16.

Adhere to the following for pH Kit installation:

1. Use CPVC, high-temperature silicone tubing, stainless, or galvanized pipe and ttings to connect condensate trap to kit.

2. Connect kit downstream of Condensate Drain Trap. See Figure 16.

3. Pipe outlet to appropriate drain. It is acceptable to use PVC or CPVC on the outlet to drain.

4. Check condensate pH periodically.

NOTE: Replacement bags are available from your Fulton local representative.

The medium in the container will neutralize the condensate of 12 MMBH for approximately 6 months. (Fulton Part No. 2-30-001580)

4 CAUTION

An uninterruptible water supply is required for the multiple boiler condensate trap and shall be connected to the ¼” (U.S. only) compression tting. The water supply maintains a water level in the drain kit to prevent accidental ue gas emission into the boiler room.

Venting Requirements

Adhere to the following venting requirements:

1. The Endura+ boiler can operate to the combined intake and ue exhaust pressure drops without altering standard capacities: See Table 4.

2. The venting system draft pressure readings at the boiler exhaust connection and air intake connection cannot exceed the maximum values stated in Table 4; and must remain relatively stable throughout all operating conditions, including the ignition sequence.

NOTE: Venting pressure is the combined result of frictional pressure drop and

natural draft (stack eect) in the combustion air intake piping (if used) and ue gas exhaust system.

3. Drastic draft changes during operation may result in the generation of excessive carbon monoxide or soot, which may aect operational reliability and condition of burner, ignition assembly, or other combustion system components leading to increased maintenance or replacement of these items.

4. The equivalent length method is not an approved engineering method for determining acceptability of a vent system due to varying burner modulation rates, ambient air temperatures, and ue gas temperatures, among other factors. Combustion air intake piping (if used) must be accounted for in an analysis of the venting system.

5. If the maximum positive pressure is exceeded, the boiler may have to be de-rated or require the installation of draft accessories such as a properly selected exhaust assist fan to prevent operational issues from occurring. If the maximum negative pressure is exceeded due to excessive natural draft (stack eect), the exhaust system may require the use of draft accessories such as a xed-position balancing bae or modulating overdraft damper.

Questions? Please Contact Your Local Manufacturer’s Representative

2-21

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

Do not terminate venting into an enclosed area.

Never use open ame or smoke from a cigarette, cigar, or pipe as a testing method during boiler installation, operation, or maintenance.

Foreign substances, such as combustible volatiles in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the boiler combustion air inlet must be piped to an outside location.

Draft accessories must be appropriate for Category II/IV installations and are not included with the boiler. Consult your venting supplier for

recommendations.

6. Adhere to local and jurisdictional codes and regulations, which may dier from recommendations and diagrams contained in this manual.

7. Site specic conditions not addressed in this manual may require additional precautions or design considerations. Consult your local Fulton Representative and venting supplier for recommendations.

NOTE: Consult your venting pipe supplier for assistance with sizing of vent

materials and other potentially required accessories.

8. The layout of the piping used for air intake and exhaust must be done in a way that facilitates smooth travel and natural ow.

9. A pressure drop calculation is an acceptable method for evaluating theoretical draft, but is not enough information to fully validate combustion air intake and ue gas exhaust vent systems. The designer and installer must use good practice and remain cognizant of important factors that cannot be captured by a pressure drop calculation such as local code requirements, accessibility for inspection and maintenance, aesthetic concerns, ue gas recirculation, stagnant vapor plumes, prevailing wind direction, nearby mechanical equipment and other design considerations

as detailed in this manual. Some recommendations:

 Avoid sharp turns, boot tees, bullhead tees, back-to-back 90

degree elbows, short radius elbows.

 Avoid extensive direction changes (ue gases being required

to turn around).

 Never direct ue stacks in a downward direction.

TABLE 4  GENERAL VENTING PRESSURE REQUIREMENTS

Endura+ Model

Number

EDR+2500 -0.10” W.C. +1.50 “ W.C. EDR+3000 -0.10” W.C. +1.50 “ W.C. EDR+4000 -0.10” W.C. +1.00 “ W.C. EDR+5000 -0.10” W.C. +1.00 “ W.C. EDR+6000 -0.10“W.C. +1.00 “ W.C.

Maximum

Negative Draft

Maximum

Positive Draft

Combustion Air Intake

Adhere to the following for installation:

1. It is the responsibility of the designer and installer of the venting system to guarantee the prevention of ue gas recirculation (ue gases being drawn into a boiler’s combustion air supply, or ue gases moving backward

through an idle boiler).

2-22

2. The installation of room exhaust fans in a boiler room is not recommended. A boiler room exhaust fan or similar equipment can create down draft in the stack or restrict the burner’s air supply which will result in poor

combustion.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

! WARNING

3. It is essential that only fresh air is allowed to enter the combustion air system. Foreign substances, such as combustible volatiles in the combustion system can create hazardous conditions.

4. Particulate matter or chemicals (example: chlorine, sulfur, freon, uorine, perchlorethylene, halogenated compounds) in the combustion air supply to the boiler will cause damage or failure to the heat exchanger and/ or burner and is not covered under warranty. High-risk situations for particulate matter to be in the air include construction and maintenance

activities. See Table 5.

4 CAUTION

NOTE: Pool and laundry room air may be contaminated with chlorine or uorine

compounds. If allowed to enter the combustion air supply, these contaminants will signicantly increase the acidity of ue gas condensate, potentialy damaging heat transfer surfaces. Damage to the heat exchanger due to poor combustion air

quality is not covered under warranty.

TABLE 5  PRODUCTS/CONTAMINANTS TO AVOID

Products to avoid

Areas with the potential to have contaminants

Products containing chloro/ourocarbons; chlorinebased products; calcium chloride products, sodium chloride products, paint and varnish removers, hydrochloric acid, muriatic acid, cements, glues, antistatic fabric softeners, Freon, drywall particles, dirt, berglass.

Dry cleaning/laundry areas; swimming pools; repair shops; processing plants; manufacturing plants, active construction sites; chemical storage; food processing plants; farms; chillers; cooling towers.

 Combustion Air Supply From the Boiler Room

Adhere to the following for installation:

1. Adequate combustion air and ventilation must be supplied to the boiler room in accordance with local codes and NFPA54/ANSI Z233.1, Section

9.3, Air for Combustion and Ventilation or CSA-B149.1 for Canada. The minimum net free area requirements in Table 6 may not supersede local and jurisdictional codes and regulations where there codes and regulations require an opening of greater net free area. The boiler room must meet the NFPA criteria for a non-conned space.

Oxygen sensors are susceptible to silicone poisoning, which can cause premature degradation. Use only "sensor safe" silicone around the boiler and on combustion air supply materials.

2. Verify combustion air is taken from the outdoors and not from the inhabited or occupied spaces within the building. Ensure space and nearby products are evaluated for the potential of combustion air

contaminants. See Table 5.

3. For installations providing two permanent openings directly communicating with the outdoors, the minimum net free area of each opening is 1 in per 4,000 BTU/hr of the total input capacity of the combined burners located in the boiler room. A high opening and a low opening is required. Ensure the high opening commences within 12 inches of the ceiling, and the low opening commences within 12 inches of the oor. See Table 6.

Questions? Please Contact Your Local Manufacturer’s Representative

2-23

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

4 CAUTION

Do not use insulation on polypropylene materials. Use of insulation may elevate pipe wall temperatures, resulting in the potential for vent material failure.

Ensure there is not negative pressure in the boiler room. The boiler room pressure must be neutral relative to the outdoors.

4. For installations providing a single permanent opening directly communicating with the outdoors, the minimum net free area of each opening is 1 in per 3,000 BTU/hr of the total input capacity of the

combined burners located in the boiler room. See Table 6.

TABLE 6  MAKEUP AIR VENTILATION OPENINGS

Boiler Input

Capacity

(MBTU/HR)

2500 4.4 4.4 5.8 3000 5.2 5.2 7.0 4000 6.9 6.9 9.3 5000 8.8 8.8 11.6 6000 10.4 10.4 14.0

5. For multiple boiler installations, multiply the number of boilers by required net free area per boiler.

6. The net free area required for the boiler(s) is in addition to the combustion or ventilation air supply requirements of other equipment sharing the same space such as water heaters, generators, air compressors, or other boilers. The boiler room must have an opening or openings not less than the total net free area required for all types of equipment.

Two Openings - Min. Net

Free Area Each (SQFT)

Low High

Single Opening Only

Min. Net Free Area

(SQFT)

7. Consider the blocking eects of louvers, grills, and screens on the net free area of each opening. Ensure ventilation openings are unobstructed.

8. Ensure there is not negative pressure in the boiler room. The boiler room pressure must be neutral relative to the outdoors.

9. Where mechanical combustion air supply systems are used, such as a combustion air supply fan or a motorized louver, they must be interlocked with the boiler control panel to prove operation prior to burner ignition and during burner operation. Where manual louvers are used, ensure they

are fully open prior to operating the boiler(s).

 Air Piped From Outside Boiler Room

The combustion air supply can be piped directly to the air inlet of the boiler.

Adhere to the following for installation:

1. An adapter kit (factory option) is required to connect the boiler air inlet to the combustion air piping. Use a rubber coupling to connect the air inlet adapter to the air intake piping.

NOTE: The weight of combustion air intake piping must not be supported by the

boiler. Ensure air intake piping is externally supported on hangers or straps.

2. The air intake must be piped out of the building if the boiler room contains contaminated air.

2-24

3. The combustion air intake termination must be located as to not be subjected to the intake/exhaust of other mechanical equipment such as other fuel red heating equipment, loading docks, generators, air handling systems, and cooling towers.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

4. Ensure the boiler room air is maintained at a dew point temperature below the temperature of combustion air. Failure to provide adequate ventilation or control dew point temperature may increase maintenance or damage boiler components.

5. The air intake system must be designed to prevent any moisture from draining to the boiler. Slope the air intake duct down away from the boiler. See Figures 18 and 20.

6. Air Intake pipes and ttings shall be Schedule 40 PVC pipe or smoothwalled galvanized steel. All Schedule 40 PVC pipe, ttings, primer and cement must conform to American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM standards) per pipe manufacturer’s requirements.

7. Intake PVC piping must be assembled using cement. This will ensure that the intake is air tight and will not allow contaminates from the boiler room into the boiler. The cement must be free owing and contain no lumps, undissolved particles or any foreign matter that adversely aects the joint strength or chemical resistance of the cement. The cement must not show gelation, stratication, or separation that cannot be removed by stirring.

8. Adhere to procedure for cementing joints (per ASTM D2855).

9. Avoid sidewall exhaust with roof-terminated intake air. This may lead to reverse stack eect when the boiler is idle.

! WARNING

Fulton accepts no liability for installation of any venting, including the selection of venting materials. Maximum allowable ue gas operating temperatures may vary by manufacturer. Consult the venting supplier for maximum allowable temperatures.

Barometric dampers must never be used in a positive pressure exhaust or direct vent sealed combustion application.

Air Filter

The air lter requires monthly inspection and, at minimum, annual replacement. See Maintenance section of this manual.

Flue Gas Exhaust Venting

The Endura+ is equipped with a vent connection at the lower rear of the boiler.

Adhere to National Fuel Gas Code (ANSI Z223.1) and the following for installation:

1. The Endura+ is a Category II/IV appliance, thus venting material must be appropriate for condensing, positive pressure applications. Any venting material supplied for the Endura+ boiler must be AL29-4C or 316L SS, listed and labeled to UL 1738, and guaranteed appropriate for the application by the manufacturer and supplier of the venting. It is also acceptable to vent the Endura+ as a Category II condensing, negative pressure, for which an upsized diameter is typically required.

2. Do not use boot tees or bullhead tees. Use inline condensate drains in place of boot tees at the bottom of a vertical rise.

3. Barometric dampers are physically open to the mechanical space. When used in a condensing boiler application with negative pressure (Category II) exhaust vent, the design must prevent ue gas condensate from draining down the outside of the stack or dripping into the space. Barometric dampers must never be used in a positive pressure exhaust or a direct vent sealed combustion application.

4. Where allowed by the authority having jurisdiction (AHJ), the exhaust may be vented using polypropylene listed and labeled to UL 1738 or ULC S636.

Do not insulate polypropylene exhaust vents.

5. Refer to Table 7 for acceptable vent materials and temperature limits.

Questions? Please Contact Your Local Manufacturer’s Representative

2-25

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

FIGURE 17  TYPICAL COMMON EXHAUST LAYOUT

SEE NOTES 4, 5, 6

FULTON ENDURA+

CONDENSING BOILER

SEE NOTE 7

SEE NOTE 8

REAR VIEW

Figure 17 Notes:

1. All installations must be in compliance with local and national codes. This is a typical arrangement for reference purposes only. Actual installations may require alternate or additional components which are not shown for clarity.

