Fulton Endura Condensing Hydronic Boiler User Manual

INSTALLATION AND

OPERATION MANUAL

Endura (EDR)

Condensing Hydronic Boilers

1,000,000 - 2,000,000 BTU/HR

Serial/ National Board Number

Model

Fulton Order

Sold To

Job Name

Date

EDR-IOM-2014-0318

EDR-IOM-2014-0318 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

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

Clearances and Serviceability .............................................................................. 2-3

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

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

Meet Water Chemistry Requirements .................................................................. 2-7

PREVENT OXYGEN CONTAMINATION .......................................................................................... 28

ELIMINATE SYSTEM AIR ..............................................................................................................2 9

Fill the Boiler With Water ..................................................................................... 2-9

Install Gas Piping .................................................................................................. 2-9

COMPONENTS REQUIRING VENTILATION TO THE OUTDOORS .................................................210

Install Condensate Drain .................................................................................... 2-11

SINGLE BOILER DRAIN TRAP .....................................................................................................211

MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP .........................................................211

Install pH Neutralization Kit ............................................................................... 2-14

Venting ............................................................................................................... 2-15

COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................216

AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................ 216

Air Filter .............................................................................................................. 2-17

Exhaust Venting ................................................................................................. 2-17

COMMON VENTING LAYOUTS FOR ENDURA .............................................................................218

VENTING TERMINATIONS ..........................................................................................................2 19

WALL THIMBLE INSTALLATION .................................................................................................220

HORIZONTAL VENT TERMINATION ............................................................................................223

Removing an Existing Boiler ............................................................................. 2-23

Electrical Connections ....................................................................................... 2-24

Assembly of Fulton Multi-Skid Systems............................................................. 2-25

SYSTEM DESIGN AND BOILER OPERATION .................................................................................3 3

Commission The Boiler: Dungs Zero Governing Gas Valve ................................... 3-3

TURNDOWN .................................................................................................................................36

SOLA Hydronic Controller for Endura ................................................................... 3-7

STATUS SUMMARY SCREEN.........................................................................................................37

CENTRAL HEAT OPERATION SCREEN ........................................................................................... 37

CENTRAL HEAT OPERATION  FIRING RATE SCREEN ................................................................... 38

CENTRAL HEAT OPERATION  SETPOINT SCREEN ....................................................................... 39

CENTRAL HEAT CONFIGURATION  SETPOINT SCREEN .............................................................39

CENTRAL HEAT CONFIGURATION  MODULATION SCREEN ......................................................39

CHANGING HIGH LIMIT SETPOINT AND VERIFYING CHANGE ..................................................310

REVIEWING STATISTICS .............................................................................................................3 12

ACCESSING LOCKOUT HISTORY .................................................................................................313

SOLA DIAGNOSTICS ...................................................................................................................315

Perform Test of Low Water Cut O ..................................................................... 3-16

Perform Test of Limit Controls ........................................................................... 3-17

Perform Test of Low Gas Pressure Switch .......................................................... 3-17

Perform Test of High Gas Pressure Switch .......................................................... 3-17

General Operation of the Boiler ......................................................................... 3-17

Maintenance 4-1

General ................................................................................................................. 4-2

Daily Maintenance and Inspection Schedule ...................................................... 4-2

Weekly Maintenance and Inspection Schedule .................................................. 4-2

Monthly Maintenance and Inspection Schedule ................................................. 4-2

Procedure for Cleaning the Air Inlet Filter .......................................................... 4-3

Annual Maintenance and Inspection Schedule ................................................... 4-3

Removing and Cleaning Burner Assembly .......................................................... 4-4

After All Repairs and Maintenance ...................................................................... 4-5

Troubleshooting ................................................................................................... 4-5

Warranty & Parts 5-1

Standard Warranty for Fulton Endura Hydronic Boilers ....................................... 5-3

Parts ..................................................................................................................... 5-5

Operation 3-1

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

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

0-1

TABLE OF CONTENTS EDR-IOM-2014-0318

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Please Contact Your Local Manufacturer’s Representative

1-1

INTRODUCTION EDR-IOM-2014-0318 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 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 WARRANTY & PARTS

3 4 5

Questions? Please Contact Your Local Manufacturer’s Representative

2-1

INSTALLATION EDR-IOM-2014-0318 SECTION 2

! 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.

4 CAUTION

This boiler is certi ed for indoor installation only. This boiler may not be  eld retro tted.

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.

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 be of the sealed combustion/direct vent type 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

 ASME safety relief valve

 Installation and Operation Manual

 Test  re report

 Wiring diagram

 Temperature and pressure (T&P) gauge

 1 can touch up paint

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.

2-2

SECTION 2 EDR-IOM-2014-0318 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.

! 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.

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 in the vertical position. Concrete is strongly recommended. The surface must be elevated a minimum of 4” (102 mm) above the  oor.

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 maximum lengths for horizontal or vertical venting if sealed combustion will be used. See Clearances and Serviceability section of this manual.

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

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

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

Do not use to directly heat swimming pool.

Questions? Please Contact Your Local Manufacturer’s Representative

2-3

INSTALLATION EDR-IOM-2014-0318 SECTION 2

TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS

MODEL EDR 1000 1500 2000

Input Million BTU/Hr kW

Fuel Cons. @ rated cap. (Nat. Gas) FT3/Hr M3/Hr

Output at AHRI Test Condition BHP KCal/h

Electrical Req. (Amps)* 120V, 60Hz, 1 Phase

Water Content Gal Liters

Dry Weight LBS KG

Operating Weight LBS KG

Alternate gas pressure arrangements may apply. Please verify gas pressure ratings for your boiler by viewing the boiler name plate.

Typical 120 VAC controls allow for a +10% and a -15% voltage  uctuation. Voltages lower than 120 V can result in slightly decreased available output.

*Standard con gurations. Alternate voltages may be available as an option; please consult factory.

Note: All dimensions are approximate and are subject to change without notice.

1.0

293

1000

28.32

28.4

239,396

10 20 20

189

1430

649

184 8

838

1.5 411

1500

42.5

41.9

353,42456472,240

104 394

2260 1025

3128 1419

2.0

549

2000

56.7

102 386

2360 1071

3210 1456

TOP VIEW

MODEL EDR 1000 1500 2000

A. Boiler Width IN CM

B. Overall Boiler Height IN CM

C. Overall Boiler Depth IN CM

D. Flue Outlet Diameter IN CM

E. Water Inlet/Outlet Diameter IN CM

F. Min. Clearance (top) IN CM

G. Air Inlet Diameter (top access) IN CM

Min. Clearance (sides) IN CM

28 72

172. 7

49.75

126.4

15.2

5.08

18 46

15.2 5

2.5

33.9 86

203.2

60.6

153.8

15.2

10.2

18 46

20.3

2.5

33.9 86

203.2

60.6

153.8

15.2

10.2

18 46

20.3

2.5

2-4

FRONT VIEW RIGHT SIDE VIEW BACK VIEW

FIGURE 1  VIEWS OF ENDURA HYDRONIC BOILER

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

(Figure 1). This will allow access around the equipment to facilitate maintenance and a safe work environment. An 1 inch (25.4 mm) side clearance is acceptable between any number of boilers. Custom con gurations may not allow 1 inch (25.4 mm) side clearance. Although a 1 inch (25.4 mm) side clearance is permitted, allowing 24 inches (610 mm) will facilitate and expedite maintenance and any advanced troubleshooting.

NOTE:  Side panels are latched; however, maintenance

and service does not require boiler access through side panels. All maintenance and service can be performed from front, rear, and top of boiler.

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

4. Do not place any boiler room accessories, or other components, on the Endura skid.

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:

NOTE:  Each boiler is equipped 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.

TABLE 2  SAFETY RELIEF VALVE INLET AND OUTLET SIZES

Model Trim Pressure

PSI (kPa)

EDR-1000 30 (206.84)

through

160 (1103.16)

EDR-1500 30 (206.84) 1 (25.4) 1 1/4 (31.75)

60 (413.69) 3/4 (19.05) 1 (25.4)

100 (689.48) 3/4 (19.05) 1 (25.4)

125 (861.84) 3/4 (19.05) 1 (25.4)

160 (1103.16) 3/4 (19.05) 1 (25.4)

EDR-2000 30 (206.84) 1 1/4 (31.75) 1 1/2 (38.1)

60 (413.69) 1 (25.4) 1 1/4 (31.75)

100 (689.48) 3/4 (19.05) 1 (25.4)

125 (861.84) 3/4 (19.05) 1 (25.4)

160 (1103.16) 3/4 (19.05) 1 (25.4)

Inlet Size inch (mm)

3/4 (19.05) 1 (25.4)

Outlet Size inch (mm)

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

» Be connected to the coupling located in the

top of the boiler.

» Be installed in the vertical position.

NOTE:  Safety relief valve size is determined by trim

pressure and is supplied in the trim kit along with appropriate bushing, inlet and outlet sizes. See Table 2. Standard trim pressure is 60 PSIG.

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: Valve is shipped loose and must be installed by the contractor.

FIGURE 2  SAFETY VALVE LOCATION

Questions? Please Contact Your Local Manufacturer’s Representative

2-5

INSTALLATION EDR-IOM-2014-0318 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.

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, each location must be analyzed and treated accordingly.

Adhere to the following for water piping installation (See Figure 3):

1. Isolation valves are recommended on both water connections for ease of service.

2. Install piping so that the boiler is not supporting any additional piping.

3. Install manual purging valves in all loops and zones. Install a pressurereducing (automatic  ll) valve in the cold water  ll line to the boiler system. 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. Clearance from hot water pipes to combustibles must be at least 6 inches (152 mm).

4. When used in conjunction 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.

5. Include the following in the mechanical equipment in the hydronic heating system:

» An automatic pressure activated water make up valve with back

 ow preventer. It must be set to maintain required Net Positive

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

2-6

» 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.

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.

NOTE:  The Fulton Endura boiler does not require a primary/secondary  ow

piping system. Although primary/secondary is an acceptable con guration, the boiler does not have a minimum return water temperature requirement and the heat exchanger will not be harmed by low  ow or zero  ow conditions. See Figure 3 for a sample piping layout.

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

! WARNING

6. Install  ltration to remove particulates if appropriate. A #10 mesh size is suggested.

7. Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate.

8. Install corrosion coupon holder to assess corrosion inhibitor performance if appropriate.

9. Before installing a 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 and any foreign matter. The hydronic system must be completely  ushed prior to installing the boiler itself.

NOTE:  Although motorized isolation valves are not required in a primary

only arrangement , they can help ensure system e ectiveness. Proper control strategy must be used to ensure  ow paths in the hydronic loop and residual heat in pressure vessel can be adequately dispersed when a boiler is disabled.

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.

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.

 Chloride: Less than 200 ppm

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.

Questions? Please Contact Your Local Manufacturer’s Representative

2-7

INSTALLATION EDR-IOM-2014-0318 SECTION 2

MAKE UP

WATER

AIR

SEPARATOR

SYSTEM SUPPLY

WATER

SYSTEM

RETURN WATER

MOTORIZED

ISOLATION VALVE

(OPTIONAL)

EXPANSION

TANK

AIR SEPARATOR AND EXPANSION

TANK AS DETERMINED

APPROPRIATE BY OTHERS

SYSTEM PUMPS AND VALVES

AS DETERMINED

APPROPRIATE BY OTHERS

FIGURE 3  SAMPLE PIPING LAYOUT

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.

 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 closed-loop system using water or water/glycol (not requiring a make-up water supply). 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. Only use mixtures formulated for hydronic systems. Do not use automotive glycol.

6. At a minimum, the hydronic  uid should be checked for glycol concentration and pH once a year.

2-8

 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

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

 Eliminate System Air

NOTE:  There are no built-in boiler air eliminating features.

Adhere to the following for air elimination:

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

2. To prevent scale 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.

3. If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator.

4. If an air cushion type expansion tank is used, pipe tank directly into boiler supply.

5. On multi-zoned systems (or a system with both space and domestic water heating), air elimination must be provided either in the common piping or on every loop.

6. When the boiler is installed at a higher level than baseboard radiation (if used), air elimination must be provided directly above the unit.

4 CAUTION

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.

Fill the Boiler With Water

To be sure that the boiler is not air-bound, open the pressure-relief 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.

Install Gas Piping

The Endura boiler is factory test  red and combustion is adjusted per the boiler data plate and test  re sheet.

The gas train components are con gured to operate at speci c gas pressure requirements. The speci c requirements for each boiler are called out on the boiler nameplate, located on the back of the boiler.

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.

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

3. 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.

4. The boiler must be disconnected at the boiler manual shuto valve

Questions? Please Contact Your Local Manufacturer’s Representative

2-9

INSTALLATION EDR-IOM-2014-0318 SECTION 2

! WARNING

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

4 CAUTION

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

(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.).

5. 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.

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

7. 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.

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

9. 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.

10. 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.

11. The boiler must be disconnected at the boiler shut o valve from the gas supply piping system during any pressure testing of the system.

NOTE:  In cases where a vent line connection must be used on the gas

pressure regulator must be piped to outdoor air by the installer in accordance with the National Fuel Gas Code, ANSI Z223.1-1991 or latest addenda. In Canada gas installations must by in accordance with the current CAN/CSA B149.1 and 2 and/or local codes.

 Components Requiring Ventilation to the Outdoors

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

 Gas valve on the main fuel train

 Lock-up regulator on the main fuel train

 Regulator on the ignition enrichment line

An authority having jurisdiction may not permit the use of a vent limiter. In this case, please use the following general guidelines:

 A parts kit must be ordered from your Fulton manufacturer’s representative

for plumbing the vent lines outside the cabinet. Improper plumbing will cause the cabinet to lose its sealing, which can lead to improper combustion and bypassing of the air  lter. Instructions are included in the kit.

2-10

 Start with the vent and cabinet bulkhead size, and as soon as is practical

increase the pipe size one diameter.

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

 For every ten feet of pipe run, increase the pipe size one diameter.

 Protect the vent termination from water, dust and insects.

Install Condensate Drain

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

 Single Boiler Drain Trap

The condensate drain kit is Fulton Part Number 4-57-005500. The drain kit must be con gured one per boiler, with a maximum of 4.0 mm BTU total.

Adhere to the following for installation:

1. The 1 inch (25.4 mm) condensate drain will be reduced and connected to the 3/4 inch (19.05 mm) inlet on the base of the drain kit.

2. 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).

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

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

! 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

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

5. Connect the 3/4 inch (19.05 mm) drain 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).

 Multiple Boilers Sharing A Common Drain Trap

The condensate drain kit is Fulton Part Number 4-57-000440. The maximum number of units to attach per condensate drain kit is 12mm BTU total.

Adhere to the following for installation:

1. The Fulton Endura boiler 1 inch (25.4 mm) condensate drain will be connected to the 1 inch (25.4 mm) inlet on the drain kit. One or more drain lines may be connected to this inlet (max of 12 MM BTU per drain).

2. If the water supply must be temporarily disconnected, the boilers must be turned o to prevent accidental  ue gas emission into the boiler room.

3. 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.

4. A condensate collecting tank and condensate pump will be required if a  oor drain is not available to collect condensate (collecting tank and pump

Questions? Please Contact Your Local Manufacturer’s Representative

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INSTALLATION EDR-IOM-2014-0318 SECTION 2

FIGURE 4  CONDENSATE DRAIN PIPING FOR ENDURA BOILERS

REAR VIEW

Figure 4 Notes:

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

 Header material to be galvanized steel or 316L stainless.

 Header should be taken to the lowest point possible and

maintain a minimum 5.5 inch (14.2 cm) drop from 1.5 inch (38.1 mm) condensate drain kit/trap outlet. See Detail A.

 1.5 inch (38.1 mm) condensate drain kit/trap outlet is never

to be above 1 inch boiler condensate outlet.

 For multiple boiler installation, maintain and minimum pipe

size of 1 inch (25.4 mm) for the header piping.

 The maximum capacity to attach per condensate drain kit is

12 MMBH total.

Detail A

Condensate

Drain Kit

0.25” U.S. TAPPING PROVIDED FOR WATER CONNECTION TO MAINTAIN WATER SEAL

5.5 INCH 14.2 CM MINIMUM

2-12

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

TABLE 3  NOMINAL PIPE SIZE

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

ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. Pressure drop of

0.5”wc/Equivalent length of pipe (feet)

Feet (meter)

Te e Feet (meter)

20 40 60 80 100 150 200

FIGURE 5  FULTON PH NEUTRALIZING KIT WITHOUT PUMP

Questions? Please Contact Your Local Manufacturer’s Representative

2-13

INSTALLATION EDR-IOM-2014-0318 SECTION 2

30 3/8

[771]

3 13/16

[97]

(TYP.)

TOP VIEW

10 3/4

[273]

11 1/4 [286]

1" NPT

CONNECTION

TO BOILER

FRONT VIEW

FIGURE 6  FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK

are not supplied with the boiler).

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

12 1/2

[318]

ISOMETRIC VIEW

1. Neutralizer Kit with Magnesium Oxide

2. Condensate Drain Kit Assembly

3. 1 1/2” by 3” NPT Stainless or Galvanized Nipple

1 1/2" PLASTIC FITTING CONNECTION TO DRAIN

4. 1 1/2” Stainless or Galvanized Union

recommends connecting it 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).

6. 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.

7. 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).

8. (U.S. Only) Attach a ¼” water supply to the compression  tting on the  oat. The water line must be connected to an uninterruptible supply. Fulton

2-14

Install pH Neutralization Kit

The pH Neutralization Kit is a Fulton-provided kit designed to bring the pH level of the boiler’s condensate to a neutral level. It is not a replacement or alternative for the Condensate Drain Trap. See Figure 5.

Adhere to the following for pH Kit installation:

1. Use stainless or galvanized pipe and  ttings to connect condensate drain to kit.

2. Connect kit downstream of Condensate Drain Trap. See Figure 6.

3. Pipe outlet to appropriate drain.

4. Check condensate pH periodically.

SECTION 2 EDR-IOM-2014-0318 INSTALLATION

NOTE:  Replacement bags are available from your Fulton local

representative. The medium in the container will neutralize the condensate of 12 MM Btu’s for approximately 6 months.

Venting

Adhere to the following venting requirements:

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

2. The pressure drop readings at the boiler exhaust connection and air intake connection cannot exceed the maximum value stated in Table 4. This means that the combined pressure drop through the air intake venting (if installed) and exhaust venting cannot exceed the maximum value stated in Table 4; this is typically approximately 35 feet (10.6 m) with 4 elbows of connection size piping. Alternative distances and number of elbows may be appropriate if determined by the venting designer to be within the pressure drop ranges in Table 4. If pressure drop is exceeded, the boiler may have to be de-rated or operational issues will result. Also, the pressure at the boiler exhaust connection must not exceed a maximum negative value as stated in the table. This pressure must remain relatively constant throughout the operation of the boiler. Drastic draft changes during operation may result in generation of excessive carbon monoxide or soot. To decrease termination noise, increase the venting size at the termination points. This will slow the air velocity causing a reduction in noise. Do not terminate the venting in an enclosed area. Care must be taken when selecting the orientation of the terminations.

! WARNING

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

materials and other potentially required accessories.

3. Do not use boot tees or bullhead tees.

4. Barometric dampers should never be used in a condensing boiler application even if the draft is negative, this is because barometric dampers physically open to the mechanical room and it will be possible for  ue gas condensate to drain down the outside of the stack.

5. The air intake system must be designed to prevent any moisture from draining to the boiler.

6. The layout of the piping used for air intake and exhaust must be done in a way that facilitates smooth travel and natural  ow. Performing a pressure drop calculation isn’t enough information to make sure a draft system will perform adequately. Good practice must be used by the designer and installer. Some recommendations:

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

degree elbows, short radius elbows especially right at the connections to the boilers

 Avoid extensive direction changes ( ue gases being required

Questions? Please Contact Your Local Manufacturer’s Representative

2-15

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Fulton Endura Condensing Hydronic Boiler User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual