Fulton Endura Condensing Hydronic Boiler User Manual

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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

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 BoilerTrim .................................................................................................	2-5
InstallWater Piping..............................................................................................	2-6
MeetWater Chemistry Requirements..................................................................	2-7
PREVENT OXYGEN CONTAMINATION..........................................................................................	2-8
ELIMINATE SYSTEM AIR ..............................................................................................................	2-9
Fill the BoilerWithWater .....................................................................................	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
ExhaustVenting .................................................................................................	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

Operation	3-1
Perform Pre-Start-Up Inspection	......................................................................... 3-2
Fill and Purge the System.....................................................................................	3-2
CommissionThe Boiler.........................................................................................	3-3

SYSTEM DESIGN AND BOILER OPERATION.................................................................................	3-3
CommissionThe Boiler: Dungs Zero Governing GasValve...................................	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
PerformTest of LowWater Cut Off .....................................................................	3-16
PerformTest of Limit Controls ...........................................................................	3-17
PerformTest of Low Gas Pressure Switch ..........................................................	3-17
PerformTest 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
StandardWarranty for Fulton Endura Hydronic Boilers	....................................... 5-3
Parts .....................................................................................................................	5-5

0-1

Questions? Please Contact Your Local Manufacturer’s Representative

TABLE OF CONTENTS

EDR-IOM-2014-0318

0-2

INTRODUCTION

INTRODUCTION	1
INSTALLATION	2
OPERATION	3
MAINTENANCE	4
WARRANTY & PARTS	5

1-1

Questions? Please Contact Your Local Manufacturer’s Representative

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 staff 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, qualified 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 qualified and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training specific to this product.

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.

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 effectiveness.

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 specific 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.

1-2

INSTALLATION

INTRODUCTION	1
INSTALLATION	2
OPERATION	3
MAINTENANCE	4
WARRANTY & PARTS	5

2-1

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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 certified for indoor installation only. This boiler may not be field retrofitted.

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-fired, ultra highefficiency boiler. The boiler can either be of the sealed combustion/direct vent type or utilize conventional combustion air intake and flue 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-certified 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 fired 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 configuration has been designed specifically for your application.

This Endura boiler is to be installed as part of a hydronic heating system. A qualified 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 fire 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 fitted in a correct and safe manner.

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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 difficulty in the future. Correct placement is the first step to trouble-free installation, operation, and maintenance.

Adhere to the following for placement and rigging:

1.Check building specifications for permissible floor 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 certified for indoor installation only.

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 floor.

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

! 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.

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 classification, 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 fire.

4 CAUTION

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

Do not use to directly heat swimming pool.

2-3

Questions? Please Contact Your Local Manufacturer’s Representative

Fulton Endura Condensing Hydronic Boiler User Manual

INSTALLATION

EDR-IOM-2014-0318

SECTION 2

TABLE 1 - BOILER DIMENSIONS AND OPERATING REQUIREMENTS

MODEL EDR		1000	1500	2000

Input Million	BTU/Hr	1.0	1.5	2.0
	kW	293	411	549

Fuel Cons. @ rated cap. (Nat. Gas)
	FT3/Hr	1000	1500	2000
	M3/Hr	28.32	42.5	56.7
Output at AHRI Test Condition
	BHP	28.4	41.9	56
	KCal/h	239,396	353,424	472,240
Electrical Req. (Amps)*		10	20	20
120V, 60Hz, 1 Phase		10	20	20
120V, 60Hz, 1 Phase

Water Content	Gal	50	104	102
	Liters	189	394	386

Dry Weight	LBS	1430	2260	2360
	KG	649	1025	1071

Operating Weight	LBS	1848	3128	3210
	KG	838	1419	1456

MODEL EDR		1000	1500	2000

A. Boiler Width	IN	28	33.9	33.9
	CM	72	86	86

B. Overall Boiler Height	IN	68	80	80
	CM	172.7	203.2	203.2

C. Overall Boiler Depth	IN	49.75	60.6	60.6
	CM	126.4	153.8	153.8

D. Flue Outlet Diameter	IN	6	6	8
	CM	15.2	15.2	15.2

E. Water Inlet/Outlet Diameter	IN	2	4	4
	CM	5.08	10.2	10.2

F. Min. Clearance (top)	IN	18	18	18
	CM	46	46	46

G. Air Inlet Diameter (top access)	IN	6	8	8
	CM	15.25	20.3	20.3

Min. Clearance (sides)	IN	1	1	1
	CM	2.5	2.5	2.5

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 fluctuation. Voltages lower than 120 V can result in slightly decreased available output.

*Standard configurations. Alternate voltages may be available as an option; please consult factory.

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

TOP VIEW

	F
	G
	E
	B
	D
	E
A	C

FRONT VIEW

RIGHT SIDE VIEW

BACK VIEW

FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER

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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 configurations 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:

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: Each boiler is equipped with a pressuretemperature 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		Inlet Size	Outlet Size
	PSI (kPa)		inch (mm)	inch (mm)
EDR-1000	30 (206.84)		3/4 (19.05)	1	(25.4)
	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)

Note: Valve is

shipped loose

and must be

installed by the

contractor.

FIGURE 2 - SAFETY VALVE LOCATION

2-5

Questions? Please Contact Your Local Manufacturer’s Representative

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.

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 shutoff 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 flushed 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 fill) valve in the cold water fill 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 flow 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 flow 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.

»Air removal equipment, including an air separator and automatic breather valves, along with a functioning expansion tank . Each must be designed to system specifications.

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

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EDR-IOM-2014-0318

INSTALLATION

6.Install filtration 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 flushed prior to installing the boiler itself.

NOTE: Although motorized isolation valves are not required in a primary only arrangement , they can help ensure system effectiveness. Proper control strategy must be used to ensure flow 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.

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.

! 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.

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 flammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

2-7

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INSTALLATION

EDR-IOM-2014-0318

SECTION 2

		MAKE UP
		WATER
		AIR SEPARATOR
	MOTORIZED	SYSTEM
	MOTORIZED	SUPPLY
	ISOLATION VALVE	SUPPLY
	ISOLATION VALVE	WATER
	(OPTIONAL)	WATER
	(OPTIONAL)

SYSTEM PUMPS AND VALVES

AS DETERMINED

APPROPRIATE BY OTHERS

EXPANSION

TANK

AIR SEPARATOR AND EXPANSION

TANK AS DETERMINED

APPROPRIATE BY OTHERS

SYSTEM

RETURN WATER

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 flow 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 efficiency 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 fluid should be checked for glycol concentration and pH once a year.

 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 fittings

Do not use oxygen permeable materials anywhere in the water system

Repair leaks in the system quickly

Eliminate fittings wherever possible

Use air elimination devices in system piping

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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.

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 flow of water is observed. Close the valve and finish filling the system.

Install Gas Piping

The Endura boiler is factory test fired and combustion is adjusted per the boiler data plate and test fire sheet.

The gas train components are configured to operate at specific gas pressure requirements. The specific 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 fittings. 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 shutoff valve

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.

2-9

Questions? Please Contact Your Local Manufacturer’s Representative

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.

Do not use matches, candles, flame 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 fittings 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 off 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 liquefied petroleum gases. Do not use Teflon tape on gas line threads.

10.After gas piping is completed and before wiring installation is started, carefully check all piping connections, (factory and field), for gas leaks. Use a soap and water solution.

11.The boiler must be disconnected at the boiler shut off 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 filter. Instructions are included in the kit.

Start with the vent and cabinet bulkhead size, and as soon as is practical increase the pipe size one diameter.

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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 configured 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 floor 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.

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 overflow 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 off to prevent accidental flue 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 fl oor drain is not available to collect condensate (collecting tank and pump

! 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.

If the water supply must be temporarily disconnected from the condensate drain trap, the boilers must be turned off to prevent accidental flue 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 fitting on the condensate drain. The water supply maintains a water level in the drain kit to prevent accidental flue gas emission into the boiler room.

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FIGURE 4 - CONDENSATE DRAIN PIPING FOR ENDURA BOILERS

Detail A

Condensate

Drain Kit

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.

0.25” (U.S.) TAPPING PROVIDED FOR WATER CONNECTION TO MAINTAIN WATER SEAL

5.5 INCH (14.2 CM) MINIMUM

Detail A

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TABLE 3 - NOMINAL PIPE SIZE

Nominal		ID		Equivalent Pipe Length		Max Capacity in ft3 of natural gas per hour. Pressure drop of
Pipe Size						0.5”wc/Equivalent length of pipe (feet)

Inch (mm)		Inch (mm)		90 Elb	Tee	20	40	60	80	100	150	200
				Feet	Feet
				(meter)	(meter)

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

FIGURE 5 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP)

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30 3/8 [771]

3 13/16	12 1/2
[97]	[318]
(TYP.)

		TOP VIEW
					1
					3
10 3/4			3		4
10 3/4			3
	[273]
11 1/4		1" NPT		2	ISOMETRIC VIEW
11 1/4				2
[286]
[286]	CONNECTION		1.	Neutralizer Kit with Magnesium Oxide
	CONNECTION		1.	Neutralizer Kit with Magnesium Oxide
		TO BOILER	2.	Condensate Drain Kit Assembly
			2.	Condensate Drain Kit Assembly
			3.	1 1/2” by 3” NPT Stainless or Galvanized Nipple
		1 1/2" PLASTIC FITTING	4.	1 1/2” Stainless or Galvanized Union
		CONNECTION TO DRAIN

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.

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 fl 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 overfl 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 fi tting on the float. The water line must be connected to an uninterruptible supply. Fulton

recommends connecting it before the“fast fill”valve to the boiler supply but after the back fl ow preventer to avoid contamination of a potable water supply.

Maximum allowable water pressure to the compression fitting is 100 PSI (689.5 kPa).

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 fittings 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.

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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 flue 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.

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 flue 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 flow. 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 (flue gases being required

! 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.

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Questions? Please Contact Your Local Manufacturer’s Representative

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