2. This drawing is not for construction purposes.

3. Adhere to clearance and installation requirements.

4. The common exhaust header should be maintained at a slight negative pressure within the requirements of the boiler. A positive pressure common header will require draft accessories to guarantee ue gases cannot travel backward through an idle boiler.

5. A constant diameter common header is recommended. Do not use the static regain method.

6. A minimum 1/4” rise per foot run is required.

7. A 45° reducing tee or elbow in the direction of ow is recommended. Straight or 90° tees must not be used.

2-26

8. Do not use boot tees or bull head tees.

ISOMETRIC VIEW

9. Endura+ boilers cannot be common vented with other equipment.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

The use of PVC/CPVC or Radel® (polyphenylsulfone) in venting systems is prohibited.

6. A stainless steel adapter (not supplied) specic to vent manufacturer type and material will be required. Consult the venting supplier for guidance.

7. Adequate provision must be made to support the weight of the exhaust venting. It cannot be supported by the boiler exhaust connection.

8. Follow the venting manufacturer’s instructions for installation of exhaust venting.

9. Horizontal vents must allow for ue gas condensate to drain back to the boiler exhaust connection with a minimum pitch of ¼” (7 mm) per foot (300 mm) run. Failure to do so can create a condensate pocket, which can result in an inoperative boiler. There must be no low spots in the exhaust vent, as this can also result in a condensate pocket. A high spot acceptable, provided the minimum pitch is maintained in both directions.

10. The boiler control will automatically disable and reset the burner should the ue gas temperature exceed the stack limit setting. The factory default stack limit may be eld adjusted (See Operation) for installations utilizing a material in Table 7 approved for higher ue gas temperatures.

! WARNING

11. If stack drains are installed, they must be properly pitched and combined with the boiler ue gas condensate drain piping into the condensate drain trap.

TABLE 7  ACCEPTABLE EXHAUST VENTING MATERIALS

Venting

Material

Maximum

Flue Gas

Temperature

AL29-4C

(UL1738)

600° F

(315° C)

316L SS

(UL1738)

550° F

(287° C)

Polypropylene

(UL 1738)

230° F

(110° C)

TABLE 8  FULTON APPROVED FLUE GAS VENTING ADAPTERS*

Manufacturer Line Material Part/Catalog Number

EDR+2500/3000 EDR+6000

M&G DuraVent® FasNSeal® AL29-4C

Schebler eVent™ AL29-4C Consult Vendor Consult Vendor

Selkirk® Heat-

Fab®

Saf-T Vent® AL29-4C 96EDRPLUS Consult Vendor

810013180

(2-35-001655)

810013438

(2-35-001654)

Jeremias® GOV 444 SS SWKL8FBA-ENDPLUS Consult Vendor

*Note: This table lists factory approved ue gas venting adapters; other manufacturers may be used provided they meet the special gas vent requirements of this boiler.

Questions? Please Contact Your Local Manufacturer’s Representative

2-27

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

Common Venting Layouts for Endura+

It is possible to combine the air intake and/or exhaust venting of multiple Endura+ boilers. The pressure drop across the entire common system, the combined total of both air intake and exhaust, must comply with the draft pressure requirements for an individual boiler, see Table 4.

Refer to Figure 17 and adhere to the following for installation:

1. Consult your venting supplier for guidance in designing common vented installations. The system must be designed to prevent backow of exhaust gases through idle boilers.

2. Endura+ boilers are not approved for combined venting with other equipment such as steam boilers, water heaters, generators, and other types of Fulton equipment.

3. A constant diameter common header is recommended. Do not use the static regain method.

4. A minimum 1/4” rise per foot run is required for horizontal sections.

5. Where individual stacks transition into the common header, a 45 degree reducing tee or elbow in the direction of ow is recommended. Straight-in or 90

degree tees must not be used.

When designing a draft system for a quantity of two or more Endura+ boilers, the following items must be considered and addressed by the parties responsible for designing and providing that system:

3. Precautions must be taken to ensure that the draft pressure at each boiler is maintained within in the required range (refer to Table 4) throughout all conditions while also maintaining a slight negative draft pressure in the common exhaust header. Consider all possible operating conditions of the exhaust system specic to the application, including:

 Low and high ue gas temperatures

 Low and high ambient air temperatures

 All boilers operating at their maximum input

rating capacity

 One boiler in the system operating at the low re

position

 No boilers on, pre-purge and ignition

4. Consider the natural draft eects associated with vertical exhaust vent rise. Over-draft control accessories, such as modulating stainless steel dampers, may be required to mitigate a negative pressure exceeding the value in Table 4. An undersized common exhaust vent or pressure drop due to horizontal run can create a positive pressure common exhaust situation which may require a mechanical draft assist (exhaust fan) system.

5. If the common exhaust conguration does not allow for a stable negative pressure under all operating conditions then a mechanical draft assist system, such as a variable speed exhaust fan, may be required.

Venting Terminations

` COMMON VENTING EXHAUST BACKFLOW PREVENTION

1. When combining the exhaust vents of multiple Endura+ boilers, the system must be designed to guarantee ue gas and exhaust will not backow through an idle boiler. This requires appropriately sizing the common exhaust vent to maintain a slight negative draft pressure throughout all operating conditions. Alternative solutions may be considered provided the solutions to prevent ue gas recirculation (FGR), exhaust backow, and unacceptable draft pressures have been thoroughly evaluated by the venting designer and supplier.

2. It is recommended to install individually piped intake vents or use neutral pressure boiler room air with a common exhaust system. For common exhaust vent applications also combining combustion air intake (CAI) vents into a common pipe, it is necessary to size the common CAI pipe for a negligible pressure loss.

2-28

Adhere to the National Fuel Gas Code (ANSI Z223.1) and the following for installation:

1. Do not terminate the venting in an enclosed area. Care must be taken when selecting the orientation of the terminations.

2. All vent pipes and ttings must be installed with appropriate air 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 oors, walls, roofs, or framed spaces (See Figures 18, 19 and 20). The air space clearances should be observed to joists, studs, sub oors, plywood, drywall or plaster enclosures, insulating sheathing, rafters, roong, and any other material classed as combustible.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

NOTES:

1) HORIZONTAL SECTIONS MUST ADHERE TO A MINIMUM 1/4 INCH PER FOOT (1 MM PER 48 MM) RISE TO RUN RATIO

2) MAINTAIN A MINIMUM 9 INCH (229 MM) AIR SPACE CLEARANCE TO COMBUSTABLES, WIRE, AND INSULATION

3) INSTALL SUPPORT STRAPS AT 5 FT (152 CM) HORIZONTAL INTERVALS AND AT ELBOWS

ENDURA+

HYDRONIC

BOILER

( SIDE VIEW )

TYPICAL ROOF PENETRATIONS

COMBUSTION AIR FROM THE OUTDOORS

( SUGGESTED INSTALLATION CONFIGURATIONS )

MIN 4 FT (122 CM)

ADJUSTABLE FLASHING

METAL PLATE

FIRE STOP

ADJUSTABLE

FLASHING

ADHESIVE SEAL

STORM COLLAR

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

FLUE GAS EXHAUST TERMINATION

(RAIN CAP NOT REQUIRED)

IF SNOW ACCUMULATION

IS APPLICABLE, OPENING TO BE

MIN 1 FT (30 CM ) ABOVE

THIS NORMALLY EXPECTED LEVEL.

DO NOT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

SCH40 PVC PIPE (TYPICAL)

REFERENCE TABLE 1 FOR MIN CAI DIAMETER

STORM COLLAR

FLEXIBILE RUBBER PIPE COUPLING

FLUE GAS EXHAUST DIRECTION OF FLOW

COMBUSTION AIR INLET (CAI)

DIRECTION OF FLOW

STORM COLLAR (FOR DOUBLE WALL)

AIR INTAKE ADAPTER

(STYLE & LOCATION VARIES)

MIN 4 FT (122 CM)

ABOVE AIR

INTAKE PIPING

UL-1738 APPROVED EXHAUST VENT MATERIAL

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

FLEXIBLE HOSE

CONDENSATE TRAP (STYLE VARIES)

IN LINE STACK DRAIN (RECOMMENDED FOR HIGH CONDENSATE PRODUCTION RATE APPLICATION)

APPLIANCE ADAPTER CONSULT FLUE MFG FOR SELECTION REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER

CAUTION:

SEPARATE AIR INTAKE AND EXHAUST TERMINATIONS AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION (FGR) DURING DIFFERENT WIND CONDITIONS.

EXHAUST STACK IS DOWNWIND

OF AIR INTAKE OPENING

FIGURE 18  ROOF PENETRATION DETAILS

Questions? Please Contact Your Local Manufacturer’s Representative

2-29

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

NOTES:

1) HORIZONTAL SECTIONS MUST ADHERE TO A MINIMUM 1/4 INCH PER FOOT (1 MM PER 48 MM) RISE TO RUN RATIO

2) MAINTAIN A MINIMUM 9 INCH (229 MM) AIR SPACE CLEARANCE TO COMBUSTABLES, WIRE, AND INSULATION

3) INSTALL SUPPORT STRAPS AT 5 FT (152 CM) HORIZONTAL INTERVALS AND AT ELBOWS

ENDURA+

HYDRONIC

BOILER

( SIDE VIEW )

TYPICAL ROOF PENETRATION

COMBUSTION AIR FROM THE ROOM

( SUGGESTED INSTALLATION CONFIGURATIONS )

ADJUSTABLE FLASHING

METAL PLATE

FIRE STOP

FLUE GAS EXHAUST TERMINATION

(RAIN CAP NOT REQUIRED)

DO NOT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

STORM COLLAR

FLUE GAS EXHAUST DIRECTION OF FLOW

STORM COLLAR (FOR DOUBLE WALL)

UL-1738 APPROVED EXHAUST VENT MATERIAL

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

FLEXIBLE HOSE

CONDENSATE TRAP (STYLE VARIES)

IN LINE STACK DRAIN (RECOMMENDED FOR HIGH CONDENSATE PRODUCTION RATE APPLICATIONS)

APPLIANCE ADAPTER CONSULT FLUE MFG FOR SELECTION REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER

CAUTION:

ADEQUATE COMBUSTION AIR AND VENTILATION MUST BE SUPPLIED TO THE BOILER ROOM IN ACCORDANCE WITH LOCAL CODES AND NFPA54/ANSI Z233.1, SECTION 9.3, AIR FOR COMBUSTION AND VENTILATION OR CSA-B149.1 FOR CANADA. THE MINIMUM NET FREE AREA REQUIREMENTS IN TABLE 6 MAY NOT SUPERSEDE LOCAL AND JURISDICTIONAL CODES AND REGULATIONS REQUIRING A GREATER NET FREE AREA. THE MORE STRINGENT OF THE TWO SHALL PREVAIL.

12 INCH (305 MM)

UPPER COMBUSTION AIR LOUVER

MINIMUM NET FREE AREA

1 IN

PER 4,000 BTU/HR

(645 MM

PER 1.17 KW)

12 INCH (305 MM)

LOWER COMBUSTION AIR LOUVER

MINIMUM NET FREE AREA

1 IN

PER 4,000 BTU/HR

(645 MM

PER 1.17 KW)

FIGURE 19  ROOF PENETRATION WITH COMBUSTION AIR LOUVERS DETAIL

2-30

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

FIGURE 20  SIDEWALL PENETRATION DETAIL

TYPICAL SIDE WALL PENETRATIONS

( SUGGESTED INSTALLATION CONFIGURATIONS )

WALL TERMINATIONS DETAIL VIEW

NOTES:

1) HORIZONTAL SECTIONS MUST ADHERE TO A MINIMUM 1/4 INCH PER FOOT (1 MM PER 48 MM) RISE TO RUN RATIO

2) MAINTAIN A MINIMUM 9 INCH (229 MM) AIR SPACE CLEARANCE TO COMBUSTABLES, WIRE, AND INSULATION

3) INSTALL SUPPORT STRAPS AT 5 FT (152 CM) HORIZONTAL INTERVALS AND AT ELBOWS

CAUTION:

SEPARATE AIR INTAKE AND EXHAUST TERMINATIONS AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION (FGR) DURING DIFFERENT WIND CONDITIONS.

UL-1738 APPROVED

EXHAUST VENT MATERIAL

REFERENCE TABLE 1 FOR MIN CAI DIAMETER

SCH40 PVC PIPE (TYPICAL)

FLEXIBILE RUBBER

PIPE COUPLING

AIR INTAKE ADAPTER

(STYLE & LOCATION VARIES)

EXHAUST STACK IS DOWNWIND

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

MINIMUM RISE TO RUN RATIO:

1/4” PER FOOT (1 MM PER 48 MM)

UP TOWARDS TERMINATION

MINIMUM RISE TO RUN RATIO:

1/4” PER FOOT (1 MM PER 48 MM)

DOWN TOWARDS TERMINATION

COMBUSTION AIR INTAKE (CAI)

DIRECTION OF FLOW

FLUE GAS EXHAUST DIRECTION OF FLOW

OF AIR INTAKE OPENING

MINIMUM 4 FT (122 CM) ABOVE THE

COMBUSTION AIR INLET TERMINATION

DO NOT PLACE

INSULATION IN

REQUIRED AIR SPACE

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

FLUE GAS EXHAUST TERMINATION

MINIMUM 10 FT (305 CM)

HORIZONTAL AWAY FROM THE

FLUE GAS EXHAUST TERMINATION

MINIMUM 10 FT (305 CM) HORIZONTAL

AND 4 FT (122 CM) ABOVE THE

COMBUSTION AIR INLET TERMINATION

OPENING TO BE MIN 1 FT (30 CM)

ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

ENDURA+

HYDRONIC

BOILER

( SIDE VIEW )

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

Questions? Please Contact Your Local Manufacturer’s Representative

IN LINE STACK DRAIN (RECCOMENDED FOR HIGH CONDENSATE PRODUCTION RATE APPLICATIONS)

APPLIANCE ADAPTER CONSULT FLUE MFG FOR SELECTION REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER

FLEXIBLE HOSE

CONDENSATE TRAP (STYLE VARIES)

2-31

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

SCREW OR BOLT EACH THIMBLE COLLAR TO WALL

(TYPICAL 4 PLACES)

3. 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 held responsible for the eects such adverse conditions may have on the operation of the boilers.

4. The required minimum air space clearances also apply to electrical wires and any kind of building insulation.

5. Listed termination parts must be used.

6. Select the air intake point of penetration where a minimum of 1/4” per foot (6.35 mm per .3 m) upward pitch can be maintained.

ORIENT CLAMPS AND COLLAR AS REQUIRED

3½ INCH OR

4.35 CM AIR GAP ALL AROUND

THRU PIPE

DIAMETER “C”

STAINLESS

PIPE RETAINING

CLAMP, TYPICAL

EACH SIDE

WIDTH TO VARY WITH

WALL THICKNESS

DIAMETER “B”

ADJUSTABLE

WALL THIMBLE

END VIEW

DIAMETER “A” COLLAR

7. It is recommended to install a mesh bird screen, with minimum 1/2” by 1/2” openings, at the combustion air intake termination. Climates subject to extreme cold may require alternate congurations to provide an increased surface area, such as cylindrical basket screens. Consult your venting supplier for recommendations.

8. It is important to locate the exhaust termination in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions. If terminating into a prevailing wind, direct elbow upward. Avoid areas (example: courtyards) where swirling high winds may be present.

9. Fulton does not recommend the use of rain caps on the ue termination. Rains caps contribute to ice buildup, stagnant vapor plumes, ue gas recirculation (FGR), and

additional vent pressure loss. See Figures 18 and 19.

 Wall Thimble Installation

Adhere to the following for installation (see Figure 21):

1. The thimble is inserted through the wall from the outside.

2. Secure the outside ange to the wall with nails or screws, and seal with adhesive material.

3. Install the inside ange to the inside wall, secure with nails or screws, and seal with adhesive material.

4. Pass the vent pipe through the thimble from the outside and join to the rest of the vent system. Seal the pipe to the thimble ange with adhesive material.

5. Install two pipe retaining clamps around the intake as well as vent pipes on both ends of the wall thimble (on the inside and outside of the wall) through which intake and vent pipes are passed. They will prevent the intake

and vent pipes from being pushed or pulled.

VARIABLE

(MIN. 3 ¼ IN) – (MAX. 20 INCHES) (MIN. 8,255 CM – MAX. 50,8 CM)

FIGURE 21  WALL THIMBLE INSTALLATION

 Roof Vent Termination

Adhere to the following for installation (see Figures 18, 19):

1. The minimum vent height should extend at least 3 feet (0.9 m) above the roof, or at least 2 feet (0.6 m) above the highest part of any structure within 10 feet of the vent.

2. When installing inlet and exhaust terminations above the roof, the exhaust outlet must be installed 4 feet (1.22 m) minimum above and 4 feet (1.22 m) minimum downwind from air supply inlet to prevent exhaust recirculation.

 Side Wall Vent Termination

Adhere to the following for installation (see Figure 20):

NOTE: The vent termination is joined to the vent pipe outside

the wall. Use the same joining procedures for vent pipe and ttings.

1. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain the pitch of the vent and provide sealing. Use adhesive material to seal around the vent on both sides of the wall. When penetrating a combustible wall, a wall thimble must be used. Minimum wall thickness through which vent system may be installed is 3.25 inches (8.26 cm). Maximum wall thickness through which vent system may be installed is 20 inches (50.8 cm).

2-32

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

2. The termination of the vent system must be at least 12 inches (30.48 cm) above the nished grade, or at least 12 inches (30.48 cm) above normal snow accumulation level (for applicable geographical areas).

3. The termination of the vent system shall not be located over trac areas such as public walkways, or over an area where condensate or vapor could create a nuisance or hazard.

4. Do not terminate below operable windows and building openings unless exception is granted by the authority having jurisdiction.

5. The vent terminations must be at least 4 ft (1.22 m) horizontally from electric meters, gas meters, regulators, and relief equipment.

6. When installing inlet and exhaust terminations on the same wall, the exhaust outlet must be installed 4 feet (1.22 m) minimum above and 10 feet (3.05 m) minimum downwind from air supply inlet to prevent ue gas recirculation.

7. Under certain wind conditions, some building materials may be aected by ue products expelled in close 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. Flue should be directed away from surfaces, if possible.

! WARNING

Removing an Existing Boiler

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation:

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage or restriction, leakage, corrosion or other deciency, which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close replace dampers.

4. Place the appliance being inspected in operation. Follow the lighting instructions. Adjust the thermostat so that the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main

Questions? Please Contact Your Local Manufacturer’s Representative

2-33

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

burner operation. Do not use the ame of a match or candle or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, replace dampers and any other gas-burning appliance to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the common vent system should be resized to approach the minimum size as determined using the appropriate tables.

Assembly of Fulton Multi-Skid Systems

Adhere to the following for multi-skid engineered systems:

1. Refer to the Fulton mechanical/electrical drawings during assembly.

2. Ensure that equipment orientation allows for operation interface and maintenance.

3. Align the skids as shown on the drawings ensuring that skid fasteners (skid joint angles) are matched. The skid joint angles are a matched set and the edges of the fasteners should be exactly aligned.

NOTE: Do not bolt the skids to the housekeeping pad/oor until all of the piping

has been reassembled and tightened.

4. Ensure the skids are level and at before fastening the skids together with the supplied bolts. The skids should be leveled front to back, side to side and corner to corner. Failure to properly level the skids will result in piping misalignment. A level or laser level should be used to verify skid alignment (when a standard level is used, the length should be appropriate for the skid). If assembling multi-component support stands, attach sections using the supplied bolts through the tank frame mounting plates. These should be hand tight until all of the piping is assembled.

NOTE: Skids are leveled at the factory using a laser level.

5. Connect the piping between the skids by matching the union connections and/or ange stamps and tightening. Refer to the mechanical drawing as necessary to conrm location of spool pieces etc. as the ange stamps are shown on the drawing in hexagonal callouts. The ange stamps should matched and aligned (the ange stamps should be directly across from one another. Rotating a ange will result in piping misalignment). Bolts should be hand tight until all of the piping is assembled. Refer to the appropriate instructions to tighten the anges to the required torque specications. Support pipe runs as required.

6. Ensure that a low point drain is installed in the piping.

2-34

7. Connect the conduit runs between the skids and tighten conduit connectors.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

8. Locate the supplied wiring for the equipment and pull wiring through the appropriate conduit runs. Electrical wires are labeled for easy landing. Connect all wiring per the Fulton supplied electrical drawings.

9. If a header is supplied, mount the header as shown in the mechanical drawing.

NOTE: For piping supplied in sections, make up and connect hand tight until all

sections are in place to ensure sections align properly. Sections are match marked for reassembly.

10. Tighten all connections, including threaded and anged factory connections which may loosen during shipment.

11. Pneumatically test the piping (at 15 psig [103 kPa] maximum) prior to lling the systems.

12. Check bolts and connections for tightness after the rst heat up cycle. Retorquing may be required.

Relocating the EDR+ 6000 Panel Box to Opposite Side

The electrical panel box can be relocated to the opposite side of the boiler if needed.

! WARNING

The rating of each external device contact is the maximum allowable amperage of the contact.

Proceed as follows:

1. Carefuly remove the side panel with the vented cover that contains the electrical panel box. Remove the side panel with the solid cover on the opposite side of the boiler where the electrical panel box will be moved to.

2. Loosen and remove the four bolts currently holding the electrical panel box in place.

3. Slowly, using caution, slide the electrical panel box along the rail to the opposite side of the boiler while carefully rotating it 180 degrees.

NOTE: Ensure not to twist, yank, disconnect or cut any of the wires that connect

the electrical panel box to the boiler components.

4. Reinstall the four bolts holding the electrical panel box in place on the new side of the boiler.

5. Reinstall the panel with the solid cover on the empty side, and replace the panel with the vented cover on the side with the electrical panel box.

Questions? Please Contact Your Local Manufacturer’s Representative

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INSTALLATION EDRP-IOM-2019-0212 SECTION 2

! WARNING

Electrical Connections and Devices

NOTE: This boiler is factory congured for site voltage and is not intended for eld

conversion. See data plate on rear of boiler cabinet for rating.

The boiler is designed to operate within the following limits at the connection terminals:

 AC power supplied is within +/- 10% of the motor rated voltage with the

rated frequency applied; or AC power supplied is within +/- 5% of the rated frequency and with the rated voltage; or a combined variation in voltage and frequency of +/-10% (sum of absolute values) of rated values provided the frequency variation does not exceed +/-5% of rated frequency.

 When installed in a 208/3/60 service, the minimum supply voltage applied

to the boiler terminals is 207 volts and must always be met.

 When installed in a 575/3/60 service, the maximum supply voltage applied

to the boiler terminals is 600 volts and must always be met.

NOTE: There is no warranty on components that fail due to improper electrical

service.

Full Load Amps (FLA) is the measured amperage for the boiler at its maximum operating condition at rated voltage. The type of breaker/fusing selected, in combination with the FLA, will aect proper circuit sizing/protection. Please refer to your state’s adoption of NEC or the authority having jurisdiction for proper sizing/selection. Refer to Table 1 for FLA requirements.

A connection box has been provided on the back of the unit for high voltage wiring. A conduit knock-out has been provided on the top of the unit for low voltage and communication wiring. Do not run Building Management System (BMS), low voltage wiring, or any other communication wiring into the high voltage box. Do not relocate connection locations.

The Endura+ cabinet has removable panels to facilitate access. Do not run conduit through or over access panels.

Adhere to the following when making electrical connections:

1. Install wiring and ground in boiler in accordance with authority having jurisdiction or in absence of such requirements National Electrical Code, ANSI/NFPA 70.

2. Connect power to the boiler inside of the customer connection box using connectors rated for the minimum in Table 1, and are compliant with local electrical codes.

2-36

3. Provide separate power supplies for external devices. Do not power external devices through the boiler.

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

Note: EDR+2500/3000 Customer Connections on Rear of Electrical Panel

REFERENCE 460V ELECTRICAL SCHEMATIC DIAGRAM

Questions? Please Contact Your Local Manufacturer’s Representative

2-37

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

CONTROLS

STEP-DOWN

TRANSFORMER

SAFETY AND

CONTROL RELAY

RAIL

CONTROL MODULES

FLAME

PROGRAMMER

BLOWER

VSD

2-38

REFERENCE 460V ELECTRICAL SCHEMATIC DIAGRAM CONTINUED

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

CONTROLS

STEP-DOWN

TRANSFORMER

Note: Customer Connections on Rear of Electrical Panel

SAFETY AND

CONTROL RELAY

RAIL

CONTROL MODULES

BLOWER

VSD

3Φ High Voltage 120 VAC

FLAME

PROGRAMMER

FIGURE 22  EDR+2500/3000 PANEL BOX LAYOUT

Questions? Please Contact Your Local Manufacturer’s Representative

2-39

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

 Junction Box Locations for Field Wiring

Connections (Figure 23) are provided for routing eld wiring to the boiler control panel. Do not run wiring directly through the removable or hinged panels doors.

LOW VOLTAGE

CONNECTION

HIGH VOLTA GE

CONNECTION

3. The supply header temperature sensor must be utilized. Wire the sensor to a boiler "header RTD supply" connection and install downstream of the boilers in the common supply water header for proper operation of the sequenced plant. (See Figures 4 - 7).

4. Additional devices and sensors may be required, and will vary by application.

5. Communication between boilers is performed using an industrial Ethernet/IP network protocol. The Endura+ boilers must be on a private network not shared with other equipment or devices. Cable type must be shielded Cat5e or shielded Cat6. Two boilers may be directly connected; an IP switch is required for 3 to 10 boilers. Install the IP switch in a clean, dry location.

6. See the Operation section for information on programming this feature.

` INTEGRATION WITH THE SYNEX CONTROLS MODSYNC

SEQUENCING SYSTEM

Reference the Installation, Operation & Maintenance Manual and Electrical Schematic for the Synex Controls ModSync Sequencing System.

FIGURE 23  HIGH VOLTAGE AND LOW VOLTAGE

CONNECTION LOCATIONS TYPICAL

 Electrical and Controls Options

The electrical and controls options required and supplied will vary depending on the unique requirements and piping arrangements of the hydronic system. See Electrical Schematic Diagrams for locations of eld wiring connections on the below electrical devices and controls options. See Figure 22 for typical panel box layout. Layout varies by model.

The rating of each external device contact is the maximum allowable amperage of the contact.

` INTEGRATED LEAD/LAG SEQUENCING WIRING

1. The Endura+ includes integrated sequencing capabilities for up to ten boilers. When congured, the boiler control system will automatically lead/lag boilers and operate burner ring rates in parallel as necessary to maintain a hydronic setpoint.

2. The lead boiler, and all lag boilers, are automatically rotated.

` SUPPLER HEADER TEMPERATURE SENSOR

1. A eld-installed hydronic supply sensor and well are used for temperature control.

2. This sensor is required for any multiple boiler installation utilizing the integrated sequencing capabilities of the Endura+.

3. This sensor is required for single boiler installations with primary-secondary piping arrangements to monitor the primary loop.

4. The sensor monitors hydronic loop temperature in the common supply piping as a process variable for sequencing and modulation purposes. The control uses this information when comparing actual loop temperature to setpoint.

5. Install the sensor downstream of the boilers in the common supply water header. The well must be directly in the path of ow and not isolated with a valve to provide an accurate temperature reading. Do not install the supply header temperature sensor in the return water header.

6. See Figures 4  7 for the proper installation location in

hydronic piping.

1/2

” NPT

2-40

SECTION 2 EDRP-IOM-2019-0212 INSTALLATION

` OUTDOOR AIR TEMPERATURE SENSOR KIT

1. If outdoor air temperature reset capabilities are to be utilized, an outdoor air temperature sensor kit is required and eld wired to a boiler.

2. An outdoor air temperature sensor kit is not required if using xed setpoint (no outdoor reset), or if the boiler control is receiving an external hydronic setpoint signal over a communication protocol or analog signal.

3. The sensor must be installed on an exterior wall, in a location that will not be exposed to direct sunlight or inuenced by other mechanical equipment.

` DOMESTIC HOT WATER DHW TEMPERATURE SENSOR

1. This Endura+ boiler is capable of providing indirect domestic hot water through a heat exchanger. A domestic hot water temperature sensor is used for this application. The Endura+ boiler is for closed loop applications only; open loop must not be directly heated by the boiler.

2. The sensor may be installed in the domestic hot water constant recirculation supply piping, or the domestic hot water storage tank.

duty plus one backup, with automation rotation. The pumps cannot be powered directly through the boiler panel; a variable speed drive (not provided) is required.

2. Pump modulation is provided via a 0-10 VDC output signal for each pump.

3. The pump start/stop contacts have a maximum rating of 6 Amps at 120 VAC.

` DEDICATED BOILER PUMP CONTROL

1. Some installations may utilize primary-secondary piping arrangements instead of variable primary piping arrangements. In these instances, the boiler (primary) loop is decoupled from the system (secondary) loop, and a dedicated boiler pump will be required to provide ow through the boiler.

2. The boiler controller provides a dedicated boiler pump start/stop signal only; the pump cannot be powered through the boiler panel. An external motor starter or variable speed drive (not provided) is required to control the circulator pump.

3. The pump contact has a maximum rating of 6 Amps at 120 VAC.

` MOTORIZED ISOLATION VALVE CONTROL

1. A control relay is provided in the boiler control panel to operate a two-position 120/1/60 motorized isolation valve. The valve type may be either power-open / power-close, power-open / spring-close, or spring-open / power-close.

2. A motorized isolation valve is used in variable primary piping arrangements, in accordance with ASHRAE

90.1-2013, to prevent ow from traveling through idle boilers.

3. The lead boiler motorized isolation valve will remain open when all boilers are idle to provide a path of ow in the hydronic system. See the Operation section for programming motorized isolation valve control.

` VARIBLE SPEED SYSTEM PUMP CONTROL

1. The boiler controller provides start/stop and variable speed control for two system (secondary) pumps, one

4. Can be modulated only if system pump feature is not used. A 0-10 VDC output is provided.

` ALTERNATE COMMUNICATION PROTOCOL GATEWAY

Reference the Manual Supplement for Endura+ Gateways for BACnet and other protocols.

` REMOTE BOILER ENABLE/DISABLE

1. A contact may be utilized to enable and disable each boiler individually. Remove the jumper, and wire to a remote control panel.

2. Closing the contact enables the individual boiler to become available to start. When the contact is open, the boiler will remain in a disabled state.

3. The remote boiler enable/disable contact provides a 24 VDC signal. Do not apply an external power source to

the remote boiler enable/disable contact; wire only to dry contacts.

4. Modbus remote boiler enable/disable is also available.

Questions? Please Contact Your Local Manufacturer’s Representative

2-41

INSTALLATION EDRP-IOM-2019-0212 SECTION 2

` REMOTE ANALOG SETPOINT

1. An external hydronic loop setpoint signal may be sent using an analog signal. This may be either 4-20 mA or 0-10 VDC.

2. When using integrated lead/lag functionality, the setpoint signal may be sent to one boiler only. See section on Universal Data.

` GENERAL ALARM CONTACT

A dry contact is provided for annunciation of a general alarm condition. It is rated for 6 Amps maximum.

` AUXILIARY 2ND LOW WATER CUTOFF

1. This hydronic boiler includes one factory installed low water cut o (LWCO) device in compliance with CSD-1. Some authorities having jurisdiction (AHJ) may require the use of a 2nd (auxiliary) LWCO.

2. Where required, a 120 VAC probe type LWCO (P/N 2-40-

000418) may be installed in the outlet piping of the boiler. The probe must not be isolated from the boiler by any valve.

` AUXILIARY SAFETY INTERLOCK FOR EXTERNAL DEVICES

1. When the Endura+ boiler receives a call for heat, the startup sequence rst checks for completed interlock circuits. If an interlock circuit is open, the boiler control will not begin the ignition sequence until it is closed.

2. A jumper is factory installed in the interlock circuits. For applications requiring a safety interlock, this jumper may be removed with terminals wired into the dry contacts of an external device.

3. The interlock contacts provide a 24 VDC signal. Do not

apply an external power source to the interlock contacts; wire only to dry contacts.

4. Typical uses for the safety interlock include but are not limited to: motorized isolation valve end switches, proof of exhaust draft assist fan operation, motorized combustion air intake louvers.

5. Multiple safety interlocks may be used, wired in series.

6. Interlocks may be renamed for simpler troubleshooting.

` EMERGENCY STOP ESTOP

3. Remove the jumper, and install the low water relay into the 2nd LWCO base.

4. Alternate 120 VAC LWCO devices may be used. They are wired to the jumper terminal blocks.

` BOILER STATUS CONTACT

A dry contact is provided for remote monitoring of boiler status. When the main gas valve is enabled, the contact is closed.

` BOILER DEMAND CONTACT

A dry contact is provided for remote monitoring of boiler demand. When the boiler has a call for heat, the contact is closed.

1. A contact is provided to perform an emergency shutdown of the boiler. Remove the jumper and wire to an emergency shutdown switch or remote control panel.

2. Opening the contact will shut down the boiler.

3. The E-Stop contact provides a 120 VAC signal. Do

not apply an external power source to the E-Stop contacts; wire only to dry contacts.

2-42

OPERATION

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE

Questions? Please Contact Your Local Manufacturer’s Representative

3-1

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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. Failure to follow instructions may result in a re or explosion, causing property damage, personal injury, or loss of life.

This boiler is equipped with an ignition device, which automatically lights the burner. Do not try to light the burner by hand.

Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any other appliances.

Use only your hand to turn the valve handle. Never use tools. If the knob will not turn by hand, don’t try to repair it. Call a qualied service technician. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

Perform Pre-Start-Up Inspection

Prior to start-up, perform the following:

1. If you smell gas:

 Do not try to light any appliance.  Do not touch any electrical switch; do not use any phone in your building.  Immediately call your gas supplier from a neighbor’s phone.

2. Ensure the boiler is located with the proper clearances as shown in the Clearances and Serviceability section of this manual.

3. Ensure that relief valves have been properly piped to oor drains.

4. Ensure ue gas from the boiler is properly vented.

5. Ensure the water system has been ushed and is free of debris.

6. Ensure combustion air openings are not obstructed in any way and have adequate capacity.

7. Ensure there are no ammable liquids, materials or hazardous fumes present in the environment.

8. Ensure nothing was damaged or knocked loose during installation and/or shipment.

9. Inspect the main gas train and trim assembly to be sure they were not damaged during shipment and/or installation.

10. Verify fan rotation direction is clockwise when viewed from the back of the boiler.

WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the re department.

A qualied installer, service agency or the gas supplier, must perform installation and service.

Do not use this boiler if any part has been under water. Immediately call a qualied service technician to inspect the boiler and to replace any impacted part of the control system.

Fill and Purge the System

Completely ll and purge the heating system as follows:

1. Close combination shuto/purge valve in supply, all drain cocks, the shuto valve for the pressure reducing (ll) valve, and all manual air vents.

2. Open a system valve, or ll through a drain connection.

3. Water will now begin to ll the system. Open the safety relief valve. Continue lling until a constant stream of water (no bubbling) is discharged from the safety relief valve.

4. At this point, the system has been initially lled. However, air pockets may still remain at high points in the system and in heating loops above the level of the safety relief valve valve. It is quite possible, depending on the particular system that all piping above the safety relief valve still contains air. If manual vents are installed on the system high points, these should be opened to vent these locations. When only water is discharged from all vents, the initial purging is complete.

5. With the gas shuto valve closed, turn on 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.

6. Check temperature/pressure indicator reading, which should equal the pressure-reducing (ll) valve set pressure. No more water should be entering the system. Close the shuto valve on the cold-water ll line.

3-2

SECTION 3 EDRP-IOM-2019-0212 OPERATION

7. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system, repair leaks and rell/purge the system. If no pressure drop is detected for a period of two hours under pressure, the system may be considered watertight.

8. When purging is completed, make sure the following are open— combination shut-o/purge valve, shuto valve to pressure reducing (ll valve), shuto valve in cold water ll line, and shuto valve in return line.

9. Make sure the following are closed - all drain cocks, the vent on the combination shuto-purge valve, & all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler.

10. Open fuel shuto valve, allowing fuel to ow to boiler.

Commission The Boiler

Adhere to the following when commissioning the boiler:

1. Verify with authorized personnel that the gas lines have been purged. Do not proceed without verication.

2. Familiarize all personnel on all aspects of boiler use, safety, and contents of this manual. This includes, but is not limited to, the use of the controls, lighting, and shutdown procedures.

3. Review the unit-specic burner and control schematics, and follow appropriate instructions.

NOTE: Warranty coverage is valid only if the boiler is commissioned (“started

up”) by a factory authorized service technician with a valid Endura+ Certicate of Authorization. The commissioning agency must successfully complete and return the Fulton Installation and Operation Checklist report (“Start-up Report”) to Fulton within twelve (12) weeks of start-up. Combustion and maintenance records detailing compliance with the Installation, Operation and Maintenance manual

must be produced for warranty consideration.

! WARNING

Do not attempt to start the boiler for any testing before lling and purging the boiler. A dry re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty.

Before commissioning the boiler, verify with authorized personnel that the gas lines have been purged.

Never attempt to operate a boiler that has failed to pass all the safety checks.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage could occur.

4 CAUTION

 System Design and Boiler Operation

The Endura+ boiler must be installed in an appropriately designed system per Installation section of this manual.

1. The boiler shall be operated/controlled to ensure the boiler does not cycle more than 12,000 times per year.

2. The hydronic system may be operated with a temperature dierential across the boiler inlet and outlet (delta-T) up to 100°F (55.5°C) when using ≥ 35 psi water as the heat transfer uid. For systems with water/ glycol solutions, ensure the delta-T does not exceed 40°F (22°C). The factory default maximum delta-T modier is 40°F (22°C). Consult your Fulton representative for operating requirements and conguration for

applications requiring a higher delta-T.

3. Site-specic conditions, including combustion air temperature, elevation, fuel temperature, caloric value of the fuel, combustion air system design, exhaust system design, voltage uctuations and other factors, will impact boiler performance.

4. Performance factors aected may include but are not limited to input/ output ratings, eciency, modulation rates and emissions.

Questions? Please Contact Your Local Manufacturer’s Representative

Do not use this equipment if any part has been under water or subjected to heavy rains/water. Immediately call a qualied service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

The thermal shock warranty does not cover damage due to cyclic fatigue.

3-3

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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.

4 CAUTION

Commissioning/Start up by a nonFulton authorized person will void the product warranty.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

Maximum allowable working pressure and operating temperature are 160

psig (1103 kPa) and 210°F (99°C), respectively. Aquastats are set at 200°F (93°C). Operating > 185°F (88°C) may

result in nuisance high-limit trips.

5. The Fulton factory Test Fire Report should be used as a point of reference in commissioning settings for the boilers in the eld, however a factory certied service technician should account for all site conditions when nalizing operational settings.

 Turndown

All Endura+ boilers are congured at the factory with a default modulation range (turndown ratio). Wind eects on combustion air supply and exhaust terminations, natural draft “stack eect,” and gas delivery systems (among other site factors) will ultimately determine what turndown settings are optimal for each application. Consult your local manufacturer’s representative or service organization with factory authorization specic to the Endura+ product line for guidance.

Operation Modiﬁers

The Endura+ boiler has built in protection features to modify boiler operation in the event certain system conditions approach or exceed operation requirements. Operation modiers are intended to supplement, not replace, good practice in system design, installation and operation. The following features are provided and take priority over local or remote instruction:

1. The control will automatically reduce the fan speed, air and gas positions should the boiler water exceed the factory default maximum outlet temperature of 185°F. Consult your Fulton representative for operating requirements and conguration for applications requiring higher outlet temperatures up to 200°F.

NOTE: In the event of a High Limit Aquastat lockout, a manual reset will be

required.

2. The dierence between the inlet and outlet temperature (delta-T) is monitored. If the delta-T approaches the limit specied in System Design and Boiler Operation, the control will reduce the fan speed, air and gas position. The delta-T limit will scale down with lower ring rates as the minimum ow rate limit becomes the dominant parameter. A warning is enunciated after two recoverable events. A non-recoverable event due to

zero or low water ow will trigger a low ow alarm.

Siemens LMV3 Control

The Siemens LMV3 system is a fully packaged burner management system, linkageless control and rst out annunciator.

A Siemens AZL display or ACS410 software will be required (not provided) for the authorized service technician to perform conguration of the LMV3.

The left and right arrow keys are used for scrolling through the menu and changing controller parameters. Pressing the Enter button accepts the menu and parameter changes. It is possible to return to the main menu at any time by repeatedly pressing ESC (Escape). See Figure 24.

3-4

SECTION 3 EDRP-IOM-2019-0212 OPERATION

FIGURE 24  SIEMENS AZL DISPLAY

Questions? Please Contact Your Local Manufacturer’s Representative

3-5

OPERATION EDRP-IOM-2019-0212 SECTION 3

 Before Modifying LMV Parameters

The boiler must be placed in “Commissioning Mode” before modifying any LMV parameters. Set-up must be fully completed prior to automatic operation of the boiler.

 Steps to Enter Parameters

1) Press and hold the “F” and “A” buttons simultaneously.

a. “Code” will be displayed.

2) When releasing “F” and “A”, 7 bars appear the rst of which ashes.

3) Press the “-“ or “+” button to select the rst number of the national board number and press enter (i/reset) button after each selected number.

NOTE: The service password is “00000.”

4) After entry of the last number, the password must be conrmed by pressing enter (i/reset) button.

5) After correct entry of password, PArA appears for a maximum of 2 seconds.

6) Parameter 400 will ash.

a. Use the “-“or “+” button for scrolling to the desired parameter.

b. Press the enter (i/reset) button to enter the selected parameter level.

 Adjusting Fuel/Air Curve

NOTE: Fulton Endura+ boilers are factory test red and pre-programmed with values in the fuel/air curve (P0-ignition to P9-high

re).

With the burner on, follow the below steps for making eld changes to the fuel/air curve points. A calibrated ue gas analyzer is required to complete these steps and must be properly inserted into the boiler ue exhaust vent while making changes to the fuel/air curve points. The boiler controller must be placed in Commissioning Mode before making any adjustments.

3-6

SECTION 3 EDRP-IOM-2019-0212 OPERATION

1) Conrm position of the fuel selection switch where applicable.

2) Enter the password and parameter “400” will ash.

3) Press the enter (i/reset) button 2 times.

a. “P1” will ash and the curve point will be displayed.

NOTE: P0 is the ignition position. Verify proper combustion

at the ignition position.

4) With “P1” ashing the fuel or air actuator may be individually selected for combustion adjustments.

a. For the fuel actuator keep the “F” button depressed and press the “-“ or “+” button to adjust the fuel actuator.

i. Any changes are automatically saved.

ii. Release the “F” button.

b. For the air actuator keep the “A” button depressed and the press the “-“ or +” button to adjust the air actuator.

i. Any changes are automatically saved.

ii. Release the “A” button.

c. With “P1” ashing use the “+” for the next curve point and the “-“ for going back to the previous curve point.

d. Repeat steps “a.” and “b.” above if changes are required at any other curve point.

Questions? Please Contact Your Local Manufacturer’s Representative

3-7

OPERATION EDRP-IOM-2019-0212 SECTION 3

 Manual Control (Manual Request for Output)

1) Burner is in operation mode.

a. The display shows oP: on the left, the percentage of the current output on the right.

2) Press and Hold the F button for 1 second.

a. The display shows LoAd:, the current output ashes.

3) Still holding the F button press the – or + to adjust the required output in manual.

a. The display shows LoAd:, still holding the F button the new output ashes.

4) Release the F button.

a. The current manual output ashes; oP: is still displayed on the left solid indicating that manual control is activated.

5) Press and hold the – and + for 3 seconds to return to automatic mode.

a. The output will no longer ash, oP: will be displayed on the left solid and the operating percentage will be displayed on the right.

3-8

SECTION 3 EDRP-IOM-2019-0212 OPERATION

 Parameter Backup

1. Press and hold “F” and “A” until Code is displayed.

a. Then enter unit national board number press enter once complete.

2. “400: Set” will be displayed

a. Press the”-“arrow three times until “000: Int” is displayed.

b. Press the Enter button to get into “100:Int” parameters.

3. Backup procedure:

a. Press the “+” button and go to P-050 (050 will be ashing).

b. Press enter > bAC_uP is displayed.

c. Press enter > 0 is displayed.

d Press “+” button and 1 is ashing

e. Press enter, after about 5 seconds a 0 appears on the display indicating the end of the backup process.

NOTE: If an error occurs during the backup process,

a negative value is displayed. For troubleshooting, go to error code 137 to view diagnostic code.

Questions? Please Contact Your Local Manufacturer’s Representative

3-9

OPERATION EDRP-IOM-2019-0212 SECTION 3

 Parameter Restore

1. Press and hold “F and A” until Code is displayed

a. Then enter unit national board number press enter once complete.

2. “400: Set” will be displayed

a. Press the “-“arrow two times until “100: PArA” is displayed.

b. Press the Enter button to get into “100” parameters.

c. Press the “+” arrow until parameter 113 is reach enter into the parameter and record the Burner ID#.

d. This is required for performing the Restore process.

3. Restore procedure:

a. Go to “000: Int” parameter enter in and go to P-050 (050 will be ashing).

b. Press enter > bAC_uP is displayed.

c. Press “+” button to select “rEStorE”.

d. Press enter > 0 is displayed.

e. Press “+” button and 1 is ashing

f. Press enter, after about 5 seconds a 0 appears on the display indicating the end of the backup process.

NOTE: If an error occurs during the Restore process, a

negative value is displayed. For troubleshooting, go to error code 137 to view diagnostic code.

3-10

SECTION 3 EDRP-IOM-2019-0212 OPERATION

! 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.

Questions? Please Contact Your Local Manufacturer’s Representative

3-11

OPERATION EDRP-IOM-2019-0212 SECTION 3

! WARNING

Tampering with safety devices or unauthorized bypassing of the boiler control system will void the pressure vessel warranty.

Using the Endura+ PURE Control™ Interface

Reference the Endura+ Installation and Operation Manual PURE Control™ Addendum for detailed instuctions on the controls system. The boiler control

system features an integrated color touchscreen display through which many commissioning and operation tasks are performed, including temperature control and multiple boiler sequencing setup. The graphical interface is navigated by touch using your nger or a stylus. The screenshots and

information in this section will guide you through the menu screens.

 Navigation

The control will enter a screensaver mode (shown below) after several minutes with no interaction. Tap the screen to exit the screensaver.

The Menu screens are grouped into categories, and each serves a unique function for changing parameters or viewing statuses. To change categories, tap the desired category in the left sidebar menu. A navigation screen provides access to screens within each category. Tap the “back” button to return to

category navigation.

3-12

SECTION 3 EDRP-IOM-2019-0212 OPERATION

A listing and functional description of each of the graphical icons found witrhin the touchscreen menus is provided below in Table 10.

TABLE 10  GRAPHICAL ICON REFERENCE MENU

Button Function

Returns to the parent category.

Tap to display information based on the screen currently selected.

Green: No alarm condition. Tap to see Alarm History.

Yellow: Warning or Soft Alarm active. Tap to see Alarm History.

Red: Alarm or Lock-Out active. Tap to see Alarm History.

Green: Maintenance Inactive. Tap to go to the Maintenance screen.

Yellow: Time For Service - Tap to go to the Maintenance screen.

Green: Locked - Some screens may not be accessible as congured by the boiler plant administrator. Tap the icon and enter the administrative password to unlock.

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

4 CAUTION

A temperature exceeding 120°F** (48 C) in the boiler room may cause premature failure of electrical components. Provisions should be made to maintain an ambient temperature of 120°F** (48 C) or less (the panel box interior should not exceed 125°F** [51 C]).

**Pumps, PLC or ModSync panels may require lower ambient temperatures or additional cooling.

Yellow: Unlocked - Screens locked by the boiler plant administrator are now accessible. Tap the icon again to lock. The screen will automatically re-lock after 1-10 minutes (user adjustable).

Green: Lead/Lag Network Active. Tap to enter Ethernet/IP Status.

Red: Lead/Lag Network Communication Lost or Recovering. Tap to enter Ethernet/ IP Status.

Gray: Lead/Lag Network Inactive. Tap to enter Ethernet/IP Status.

Questions? Please Contact Your Local Manufacturer’s Representative

3-13

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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.

Endura+ PURE Control™ Menu Screen Functions

 Boiler Control

General individual boiler and ancillary functionality is accessed through this category.

` BOILER STATUS

The screen shown below summarizes information and sensor status for the boiler.

` SAFETY DEVICE STATUS

Devices will either have a green circle to the left indicating closed circuit or a red circle indicating the device is open. The device indicated as the “open limit” is the rst device in the safety circuit open and should be the rst device addressed

during troubleshooting.

Once the boiler is full of water, the following test of low-water cuto can be accomplished:

1. Navigate to and tap the Test Low Water button on the screen.

2. Reset the Low Water condition by tapping the Reset Low Water button.

3. Perform appropriate test for any secondary Low Water controls.

` OPERATOR CONTROL

This screen is used for multiple functions: Start/Stop Deviations, Anti-Cycle Timer, and Manual Burner Control.

The start and stop deviations instruct the burner when to enable and disable around the setpoint temperature. Increasing the range will reduce cycling but may result in larger temperature uctuations.

3-14

SECTION 3 EDRP-IOM-2019-0212 OPERATION

When in Automatic Control, the temperature controller will modulate the burner to a ring rate necessary to achieve the setpoint. To enter Manual Control, tap the “Automatic Control” button, and it will change to “Manual Control.” Enter a “Manual Firing Rate” in the box, and press OK to conrm. When nished with maintenance, return to this screen and place the boiler back into Automatic Control.

The Anti-Cycle Timer, if used, will prevent the burner from ring for a minimum amount of time between cycles

` BOILER HISTORY

Various data points of operational history are summarized on this screen.

` ALARM HISTORY

This screen provides a chronological list of alarms. Pressing the “View Alarm Info” button will expand a selected alarm for additional information and

troubleshooting tips.

` MAINTENANCE LOG

Access a history of preventative maintenance and repairs. Tapping “View Entry” will expand detail on a previous record. Add a record of service by tapping “New

Entry” and completing the record.

! 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.

` ISOLATION VALVE

This screen will only be accessible if Isolation Valve is selected. See Auxiliary Conguration in Admin.

The isolation valve can be placed in manual control or automatic. When using manual, ensure all boilers are not placed in manual close while the system pumps are in operation. In automatic control, a Close Delay Timer can be set to keep the boiler’s isolation valve open for the prescribed time when a boiler no longer has a call for heat. The Delta T Close Delay feature will hold the boiler isolation valve open until residual heat is removed from the heat exchanger and the Delta T drops to the selected value. When enabled, the isolation valve will not close until both conditions

are satised. One valve will always remain open when lead/lag is used.

` PRIMARY PUMP

This screen will only be accessible if Use Pump Control and Boiler Pump is selected. See Auxiliary Conguration in Admin.

The purpose of this screen is to enable and disable a dedicated boiler pump (primary pump) for Primary / Secondary piping arrangements only.

The pump can be placed in automatic control or manual. In automatic control, the Stop Delay Timer will continue operating the pump for the prescribed time after the call for heat ends. The Delta T Stop Delay will continue operating the pump until residual heat is removed from the heat exchanger and the Delta T drops to the selected value. When enabled, the pump will continue operation

until both conditions are satised.

Questions? Please Contact Your Local Manufacturer’s Representative

3-15

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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.

` SECONDARY PUMPS

This screen will only be accessible if Secondary Pumps is selected. See Auxiliary Conguration.

Pumps may be congured to maintain either system delta-P or delta-T. Rotation is automatic.

 Lead/Lag

Integrated multiple boiler sequencing “Lead/Lag” is congured and monitored through this category and Admin. Ensure the boilers are on a private Ethernet/IP network shared with no other devices before continuing setup.

To function properly on the network, the Local Ethernet/IP Address of each boiler must be specically set on the System Conguration screen in the Admin category:

Boiler 1 – 192.168.1.100 Boiler 6 – 192.168.1.105

Boiler 2 – 192.168.1.101 Boiler 7 – 192.168.1.106

Boiler 3 – 192.168.1.102 Boiler 8 – 192.168.1.107

Boiler 4 – 192.168.1.103 Boiler 9 – 192.168.1.108

Boiler 5 – 192.168.1.104 Boiler 10 – 192.168.1.109

Physical wiring of the local boiler network uses Ethernet Port 1. Wiring for the Ethernet/IP network will change based on the number of boilers in the system. For systems with two boilers, a single shielded Ethernet cable can be wired directly between the boilers. For systems with more than two boilers, each boiler will need to have a shielded Ethernet home run back to the Ethernet switch (ships loose in trim kit when ordered).

To enable Lead/Lag functionality, use the Auxiliary Conguration screen under the Admin category. Set the Number of Boilers eld to the number of boilers to be controlled. These steps must be completed at each boiler. Ensure the

Universal Data, also under Admin, is properly congured for data sources.

` LEAD/LAG CONFIGURATION

This screen is used to set sequencing preferences.

 Lead/Lag priority determines how the boilers are sequenced, either by

cycles only, hours only, or an optimized algorithm.

 Number of boilers displays how many boilers the Lead/Lag system expects

to have under control.

 Lead start is how far below setpoint before the lead boiler turns on.

 Lead stop is how far above setpoint before the lead boiler turns o.

3-16

 The aggressive-passive slider determines how quickly lag boilers are

enabled. Slid all the way to the aggressive side, the last lag boiler will come on when the control variable reaches 50%; all the way to the passive side,

the last lag boiler will come on at 90% control variable.

SECTION 3 EDRP-IOM-2019-0212 OPERATION

 PID Control

Local PID and ring rate modiers are accessed in this category.

` LOCAL PID

Use the slider to set how passive or aggressive the control will act to meet setpoint when the boiler is in local (standalone) mode. See Lead/Lag PID for PID

control of plants with multiple boiler sequencing.

` LOW FIRE HOLD

The boiler can be locked to low re rate after ignition for a set period of time. This period of time can be enabled/disabled and adjusted on this screen.

` FREEZE PROTECTION

Two stages of freeze protection are provided. Stage 1 is only available if the boiler (primary) pump is enabled in a primary secondary piping system. When the boiler vessel water temperature falls below a congured temperature, the boiler (primary) pump will be enabled until the set temperature has been reached.

Stage 2 enables the burner if the boiler vessel water temperature falls below a congured temperature. The burner is held at low re until the set temperature

has been reached.

! 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.

` OUTLET MONITORING

In addition to the mechanical Aquastat temperature high limit, the boiler includes a digital control soft high limit available on the Outlet Monitoring screen.

NOTE: If a high temperature condition occurs exceeding the high limit setting on

the mechanical Aquastat, the boiler will require a manual reset accomplished by pressing the red Aquastat reset button.

The soft high limit acts to prevent nuisance manual reset high limit trips. If the boiler outlet temperature exceeds the soft high limit, the burner will be driven to low re until the outlet temperature is reduced to the value assigned in the Soft

Limit Reset.

` RATE OF CHANGE

When Rate of Change is enabled, the burner ring rate will slowly change should a condition occur where the ring rate increases at a rate greater than as

permitted by the operator.

` COLD START

This feature allows the boiler to slowly reach temperature when receiving a demand at a cold water condition as congured. When enabled, this modier will take priority over the PID until the congured time or the congured boiler water

temperature is reached.

Questions? Please Contact Your Local Manufacturer’s Representative

3-17

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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.

 Setpoint

The boiler or multiple boiler system will maintain supply water temperature based on a setpoint temperature. This setpoint can come from a variety of sources, including by calculation from an outdoor air temperature sensor, a remote signal from the Building Management System (BMS), or from a static

manually entered setpoint.

` SETPOINT CONFIGURATION

The Setpoint Source screen allows for the selection between the various setpoint sources available.

When in Outdoor Reset mode, the control will automatically calculate the hydronic loop setpoint based on the settings congured on the Outdoor Reset screen.

BMS Analog will monitor either the 4-20mA or 0-10VDC contacts for a remote setpoint signal; the BMS Analog screens are used for the linearization settings for the control signal.

When in BMS Network mode, the control will maintain setpoint based on the Modbus RTU write point. Protocol conversion gateways are available for alternate

communication protocols including BACnet and LonWorks.

` OUTDOOR RESET

Outdoor air reset curves are congured through the Outdoor Reset screens. The normal (occupied) setpoint curve and the setback (unoccupied) setpoint curve are congured through separate screens.

The hydronic loop temperature setpoint will be calculated based on congured outdoor air and setpoint high and low temperature values. When the outdoor air temperature reaches a warm weather shutdown Outdoor Air Cuto temperature, the boilers will be disabled until outdoor air temperature has decreased by the

value assigned in the Cuto Reset.

` BMS ANALOG 420MA AND 010VDC

High and low setpoint values must be assigned for correct linearization.

 Scheduling

The Scheduling system allows for the operator to congure when the normal (occupied) setpoint will be maintained. When outdoor reset is enabled, the normal setpoint curve will establish setpoint during these time frames with the setback (unoccupied) setpoint curve establishing setpoint for all other times. See the Outdoor Reset screen in Setpoint.

3-18

SECTION 3 EDRP-IOM-2019-0212 OPERATION

 Trending

Trending data is continuously recorded by the control and can be enabled or disabled by the operator. Tap the “Next Curve” button to navigate through data

types.

 Admin

Administrative functions are used during initial commissioning, troubleshooting and other advanced tasks.

` SYSTEM CONFIGURATION

The System Conguration screen is used for saving (backup) and loading of program settings. The time and date is also congured on this screen. The backup battery status is shown in the bottom right of the screen. Loss of power without

an operational battery will result in lost program settings.

` SENSOR STATUS

An overview of boiler and auxiliary sensor status is available on this screen.

` AUXILIARY CONFIGURATION

! 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.

Through this screen, the system type, setpoint sources, sensors, vent material, and altitude are assigned. This must be individually congured for each boiler in

the network.

` UNIVERSAL DATA CONFIGURATION

The Universal Data system allows the boilers to share vital data over the Ethernet/ IP Boiler Network without having to wire individual sensors to each boiler, or write commands to each boiler. Congure the Universal Data sources at each boiler, for that specic boiler.

 Physically Wired – The control will look to its own I/O inputs for the

information it needs and will then share that information with the Boiler Network.

 Boiler Network – The control will look to the local Ethernet/IP network for

the information it needs. In order for this to work, one boiler will need to share that information with the network setup as either physically wired or BMS network.

 BMS Network – The control will look to the Building Management Network

for the information that it needs and will share it with the rest of the boiler network.

 Please note that each signal/sensor can be independently congured,

meaning one boiler could provide a setpoint to the boiler network, and another could provide the system header temperature, for instance.

Questions? Please Contact Your Local Manufacturer’s Representative

3-19

OPERATION EDRP-IOM-2019-0212 SECTION 3

! 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.

` USER CONFIGURATION

An administrator password can be assigned to the control to prevent unauthorized access. The selected screens will require entry of the administrator

password prior to access. The password may be up to 10 characters in length.

Commissioning Mode

The boiler must be placed in commissioning mode prior to adjusting combustion parameters. This screen is intended for trained factory authorized technicians. This allows easy access to locking the SAS valve, and adjustments to %O2 setpoint for the O2 Compensation system at the ring rate ranges. Place the SAS Control into No Lock and tap the Complete Commissioning button when setup is fully completed to return to normal operation.

Perform Test of Limit Controls

Fire the boiler and test the high limit control as follows:

1. Alter high temperature limit to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the boiler locks out. This condition has to be manually reset.

2. Alter the high limit cut o temperature to normal level, typically 10-20 degrees above set point.

Perform Test of Low Gas Pressure Switch

Test the low gas pressure switch as follows:

1. With the boiler running turn up the low gas pressure switch until a lock out is annunciated.

2. Return the switch to normal setting, re-start the boiler.

Perform Test of High Gas Pressure Switch

Test the high gas pressure switch as follows:

1. With the boiler running turn down the high gas pressure switch until a lock out is annunciated.

2. Return the switch to normal setting, re-start the boiler.

General Operation of the Boiler

3-20

Excessive cycling will reduce the useful life of any piece of mechanical equipment. Endura+ boilers should be operated and controlled so the boiler cycles less than 12,000 times per year.

MAINTENANCE

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE

Questions? Please Contact Your Local Manufacturer’s Representative

4-1

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

! WARNING

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

What to do if you smell gas: Do not try to light the appliance. Do not touch any electrical switch. Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the re department.

General

Your Endura+ boiler has been designed to provide years of trouble free performance. To ensure continued safety and eciency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

Daily, Weekly and Monthly Maintenance and Inspection are considered good practice for any boiler, and is applicable to the full line of Endura+ boilers. It is also good practice for any boiler installation to perform a thorough review of the overall system on a regular basis, and after any maintenance procedures. Any potential issues should be noted and followed up on to ensure safety and reliability of all relevant equipment. System review items may include:

 Looking for discoloration of any painted equipment, boiler jacket panels,

and/or insulation used in system piping.

 Carefully checking for gas leaks using a combustible gas detector during

commissioning and regular inspactions; a Gasmate® 0119 or equivalent is recommended. This includes, but is not limited to, gas delivery system, gas train ttings, pressure switches, gas valves, regulators, conduit connections to gas devices, and pre-mix delivery components.

 Looking for evidence of leaks including the air intake/exhaust systems,

boilers, hydronic system piping, pumps, valves and other system components.

 Once boilers are running, making sure there are no ue gases around the

boilers, or in the boiler room.

NOTE: Combustion analysis and adjustment schedule can vary based on boiler

application and seasonal conditions. Biannual or quarterly adjustment may be optimal in some applications—for example, systems operating as both winter

heat and summer reheat.

Daily Maintenance and Inspection Schedule

After initial start-up by qualied personnel, linkage, control settings, and fuel pressures should not be readjusted.

4 CAUTION

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 Heating Solutions Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4-2

Daily maintenance and inspection must include the following:

1. Observe operating temperature and general conditions.

2. Verify that the ow of combustion and ventilating air to the boiler is not obstructed.

3. Boiler area is free and clear of any combustible materials, including ammable vapors and liquids.

Weekly Maintenance and Inspection Schedule

Weekly maintenance and inspection must include the following:

1. Observe the conditions of the main ame. Correct fuel/air adjustment is essential for the ecient and reliable operation of this boiler. If an adjustment to the combustion is necessary, the ue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to

set conditions.

SECTION 4 EDRP-IOM-2019-0212 MAINTENANCE

Monthly Maintenance and Inspection Schedule

Monthly maintenance and inspection must include the following:

1. Test high-limit control by reducing setting below the operating temperature; burner should shut o. After readjusting the setpoint, reset the control.

2. Test operating temperature control by reducing temperature setting as necessary to check burner operation.

3. Check ue gas temperature at outlet. If there is a temperature increase over previous readings, the probable cause is soot or water-scale build-up on the tubes. Consult your Fulton representative immediately if there is a concern.

4. Test low gas pressure switch and high gas pressure switch utilizing the procedure in Operation section of this manual.

5. Inspect the combustion air inlet lter. If dust, lint or debris has accumulated such that the lter appears heavily loaded visually, replace the lter

immediately.

Replacing the Combustion Air Inlet Filter

! WARNING

Never use open ame or other sources of ignition to check for gas leaks.

Ensure boiler is o and cooled with proper lockout-tagout per local codes prior to service and maintenance.

4 CAUTION

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

The combustion air inlet lter must be replaced at a minimum once per year. Active construction sites and installations with high airborne contaminants will require more frequent replacement.

Proceed as follows:

1. Remove the lter. The lter sits in the slot on the suction side of the blower inside the boiler cabinet.

2. If debris has plugged or contaminated the lter, the lter must be replaced.

NOTE: Operating the burner with the combustion air inlet lter removed will void

the burner warranty. A clean lter of the same Fulton part number (type, size and style) must be installed while the boiler is in operation.

3. Return the lter to its original position in the slot, verify orientation.

Replacing or Updating the Boiler Control

Only update the software or rmware when directed by the factory. Lead/Lag integration requires the same rmware and software version on all units.

Do not allow oil leaks, dust, or dirt to accumulate around the boiler.

Questions? Please Contact Your Local Manufacturer’s Representative

4-3

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

! WARNING

Personnel performing burner assembly maintenance must wear appropriate respiratory protection. Failure to do so may result in the inhalation of refractory ceramic bers.

4 CAUTION

Annual Maintenance and Inspection Schedule

Annual maintenance and inspection must be performed prior to each heating season, and includes but is not limited to the following tasks, which must be done by a factory trained technician:

1. Inspect the fuel train, burner and control panel to be sure components are free of debris and are properly attached to the boiler.

2. Replace the combustion air inlet lter with a new lter of the same Fulton part number (type, size and style).

3. Inspect exible premix couplings; replace immediately if damaged or worn.

4. Examine the venting system (air intake and exhaust piping):

 Check all joints and pipe connections for tightness.

 Check piping for corrosion or deterioration.

 Check that the piping is clear of debris.

 Check that the condensate drain system is functioning.

5. Inspect the hydronic heating system for other problems.

6. Leak test the gas valves.

7. Clean the low water cut-out probe on the water outlet pipe. This can be accessed via the top removable panel.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

Burner gaskets must not be reused. Gaskets are designed for one-time use only.

Using nuts and washers not provided by Fulton can lead to ue gas leakage and cause damage to the studs.

Follow proper safety precautions when using a ladder.

8. Remove and inspect burner. Clean as necessary. See Removing, Inspecting and Cleaning Burner section of this manual.

9. Test relief valve per manufacturer instructions by lifting the lever for 5 seconds and allowing the valve to snap shut. Please see the manufacturer’s recommendations on the relief valve tag.

10. Perform combustion analysis and adjust if necessary. A low O level, resonance or harmonic can indicate a need for burner service.

11. Replace the O sensor with a new sensor. Press “Reset O” on the Maintenance screen.

O2 Compensation Measurement

The Fulton authorized service technician’s gas analyzer measures O% after ue gas moisture removal, while the boiler O sensor measurement is made without removal of the moisture. For operator convenience, the boiler O sensor “wet” value is approximated to a “dry” value for control screen display purposes. This approximation may deviate from the test apparatus; the compared values should be within ±1.0% O. Discrepancies may be observed if the technician’s gas analyzer

has not been properly calibrated per manufacturer instructions and time interval.

NOTE: THE O COMPENSATION READOUT IS NOT A REPLACEMENT FOR A

CALIBRATED FLUE GAS ANALYZER. Under no circumstances should the O compensation readout value be used for combustion adjustment and verication; a calibrated ue gas analyzer is required.

4-4

SECTION 4 EDRP-IOM-2019-0212 MAINTENANCE

Removing, Inspecting and Cleaning Burner

For the following procedure, be sure to reference Figures 25 and 26.

1. A burner maintenance parts kit is required to complete the following steps. Contact your Fulton representative to purchase this parts kit before proceeding, please have your National Board number ready to expedite service.

2. EDR+2500/3000 Only: Access to the burner is provided through the top of the cabinet, removing a side panel will facilitate access.

3. EDR+4000-6000 Only: Access to the burner is provided through the front cabinet door.

4. Loosen the hose clamps on exible couplings and remove the premix elbow.

5. Remove safety and control devices from the burner ange, including the ignition assembly, UV ame scanner, and O bypass line.

6. Loosen and remove the nuts and washers from the burner ange. Take care to properly handle and store the hardware during maintenance.

NOTE: Due to unique hardware specications, alternate hardware must not be

substituted. If hardware is lost or damaged, contact your Fulton representative for replacements.

! WARNING

Specied torque values are mandatory to ensure safe and reliable oeration of the boiler. Failure to properly torque hardware may result in PERSONAL INJURY, DEATH, or property damage.

O bypass line is hot; contact with ammable materials can cause a re. Do not touch or work on the O system while hot.

THE O COMPENSATION READOUT IS NOT A REPLACEMENT FOR A CALIBRATED FLUE GAS ANALYZER. Under no circumstances should the O2 compensation readout value be used for combustion adjustment and verication; a calibrated ue gas analyzer is required.

7. Carefully remove the burner from the combustion chamber and cabinet, taking precaution to ensure the burner metal ber material does not make contact with any other surfaces.

NOTE: Do not use liquids or brushes when cleaning the burner.

8. Visually inspect the interior and exterior of the burner for debris. If debris is present, use a compressed air blow gun with air pressure of 30 psi (2 bar) to maximum 72.5 psi (5 bar). The blow gun must be a minimum 0.40 inches (1 cm) from the surface of the burner. Carefully vacuuum debris from the inside of the burner.

NOTE: The combustion air supply must meet the requirements detailed in

the Installation section. Combustion air contaminants can lead to excessive maintenance or damage to burner components. The MERV 8 lter will capture 90+% of particles from 3-10 microns, but a small percentage will pass through to the burner head. Installations with poor combustion air quality may require burner cleaning more frequently than the annual service. A dirty burner may experience audible combustion harmonics within the normal operating range, requiring a need for cleaning. Damage due to poor combustion air quality is not covered under the warranty. A damaged burner will require replacement.

Questions? Please Contact Your Local Manufacturer’s Representative

4-5

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

! WARNING

9. Carefully reinstall the burner: Replace both burner gaskets, do not reuse the burner gaskets. Apply C5-A Antiseize (PN 2-12-000191) to threads, and reinstall the burner ange washers and nuts using only originally supplied or genuine Fulton replacement hardware. Tighten in a star pattern.

 EDR+2500/3000 Only: Verify torque to 23 ft-lbs.

 EDR+4000-6000 Only: Verify torque to 20, 40, then 45 ft-lbs. in

three stages. A 6-point 7/8” crowfoot socket wrench is required.

10. Reinstall the ignition assembly with a new O-ring using Parker Super-OLube and apply C5-A Antiseize (PN 2-12-000191) to screws.

 EDR+2500/3000 Only: Verify torque to 27 in-lbs. Apply

Permatex 22058 di-electric grease to electrical connections.

NOTE: Fulton recommends annual replacement of the EDR+2500/3000 ignitor.

Always inspect the ignitor for small ceramic cracks, corrosion on any of the electrical connectors, and dimensional drift on the spark gap. If any of these are found, the ignitor must be immediately replaced.

 EDR+4000-6000 Only: Verify torque to 60 in-lbs.

NOTE: The ignition electrode on the EDR+5000/6000 pilot assembly requires

annual inspection, but is not intended to be replaced on an annual basis. See Inspecting the Pilot Ignition Assembly.

11. Reinstall the O sensor and verify torque to 26-33 ft-lbs. Reconnect the O bypass line. Ensure sensor wiring cannot contact the bypass line.

NOTE: The O sensor is intended to be replaced annually. Sites with air

contaminants such as silicone/RTV use in the boiler room may requirement more frequent replacement due to sensor poisoning. Use of “sensor safe” silicones/RTV is required.

12. Reinstall and hand tighten the UV scanner. EDR+2500/3000 Only: Verify wiring is below the top cabinet panel.

13. Reinstall pre-mix elbow exible coupling and tighten hose clamps.

 EDR+2500/3000 Only: Verify torque to 40 in-lbs.

 EDR+4000-6000 Only: Verify torque to 45 in-lbs.

14. Reinstall cabinet panels.

15. Perform a full combustion analysis and adjust if necessary.

4-6

SECTION 4 EDRP-IOM-2019-0212 MAINTENANCE

Inspecting the Pilot Ignition Assembly

NOTE: This section applies only to Endura+ boilers equipped with a pilot ignition.

The pilot assembly requires annual inspection; although it is considered a wearitem it is not intended to be replaced on an annual basis.

1. Remove the pilot ignition assembly from the burner ange.

2. Inspect for corrosion in the raja connector on the pilot and on the ignition wire. Replace if found.

3. Inspect insulator for cracks, dirt, oils or soot. Clean if necessary. Replace if any cracks are found or it cannot be cleaned.

4. Verify that the pilot orice is clean. Clean if obstructed.

5. Verify that the spark gap to the tube is 3/16” (4.763 mm) within tolerance +/1/16” (1.588 mm), adjust if needed.

6. Inspect that the insulation block around the pilot when installed has not lost structural integrity. Replace with original Fulton part if needed.

7. Reinstall the pilot ignition assembly per the instructions detailed in Removing, Inspecting, and Cleaning Burner.

After All Repairs and Maintenance

1. Perform all Safety Checks as described in the Operation section.

2. Fire the boiler and perform a full combustion verication. Make adjustments as necesary.

3. Complete the “Installation and Operation Report” for Endura+ boilers and retain in the boiler’s maintenance records.

NOTE: Accurate and complete combustion and maintenance records detailing

compliance with the Installation, Operation and Maintenance Manual must be produced for warranty consideration.

Questions? Please Contact Your Local Manufacturer’s Representative

4-7

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

BILL OF MATERIAL

DESCRIPTIONPART NUMBERITEM

3/4" NPT SIGHT OBSERVATION PORT2-12-0000121

LOCTITE C5-A COPPER ANTI-SEIZE2-12-0001912

029 1/16" AFLA S O-RING 1 5/8" OD (MCMASTER #5240T215)2-12-315003

EDR+ 3000 BU RNER TO PV GASKET2-12-3150057

EDR+ 3000 PREMIX TO BURNER GAS KET2-12-3150079

EDR+ 3000 SPARK IGNITION ASS EMBLY2-20-315100

3/8-16 NiCu400 HEX NUT (MONEL400)2-22-00015627

3/8" BELLEV ILLE WASHER (INCON EL 718,.385" ID X 1.25" OD X .125" THK, .021" DISH)2-22-00035331

10-32 X 1/4" LONG S.S. TORX SCREW (MCMASTER #96710A572)

3/4" - 14 NPSM THERMAL BARRIER FOR FLAME DETECTOR2-40-00046473

SIEMENS LMV 2-3 HIGH SENSITIVITY UV SCANNER2-40-00110774

EDR+ 3000 BU RNER2-40-31500076

NPD - 02 SENS OR (BOSCH LSU ADV WIDEBAND LAMBDA SE NSOR)2-45-31550192

EDR+ 3000 PREMIX RETAINER

PLATE2-50-31511199

EDR+ 2500 / EDR+ 3000 BURNER VOLUME REDUCER / PREMIX INLET ASSEMBLY5-10-315300105

INSTALL 2" DURABLANKET (2-12-880103) BETWEEN THE HEAT SH IELD AND THE TOP FLANGE OF THE FURNACE IN AREAS SHOWN. BE SU RE THAT NO INSULATION PROTRUDES PAS T THE INSIDE DIAMETER OF THE TOP FLANGE AND NOT PAST ANY CUTOUTS THROUGH THE TOP FLANGE. ONCE INSULATION IS IN PLACE USE RIGIDIZER (2-12-000196) ON THE EXPOSED INSULATION.

INSULATION INSTALLATION DETAIL

2-22-31502136

Bill of Material

Item Part Number Description

1 2-12-000012 3/4” NPT Sight Observation Port

2 2-12-000191 Loctite C5-A Copper Anti-seize

5 2-12-315003 029 1/16” AFLAS O-Ring 5/8” OD

7 2-12-315005 EDR+ 3000 Burner to PV Gasket

9 2-12-315007 EDR+ 3000 Premix to Burner Gasket

11 2-20-315100 EDR+3000 Spark Ignitiion Assembly

27 2-22-000156 3/8-16 NICu400 Hex Nut

31 2-22-000353

36 2-22-315021 10-32 x 1/4” Long S.S. Torx Screw

73 2-40-000464 3/4” - 14 NPSM Thermal Barrier for Flame Detector

74 2-40-001107 Siemens LMV2-3 High Sensitivity UV Scanner

76 2-40-315000 EDR+3000 Burner

92 2-45-315501 O2 Sensor

99 2-50-315111 EDR+3000 Premix Retainer Plate

105 5-10-315300 EDR+2500/3000 Burner Volume Reducer/Premix Inlet Assembly

3/8” Belleville Washer (Inconel 718, .385” ID x 1.25” OD x .125 THK, .021” Dish)

WASHER ORIENTATION DETAIL

(SHOWN PR ETORQUE FOR CLARIFICATION)

BELLEVILLE WASHERS MUST BE IN STALLED IN THE ORIENTATION SHOWN.

APPLY PARKER SU PER-O-LUBE

DURING INSTALLAT ION

APPLY LOCTITE COP PER C5-A ANTI-SEIZE

(2-12-000191), & TO RQUE TO 27 IN. LBS., (TYP. 2 PLCS.)

APPLY LOCTITE C OPPER C5-A ANTI-SEIZE (2-12-0001 91),

TIGHTEN 1.5 - 3.0 TURNS PA ST FINGER TIGHT

TORQUE TO 26-33 FT. LBS.

APPLY LOCTITE C5 -A COPPE R ANTI-SEIZE (2-12-000191) TO THREADS WHEN IN STALLING 02 BYPASS TUBE. FULLY IN SERT TUBE INTO FITTING , TIGHTEN THE NUT UNTIL THE TUBE WILL NOT TURN O R MOVE AXIALLY. THEN TIGHTEN FITTING 1 1/4 MORE REVOLUTIONS

APPLY LOCTITE C5 -A COPPER ANTI-SEIZE (2-12-000191), & TO RQUE TO 23 FT. LBS. (SEE WASHER ORIE NTATION DETAIL VIEW

27 31 2

FOR PROPER BELLEV ILLE WASHER INSTALLATION, (T YP. 12 PLCS.)

(2 PC.)

105

BE SURE THE COR RECT GASKET AND ORIENTATION IS US ED AT THIS LOCATION

4-8

FIGURE 25  EDR+ 2500/3000 BURNER ASSEMBLY

SECTION 4 EDRP-IOM-2019-0212 MAINTENANCE

BURNER / PREMIX ASSEMBLY

BILL OF MATERIAL

T NUMBER

2-000012

2-000721

2-315008

2-315011

2-000058

2" - 3" STEEL WORM DRIVE HOSE CLAMP (MCMASTER # 5 407K22)

2-315006

1/2" BELLEVILLE WA SHER (SS301, 0.519"ID x 1.24"OD x 0.125"THK (SOLON#820125301)

2-315039

1/4-20 X 5/8" LONG S.S. TORX SCREW (MCMASTER #90 600A128)

2-315040

3/4" - 14 NPSM THE RMAL BARRIER FOR FLAME DETECT OR

0-000464

0-001107

0-315600

NPD - 02 SENSOR (BO SCH LSU ADV WIDEBAND LAMBDA SENSOR)

5-315501

0-315310

EDR+ 6000 BURNER VOLUME REDUCER/ PREMIX INLET A SSEMBLY

0-315315

0-315675

0-315680

0-315694

2-880103) BETWEEN

TOP FLANGE OF THE OWN. BE SURE THAT ES PAST THE INSIDE

ANGE AND NOT PAST

GH THE TOP FLANGE .

LACE USE RIGIDIZER

XPOSED INSULATIO N.

BELLEVILLE WASHERS MUST BE INSTALLED

IN THE ORIENTAT ION SHOWN.

D N.

WASHER ORIENTATIO

(SHOWN PRETORQUE FOR CLARIFICATION)

Bill of Material

Item Part Number Description

1 2-12-000012 3/4” NPT Sight Observation Port

2 2-12-000721 029 1/16” Vitton O-Ring 1.625 OD

4 2-12-315008 2” ID x 6” Neoprene Flexible Coupling

6 2-12-315011 EDR+ 6000 Premix / Furnace Gasket

25 2-22-000058 1/2-13 Hex Nut, GR. 2H

34 2-22-315006 2” - 3” Steel Worm Drive Hose Clamp

41 2-22-315039 1/2” Belleville Washer (SS301, 0.519” ID x 1.24” OD x 0.125” THK

42 2-22-315040

1/4-20 x 5/8” Long S.S. Torx Screw

70 2-40-000464 3/4” - 14 NPSM Thermal Barrier for Flame Detector

73 2-40-001107 Siemens LMV2-3 High Sensitivity UV Scanner

76 2-40-315600 EDR+6000 Mesh Burner

89 2-45-315501 O2 Sensor

95 5-10-315310 250 Hz Resonator Capped Tube

96 5-10-315315 EDR+6000 Burner Volume Reducer/Premix Inlet Assembly

107 5-10-315675 EDR+6000 Premix Retainer Plate

110 5-10-315680 EDR+6000 Pilot Assembly

119 5-10-315694 EDR+6000 Pilot Insulation

AN ALTERNATE TOO L MUST BE USED

TO TORQUE THESE TWO NUTS. BE

SURE TO ADJUST TORQUE WRENCH TO

ACCOMODATE THE CHANGE OF GEOMETRY.

6 76 6 96 107

BELLEVILLE WASHERS MUST BE INSTALLE

IN THE ORIENTATION SHOW

N DETAIL

(2 PCS.)

APPLY LOCTITE COPP ER C5-A ANTI-SEIZE (2-12-000191 ),

TIGHTEN 1.5 - 3.0 T URNS PAST FINGER TIGHT

APPLY LOCTITE COP PER C5-A ANTI-SEIZE (2-12-000191), & TO RQUE TO 60 I

(TYP. 2 PLCS.)

110

APPLY PARKER SUP ER-O-LUBE

DURING INSTALLATI ON

ITEM

107

110

119

N. LBS.,

INSTALL 2" DURABL ANKET (2-1

THE HEAT SHIELD A ND THE

FURNACE IN AREAS SH NO INSULATION PR OTRUD DIAMETER OF THE TOP FL

ANY CUTOUTS THR OU

ONCE INSULATION IS IN P

(2-12-000196) ON THE E

PAR

2-1

2-2

2-4

5-1

Questions? Please Contact Your Local Manufacturer’s Representative

APPLY LOCTITE CO PPER C5-A ANTISEIZE

(2-12-000191) TO THREADS WHEN

INSTALLING 02 BYP ASS TUBE. TRIM

1" OFF 02 LINE THEN FULLY INSERT

TUBE INTO FITTING , TIGHTEN THE NUT

UNTIL THE TUBE W ILL NOT TURN OR MOVE

AXIALLY. THEN TIG HTEN FITTING 1 1/4 MORE

REVOLUTIONS.

FIGURE 26  EDR+ 40006000 BURNER ASSEMBLY

TORQUE TO 26 - 33 FT. LBS.

APPLY LOCTITE CO PPER C5-A ANTI-SEIZE (2-12-000191 ), & TORQUE TO 45 FT. LBS. IN THREE STAGES

(SEE WASHER ORI ENTATION DETAIL VIEW FOR

PROPER BELLEVI LLE WASHER INSTALLATION, (TY P. 14 PLCS.)

(TORQUE SPEC: 20 IN. LBS.)

4-9

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

Troubleshooting

Use the following tables as a guide to troubleshooting your boiler.

PROBLEM CAUSE CHECK

Control does not illuminate 24 VDC Power Supply Check fuse or circuit breaker. Reset or replace as

necessary.

Fan will not start High temperature is tripped 1. Check sensor wiring connector.

2. Check resistance.

3. Replace sensor if faulty.

Low gas is tripped 1. Reset switch, making sure to listen for audible

click.

2. Replace switch if setting is below actual pressure.

High gas is tripped 1. Reset switch, makiing sure to listen for audible

click.

2. Replace switch if setting is above actual pressure.

Flame detector has detected light/scanner 1. Identify light source, remove

2. Replace ame detector

Air switch is made when fan is not on 1. Adjust, if necessary.

2. Reset switch

3. Replace switch Blower contactor made when fan not on Replace motor contactor Gas valve proof of closure defective Replace valve Loose wire connection Check wiring

High Back Pressure Switch trip/boiler shutdown

Main ame failure during ring period

Ignion Failure If UV scanner does not detect the ame during the

VFD Manual Lockout aer

Power Outage

Excessive Vent Pressure This condion will automacally recycle, so the

boiler will try to relight. The venng should be checked for obstrucons and cleaned. Check switch seng.

Main gas control valve is de-energized and the control goes into “lockout” mode. Flame failure occurs and the indicator is illuminated.

4-second trial-for-ignion period, the gas valve and spark ignion are de-energized. At this me a safety lockout occurs.

A power outage greater than 15 seconds but less than 25 seconds.

The programmer must be manually reset. Check wire connecons.

Idenfy and correct.

Reset the VFD lockout.

4-10

SECTION 4 EDRP-IOM-2019-0212 MAINTENANCE

PROBLEM CAUSE CHECK

Main ame fails Ignition issue 1. Visually verify spark.

2. Replace igniter or transformer, as needed.

Gas valve not set properly Verify the last elbow gas pressure matches the start

up report.

Flame detector failure 1. Visually verify the ame through the sight glass.

2. Remove ame detector and visually verify the ame through the scanner tube.

3. Verify the ame detector eye is not dirty.

4. Replace scanner.

Insucient Gas Supply 1. Verify the manual shut-o valves are open,

allowing gas ow through the gas train.

2. Adjust incoming gas pressure to match the start

up report. Gas Filter Blocked Replace gas lter. Air supply blocked Verify venting is not obstructed and lter is not

plugged.

Boiler fails while modulating

Poor combustion Gas valve not set properly Adjust gas valve settings. Manual Reset limit device

trips Power outage to the boiler

room Gas Pressure alarm is

annunciated

Gas valve not set properly Verify the last elbow matches the start up report.

Air supply blocked (direct vent only) Verify venting is not obstructed.

Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit

Entire boiler system is disabled and de-energized. When power has returned, the boiler will have to be

Either insucient gas pressure or the gas pressure to the manifold is too high for safe and proper operation of the boiler. This shuts down the burner. When gas pressure is restored, the annunciated alarm will remain on and the boiler will remain locked out until the gas pressure switch is manually reset.

DO NOT reset without determining and correcting

the cause.

manually reset, as it will be in the lockout position

Locate cause and correct. In the event of a high

gas manifold pressure condion, qualied service

personnel must correct the problem before

restarng the boiler.

High water temp alarm is annunciated

Burner harmonic or resonance

Questions? Please Contact Your Local Manufacturer’s Representative

Boiler water has exceeded both the operating and high-limit temperature. When the water temperature falls below the high-limit temperature, the boiler will remain locked out until the controller is manually reset.

Improper combustion parameters or fouled lter or burner.

Locate cause and correct. Once the control is reset,

the sequence returns to normal operation provided

that the other limits are satised.

1. Inspect air lter, replace if dirty.

2. Inspect burner, clean according to maintenance

instructions if dirty.

3. Verify combustion at all operating points.

4. Proceed to resonator adjustment ONLY AFTER

verifying he above. Consult factory for resonator

adjustment.

4-11

MAINTENANCE EDRP-IOM-2019-0212 SECTION 4

4-12

PAGE INTENTIONALLY LEFT BLANK

No part of this Installation, Operation, and Maintenance manual

may be reproduced in any form or by any means without

permission in writing from Fulton Group N.A., Inc.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of Fulton Group N.A., Inc., a global manufacturer of steam,

hot water and thermal uid heat transfer systems.

Fulton Heating Solutions

6288 Running Ridge Road, Syracuse, NY 13212 Call: (315) 298-5121 • Fax: (315) 298-6390

The heat transfer innovators

www.fulton.com

EDRP-IOM-2019-0212

FULTON Endura+ Series, EDR+ 2500, EDR+ Series, EDR+ 3000, EDR+ 4000 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual