FULTON Endura EDR-750, Endura EDR-1000, Endura EDR-1500, Endura EDR-2000 Installation And Operation Manual

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INSTALLATION AND

OPERATION MANUAL

Endura (EDR)

Condensing Hydronic Boilers

750,000 - 2,000,000 BTU/HR

Serial/ National Board Number

Model

Fulton Order

Owner

Site Name

Date

EDR-IOM-2019-0212

EDR-IOM-2019-0212 TABLE OF CONTENTS

Introduction 1-1

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

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

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

Installation 2-1

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

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

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

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

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

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

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

Meet Water Chemistry Requirements ................................................................ 2-10

PREVENT OXYGEN CONTAMINATION ........................................................................................211

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

Fill the B oiler With Water ................................................................................... 2-12

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

INLET GAS PRESSURE ................................................................................................................213

GAS PRESSURE REQUIREMENTS ...............................................................................................213

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

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

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

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

MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP .........................................................216

Install pH Neutralization Kit ............................................................................... 2-19

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

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

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

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

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

Exhaust Venting ................................................................................................. 2-25

COMMON VENTING LAYOUTS FOR ENDURA .............................................................................228

VENTING TERMINATIONS ..........................................................................................................232

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

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

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

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

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

Electrical Connections and Devices .................................................................... 2-35

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

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

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

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

Commission The Boiler: Zero Governing Gas Valve .............................................. 3-4

TURNDOWN .................................................................................................................................37

SOLA Hydronic Controller - General Operation .................................................... 3-8

STATUS SUMMARY SCREEN.........................................................................................................38

CENTRAL HEAT OPERATION SCREEN ...........................................................................................38

CENTRAL HEAT OPERATION  SETPOINT SCREEN .....................................................................310

CENTRAL HEAT CONFIGURATION  SETPOINT SCREEN ...........................................................310

CENTRAL HEAT CONFIGURATION  MODULATION SCREEN ....................................................310

CHANGING HIGH LIMIT SETPOINT AND VERIFYING CHANGE ..................................................311

REVIEWING STATISTICS .............................................................................................................313

ACCESSING LOCKOUT HISTORY .................................................................................................314

SOLA DIAGNOSTICS ...................................................................................................................316

SOLA Hydronic Controller - Options Conguration ............................................ 3-17

LEAD/LAG INTEGRATED SEQUENCING .....................................................................................317

DOMESTIC HOT WATER DHW TEMPERATURE SENSOR..........................................................321

REMOTE 420 MA SIGNAL FOR SETPOINT ................................................................................322

SUPPLY HEADER TEMPERATURE SENSOR ................................................................................323

OUTDOOR AIR TEMPERATURE SENSOR ....................................................................................324

STACK LIMIT ...............................................................................................................................326

DEDICATED BOILER PUMP .........................................................................................................327

MOTORIZED ISOLATION VALVE SET UP .....................................................................................328

ENABLING BURNER FIRE RATE OUTPUT ...................................................................................329

SYSTEM PUMP ENABLE/DISABLE SIGNAL ...............................................................................329

Perform Test of Low Water Cut O ..................................................................... 3-31

Perform Test of Limit Controls ........................................................................... 3-31

Perform Test of Low Gas Pressure Switch .......................................................... 3-31

Perform Test of High Gas Pressure Switch .......................................................... 3-31

General Operation of the Boiler ......................................................................... 3-31

Maintenance 4-1

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

Daily Inspection Schedule ................................................................................... 4-2

Weekly Maintenance Schedule ........................................................................... 4-2

Monthly Maintenance Schedule .......................................................................... 4-2

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

Annual Maintenance Schedule ............................................................................ 4-3

Replacing Gas Valve Internal Filter ....................................................................... 4-4

Removing and Cleaning Burner Assembly .......................................................... 4-5

Verication of Ignition Gap .................................................................................. 4-6

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

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

Operation 3-1

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

0-1

TABLE OF CONTENTS EDR-IOM-2019-0212

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE

3 4

Questions? Please Contact Your Local Manufacturer’s Representative

1-1

INTRODUCTION EDR-IOM-2019-0212 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

 Material inspections

 Manufacturing process inspections

 American Society of Mechanical Engineers (ASME)

welding inspection

 ASME hydrostatic test inspection

 Electrical components inspection

 Operating test

 Final engineering inspection

 Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, qualied installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are qualied and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training specic to this product.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

 WARNINGS must be observed to prevent serious injury

or death to personnel.

 CAUTIONS must be observed to prevent damage

or destruction of equipment or loss of operating eectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z223.1/NFPA 54 latest edition, and the specic instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure and operating temperature of 160 psig and 210˚ F (99˚ C) respectively.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE

3 4

Questions? Please Contact Your Local Manufacturer’s Representative

2-1

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

4 CAUTION

The standard conguration for this boiler is certied for indoor installation only.

This boiler is not designed for use in systems where water is continuously replenished. The warranty is valid for closed loop systems only.

Fulton cannot be held responsible for the selection, engineering, installation, or sizing of any additional equipment or components of the hydronic heating system.

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

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-2019-0212 INSTALLATION

Placement & Rigging

Proper placement of your Fulton product is essential. Attention paid to the following points will save a great deal of diculty in the future. Correct placement is the rst step to trouble-free installation, operation, and maintenance.

Adhere to the following for placement and rigging:

1. Check building specications for permissible oor loading. Use Table 1 for unit reference.

2. Conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction and/or the U.S. to the National Fuel Gas Code, latest edition. Authorities having jurisdiction should be consulted before installations are made. Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

3. Since an external electrical source is utilized, the boiler, when installed, must be electrically ground in accordance with the National Electric Code, American National Standards Institute (ANSI) National Fire Protection Association (NFPA) 70, latest edition.

4. Standard Endura boilers are certied for indoor installation only.

! 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. Do not install the boiler on springs.

7. Provide combustion and ventilation air in accordance with applicable provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section

5.3, Air for Combustion and Ventilation.

8. Locate the boiler so that the air supply and exhaust piping between the boiler and outside wall/roof are within the maximum lengths for horizontal or vertical venting if sealed combustion will be used. See Clearances and Serviceability section of this manual.

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.

Questions? Please Contact Your Local Manufacturer’s Representative

Do not use to directly heat swimming pool.

2-3

INSTALLATION EDR-IOM-2019-0212 SECTION 2

TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS

MODEL EDR 750 1000 1500 2000

Input MM BTU/Hr kW

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

Output at AHRI Test Condition BHP KCal/h

Natural Gas Pressure W.C. 4-2 8 4-28 4-2 8 4-28

Electrical* 120 V, 60 Hz, 1 Phase

Water Content Gal Liters

Dry Weight LBS KG

Operating Weight LBS KG

.75

219

750

21.2

21.7

183,638

20 Amp (10FL A)

189

1430

649

184 8

838

1.0

293

1000

28.32

28.4

239,396

20 Amp (10FL A)

189

1430

649

184 8

838

1.5 411

1500

42.5

41.9

353,4 24

25 Amp (20FLA)

104 394

2260 1025

3128 1419

2.0

549

2000

56.7

472, 240

25 Amp (20FLA)

102 386

2260 1071

3210 1456

MODEL EDR 750 1000 1500 2000

A. Boiler Width IN CM

B. Overall Boiler Height IN CM

C. Overall Boiler Depth IN CM

D. Exhaust Outlet Diameter (ID) IN CM

E. Water Inlet/Outlet Diameter IN CM

F. Min. Clearance (top) IN CM

G. Air Inlet Diameter (top access) IN CM

H. Min. Clearance (sides) IN CM

Alternate gas pressure arrangements may apply based on conguration and/ or local code requirements. Please verify gas pressure ratings for your boiler by viewing the boiler name plate and consulting with the authority having jurisdiction. 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 may be available as an option; please consult factory. Note: All dimensions are approximate and are subject to change without notice.

28 72

67. 8

172. 2

50.2

12 7.5

15.2

5.08

18 46

15.2 5615.2 5820.3

2.5

28 72

67. 8

172. 2

50.2

12 7.5

15.2

5.08

18 46

2.5

33.9 8633.9

203.2

60.6

153.8

15.2

10.2

18 46

2.5

203.2

60.6

153.8

15.2

10.2

18 46

20.3

2.5

TOP VIEW

2-4

FRONT VIEW RIGHT SIDE VIEW BACK VIEW

FIGURE 1  VIEWS OF ENDURA HYDRONIC BOILER

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

Clearances and Serviceability

Adhere to the following for clearances and serviceability:

1. All local and national codes (NFPA, ANSI, UL, CSA, ASME) must be followed for proper clearances and serviceability for your boiler or heater. Authorities having jurisdiction should be consulted before installations are made.

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

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 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-750

EDR-1000

EDR-1500

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

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)

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)

Outlet Size inch (mm)

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 upright 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.

Questions? Please Contact Your Local Manufacturer’s Representative

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

FIGURE 2  SAFETY VALVE LOCATION

2-5

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

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

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

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

Install Water Piping

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

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

 Manual isolation valves are recommended on both water connections for

ease of service.

 Install piping so that the boiler is not supporting any piping load.

 Install manual purging valves in all loops and zones.

 Install a pressure-reducing (automatic ll) valve in the cold water ll line to

the boiler system.

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

water must be kept to a minimum. This is best achieved by ensuring immediate repair of all leaks and maintaining system pressure.

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

diverting valves will not isolate air separator(s) and/ or expansion tank(s) from the boiler.

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

combustibles.

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.

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

medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. If the boilers are connected to heating coils (located in air handling units) where they may be exposed to refrigerated air circulation, such boiler piping systems must be equipped with ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

 Include the following in the mechanical equipment in the hydronic

heating system:

» 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 should be designed to add water to the system at the outlet of the boiler but should not be fed directly into the boiler.

» Air removal equipment, including an air separator and automatic

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

be designed to system specications.

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.

2-6

 Install ltration in the common loop or per boiler to remove particulates if

appropriate. A #4 or ner mesh size is required.

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

! WARNING

 Install bypass chemical feeder for corrosion inhibitor maintenance if

appropriate.

 Install corrosion coupon holder to assess corrosion inhibitor performance if

appropriate.

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

system piping and any other components of the system are clean and free of debris and any foreign matter. The hydronic system must be completely ushed prior to installing the boiler.

FIGURE 3  TYPICAL WATER SIDE PRESSURE DROP

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.

 Variable Primary Piping Arrangement

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

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

conguration, it is not required.

Adhere to the following for variable primary piping arrangements:

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

loop at design ow. See Figure 3 for the water side pressure drop through

the boiler. The Endura boiler does not have a minimum ow requirement. It will automatically perform a safe shutdown in the event of a low ow or zero ow condition; however, proper design ow will be required to deliver heat to users and prevent nuisance high temperature limit trips.

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

ow through idle boilers accordance with ASHRAE 90.1-2013 (6.5.4.3.2). Blending of unheated supply water may impact temperature control operation or cause manual reset high temperature lockouts. One

Questions? Please Contact Your Local Manufacturer’s Representative

2-7

INSTALLATION EDR-IOM-2019-0212 SECTION 2

INITIAL RELEASE

--- --- --- --- ---

REVISION HISTORY

REMOVED CONDENS ATE PIPING, UPDATED

CALLOUTS & DESCRIP TION. M.E.B 1/20/15

N/A N/A

SMT

2/2/15

N/A

KDB

1/30/15

REVISION HISTORY

SES

FOR

FULTON ENDURA CONDENSING HYD RONIC BOILER

VARIABLE SPEED SYSTEM PUMP

EXPANSION TANK

NOTES:

THIS IS A TYPICAL A RRANGEMENT FOR REFERENCE PUR POSE ONLY. ACTUAL INSTA LLATIONS MAY REQUIRE ADDITION AL COMPONENTS WHIC H ARE NOT SHOWN FOR CLARITY.

HEATING HOT WATER RETURN

AIR REMOVAL

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

HEATING HOT WATER SUPPLY

ONDENSING HYDR ONIC BOILERS

FULTON ENDURA

RETURN

WATER TEMPERATUR E

SENSOR

HEATING HOT

WATER RETURN

TWO POSITION MOTORIZED ISOLATION VALVE

SUPPLY WATER TEMPERATURE SENSOR

REVERSE RETURN (SEE NOTE 4)

AIR REMOVAL

VARIABLE SPEED SYSTEM PUMP

EXPANSION TANK

NOTES:

THIS IS A TYPICAL A RRANGEMENT FOR REFERENCE PUR PO ONLY. ACTUAL INSTA LLATIONS MAY REQUIRE ADDITION AL COMPONENTS WHIC H ARE NOT SHOWN FOR CLARITY.

THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.

REFER TO THE INS TALLATION AND OPERATION MANUALS INFORMATION REGA RDING CLEARANCES AND INSTALLA TI REQUIREMENTS.

THE PIPING CONF IGURATION SHOULD UTILIZE A REVER SE

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

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

HEATING HOT WATER SUPPLY

2-8

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

INITIAL RELEASE

--- --- --- --- ---

OSES

FOR

ION

REMOVED CONDENS ATE PIPING, UPDATED

CALLOUTS & DESCRIP TION. M.E.B. 1/20/15

N/A N/A

SMT

2/2/15

N/A

KDB

1/30/15

REVISION HISTORY

OR N

EV REVISION DESCRIP TION CHECKED B.O.M. MECH. EN G ELEC. ENG APPROVED

HEATING HOT ATER RETURN

REVISION HISTORY

FULTON ENDURA CONDENSING HYD RONIC BOILER

SUPPLY WATER

TEMPERATURE

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

AIR REMOVAL

SENSOR

CLOSELY SPACED TEES

(<4 DIAMETERS)

BOILER (PRIMARY) PUMP

SEE NOTE 4

SYSTEM

(SECONDARY)

PUMP

HEATING HOT

WATER SUPPLY

EXPANSION TANK

NOTES:

THIS IS A TYPICAL A RRANGEMENT FOR REFERENCE PUR P ONLY. ACTUAL INSTA LLATIONS MAY REQUIRE ADDITION COMPONENTS WHIC H ARE NOT SHOWN FOR CLARITY.

THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.

REFER TO THE INS TALLATION AND OPERATION MANUALS INFORMATION REGA RDING CLEARANCES AND INSTALLA T REQUIREMENTS.

Questions? Please Contact Your Local Manufacturer’s Representative

CONDENSING HYD RONIC BOILERS

FULTON ENDURA

BOILER (PRIMARY)

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

HEATING HOT

WATER SUPPLY

PUMP

SYSTEM (SECONDA RY) PUMP

AIR REMOVAL

EXPANSION TANK

SUPPLY WATER TEMPERATURE SEN SOR

CLOSELY SPACED TEES

SEE NOTE 5

(<4 DIAMETERS)

RETURN WATER TEMPERATURE SENS OR

HEATING HOT WATER RETURN

REVERSE RETURN (SEE NOTE 4)

NOTES:

THIS IS A TYPICAL A RRANGEMENT FOR REFERENCE PUR POS

1. ONLY. ACTUAL INSTA LLATIONS MAY REQUIRE ADDITION AL COMPONENTS WHIC H ARE NOT SHOWN FOR CLARITY.

THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.

REFER TO THE INS TALLATION AND OPERATION MANUALS F

3. INFORMATION REGA RDING CLEARANCES AND INSTALLA TIO REQUIREMENTS.

THE PIPING CONF IGURATION SHOULD UTILIZE A REVER SE

4. RETURN HEADER T O PROPERLY BALANCE FLOW ACROSS TH BOILERS. WHERE REVERSE RETURN CANNOT BE USED, IT IS RECOMMENDED TO INSTALL A BALANCING VALVE PER B OILE

CENTER TO CENTER DISTANCE BETWEEN BOILER (PRIM ARY) SUPPLY AND RETUR N MANIFOLDS SHOULD BE 4 PIPE

2-9

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

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

motorized isolation valve should be installed per boiler; two-position type actuator, open or closed. It is acceptable to install the valve on either the inlet or the outlet piping of each boiler.

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

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

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

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

recommended to install a balancing valve per boiler.

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

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

 Primary-Secondary Piping Arrangement

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

Adhere to the following for primary-secondary piping arrangements:

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

a hydraulic separator.

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

separated by four pipe diameters or less.

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

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

 For multiple boiler systems:

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

into the secondary (system) piping. Do not use separate connections for each boiler into the secondary piping.

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

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

Meet Water Chemistry Requirements

2-10

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

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

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

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

brass.  Chloride: Less than 200 ppm  Hardness: Less than 3.5 grains per gallon (60 ppm) in make-up/ll water.

Calcium buildup on heating surfaces is not covered under warranty.

Adhere to the following:

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

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

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

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

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

! WARNING

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

4 CAUTION

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

 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. The maximum concentration is 50% glycol by volume. Only use mixtures formulated for hydronic systems. DOWFROSTTM HD is recommended. Do not use automotive glycol.

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

 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.

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

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-11

INSTALLATION EDR-IOM-2019-0212 SECTION 2

 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 on the suction side of the system circulator(s).

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

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.

Gas Supply Piping

The Endura is a gas red fully modulating boiler that requires gas delivery at a relatively constant pressure and caloric content. This ensures ecient and reliable combustion. A lock-up style regulator is factory-mounted in the gas train. Do not modify the gas train.

The packaged gas train (See Figure 8) is congured to operate at specic gas pressure requirements. The requirements are detailed on the boiler name plate, located on the back of the

boiler.

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

Measure inlet supply gas pressure here

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 pressurerelief valve located at the rear of the boiler. Leave the relief valve open until a steady ow of water is observed. Close the valve and nish lling the system.

Fuel Train Inlet Note: Measure Inlet gas pressure here

Lockup Regulator with Integral Vent Limiter

FIGURE 9  MEASURING INLET GAS PRESSURE

Main Gas Valve (see Figure 26)

2-12

FIGURE 8  TYPICAL GAS TRAIN VARIES BY SIZE/MODEL

Ignition Enrichment Regulator with Integral Vent Limiter

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

 Inlet Gas Pressure

Adhere to the following:

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

Verify pressure is within allowable range.

 Dynamic inlet gas pressure: Measure while boiler is in

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

 The gas delivery system must provide a stable and

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

 Maximum inlet gas pressure drop from static to

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

Canada). The stricter of the two shall apply.

 Gas Pressure Requirements

The minimum gas pressure required is 4” W.C. For gas pressures exceeding 28”W.C. (14”W.C. Canada), a step down regulator

(not supplied) must be installed in the gas supply piping.

 If the level of pipe system cleanliness is unacceptable

or unknown, it is recommended that a gas lter be installed prior to the regulator.

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

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

 When installed in close proximity to an appliance, some

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

 The body size should never be larger than the pipe size.

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

 The inlet pressure used for sizing should be measured

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

 Line Gas Pressure Regulation

When inlet gas pressure exceeds 28”W.C. (14”W.C. Canada), a line gas pressure regulator is required to step the gas pressure down below maximum pressure.

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

 A sediment trap is recommended prior to the inlet of

the regulator.

TABLE 3  SCH 40 PIPE NATURAL GAS CAPACITY

Nominal Pipe Size

Inch (mm) Inch (mm) 90 Elb

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

ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. 14”wc pressure.

Pressure drop of 0.5”wc. Equivalent length of pipe (feet)

Feet (meter)

Tee Feet (meter)

20 40 60 80 100 150 200

 Consult the regulator manufacturer for orice selection.

 If two or more springs are available for a particular

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

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-13

INSTALLATION EDR-IOM-2019-0212 SECTION 2

SEE NOTE 2,3

INITIAL RELEASE

--- --- --- --- ---

REVISION HISTO RY

S WITH GREATER THAN 28"

UPPLIED.

EQUIVELENT TO THE

. THIS PIPE MUS T BE PE BETWEEN REG ULATOR ALVES, OR ELBOW S.

BE INSTALLED WIT H A OF PIPE BETWEEN THE

ER FUEL TRAIN INLE T.

NSTRUCTION PUR POSES.

AND OPERATION M ANUAL FO R S HEADER SIZING , CLEARA NCES QUIREMENTS.

Appliance regulators must not be used as line gas pressure regulators to step down the gas pressure. For additional information regarding gas regulator selection and installation consult your regulator manufacturer, any applicable local codes or ordinances, the standard for line pressure regulators ANSI Z21.80/CSA 6.22, and The National Fuel Gas Code NFPA 54/ANSI Z223.1.

Gas Piping Installation

Adhere to the following for gas piping installation:

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

2. Install a manual gas shuto valve and union prior to the boiler.

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

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

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

2.0 psig (55 inch W.C.).

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

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

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

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

FIGURE 10  ENDURA SINGLE BOILER GAS SUPPLY PIPING

2-14

GAS SUPPLY

LINE GAS PRESS URE REGU LATOR (SEE NOTE 1)

MANUAL SHUTOFF VALVE

Notes:

1. Required for installation with greater than 28”W.C. (14”W.C. Canada) inlet pressure, eld supplied.

NOTES:

2. Required 10 pipe diameters equivalent to the

REQUIRED FOR INS TALLATION

1. W.C. INLET PRESSU RE. FIELD S

regulator connection size. This pipe must be

REQUIRED 10 PIPE DIAMET ERS

straight, uninterrupted pipe between regulator

REGULATOR CONN ECTION SIZE STRAIGHT UNINT ERRUPTED PI

outlet and and any ttings, valves, or elbows.

OUTLET AND ANY F ITTINGS, V

THE LINE REGUL ATOR SHOULD

3. MINIMUM OF 10 LI NEAR FEET REGULATOR OUTL ET AND BOIL

3. The line regulator should be installed with a

THIS DRAWING I S NOT FOR CO

minimum of 10 linear feet of pipe between the

REFER TO THE INS TALLATION

regulator outlet and boiler fuel train inlet.

INFORMATION REG ARDING GA AND OTHER INST ALLATION RE

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

INITIAL RELEASE

--- --- --- --- ---

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

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

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

REVISION DESCRIP TION B.O.M. ELEC . ENG M ECH. ENG CHECKED APP ROVED

REVISION HISTO RY

` MULTIPLE BOILER INSTALLATION

When gas supply pressure exceeds 28” W.C. (14”W.C. Canada), it is recommended that an individual line gas pressure regulator be used to step-down the gas pressure at each boiler.

When a single regulator is used for multiple boilers the regulator must be appropriate for the entire gas delivery turndown range. This includes all boilers on at full re to one boiler on at low re.

SEE NOTE 2,3

LINE GAS PRESSU RE REGULATOR (SEE NOTE 1)

MANUAL SHUTOFF VALVE

GAS SUPPLY

SEDIMENT TRAP

FIGURE 11  ENDURA MULTIPLE BOILER GAS SUPPLY PIPING

Notes:

NOTES:

REQUIRED FOR INS TALLATIONS WITH GREATER THA N 28"

1. W.C. INLET PRES SURE. FIELD SUPPLIED.

1. Required for installation with greater than 28”W.C. (14”W.C. Canada) inlet pressure, eld supplied.

2. Required 10 pipe diameters equivalent to the regulator connection size. This pipe must be straight, uninterrupted pipe between regulator outlet and and any ttings, valves, or elbows.

REQUIRED 10 PIP E DIAMETERS EQUIVELENT T O THE

2. REGULATOR CONN ECTION SIZE. THIS PIPE MUST BE STRAIGHT UNINT ERRUPTED PIPE BETWEEN R EGUALTOR OUTLET AND ANY FITTINGS, VALVES, OR ELBOW S.

THE LINE REGUL ATOR SHOULD BE INSTALLED W ITH A

3. MINIMUM OF 10 LINEAR FEET OF PIPE BETWEE N THE REG

ULATOR OUTLET A ND BOILER FUEL TRAIN INLE T.

THIS DRAWING IS NOT FOR CONSTRUCTION PU RPOSES.

REFER TO THE INS TALLATION AND OPERATION MANU AL FOR INFORMATION R EGARDING GAS HEADER SIZI NG CLEARANCE AND OTHER INS TALLATION REQUIREMENTS.

3. The line regulator should be installed with a minimum of 10 linear feet of pipe between the regulator outlet and boiler fuel train inlet.

Questions? Please Contact Your Local Manufacturer’s Representative

2-15

INSTALLATION EDR-IOM-2019-0212 SECTION 2

 Components Requiring Ventilation to the

Outdoors

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

 Lock-up regulator on the main fuel train

 Regulator on the ignition enrichment line

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

 Drill an appropriately sized penetration for each vent

line through the topmost panel on the rear of the boiler cabinet (Figure 12). Do not install any vent lines through removable latching panels. Properly seal around the pipe with silicone to maintain a sealed cabinet and ensure combustion air will not bypass the lter.

 Each component must have a separate vent line to

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

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

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

 Protect the vent termination from debris, dust and

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

 Single Boiler Drain Trap

The single boiler condensate drain trap is Fulton Part Number 4-57-005500. The drain trap must be congured one per boiler, with a maximum of 4.0 mm BTU total. (See Figures 13 and 15).

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 trap.

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 13) must be CPVC, galvanized, or stainless steel, and be free of leaks. Copper, carbon steel/iron pipe, or PVC are not acceptable.

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

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

12 feet (3.65 m).

NOTE: Ensure piping will not be exposed to freezing

temperatures.

Install Condensate Drain Trap

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

FIGURE 12  TOPMOST REAR PANEL

When required, run the vent line(s) through this panel

2-16

 Multiple Boilers Sharing A Common Drain Trap

The multiple boiler condensate drain trap is Fulton Part Number 4-57-000440. The maximum number of units to attach per condensate drain trap is 12mm BTU total. (See Figures 14 and

16).

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

DETAIL B

CONDENSATE

DRAIN KIT

DETAIL B

CONDENSATE

DRAIN KIT

DETAIL B

CONDENSATE

DRAIN KIT

DETAIL B

CONDENSATE

DRAIN KIT

DETAIL A

CONDENSATE

DRAIN KIT

DETAIL A

CONDENSATE

DRAIN KIT

FIGURE 13  CONDENSATE DRAIN PIPING FOR INDIVIDUAL ENDURA BOILER

Questions? Please Contact Your Local Manufacturer’s Representative

DETAIL B

Figure Notes:

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

2. Header material must be CPVC, galvanized steel, or stainless steel.

3. Condensate drain trap is never to be above boiler condensate outlet.

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

5. Housekeeping pad required, minimum 4 inch (102 mm).

2-17

INSTALLATION EDR-IOM-2019-0212 SECTION 2

FIGURE 14  CONDENSATE DRAIN PIPING FOR MULTIPLE ENDURA BOILERS

HEADER MUST BE AT

FLOOR (NOT PAD) HEIGHT

Figure Notes:

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

2. Header material must be CPVC, galvanized steel, or stainless steel.

3. 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.

4. 1.5 inch (138.1 mm) condensate drain kit/trap outlet is never to be above 1 inch boiler condensate outlet.

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

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

DETAIL A

CONDENSATE

DRAIN KIT

DETAIL A

0.25” (U.S.)

tapping pro-

vided for wa-

ter connection

to maintain

water seal.

See Note 4

See Note 3

7. Housekeeping pad required, minimum 4 inch (102 mm).

2-18

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

RIGHT SIDE VIEW

1 ½

1

7 ¾

10 

10 

6 ½

7 

FRONT VIEWTOP VIEW

(COVER NOT SHOWN)



" (TYP. )

¼"

WATER SUPPLY

CONNECTION

FRONT VIEWBACK VIEWTOP VIEW

6½

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 trap. 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 are not supplied with the boiler.)

5. All piping (Figure 14) must be CPVC, galvanized, or stainless steel, and be free of leaks. Copper, carbon steel/iron pipe or PVC 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 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. Attach a ¼” water supply to the compression tting on the oat. The water line must be connected to an uninterruptible supply. Fulton 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).

NOTE: Ensure piping will not be exposed to freezing

temperatures.

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 more neutral level. It is not a replacement or alternative for the Condensate Drain Trap. See Figures 17 and 18.

5 

" NPT

4 



" NPT



FIGURE 15 SINGLE BOILER CONDENSATE DRAIN TRAP

FIGURE 16  MULTIPLE BOILER CONDENSATE DRAIN TRAP

Questions? Please Contact Your Local Manufacturer’s Representative

2-19

INSTALLATION EDR-IOM-2019-0212 SECTION 2

TOP VIEW

TANK COVER REMOVED FOR CLARITY

ISOMETRIC VIEW

ISOMETRIC VI EW

FRONT VI EW

TOP VIEW

ISOMETRIC VI EW

FRONT VI EW

TOP VIEW

LEFT VIEW

MULTIPLE BOILER

ASSEMBLY

1½" N.P.T.

OUTLET

16 3/4

12 ½

113/8

1½" N.P.T.

6 ½

INLET

2 3/4

FRONT VIEW RIGHT VI EW

2 3/4

FIGURE 17  FULTON PH NEUTRALIZING KIT

SINGLE BOILER

ASSEMBLY

2-20

ISOMETRIC VI EW

Multiple Boilers Individual Boiler

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

FIGURE 18  FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK

ISOMETRIC VI EW

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

Adhere to the following for pH Kit installation:

1. Use CPVC, stainless, or galvanized pipe and ttings to connect condensate trap to kit.

2. Connect kit downstream of Condensate Drain Trap. See Figure 18.

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

4. Check condensate pH periodically.

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

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

Venting Requirements

Adhere to the following venting requirements:

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

! WARNING

4 CAUTION

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

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

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

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

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

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

5. If the maximum positive pressure is exceeded, the boiler may have to be de-rated or require the installation of draft accessories such as a properly selected exhaust assist fan to prevent operational issues from occurring. If the maximum negative pressure is exceeded due to excessive natural draft (stack eect), the exhaust system may require the use of draft accessories such as a xed-position balancing bae or modulating overdraft damper. Draft accessories must be appropriate for Category II/IV installations and are not included with the boiler. Consult your venting supplier for recommendations.

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-21

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

Do not terminate venting into an enclosed area.

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

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

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

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

materials and other potentially required accessories.

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

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

as detailed in this manual. Some recommendations:

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

degree elbows, and short radius elbows.

 Avoid extensive direction changes (ue gases being required

to turn around).

 Never direct ue stacks in a downward direction.

TABLE 4  GENERAL VENTING PRESSURE REQUIREMENTS

Endura Model

Number

EDR 750 -0.04” W.C. +1.50 “ W.C. EDR 1000 -0.04” W.C. +1.50 “ W.C. EDR-1500 -0.04” W.C. +1.50 “ W.C. EDR-2000 -0.04” W.C. +1.50 “ W.C.

Maximum

Negative Draft

Maximum

Positive Draft

Combustion Air Intake

Adhere to the folllowing for installation:

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

2. The installation of room exhaust fans in a boiler room is not recommended. An exhaust fan or similar equipment can create down draft in the stack or restrict the burner’s air supply, resulting in poor combustion.

2-22

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

4. Particulate matter (example: sheetrock, berglass, cement, plaster board, dirt, dust, lint) or chemicals (example: chlorine, sulfur, freon, uorine,

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

perchlorethylene, halogenated compounds) in the combustion air supply to the boiler will cause damage or failure to the heat exchanger and/ or burner, and is not covered under warranty. High-risk situations for particulate matter to be in the air include construction and maintenance

activities. See Table 5.

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

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

quality is not covered under warranty.

TABLE 5  PRODUCTS/CONTAMINANTS TO AVOID

Products to avoid

Areas with the potential to have contaminants

Products containing chloro/ourocarbons; chlorine-based products; calcium chloride products, sodium chloride products, paint and varnish removers, hydrochloric acid, muriatic acid, cements, glues, antistatic fabric softeners, Freon, drywall particles, dirt, berglass

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

! WARNING

4 CAUTION

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

Particulate matter or chemicals (example: chlorine, uorine, perchlorethylene, halogenated compounds) in the combustion air supply to the boiler will cause damage or failure to the burner. High-risk situations for particulate matter to be in the air include construction and maintenance activities. See Table 5.

 Combustion Air Supply From the Boiler Room

Adhere to the following for installation:

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

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

2. Verify combustion air is taken from the outdoors and not from the inhabited or occupied spaces within the building. Ensure space and nearby products are evaluated for the potential of combustion air contaminants. See Table 5.

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

4. For installations providing a single permanent opening directly communicating with the outdoors, the minimum net free area of each opening is 1 in per 3,000 BTU/hr of the total input capacity of the combined burners located in the boiler room. See Table 6.

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-23

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

4 CAUTION

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

TABLE 6  MAKEUP AIR VENTILATION OPENINGS

Boiler Input

Capacity

(MBTU/HR)

Two Openings Min. Net

Free Area Each (SQFT)

Low High

Single Opening Only

Min. Net Free Area

(SQFT)

750 1.3 1.3 1.7 1000 1.8 1.8 2.3 1500 2.6 2.6 3.5 2000 3.5 3.5 4.6

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

the total net free area required for all types of equipment.

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

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

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

10. A 90˚ elbow is recommended on the air inlet to prevent debris falling into the cabinet.

 Air Piped From Outside Boiler Room

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

Adhere to the following for installation:

1. An adapter (not supplied with boiler) may be required to connect the boiler air inlet to the combustion air piping.

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

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

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

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

4. Ensure the boiler room air is maintained at a dew point temperature below the temperature of the combustion air. Failure to provide adequate ventilation or control dew point temperature may result in water or ice build-up on the combustion air piping, leading to increased maintenance or damage to boiler components.

2-24

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

See Figure 23.

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

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

manufacturer’s requirements.

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

gelation, stratication, or separation that cannot be removed by stirring.

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

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

Air Filter

The air lter requires monthly maintenance. See Maintenance section of this manual.

Exhaust Venting

! WARNING

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

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

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

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

upsized diameter is typically required.

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

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

direct vent sealed combustion application.

4. Where allowed by the authority having jurisdiction (AHJ), the exhaust may be vented using Schedule 40 PVC, Schedule 40 CPVC, or Polypropylene listed and labeled to UL 1738 or ULC S636. If venting with Schedule 40 PVC, at minimum the rst 8 inches of pipe must be Schedule 40 CPVC, see Figure 19 and Table 8. Do not insulate plastic exhaust vents. Canada only: Schedule 40 PVC, CPVC, or Polypropylene vent materials must be listed and

labeled to ULC S636.

5. Refer to Table 7 for acceptable vent materials and temperature limits. The use of cellular core PVC/CPVC or Radel® (polyphenylsulfone) in venting

systems is prohibited.

Questions? Please Contact Your Local Manufacturer’s Representative

2-25

INSTALLATION EDR-IOM-2019-0212 SECTION 2

MEH

AAF

KDB

REFFERENCE NS MAY REQUIRE

TS WHICH ARE NOT

ION PURPOSES.

ATION MANUALS FOR AND INSTALLATI ON

D BE MAINTAINED AT THE REQUIREMEN TS

COMMON HEAD ER

NTEE FLUE GASS ES AN IDLE BOILER.

ER IS RECOMMEN DED.

OD.

REQUIRED.

DIRECTION OF FLO W

ES MUST NOT BE

TEES.

--- --- --- --- ---

REVISION HISTORY

NOTES:

A CPVC STARTER P IECE IS REQUIRED WHEN VENTING IN TO PVC, AND MUST BE A MINIMUM LENGTH OF 8".

PVC

EXHAUST PIPE

PVC COUPLING

CPVC

STARTER PIECE

OUT TO

EXHAUST

TERMINATION

STAINLESS STEEL

ENDURA TO

CPVC APPLIANCE

ADAPTER

(SEE TABLE 8)

FIGURE 19  ENDURA EXHAUST VENTING

UPDATED ELBOW LOCATION. M.E.B. 8/18/14 N/A N/A

FIGURE 20  ENDURA COMMON EXHAUST VENTING; TYPICAL INSTALLATION GUIDELINES

REVISION DESCRIP TION B.O.M. ELEC. ENG MECH. EN G CHECKED APPROVED

HYDRONIC COND ENSING BOILER

FULTON ENDURA

REVISION HISTO RY

ECCENTRIC INCRE ASER

2-26

8/21/14

8/18/14

COMMON EXHAU ST HEADER

(SEE NOTES 4,5, 6)

45° REDUCING TEE (SEE NOTE 7)

UP TO TERMINATI ON

SWEEPING 90° EL BOW (SEE NOTE 8)

NOTES:

THIS IS A TYPICAL ARRANGEMENT FOR

1. PURPOSES ONLY . ACTUAL INSTALLATIO ALTERNATE OR AD DITIONAL COMPONEN SHOWN FOR CLAR ITY.

THIS DRAWING I S NOT FOR CONSTRUCT

REFER TO THE INS TALLATION AND OPER

3. INFORMATION R EGARDING CLEARANCES REQUIREM

Note: All installations must be in

compliance with local and na-

tional codes. Typical installation

diagrams in this manual are for

reference purposes only.

THE COMMON E XHAUST HEADER SHOUL

4. A SLIGHT NEGATIV E PRESSURE WITHIN OF THE BOILER. A POSITIVE PRESSURE WILL REQUIRE AC CESSORIES TO GUARA CANNOT TRAVEL BACKWARD THROUGH

A CONSTANT DIA METER COMMON HEAD

5. DO NOT USE TH E STATIC REGAIN METH

A MINIMUM 1/4" R ISE PER FOOT RUN IS

A 45° REDUCING IS RECOMMENDED . STRAIG HT OR 90° TE USED.

DO NOT USE BOOT TEES OR BULL HEAD

ENTS.

TEE OR ELBOW IN THE

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

6. A stainless steel adapter (not supplied) specic to vent manufacturer type and material will be required. Consult the venting supplier for guidance. See Figure 19.

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

8. Following the venting manufacturer’s instructions for installation of exhausting venting.

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

10. The boiler control will automatically disable and reset the burner should the ue gas temperature exceed the stack limit setting. The factory default stack limit setting is 200°F; this may be eld adjusted (See Operation) for installations utilizing a material in Table 7 approved for higher ue gas temperatures. To prevent the likelihood of automatic resets caused by approaching venting material limitations, it is suggested to use AL 29-4C, 316L, or Polypropylene in applications where return water temperatures can exceed 140°F (165°F ue gas temperatures).

11. If stack drains are installed, they must be pitched back to the boiler and combined with the boiler ue gas condensate drain piping into the

condensate drain trap.

TABLE 7  ACCEPTABLE EXHAUST VENTING MATERIALS

! WARNING

Venting Material

Maximum Flue Gas Temperature

Maximum Stack Limit Setting

AL-294C

(UL1738)

600° F

(315° C)

266° F

(130° C)

316L SS

(UL1738)

550° F

(287° C)

266° F

(130° C)

Polypropylene

(UL 1738)

230° F

(110° C)

230° F

(110° C)

Sch. 40

CPVC

200° F (93° C)

Sch. 40

PVC

200° F

(93° C)

200° F

(93° C)

TABLE 8  FULTON PART NUMBERS FOR FLUE GAS EXHAUST ADAPTERS

Manufacturer Line

M&G DuraVent® FasNSeal® AL29-4C 810010020 810010021

M&G Security SecureStack® Pro 304/316 SS SSD6FEDRUK SSD8FEDRUK

Schebler eVent™ AL29-4C EVD-AKFE-06R EVD-AKFE-08R

Selkirk® HeatFab® Saf-T Vent® AL29-4C CCA06EDR CCA08EDR

Jeremias® GOV 444 SS DWKL-FBA-EDR6 DWKL-FBA-EDR8

Metal-Fab, Inc. CORR/GUARD® AL29-4C 6FCSSBAI 8FCSSBAI

NovaFlex Z-Flex® Z-Vent® AL29-4C 2SVSAEDR6 2SVSAEDR8

NovaFlex Z-Flex® Z-Dens® Polypropylene 2ZDAEDR6 2ZDAEDR8

Centrotherm InnoFlue® Polypropylene ISSA0606 & ISVIB06 ISSA0808 & ISVIB08

M&G DuraVent® PolyPro® Polypropylene 810010023 810010025

M&G DuraVent® OEM for Endura CPVC / PVC Fulton 4-50-071005 Fulton 4-50-072005

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

Stack

Material

Part/Catalog Number

EDR-750-1500 EDR-2000

Questions? Please Contact Your Local Manufacturer’s Representative

2-27

INSTALLATION EDR-IOM-2019-0212 SECTION 2

SCREW OR BOLT EACH THIMBLE COLLAR TO WALL

 Common Venting Layouts for Endura

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

Refer to Figure 20 and adhere to the following for installation:

1. Consult your venting supplier for guidance in designing common vented installations. It is imperative to design such systems to prevent backow of exhaust gases through idle boilers.

2. Endura boilers are not approved for common venting with other equipment. Examples include steam boilers, water heaters, generators, and other types of Fulton equipment.

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

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

5. Where individual stacks transition into the common header, a 45 degree reducing tee or elbow in the direction of ow is recommended. Straight-in or 90 degree tees must not be used.

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

` COMMON VENTING EXHAUST BACKFLOW PREVENTION

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

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

(TYPICAL 4 PLACES)

ORIENT CLAMPS AND COLLAR AS REQUIRED

3½ INCH OR

4.35 CM AIR GAP ALL AROUND

THRU PIPE

DIAMETER “C”

STAINLESS

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

VARIABLE

PIPE RETAINING CLAMP, TYPICAL

EACH SIDE

DIAMETER “B”

WALL THIMBLE

WIDTH TO VARY WITH

WALL THICKNESS

END VIEW

ADJUSTABLE

DIAMETER “A” COLLAR

FIGURE 21 WALL THIMBLE INSTALLATION

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

 Low and high ue gas temperatures  Low and high ambient air temperatures  All boilers operating at their maximum input

rating capacity

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

position

 No boilers on, pre-purge and ignition

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

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

2-28

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

ENDURA

HYDRONIC

BOILER

NOTES:

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

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

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

TYPICAL ROOF PENETRATIONS

COMBUSTION AIR FROM THE OUTDOORS

( SUGGESTED INSTALLATION CONFIGURATIONS )

MIN 4 FT

(122 CM)

ADJUSTABLE FLASHING

METAL PLATE

FIRE STOP

ADJUSTABLE

FLASHING

ADHESIVE SEAL

STORM COLLAR

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

FLUE GAS EXHAUST TERMINATION

(RAIN CAP NOT REQUIRED)

IF SNOW ACCUMULATION

IS APPLICABLE, OPENING TO BE

MIN 1 FT (30 CM ) ABOVE

THIS NORMALLY EXPECTED LEVEL.

DO NOT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

SCH40 PVC PIPE (TYPICAL)

REFERENCE TABLE 1 FOR

MIN CAI DIAMETER

STORM COLLAR

FLEXIBILE RUBBER

PIPE COUPLING

FLUE GAS EXHAUST DIRECTION OF FLOW

COMBUSTION AIR INLET (CAI)

DIRECTION OF FLOW

STORM COLLAR (FOR DOUBLE WALL)

MIN 4 FT (122 CM)

ABOVE AIR

INTAKE PIPING

UL-1738 APPROVED EXHAUST VENT MATERIAL

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

CONDENSATE TRAP

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

CAUTION:

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

EXHAUST STACK IS DOWNWIND

OF AIR INTAKE OPENING

FIGURE 22  ROOF PENETRATION DETAILS

Questions? Please Contact Your Local Manufacturer’s Representative

2-29

INSTALLATION EDR-IOM-2019-0212 SECTION 2

NOTES:

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

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

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

ENDURA

HYDRONIC

BOILER

TYPICAL ROOF PENETRATION

COMBUSTION AIR FROM THE ROOM

( SUGGESTED INSTALLATION CONFIGURATIONS )

ADJUSTABLE FLASHING

METAL PLATE

FIRE STOP

FLUE GAS EXHAUST TERMINATION

(RAIN CAP NOT REQUIRED)

DO NOT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

STORM COLLAR

FLUE GAS EXHAUST DIRECTION OF FLOW

STORM COLLAR (FOR DOUBLE WALL)

UL-1738 APPROVED EXHAUST VENT MATERIAL

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

CONDENSATE TRAP

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

CAUTION:

ADEQUATE COMBUSTION AIR AND VENTILATION MUST BE SUPPLIED

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

12 INCH (305 MM)

UPPER COMBUSTION AIR LOUVER

MINIMUM NET FREE AREA

1 IN

PER 4,000 BTU/HR

(645 MM

PER 1.17 KW)

12 INCH (305 MM)

LOWER COMBUSTION AIR LOUVER

MINIMUM NET FREE AREA

1 IN

PER 4,000 BTU/HR

(645 MM

PER 1.17 KW)

FIGURE 23  ROOF PENETRATION WITH COMBUSTION AIR LOUVERS DETAILS

2-30

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

TYPICAL SIDE WALL PENETRATIONS

FIGURE 24  SIDEWALL PENETRATIONS DETAIL

( SUGGESTED INSTALLATION CONFIGURATIONS )

NOTES:

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

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

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

CAUTION:

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

UL-1738 APPROVED

EXHAUST VENT MATERIAL

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

MINIMUM RISE TO RUN RATIO:

1/4” PER FOOT (1 MM PER 48 MM)

UP TOWARDS TERMINATION

WALL TERMINATIONS DETAIL VIEW

EXHAUST STACK IS DOWNWIND

OF AIR INTAKE OPENING

MINIMUM 4 FT (122 CM) ABOVE THE

COMBUSTION AIR INLET TERMINATION

DO NOT PLACE

INSULATION IN

REQUIRED AIR SPACE

FLUE GAS EXHAUST TERMINATION

MINIMUM 10 FT (305 CM)

HORIZONTAL AWAY FROM THE

FLUE GAS EXHAUST TERMINATION

REFERENCE TABLE 1 FOR MIN CAI DIAMETER

SCH40 PVC PIPE (TYPICAL)

FLEXIBILE RUBBER

PIPE COUPLING

ENDURA

HYDRONIC

BOILER

MINIMUM RISE TO RUN RATIO:

1/4” PER FOOT (1 MM PER 48 MM)

DOWN TOWARDS TERMINATION

COMBUSTION AIR INTAKE (CAI)

DIRECTION OF FLOW

FLUE GAS EXHAUST DIRECTION OF FLOW

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

CONDENSATE TRAP

COMBUSTION

AIR INLET 90° ELBOW

1/2 INCH x 1/2 INCH

(13 MM x 13 MM)

MESH SCREEN

MINIMUM 10 FT (305 CM) HORIZONTAL

AND 4 FT (122 CM) ABOVE THE

COMBUSTION AIR INLET TERMINATION

OPENING TO BE MIN 1 FT (30 CM)

ABOVE NORMALLY EXPECTED SNOW ACCUMULATION LEVEL

LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT

Questions? Please Contact Your Local Manufacturer’s Representative

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INSTALLATION EDR-IOM-2019-0212 SECTION 2

 Venting Terminations

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

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

2. All vent pipes and ttings must be installed with appropriate air space clearances to combustibles. These air space clearances apply to indoor or outdoor vents— whether they are open, enclosed, horizontal or vertical or pass through oors, walls, roofs, or framed spaces (See Figures 22, 23 and 24). The air space clearances should be observed to joists, studs, sub oors, plywood, drywall or plaster enclosures, insulating sheathing, rafters, roong, and any other material classed as combustible.

3. To prevent the possible re-circulation of ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building congurations, etc. Fulton cannot be held responsible for the eects such adverse conditions may have on theoperation of the boilers.

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

5. Listed termination parts must be used.

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

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

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

 Roof Vent Termination

Adhere to the following for installation (see Figure 22 and 23):

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

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

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

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

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

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

additional vent pressure loss. See Figure 22 and 23.

 Wall Thimble Installation

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

1. Insert the thimble through the wall from the outside.

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

 Side Wall Vent Termination

Adhere to the following for installation (see Figure 24):

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

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

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

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

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

nuisance or hazard.

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SECTION 2 EDR-IOM-2019-0212 INSTALLATION

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

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

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

7. Under certain wind conditions, some building materials may be aected by ue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (such as an aluminum sheet) may be required to prevent staining or deterioration. Flue should be directed away from surfaces, if possible.

Removing an Existing Boiler

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

! WARNING

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

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

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

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

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

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Do not use the ame of a match or candle or smoke from a cigarette, cigar or pipe.

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-33

INSTALLATION EDR-IOM-2019-0212 SECTION 2

! WARNING

The rating of each external device contact is the maximum allowable amperage of the contact. The total Full Load Amps (FLA) of external devices wired to the Endura boiler power circuit cannot exceed 1A.

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

Assembly of Fulton Multi-Skid Systems

Adhere to the following for multi-skid engineered systems:

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

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

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

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

has been reassembled and tightened.

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

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

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

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

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

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

2-34

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

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

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

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

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

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

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

Electrical Connections and Devices

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

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

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

! WARNING

 There is no warranty on components that fail due to improper electrical

service.

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

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

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

Adhere to the following when making electrical connections:

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

2-35

INSTALLATION EDR-IOM-2019-0212 SECTION 2

TO SECOND PAGE

SIZE REFERENCE CHART

BOILER SIZE

EDR 750-1000

EDR 1500-2000

TO SECOND PAGE

2-36

EDR 750  2000 REFERENCE ELECTRICAL SCHEMATIC DIAGRAM

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

FROM FIRST PAGE

EDR 750 2000 REFERENCE ELECTRICAL SCHEMATIC DIAGRAM CONTINUED

Questions? Please Contact Your Local Manufacturer’s Representative

2-37

INSTALLATION EDR-IOM-2019-0212 SECTION 2

STOCK COMPONENTS

TB1-

SIZE REFERENCE CHART

BOILER SIZE

EDR 750-1000

EDR 1500-2000

J-FUSE (BM) 10A (2-45-000267) 25A (2-45-000278)

FLA 10A 20A

46A

52A

62A

63A

63B

203

205

206

221

222

223

OPTIONAL COMPONENTS

2-38

TB2-

TB J

212

211

201

83A

EDR 7502000 REFERENCE ELECTRICAL SCHEMATIC DIAGRAM CONTINUED

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

Fulton

SOLA

FULTON SOLA

Notes: See Reference Eletrical Schematic Diagrams for eld wiring connections. Refrence the R7910A SOLA HC (Hydronic Control) manual for additional information.

FIGURE 25  FULTON SOLA PIN LAYOUT

Questions? Please Contact Your Local Manufacturer’s Representative

2-39

INSTALLATION EDR-IOM-2019-0212 SECTION 2

 Junction Box Locations for Field Wiring

Factory mounted junction boxes (Figure 26) are provided at the rear of the boiler for routing eld wiring to the boiler control panel. Do not run wiring directly through the removable or hinged panels doors.

Electrical

Connections

2. One boiler will be designated as the MASTER, with the capability to cascade up to seven additional stages for a maximum of eight boilers. The lead boiler, or the rst to operate upon a call for heat, is automatically rotated based on boiler run hours.

3. The supply header temperature sensor must be utilized and wired to the MASTER boiler and installed downstream of the boilers in the common supply water header for proper operation of the sequenced plant.

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

5. Communication between the MASTER and additional boilers is performed using the Modbus protocol. This requires shielded, three-wire twisted pair communication wire, Belden 3106A or equivalent. Shield should only be grounded at one end and tied directly to Earth ground.

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

FIGURE 26 LINE VOLTAGE AND LOW VOLTAGE

JUNCTION BOX LOCATIONS TYPICAL

 Electrical and Controls Options

The electrical and controls options required and supplied will vary depending on the unique requirements and piping arrangements of the hydronic system. See Electrical Schematic Diagrams for locations of eld wiring connections on the below electrical devices and controls options.

` LEAD/LAG INTEGRATED SEQUENCING WIRING

1. The Fulton SOLA includes integrated sequencing capabilities. When utilized, the boiler control system will automatically cascade boilers and operate burner ring rates in parallel as necessary to maintain a hydronic setpoint.

` INTEGRATION WITH THE SYNEX CONTROLS MODSYNC

SEQUENCING SYSTEM

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

` SUPPLER HEADER TEMPERATURE SENSOR

1. A hydronic supply sensor and

000405) is used for temperature control.

2. This sensor is required for any multiple boiler installation utilizing the integrated sequencing (lead/ lag) capabilities of the Fulton SOLA.

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

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

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

1/2

” NPT well (P/N 4-30-

2-40

SECTION 2 EDR-IOM-2019-0212 INSTALLATION

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

hydronic piping.

` OUTDOOR AIR TEMPERATURE SENSOR KIT

1. If outdoor air temperature reset capabilities are to becontrolled by the Fulton SOLA, an outdoor air temperature sensor kit (P/N 4-30-000400) is required and eld wired to the MASTER boiler.

2. An outdoor air temperature sensor kit is not required if using xed water temperature operation, or if the boiler control is receiving an external hydronic setpoint signal over a communication protocol or analog signal.

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

4. A relay is provided loose with the sensor, to be wired in the eld by others.

` DOMESTIC HOT WATER DHW TEMPERATURE SENSOR

1. This Endura boiler is capable of providing indirect domestic hot water through a heat exchanger. A domestic hot water temperature sensor (P/N 4-30-

000332) is used for this application. The Endura boiler is for closed loop applications only; open loop must not be directly heated by the boiler.

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

3. See the Operation section for programming DHW priority.

` MOTORIZED ISOLATION VALVE CONTROL

` AUXILIARY SAFETY INTERLOCK FOR EXTERNAL DEVICE

1. When the Endura boiler receives a call for heat, the startup sequence rst checks for a completed LCI circuit. If the LCI circuit is open, the boiler control will remain in a standby state until it is closed. No alarms will be annunciated while the LCI is in a standby state.

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

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

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

` DEDICATED BOILER PUMP CONTROL

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

2. The boiler controller has outputs that may be used for dedicated boiler pump or domestic hot water pump control. These are intended for use as a pump start/stop signal only; the pump should not be powered through the boiler panel. An external motor starter or variable speed drive, by others, is used to control the circulator pump.

3. The device contacts (A, B, C) have a maximum rating of

7.4 Amps at 120 VAC.

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

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

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

3. The lead boiler motorized isolation valve must be eld programmed to remain open when all boilers are idle to provide a path of ow in the hydronic system. See the Operation section for programming motorized isolation valve control.

Questions? Please Contact Your Local Manufacturer’s Representative

4. For applications requiring a dry contact, use a 120 VAC control relay (P/N 2-45-880360), rated for 5 Amps maximum.

` BURNER FIRE RATE OUTPUT

1. Fulton SOLA J10 plug terminals 4, 5, and 6 may be used for either 4-20 mA or 0-10 VDC burner re rate output.

2. This can be used by an external control to monitor burner re rate, or as a signal to a dedicated boiler circulator variable speed drive.

3. The signal reverts to 4 mA / 0 VDC when idle.

4. For instructions on enabling this output, see the Operation section.

2-41

INSTALLATION EDR-IOM-2019-0212 SECTION 2

` ALTERNATE COMMUNICATION PROTOCOL GATEWAY

Reference the Manual Supplement for SOLA Gateways for for BACnet and other protocols.

` REMOTE LEAD/LAG SYSTEM ENABLE

1. A contact may be utilized to enable and disable the lead/lag boiler plant when integrated sequencing capabilities are utilized. This is intended for the MASTER boiler control panel only. Remove the 83-83A jumper and wire to remote control panel.

2. When the contact is closed, the lead/lag system is enabled and allowed to operate. When the contact is open, the boilers will remain in a standby state.

` REMOTE BOILER ENABLE

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

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

` REMOTE ANALOG SETPOINT

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

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

3. Remove the H-W1 jumper, and wire the external LWCO to the associated terminal blocks.

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

` ADDITIONAL HIGH LIMIT AQUASTAT

1. This hydronic boiler in the standard conguration features a single factory installed UL 353 temperature probe which functions as an electronic dual element temperature sensor. This satises CSD-1 CW-400 requirements of two independent temperature control devices. The authority having jurisdiction (AHJ) over the installation may require the use of an additional, third, high limit device to satisfy local code requirements. A manual reset high limit (MRHL) mechanical Aquastat (P/N 2-40-0000294) with a 200°F maximum setting may be utilized where this functionality is required.

2. The Aquastat probe and thermowell are installed in the outlet piping of the boiler. The thermowell must not be isolated from the heat exchanger with any valve.

1. An external hydronic loop setpoint signal may be sent using an analog signal. This may be either 4-20 mA or 0-10 VDC. Both signal types require a 120 VAC relay (P/N 2-45-880360) wired to the REMOTE setting of the three position control switch, rated for 5 Amps maximum. A 0-10 VDC signal additionally requires an analog signal converter module (P/N 2-45-001140).

2. When using integrated cascade functionality, the setpoint signal may be sent to the one boiler only.

` GENERAL ALARM CONTACT

A dry contact is provided for annunciation of a general alarm condition. It is rated for 5 Amps maximum.

` EXTERNAL LOW WATER CUT OFF

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

3. Heat conductive compound, also known as thermal paste, is applied during installation between the probe and thermowell to ensure accurate temperature readings.

4. Mount the Aquastat in a location that is accessible for operation and maintenance. Take care to not pinch or otherwise damage the capillary tube.

5. Remove the 72-73 jumper, and wire the Aquastat to the associated terminal blocks.

` BOILER STATUS CONTACT

A dry contact is provided for remote monitoring of boiler status. When the main gas valve is enabled, the contact is closed. This requires a 120 VAC relay (P/N 2-45-880360), rated for 5 Amps maximum.

2-42

OPERATION

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE

Questions? Please Contact Your Local Manufacturer’s Representative

3-1

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Failure to follow instructions may result in a re or explosion, causing property damage, personal injury, or loss of life.

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

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

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

Perform Pre-Start-Up Inspection

Prior to start-up, perform the following:

1. If you smell gas:

 Do not try to light any appliance.  Do not touch any electrical switch; do not use any phone in your building.

 Immediately call your gas supplier from a neighbor’s phone.

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

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

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

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

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

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

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

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

Fill and Purge the System

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

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

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

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

Completely ll and purge the heating system as follows:

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

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

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

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

5. With the gas shuto valve closed, turn on power to the boiler and operate the circulator. Circulate the system water for approximately 30 minutes to move all air to the automatic air separation point.

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

3-2

SECTION 3 EDR-IOM-2019-0212 OPERATION

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

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

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

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

! WARNING

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

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

Commission The Boiler

Adhere to the following when commissioning the boiler:

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

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

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

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

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

must be produced for warranty consideration.

 System Design and Boiler Operation

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

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

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

4 CAUTION

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

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

1. The boiler shall be operated/controlled to ensure the boiler does not cycle more than 12,000 times per year and the temperature dierential across the boiler does not exceed 100°F (56°C).

2. Site specic conditions including combustion air temperature, elevation, fuel temperature, caloric value of the fuel, combustion air system design, exhaust system design, voltage uctuations and other factors will impact

boiler performance.

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

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

Questions? Please Contact Your Local Manufacturer’s Representative

3-3

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

4 CAUTION

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

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

When commissioning is complete, SOLA control must be placed into automatic mode.

Commission The Boiler: Zero Governing Gas Valve

NOTE: In areas where NOx emission regulations apply, the O2 level should be set

so that the NOx level does not exceed local code at any point during operation. Refer to Table 10 and the factory test re report for combustion settings.

NOTE: Perform the following steps for eld commissioning with the Gas Valve

(Figure 27).

NOTE: A properly calibrated combustion analyzer will be required when making

changes to the valve settings.

1. Follow the steps in the SOLA Hydronic Controller section of this manual to access the parameters to run the boiler in manual mode.

2. Turn the boiler on and make sure that there is a call for heat. If the unit does not go directly to pre-purge, there is not a call for heat or there is an interlock open. If all interlocks are closed, the unit will drive to the max RPM for pre-purge and begin countdown.

3. When pre-purge is nished, the unit will go to the light-o point.

4. Use the Test Fire Report to verify the factory low re RPM setting. Input this setting into the SOLA manual ring rate (Figure 32). Once the boiler is at this RPM check combustion. If combustion is within the acceptable O2 range stated in Table 9 or Table 10, increase at 1,000 RPM increments to the high re RPM rate. The high re RPM rate is listed on the Test Fire Report and in the SOLA under “Modulation Conguration”, CH Maximum Modulation Rate. Once at high re take a combustion reading.

NOTE: Gas Valve adjustments will change combustion. Only minor changes

should be required due to the boiler being fully test red at the factory. Gas valve adjustments should only be made at high re and low re. If an adjustment is made at low re it will eect high re, and vice versa. It is recommended to adjust high re combustion prior to making any adjustments at low re.

5. To increase the O2 level at high re, turn the Valve Adjustment (Gas valve shutter on the downstream side of the gas valve, see Figure 26) in the negative (-) direction. To decrease O2 level, turn the Valve Adjustment screw in the positive (+) direction. Once the correct O2 level is reached slowly go back to low re and check combustion.

6. When you have reached low re RPM and if O2 adjustments are required the Valve Oset Adjustment (allen screw on the side of the valve, see Figure 26) will need to be rotated. To increase O2 turn the Valve Oset Adjustment screw in the negative (-) direction; turn in the opposite direction to decrease O2.

3-4

7. When turning the valve oset adjustment go half past the desired setting, then turn the valve oset adjustment back to arrive at the desired setting. Example: To turn the valve oset adjustment a quarter turn positive, proceed a half turn positive, then turn adjustment back a quarter turn negative. The net result is a quarter turn positive.

SECTION 3 EDR-IOM-2019-0212 OPERATION

8. Changes to either the Shutter or Oset Adjustments on the valve will alter combustion throughout the range. Once combustion setup is completed

at low and high re, perform the following steps to verify O2 repeatability:

A. Ramp the boiler from low re RPM to high re RPM.

B. From the high re RPM, ramp back to the low re RPM, record

combustion O2%.

C. Turn the boiler o.

D. Turn the boiler on and set to the low re RPM rate.

E. Verify combustion O2% at low re is consistent with the value recorded

in Step B. If it is not, reference Valve Oset Adjustment in Step 6 for low re RPM adjustments.

9. Verify combustion settings are in the range specied by Table 9.

NOTE: Proper set up of the Ignition Enrichment gas is crucial to the light-o

of the boiler and requires verication in the eld during initial commissioning. Fulton recommends the Ignition enrichment setting is veried during the yearly

preventative maintenance.

10. Once nal eld combustion is completed at low and high re, the ignition enrichment setting requires verication. Use the factory Test Fire Report to determine the factory light o RPM fan speed setting. Input the light o

RPM into the SOLA “manual ring rate” screen (Figure 33).

! WARNING

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

4 CAUTION

When making changes to the controls prole, a combustion analyzer is required.

11. Connect an inches of water column measuring device (e.g., manometer) to the enrichment gas valve test port (Figure 27). Insert combustion analyzer probe into the ue gas outlet port.

Low Gas Pressure

Switch

MBC Supply Gas

Pressure Test Port

Enrichment Regulator (Integral Vent Limiter)

Enrichment Valve with

Outlet Test Port

High Gas Pressure Switch

High Fire Shutter Adjustment

Manifold Gas Pressure Test Port

2.5 mm Allen Low Fire Oset

FIGURE 27  GAS DELIVERY SYSTEM

Questions? Please Contact Your Local Manufacturer’s Representative

3-5

OPERATION EDR-IOM-2019-0212 SECTION 3

TOP VIEW

ISOMETRIC VIEW

RIGHT SIDE VIEW

TOP VIEW

! WARNING

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

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

Test Port

FIGURE 28  ENRICHMENT GAS VALVE TEST PORT

12. Open the front access door and locate the Enrichment test button located at the top of the electrical box. Pushing the Enrichment test button (Figure 28) activates a “1-shot relay,” allowing 30 seconds to measure the Enrichment gas valve outlet pressure and stable O%. Use the factory test re report to reference the Enrichment gas valve outlet pressure and O%.

(site conditions will ultimately determine specic settings).

 For metal woven mesh burners only: Verify O percentage is within the

range listed in Table 9. Consult the factory for boilers operating with ceramic mesh burners.

NOTE: Button should only be pushed ONCE during this exercise.

3-6

FIGURE 29  ENRICHMENT TEST BUTTON

NOTE: The eld O% at low re impacts the Enrichment O%. Always set eld

combustion at low and high re prior to completing the above steps!

13. The enrichment gas regulator (Figure 27) may be used to increase or decrease the valve outlet pressure as required.

14. Once combustion is veried with a combustion analyzer place the control back into automatic mode and check all boiler safeties.

SECTION 3 EDR-IOM-2019-0212 OPERATION

NOTE: The boiler is factory-congured for standard natural gas. Contact your

authorized service organization for conversion to HD5 propane.

TABLE 9  METAL MESH BURNERS: VERIFICATION OF NATURAL GAS COMBUSTION

Light O Low Fire High Fire

MBC2500 Supply Gas Press. (“w.c.) 3 to 8 3 to 8 3 to 8

Enrichment Press. (“w.c.) 1.0 to 3.5 - -

Manifold Gas Press. (“w.c.) - -.1 to -.2 -2.8 to -3.8

Sola RPM (RPM) 2700 to 3300 1650 to 2100 7000 to 8000

EDR-750

Damper position (deg) 20 to 30 - -

MBC2500 Supply Gas Press. (“w.c.) 3 to 8 3 to 8 3 to 8

Enrichment Press. (“w.c.) 1.0 to 3.5 - -

Manifold Gas Press. (“w.c.) -.1 to -.4 -5.5 to -6.5

EDR-1000

Damper position (deg) 20 to 30 - -

MBC2500 Supply Gas Press. (“w.c.) 3 to 8 3 to 8 3 to 8

Enrichment Press. (“w.c.) 1.0 to 3.5 - -

Manifold Gas Press. (“w.c.) - -.05 to -.2 -1.8 to 3.0

EDR-1500

Damper position (deg) 20 to 30 - -

MBC2500 Supply Gas Press. (“w.c.) 3 to 8 3 to 8 3 to 8

Enrichment Press. (“w.c.) 1.5 to 3.5 - -

Manifold Gas Press. (“w.c.) - -0.18 to -0.22 -3.5 to -4.3

EDR-2000

Damper position (deg) 20 to 30 - -

O (%) 3.0 - 4.5 6 - 7.5 5 - 6

# of shutter turns - - 2 - 4

# of oset turns - 1 to -2 -

Light O Low Fire High Fire

Sola RPM (RPM) 2800 to 3500 1800 to 2400 9000 to 10000

O (%) 2.0 - 4.5 6 - 7.5 5 - 6

# of shutter turns - - 1.5 - 3

# of oset turns - -2 to +2 -

Light O Low Fire High Fire

Sola RPM (RPM) 2600 to 3000 1650 to 1800 6800 to 7500

O (%) 3.0 to 4.5 6 to 7.5 5.2 to 6.5

# of shutter turns - - 3.5 to 5

# of oset turns - +1 to -3.0 -

Light O Low Fire High Fire

Sola RPM (RPM) 2800 to 3000 1650 to 1800 7100 to 7500

O (%) 3.0 to 4.5 6.5 - 7.5 5.2 to 6.5

# of shutter turns - - 3.5 to 5

# of oset turns - +1 to -3.0 -

NOTE: The EDR-750/1000 boilers shipped before 3/28/18, EDR-1500 boilers

shipped before 8/16/17, and EDR-2000 boilers shipped before 2/28/17 may have a ceramic mesh burner. Consult the factory for combustion settings.

! WARNING

EDR-750/1000 boilers shipped before 3/28/18, EDR-1500 boilers shipped before 8/16/17, and EDR-2000 boilers shipped before 2/28/17 may have a ceramic mesh burner. Consult the factory for combustion settings.

 Turndown

All Endura boilers are congured at the factory with a default setting of 5.1 turndown. Wind eects on combustion air supply and exhaust terminations, natural draft “stack eect”, and gas delivery systems (among other site factors) will ultimately determine what turndown settings are optimal for each application. Consult your local manufacturer’s representative or service organization with

factory authorization specic to the Endura product line for guidance.

Questions? Please Contact Your Local Manufacturer’s Representative

3-7

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

SOLA Hydronic Controller - General Operation

The screen shots and information in this section will help you navigate through display parameters that would be used for initial startup.

FIGURE 30  THE SOLA CONTROLLER HOME SCREEN

 Status Summary Screen

From this screen you will be able to access any of the parameters (Figure 31) by tapping on the controller in Figure 30. You can see if the unit Demand is on and the status of the boiler from Burner State. The ring rate will show you the RPM ring rate output. Also you can see the setpoint desired.

FIGURE 31  STATUS SUMMARY SCREEN

 Central Heat Operation Screen

3-8

Access this screen (Figure 32) by pressing the Operation button from the Status Summary Screen. From the Central Heat Operation screen you will be able to change the boilers Setpoint by pressing the yellow box next to Normal. If the ring rate needs to be changed from auto to manual for maintenance and/or commissioning purposes (to be able to run the boiler anywhere in the ring range) you would press the yellow block next to Firing Rate. Pressing Firing Rate

SECTION 3 EDR-IOM-2019-0212 OPERATION

will put you into the screen shown in Figure 32. When the Setpoint or Firing Rate requires changing, a password is required. Once the password is entered correctly, the top right section of the screen will show the padlock unlocked as shown in Figure 32. See Figures 33 and 34 for changing the Setpoint and Firing Rate.

NOTE: If the boiler is not placed back in automatic mode following maintenance,

the boiler will not operate properly.

! WARNING

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

FIGURE 32  CENTRAL HEAT OPERATION SCREEN

Central Heat Operation - Firing Rate Screen

In this screen (Figure 33) the control can be changed from Automatic to Manual. When in Automatic, the control will go to the ring rate necessary to achieve the setpoint. When in Manual, the control will go to the point that is entered into the Manual Firing Rate box; specic RPMs can be entered. After a ring rate is entered, press OK and the Firing Rate Screen will close and the boiler will go that selected ring rate. When nished with maintenance, return to this screen and place the boiler back into Automatic mode.

FIGURE 33  CENTRAL HEAT OPERATION  FIRING RATE SCREEN

Questions? Please Contact Your Local Manufacturer’s Representative

3-9

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

 Central Heat Operation - Setpoint Screen

In this screen (Figure 34) the Setpoint can be changed. Press the up and down arrow or press Clear and enter the desired Setpoint. Then press OK.

FIGURE 34  CENTRAL HEAT OPERATION  SETPOINT SCREEN

 Central Heat Conﬁguration – Setpoint Screen

From the Status Summary Screen press Congure. There will be a list of Parameters, press the CH – Central Heat Conguration. You will now be in the Central Heat Conguration Screen, Central Heat screen. Press the upper right black arrow until you are in the Setpoint Screen (Figure 35). From this screen you can see this is another location where the Setpoint can be changed, but this is the only location that the on/o Hysteresis around Setpoint can be changed. To change any of these settings the sola password must be entered.

3-10

FIGURE 35  CENTRAL HEAT CONFIGURATION  SETPOINT SCREEN

 Central Heat Conﬁguration – Modulation Screen

By pressing the black arrow on the top of the page you will be able to move from

SECTION 3 EDR-IOM-2019-0212 OPERATION

the previous Setpoint screen to the Modulation Screen (Figure 36). This screen provides access to the PID (Proportional, Integral and Derivative) of the control. The sola password is also required to change these parameters.

FIGURE 36  CENTRAL HEAT CONFIGURATION  MODULATION SCREEN

 Changing High Limit Setpoint and Verifying Change

! WARNING

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

From the Status Summary Screen press Congure, then High Limits; this screen will be used to set and/or test the Outlet High Limit Setpoint (Figure 37). The sola password must be entered. By touching the Setpoint next to Outlet High Limit Setpoint you can adjust the temperature up and down for the Setpoint you desire or lower it for testing purposes. This change will require Verication. Verify as follows:

FIGURE 37  HIGH LIMITS SCREEN

1. Arrow back to the Conguration Menu and press Verify down in the lower right hand corner. Figure 38.

Questions? Please Contact Your Local Manufacturer’s Representative

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OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

FIGURE 38  VERIFICATION PROCEDURE

4 CAUTION

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

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

2. Press the Padlock in the upper right hand corner and enter the password sola (if not already unlocked) then press Begin down in the lower right hand corner. Figure 39.

FIGURE 39  VERIFICATION PROCEDURE

3. The parameters that you changed will appear; verify the change you made is correct. Then press Yes. Figure 40.

3-12

SECTION 3 EDR-IOM-2019-0212 OPERATION

FIGURE 40  VERIFICATION PROCEDURE

4. If there are no more changes the control will ask for a reset (Figure 40). This can be done by pressing the reset button on the front of the Sola control (the base) for 1 to 2 seconds.

4 WARNING

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

FIGURE 41  RESET VERIFICATION SCREEN

 Reviewing Statistics

From the Conguration Menu (Figure 42), press Statistics Conguration.

From this screen (Figure 43) cycles and hours of the boiler can be viewed. Please note that they can be cleared by pressing Clear All. This is not recommended.

Questions? Please Contact Your Local Manufacturer’s Representative

3-13

OPERATION EDR-IOM-2019-0212 SECTION 3

4 WARNING

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

FIGURE 42  ACCESSING STATISTICS CONFIGURATION SCREEN

3-14

FIGURE 43  STATISTICS CONFIGURATION SCREEN

 Accessing Lockout History

From the Main Menu screen resetting the lockout or viewing the lockout history can be accessed by pressing where Figure 44 is showing a Lockout. If there is no lockout that same bar will display History. If the control is in lockout another sub screen will be displayed and you will have the option for Ok, Lockouts, Alerts and Silence. Pressing Lockouts will display the Lockout History screen.

After the Lockout is pressed you will be placed into the Lockout History screen (Figure 45). Time and date stamp of the last fteen lockouts is displayed. Pressing Clear Lockout will clear the current lockout. By pressing the specic lockout more information on the lockout will be displayed (Figure 46).

SECTION 3 EDR-IOM-2019-0212 OPERATION

4 WARNING

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

Operating this equipment beyond its design limits can damage the equipment and can be dangerous. Do not operate the equipment outside of its limits. Do not try to upgrade the equipment performance through unapproved modications. Unapproved modications may

FIGURE 44  VIEWING LOCKOUT

cause injury, equipment damage, and will void the warranty.

FIGURE 45  CLEARING LOCKOUT

FIGURE 46  LOCKOUT INFORMATION

Questions? Please Contact Your Local Manufacturer’s Representative

3-15

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualied to operate/maintain the equipment.

4 CAUTION

For all systems, the water chemistry in the boiler must be kept within required limits. Failure to do so may cause premature pressure vessel failure and will void the warranty.

 SOLA Diagnostics

From the Status Summary screen (Figure 47), press Diagnostics.

FIGURE 47  ACCESSING DIAGNOSTICS

Pressing Burner Control I/O will place you into the I/O Status screen (Figure 47). From here you can see what the control is receiving from its inputs. A green light next to the input indicates the control’s input is made or satised. A gray circle indicates the input is not satised. This is a helpful trouble shooting screen.

3-16

FIGURE 48 BURNER CONTROL I/O

Pressing Digital I/O will place you into the Digital I/O screen (Figure 48). From here you can see what the control is receiving from its inputs. A green light next to the input indicates the control’s input is made or satised. A gray circle indicates the input is not satised. This is a helpful trouble shooting screen.

SECTION 3 EDR-IOM-2019-0212 OPERATION

! WARNING

Check daily that the equipment area is free and clear of any combustible materials, including ammable vapors and liquids.

FIGURE 49  DIGITAL I/O

Pressing Analog I/O will place you into the Analog I/O screen (Figure 50). Specic information on temperature, ring rate, ame signal and fan speed may be viewed.

FIGURE 50  ANALOG I/O

SOLA Hydronic Controller - Options Conﬁguration

The screen shots and information in this section will help you congure various options available on the Endura boiler. For further information on installation requirements refer to the electrical portion in the Installation section.

Various parameter changes required in this section will require a verication procedure. Refer to the previous general section for the verication sequence.

 Lead/Lag Integrated Sequencing

Each boiler on the network is a slave boiler and any boiler may be selected as the master. From the boiler status screen select congure and scroll to and select

Questions? Please Contact Your Local Manufacturer’s Representative

3-17

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

Lead Lag Slave Conguration. The row labeled Slave enable needs to be set to enable slave for built in lead lag master and the row Slave mode needs to be set to equalize run time. Refer to Figure 51 for factory default settings.

 Demand to Firing Delay: The amount of time allowed between a call for

heat and the enabling of the gas valve.

 Modbus Address: Each boiler on the network must have a dierent

Modbus address (up to 8 boilers total).

FIGURE 51  LEAD LAG SLAVE CONFIGURATION

One boiler on the network must be master enabled. Starting from the boiler status screen select congure. Scroll to and select Lead Lag Master Conguration. The row labeled “Master Enable” must be set to enable. Refer to Figure 52 for factory default settings.

FIGURE 52  LEAD LAG MASTER CONFIGURATION

3-18

From the Lead Lag Master Conguration screen Select the box labeled Advanced Settings in the bottom right hand corner. Use the left and right arrows to scroll to Add stage. The row labeled Method 1 needs to be set to error threshold. Refer to Figure 53 for factory default settings:

SECTION 3 EDR-IOM-2019-0212 OPERATION

 Interstage delay: The amount of time that must expire before the detection

begins.

 Detection Time: The amount of time that must expire, after the interstage

delay time has expired, before a boiler is added.

 Error Threshold: A stage is added when the error becomes excessive based

on degrees away from set point.

! WARNING

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

FIGURE 53 ADD STAGE

From the Lead Lag Master Conguration screen Select the box labeled Advanced Settings in the bottom right hand corner. Use the left and right arrows to scroll to the screen labeled drop stage. The row labeled Method 1 needs to be set to error threshold. Refer to Figure 54 for factory default settings:

 Interstage delay: The amount of time that must expire before the detection

begins.

 Detection Time: The amount of time that must expire, after the interstage

delay time has expired, before a boiler is added.

 Error Threshold: A stage is added when the error becomes excessive based

on degrees away from set point.

FIGURE 54 DROP STAGE

Questions? Please Contact Your Local Manufacturer’s Representative

3-19

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

From the Lead Lag Master Conguration screen select the box labeled Advanced Settings in the bottom right hand corner. Use the left and right arrows to scroll to the screen labeled modulation. The row labeled modulation backup sensor needs to be set to lead outlet sensor. Refer to Figure 55 for factory default settings:

 O Hysteresis: The dierential above setpoint when the boiler is turned o.

 On Hysteresis: The dierential from setpoint when the lead boiler is turned

on.

 P gain: The gain applied for the Proportional portion of the PID equation.

 I gain: The gain applied for the Integral portion of the PID equation.

 D gain: The gain applied for the Derivative portion of the PID equation.

FIGURE 55  MODULATION

From the Lead Lag Master Conguration screen Select the box labeled Advanced Settings in the bottom right hand corner. Use the left and right arrows to scroll to the screen labeled Algorithms. The two rows labeled lead selection method and Lag selection method need to be set to measured run time. Refer to Figure 56 for factory default settings:

FIGURE 56  ALGORITHMS

3-20

SECTION 3 EDR-IOM-2019-0212 OPERATION

From the Lead Lag Master Conguration screen Select the box labeled Advanced Settings in the bottom right hand corner. Use the left and right arrows to scroll to the screen labeled rate allocation. The Factory default setting for base load common is 40%.

 Rate Allocation (Figure 57): Minimum percentage of fan RPMs a boiler will

operate. All boilers in the lead lag boiler plant have to be ring prior to any boiler operating above 40% fan speed.

! WARNING

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

FIGURE 57  RATE ALLOCATION

 Domestic Hot Water (DHW) Temperature Sensor

From the boiler status screen select conguration. Scroll to and select Sensor conguration (Figure 58). The row labeled “ *S6S7 (J9-1,3) Sensor (DHW) must be set to 10K NTC dual safety.

FIGURE 58  DHW SENSOR CONFIGURATION

For a lead lag boiler plant the DHW conguration must be done through the master lead lag conguration advanced settings. From the conguration screen scroll to and select Lead Lag Master Conguration. Select the box in the bottom right hand corner labeled “advanced settings”. Using the left and right arrow

Questions? Please Contact Your Local Manufacturer’s Representative

3-21

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

keys scroll to the screen labeled Domestic Hot Water. The row labeled Demand switch needs to be set to DHW (S6). If it is desired to have the domestic hot water demand take priority over the central heat demand the priority must be set in the bottom row. See Figure 59.

For a standalone boiler the Domestic Hot water settings must be congured through the domestic hot water conguration screen found on the conguration screen menu.

FIGURE 59  LEAD LAG MASTER CONFIGURATION DHW

 Remote 4-20 mA Signal for Setpoint

Remote 4-20 mA setpoint is to be congured on the master boiler only or on a standalone boiler application. To congure a remote 4-20 mA signal for setpoint start at the boiler status screen. Select congure and scroll to and select the sensor conguration. The row labeled “*S2 (J8-6) Sensor (4-20mA remote)” needs to be set on 4-20mA as shown in Figure 60.

3-22

FIGURE 60  REMOTE 420MA SENSOR CONFIGURATION

To establish the setpoint source for a lead lag boiler plant start from the boiler status screen and select conguration. From the conguration screen scroll to and select lead lag master conguration and select the box labeled advanced settings in the bottom right hand corner. Using the left and right arrow keys scroll

SECTION 3 EDR-IOM-2019-0212 OPERATION

to the screen labeled central heat. The row labeled Setpoint Source needs to be set on S2 (J8-6) 4-20mA. Refer to Figure 61 for factory default settings:

 O Hysteresis: The dierential above setpoint when the boiler is turned o.

 On Hysteresis: The dierential from setpoint when the boiler is turned on.

 4 mA water temperature: The setpoint valued assigned to a remote 4 mA

signal

 20 mA water temperature: The setpoint valued assigned to a remote 20 mA

signal

! WARNING

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

FIGURE 61  CENTRAL HEAT CONFIGURATION SETPOINT

For a standalone boiler the remote signal for setpoint must be congured through a dierent screen. From the boiler status screen select congure and scroll to and select central heat conguration. Using the left and right arrow keys scroll to the screen labeled setpoint.

 Supply Header Temperature Sensor

The supply header temperature sensor is to be congured on the master boiler only or a standalone boiler that may require a header sensor for modulation. For further details on a standalone boiler application requiring a header sensor refer to the supply header temperature sensor section of the electrical connections and devices section. To congure a header temperature sensor start at the boiler status screen. Select congure and scroll to and select sensor conguration. The row labeled “*S5 (J8-11) Sensor” needs to be set at 10K NTC single non-safety. See Figure 62.

For a lead/lag boiler plant the header temperature sensor will be referenced for modulation by default. There is no additional conguration for the supply header sensor in a lead lag boiler plant.

The following applies to a standalone boiler utilizing a header temperature sensor for modulation only. Return to the boiler status screen and select congure. From the congure screen scroll to and select central heat conguration. Use the left and right arrow keys to scroll to the screen labeled modulation. The row labeled Modulation Sensor needs to be set at S5 (J8-11)

Questions? Please Contact Your Local Manufacturer’s Representative

3-23

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

Sensor. Refer to Figure 63 for factory default settings:

 P gain: The gain applied for the Proportional portion of the PID equation.

 I gain: The gain applied for the Integral portion of the PID equation.

 D gain: The gain applied for the Derivative portion of the PID equation.

FIGURE 62  SENSOR CONFIGURATION

3-24

FIGURE 63  CENTRAL HEAT CONFIGURATION MODULATION

 Outdoor Air Temperature Sensor

The outdoor reset temperature sensor is to be congured on the master boiler only or a standalone boiler. Starting from the status screen tap congure and then scroll to and select sensor conguration. The outdoor temperature source needs to be assigned to EnviraCOM outdoor sensor. Ensure values are as indicated in Figure 64.

Once the outdoor temperature source has been established the outdoor reset option must be enabled. For a lead/lag boiler plant this must be done through the lead lag master conguration. Return to the conguration screen and scroll to and select lead lag master conguration. Select the box in the bottom right

SECTION 3 EDR-IOM-2019-0212 OPERATION

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton

FIGURE 64  OUTDOOR AIR SENSOR CONFIGURATION

hand corner labeled advanced settings. Using the left and right arrow keys scroll to the screen labeld outdoor reset. Once at the outdoor reset conguration screen select the enable option in the row labeled “enable”. Refer to Figure 65 for factory default settings:

document may substitute for full review of documentation available from the component manufacturer.

FIGURE 65  OUTDOOR RESET CONFIGURATIONS

For a standalone boiler application the outdoor reset must be congured through a dierent screen. To access this screen start from the boiler status screen select conguration and scroll to and select outdoor reset conguration. Follow similar steps as above.

To access the outdoor reset curve select the box labeled show line in the bottom right hand corner of the outdoor reset conguration screen. The factory default curve is displayed in Figure 66. There will be two separate curves. The green curve corresponding to the normal setpoint and the red curve corresponding to the time of day setpoint. Both curves are a liner interpolation between the minimum and maximum outdoor temperatures and the normal and time of day setpoints. The setpoints can be congured through the lead lag master conguration screen for a lead lag boiler plant or through the central heat setpoint screen for a standalone boiler. The low water temperature and the minimum and maximum outdoor temperatures can be congured through the outdoor reset conguration screen displayed in Figure 65.

To enable warm weather shutdown for a lead lag boiler plant start from the boiler status screen and select congure. Scroll to and select lead lag master

Questions? Please Contact Your Local Manufacturer’s Representative

3-25

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

FIGURE 66  OUTDOOR RESET CURVES

FIGURE 67  WARM WEATHER SHUTDOWN CONFIGURATION

conguration. Select the box labeled advanced in the bottom right hand corner. Using the left and right arrow keys scroll to the screen labeled warm weather shutdown. The row labeled enable needs to be set to shutdown after demand ends.

For a standalone boiler application warm weather shutdown must be congured through a dierent screen. This screen can be found by selecting congure from the boiler status screen. Scroll to and select warm weather shutdown conguration and follow similar steps as above.

 Stack Limit

The exhaust stack temperature is displayed on the SOLA status screen. A stack limit setpoint can also be established through the SOLA control. From the conguration screen scroll to and select Stack limit. Enable the stack limit feature. This must be done for each boiler in the boiler plant. Refer to Figure 62 for factory default settings: Stack limit must not exceed exhaust material temperature limitations. See Table 7.

3-26

SECTION 3 EDR-IOM-2019-0212 OPERATION

! WARNING

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

FIGURE 68  STACK LIMIT

 Dedicated Boiler Pump

From the boiler status screen select congure. Scroll to and select pump conguration. Any available pump output, A through C, may be utilized to control the boiler pump. Select the appropriate pump output and assign the pump control to Auto. Check only the box labeled “Use for Lead Lag Master Demands” for a lead/lag boiler plant and only “Use for Local Demands” for a standalone boiler. Refer to Figure 69 for factory default settings:

 Pump Start Delay: The pump will remain o for this set time upon call for

heat.

 Overrun Time: The pump will remain running for this set time after the

boiler no longer has a call for heat.

FIGURE 69  BOILER PUMP CONFIGURATION

From the boiler pump conguration screen select the advanced box in the bottom right hand corner. Check only the boxes shown in Figure 70. Once this has been done the pump conguration has been completed.

Questions? Please Contact Your Local Manufacturer’s Representative

3-27

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

FIGURE 70  ADVANCED PUMP CONFIGURATION

 Motorized Isolation Valve Set Up

Motorized isolation valve conguration is only applicable to lead lag boiler plants utilizing two-position motorized isolation valves. Starting from the status screen tap congure and then select the pump conguration. From the pump congure screen shown in Figure 71 below you will be able to congure the boiler plants motorized isolation valve control. Any one of the available pump outputs A through C can be used to do so. For Endura boilers equipped with an isolation valve control relay, choose the pump output wired to this relay. From this screen select Auto for pump control and either pump A, B, or C for pump output. The “Use for Lead Lag Master Demands” box should be the only box selected out of the three available. Refer to Figure 71 for factory default settings.

 Pump Start Delay: The motorized valve will remain closed for this set time

upon demand.

 Overrun Time: The motorized valve will remain open for this set time after

the boiler no longer has a call for heat.

FIGURE 71  PUMP CONFIGURATION SCREEN

Next tap the advanced box in the bottom right hand corner of the pump conguration screen. You should now see the screen displayed in Figure 72 below. Check the box “X is set” in the Aux pump row. This should be the only

3-28

SECTION 3 EDR-IOM-2019-0212 OPERATION

checked box. These conguration steps must be completed on all boilers on the lead/lag network.

FIGURE 72  ADVANCED PUMP CONFIGURATION SCREEN

 Enabling Burner Fire Rate Output

This signal may be wired to a VFD or ECM (not supplied) dedicated boiler pump to vary ow with ring rate. To enable the burner re rate output, start from the SOLA home screen and select setup, control setup, then Modbus conguration. See Figure 73 for the screen that will be displayed. Set the Register Address to

667. To enable a 4-20 mA output, set the Register Value to 1, or for a 0-10 VDC output set the Register Value to 2.

! WARNING

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

FIGURE 73  ENABLING BURNER FIRE RATE OUTPUT

 System Pump Enable/Disable Signal

The control may be congured to provide an enable/disable signal which can be wired to a system pump control panel (not supplied). This will satisfy a sequence to enable the system pumps when the boiler plant is not in the warm weather shutdown or remote lead/lag disabled state.

Questions? Please Contact Your Local Manufacturer’s Representative

3-29

OPERATION EDR-IOM-2019-0212 SECTION 3

! WARNING

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

Navigate to the master boiler Pump Conguration screen and select the pump output contact where the eld wiring is terminated.

FIGURE 74  SYSTEM PUMP CONTACT CONFIGURATION SCREEN

Tap the “Advanced” button and check only the “Service active*” boxes corresponding to Central Heat and Local Lead Lag. This ensures the contact will remain active even when all boilers have satised the loop temperature and burners are idle.

3-30

FIGURE 75  SYSTEM PUMP SERVICE ACTIVE CONFIGURATION SCREEN

Opening the REMOTE LEAD/LAG ENABLE contacts at any time will disable the boilers as well as the pump contact. If Warm Weather Shutdown is enabled, and the outdoor air temperature reaches the shutdown Setpoint, the boilers and pump contact will be disabled.

The REMOTE BOILER ENABLE contacts on the LCI circuit may be used to enable/ disable individual boilers and will not interfere with this contact.

SECTION 3 EDR-IOM-2019-0212 OPERATION

Perform Test of Low Water Cut Oﬀ

Once the boiler is full of water the following test can be accomplished:

1. Turn the boiler on, this will start the Call for Heat sequence.

2. Press and hold the Low Water Test button for 3 seconds. The Low Water light should illuminate and the boiler should shut down the Call for Heat sequence.

3. Reset the Low Water condition by pressing the Low Water reset button and reset the Sola control. Boiler should start the Call for Heat sequence again.

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

Perform Test of Limit Controls

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

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

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

Perform Test of Low Gas Pressure Switch

Test the low gas pressure switch as follows:

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

2. Reset the switch to normal level, re-start the boiler.

Perform Test of High Gas Pressure Switch

Test the high gas pressure switch as follows:

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

2. Reset the switch to normal level, re-start the boiler.

General Operation of the Boiler

Excessive cycling will reduce the useful life of any piece of mechanical equipment. Endura boilers should be operated and controlled so the boiler cycles less than 12,000 times per year. Endura boilers should be operated and controlled so that the temperature dierential across the boiler does not exceed 100°F (38°C).

Questions? Please Contact Your Local Manufacturer’s Representative

3-31

PAGE INTENTIONALLY LEFT BLANK

MAINTENANCE

INTRODUCTION

INSTALLATION

OPERATION

MAINTENANCE

Questions? Please Contact Your Local Manufacturer’s Representative

4-1

MAINTENANCE EDR-IOM-2019-0212 SECTION 4

! WARNING

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

Follow all proper lockout/tagout procedures for service.

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

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

General

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

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

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

and/or insulation used in system piping.

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

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

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

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

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

boilers, or in the boiler room.

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

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

Daily Inspection Schedule

Daily inspection must include the following:

1. Observe operating temperature and general conditions.

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

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Heating Solutions Representative.

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

4-2

2. Make sure that the ow of combustion and ventilating air to the boiler is not obstructed.

3. Make sure the boiler area is free and clear of any combustible materials, including ammable vapors and liquids.

Weekly Maintenance Schedule

Weekly maintenance must include the following:

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

Monthly Maintenance Schedule

Monthly maintenance must include the following:

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

SECTION 4 EDR-IOM-2019-0212 MAINTENANCE

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

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

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

5. Inspect the combustion air inlet lter. If dust, lint or debris has accumulated, replace the lter.

Procedure for Inspecting the Air Inlet Filter

Proceed as follows:

1. Remove the lter. The lter sits in the slot above the cabinet.

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

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

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

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

! WARNING

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

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

4 CAUTION

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

Annual Maintenance Schedule

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

factory trained technician:

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

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

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

 Check all joints and pipe connections for tightness.

 Check piping for corrosion or deterioration.

 Check that the piping is clear of debris.

 Check that the condensate drain system is functioning.

4. Inspect the hydronic heating system for other problems.

5. Leak test and inspect the lter of the gas valve. See Replacing Gas Valve Internal Filter section of this manual.

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

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

7. Clean the venturi with a clean cloth to remove dust build up.

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

Questions? Please Contact Your Local Manufacturer’s Representative

4-3

MAINTENANCE EDR-IOM-2019-0212 SECTION 4

! WARNING

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

4 CAUTION

9. Check the cabinet for leaks that would allow unltered combustion air to enter the cabinet. Any leaks should be taped or caulked. Damaged gaskets must be replaced.

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

11. Perform combustion analysis and adjust if necessary. A low O level can indicate a need for burner service.

Replacing Gas Valve Internal Filter

NOTE: The lter must be inspected annually. More frequent inspections will be

required for gas delivery systems containing small debris.

If the pressure dierential across the pressure taps shown in Figure 75 exceeds 4” W.C., the lter must be replaced.

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

Burner gaskets must not be reused. Gasket is designed for one-time use only.

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

Follow proper safety precautions when using a ladder.

FIGURE 75  MAIN GAS VALVE FILTER

4-4

SECTION 4 EDR-IOM-2019-0212 MAINTENANCE

Refer to Figure 75, Table 10, and the following steps for replacing the lter:

TABLE 10  GAS VALVE FILTER PART NUMBERS

Endura Model EDR-750/1000 EDR-1500/2000 Filter Assembly 2-30-005164 2-30-005165

1. Close the upstream gas valve to interrupt the gas supply.

2. Removes screws 1 and 2.

3. Replace lter insert 3.

4. Replace screws 1 and 2 and verify torque to 22 inch-lbs.

5. Perform a complete leak and function test, reference the gas valve manual for the test procedure.

Removing and Cleaning Burner Assembly

Disassemble, inspect, and clean as follows:

1. Remove power and turn o gas supply.

3. Remove wires from ignition assembly.

4. Remove ignition assembly.

5. Remove UV Scanner.

6. Remove the (4) bolts between the fan transition and the premix elbow. Do not removed the fan transition from the blower discharge.

7. Remove the (8) bolts and washers on burner ange.

NOTE: Due to unique hardware specications, alternate

hardware must not be substituted. If hardware is lost or damaged, contact your Fulton representative for replacement.

8. Remove premix elbow.

9. Remove burner ange top gasket.

10. Remove burner by pulling up, making sure not to scrape the sides of the burner. Place burner aside, ange side down.

NOTE: Do not use liquids or brushes when cleaning the

burner.

2. With the door open, place a ladder in front of the unit.

NOTE: The top of the electrical panel is not a step; it should

not be used to support a person’s weight.

GAP BETWEEN ELECTRODE AND MESH BURNER

MESH BURNER

1/16( "-1/8")

(0.0625"-0.125")

11. Vacuum any visible debris inside the burner. Compressed air may also be used, in moderation, to clean the pores of the woven material. Use the following guidelines:

GAP BETWEEN THE ELECTRODES

NEGATIVE

ELECTRODE

POSITIVE ELECTRODE

1/8(3/32"- ")

(0.1" - 0.125")

FIGURE 76  IGNITOR GAP TOLERANCES

Questions? Please Contact Your Local Manufacturer’s Representative

4-5

MAINTENANCE EDR-IOM-2019-0212 SECTION 4

 Dislodge any particulate matter from the burner

surface matrix, keeping the air nozzle about 2” from the burner’s surface and blowing straight down the surface. Gently move the nozzle back and forth length-wise above the surface. Avoid blowing air tangentially across the surface as this may cause damage to burner surface. Allow particulate matter to fall from the burner through the air/gas inlet. A vacuum may be used at the air/gas

inlet to assist in removing particulate matter.

12. If any burner damage is detected, contact your Fulton Representative.

Reassemble as follows:

1. Reassemble in reverse order.

2. Replace with a new O-ring and apply Superolube lubricant (Fulton Part number 2-12-000661). Ensure O-ring is positioned properly between premix elbow

and fan transition.

 O-ring for EDR-750/1000 is Fulton Part Number

2-12-000236

 O-Ring for EDR-1500/2000 is Fulton Part Number

2-12-000235

Veriﬁcation of Ignition Gap

NOTE: Fulton recommends annual replacement of the

ignition electrode assembly: EDR-750/1000 part number 5-20-071003 (all burners). EDR-1500/2000 part number 5-20072000 (metal woven mesh burners only).

1. Remove ignition electrode assembly (ignitor). Visually check that the insulators are clean.

2. For re-installation or installation of a new ignitor, verify with calibrated calipers that there is a gap between electrodes greater than 0.100” (2.54 mm) and less than

0.125” (3.175 mm). See Figure 76.

3. Install the ignitor on the burner ange: Apply anti-seize compound to ignitor screws and tighten in place using a torque-rated screwdriver to 8 inch-pounds. Use only a new gasket assembly, Fulton Part Number 2-12-001261.

4. Remove the sight glass, ame scanner, and heat block. Position a light to shine into the combustion chamber through the sight glass as required.

3. Replace upper and lower burner ange gaskets.

 Burner gasket for EDR-750/1000 is 2 each, Fulton Part

Number 2-12-001270

 Burner gasket for EDR-1500/2000 is 2 each, Fulton Part

Number 2-12-001260

4. Apply belleville washers so that they crown in middle; do not use nuts or washers that are not provided by Fulton.

5. Apply anti-seize to burner ange studs and torque to 23 ft-lbs.

6. Torque nuts under the premix elbow to 19 ft-lbs. using a torque adaptor at 90 degrees from the wrench handle.

7. Reinstall ignitor or new ignitor. See verication of ignition gap for instructions.

8. Ensure door and all latches are closed when complete. The louvers in the door provide cooling air to the electrical panel. The door must be completely closed to prevent unltered air leaking into the cabinet.

5. Verify the burner head to ignitor gap with the use of a borescope. For borescopes equipped with a mirror, insert the end straight down into the combustion chamber at least 6” (152 mm) to view the ignitor from the side and bottom. For borescopes not equipped with a mirror, bend and angle the camera to obtain a necessary view.

6. Visually verify the ignition position relative to the burner head.

 The negative electrode must not be touching or

resting on the burner head.

 The two electrodes must not be touching. See

Figure 76.

 The burner to ignition gap tolerance is 0.0625”

(1.588 mm) to 0.125” (3.175 mm), it should appear visually similar to the electrode gap. See Figure 76.

7. Remove the borescope and reinstall the heat block, ame scanner, and sight glass. Apply new thread sealant to all applicable connections.

4-6

SECTION 4 EDR-IOM-2019-0212 MAINTENANCE

After All Repairs and Maintenance

1. Perform all Safety Checks as described in the Operation section.

2. Fire the boiler and perform a full combustion verication. Make adjustments as necesary.

3. Complete the “Installation and Operation Report” for Endura boilers and retain in the boiler’s maintenance records.

NOTE: Accurate and complete combustion and maintenance

records detailing compliance with the Installation, Operation and Maintenance manual must be produced for warranty consideration.

Questions? Please Contact Your Local Manufacturer’s Representative

4-7

MAINTENANCE EDR-IOM-2019-0212 SECTION 4

PART NUMBERITEM

2-12-000012

2-20-0000233

2-20-000137

2-22-000048

2-22-000156

2-22-000353

2-22-000388

2-35-000085

2-35-00026012

2-40-000976

2-40-071000

2-45-00099920

2-45-00102721

5-11-00001822

3/8" BELLEVILLE WASHER (INCONEL 718,.385" ID X 1.25" OD X .125" THK, .021" DISH)

18" LONG HIGH VOLTAGE IGNITION CABLE WITH 1/4" FEMALE CONNECTIONS

BILL OF MATERIAL

3/4" NPT SIGHT OBSERVATION PORT

3" WATER LEVEL PROBE

ENDURA DIRECT SPARK IGNITION ASSEMBLY2-20-000135

ENDURA IGNITER BRIDGE

1/4" STAR WASHER

3/8-16 NiCu400 HEX NUT (MONEL400)

10-32 X 25mm BOLT, 18.8 STAINLESS2-22-000389

1/2" X CL" - NPT SCH 40 NIPPLE

3/4" X 1/2" 150# BUSHING

HONEYWELL MINI PEEPER2-40-00016113

THERMISTOR TEMP. SENSOR DUAL ELEMENT2-40-000332

TRANSFORMER 120V 50 / 60 Hz 15.6KVPK SECONDARY 28 MA

ENDURA 750K / 1000K WORGAS MESH BURNER

FEMALE NYLON EXPANDED INSULATED CONNECTOR, 16-14 AWG2-45-000423

MOLEX CONNECTOR - 4 CIRCUITS - DUAL ROW MINI FIT2-45-00051419

16 AWG WIRE

HONEYWELL HEAT BLOCK ( 136733 )

U.O.M.QTYDESCRIPTION

EA.

2ENDURA 1000K BURNER GASKET, GRAFTECH GRAFOIL GTB2-12-0012702

EA.

210-32 FLANGE STOP NUT - NYLON INSERT - STAINLESS

EA.

9FEMALE NYLON EXPANDED INSULATED SPLICE2-45-000093

EA.

FT.

EA.

4-8

FIGURE 77  EDR 750/1000 BURNER ASSEMBLY

SECTION 4 EDR-IOM-2019-0212 MAINTENANCE

PART NUMBERITEM

2-10-071520

2-12-0000122

2-12-0012603

2-20-000023

2-20-000137

2-22-000048

2-22-000156

2-22-0003538

2-22-000390

2-35-00026012

2-35-00092913

2-40-000976

2-45-00099919

5-11-00001820

10 3/16" OD X 5 3/4" ID BURNER FLANGE WITH UV SCANNER, SIGHT GLASS AND IGNITION OPENING; 5/16" HRS PLATE SA-516 GR.70

ENDURA 1500K / 2000K BURNER GASKET, GRAFTECH GRAFOIL GTB

3/8" BELLEVILLE WASHER (INCONEL 718,.385" ID X 1.25" OD X .125" THK, .021" DISH)

18" LONG HIGH VOLTAGE IGNITION CABLE WITH 1/4" FEMALE CONNECTORS

BILL OF MATERIAL

DESCRIPTION

3/4" NPT SIGHT OBSERVATION PORT

3" WATER LEVEL PROBE

ENDURA IGNITER BRIDGE

1/4" STAR WASHER

3/8-16 NiCu400 HEX NUT (MONEL400)

10-32 FLANGE STOP NUT - NYLON INSERT - STAINLESS2-22-0003889

10-32 X 25mm BOLT, 18.8 STAINLESS2-22-000389

10-32 X 3/8" LONG S.S. TORX SCREW (96710A576)

3/4" X 1/2" 150# BUSHING

3/4" ASTM A865 MERCHANT HALF COUPLING

HONEYWELL MINI PEEPER2-40-000161

THERMISTOR TEMP. SENSOR DUAL ELEMENT2-40-000332

TRANSFORMER 120V 50 / 60 Hz 15.6KVPK SECONDARY 28 MA

ENDURA 2000K WORGAS MESH BURNER2-40-072000

MOLEX CONNECTOR - 4 CIRCUITS - DUAL ROW MINI FIT2-45-00051418

16 AWG WIRE

U.O.M.

QTY

EA.

FT.

EA.

FIGURE 78  EDR1500/2000 BURNER ASSEMBLY

Questions? Please Contact Your Local Manufacturer’s Representative

4-9

MAINTENANCE EDR-IOM-2019-0212 SECTION 4

Troubleshooting

Use the following table as a guide to troubleshooting your boiler.

PROBLEM CAUSE CHECK

No Power / Control does not illuminate

Boiler in Standby / No Call for Heat

Power / Wiring/ Connections

Controller / Settings 1. Clear and Satisfy any Lockouts or Holds

1. Verify Incoming 120VAC power.

2. Verify Control Fuse in Boiler Panel.

3. Verify 120VAC Input to 24VAC Transformer and corresponding terminal blocks.

4. Verify 24AC Output from transformer ( 20- 28VAC) and corresponding terminal blocks.

5. Verify 24VAC at SOLA base (pins J8-1, J8-2) and corresponding terminal blocks.

6. Verify 24VAC at SOLA display (pins 7, 8) and corresponding terminal blocks.

1. Verify LCI circuit input at SOLA base including switch position, Auxiliary Interlocks, and BMS Enable/Disable contact closure (pin J6-3).

2. Verify ILK circuit input at SOLA base including Limit String and Auxiliary Safeties (pin J5-1).

3. Verify STAT circuit input at SOLA base including switch position, and BMS Enable/Disable contact closure (pin J8-3).

If boiler is in Central Heat (Standalone) mode:

1. Verify Central Heat mode is enabled (Conguration Menu >> CH - Central Heat Conguration >> CH Enable under Central Heat Heading)

2. Verify Setpoint and Hysteresis settings (Conguration Menu >> CH - Central Heat Conguration >> Setpoint Heading)

3. Verify that the Warm Weather Shutdown is not active (Conguration Menu >> Warm Weather Shutdown Conguration)

If boiler is in Lead / Lag (Multiple Boiler Sequencing) mode:

1. Verify Staging Method at Master boiler (Conguration Menu >> Lead Lag Master Conguration >> Advanced Settings >> Method 1 under Add Stage Heading)

2. Allow time for Detection and Interstage Delay Times to expire at Master boiler (Conguration Menu >> Lead Lag Master Conguration >> Advanced Settings >> Add Stage Heading)

3. Verify Setpoint and Hysteresis settings (Conguration Menu >> Lead Lag Master Conguration >> Advanced Settings >> Add Stage Heading)

4. Verify that the Warm Weather Shutdown is not active (Conguration Menu >> Lead Lag Master Conguration >> Advanced Settings >> Warm Weather Shutdown Heading)

LCI OFF - Lockout or Hold 63Power / Wiring /

ILK OFF - Lockout or Hold 67Power / Wiring /

Fan speed not proved Lockout or Hold 62

Light o rate proving failed

- Lockout or Hold 122

Purge rate proving failed -

Lockout or Hold 123

Connections

Controller / Sengs Check the Alarm History to determine what triggered the fault Details >> History >> Lockouts

Power / Wiring /

Connecons

Boiler / Maintenance Items

4-10

Verify LCI circuit input at SOLA base including switch posion, Auxiliary Interlocks, and BMS

Enable/Disable contact closure (pin J6-3)

Verify ILK circuit input at SOLA base including Limit String and Auxiliary Safees (pin J5-1)

>> Select the desired lockout to see the ‘First out’

** A Yellow Hold is not an issue unless the fan speed does not reach the required rate and locks out.

1. Verify Incoming 120VAC power

2. Conrm that the Blower is running

3. Conrm the Fuse for the Blower.

4. Conrm the wiring harness and connecon for 120VAC power.

5. Conrm the wiring harness and connecons between the blower and SOLA base (J2 plug).

1. Pull and Clean the Burner with compressed air (requires burner gaskets)

2. Check for blockages or obstrucons in the Air Intake or Exhaust venng.

3. Verify that the 3-posion damper is opening AND closing to the appropriate posions.

SECTION 4 EDR-IOM-2019-0212 MAINTENANCE

PROBLEM CAUSE CHECK

Flame lost early in run Lockout 107

Ignition failed - Lockout 109

Power / Wiring/ Connections

Controller / Settings Increase light o RPM rate (Congure Menu >> Burner Control Timings and

Boiler / Maintenance Items 1. Verify that the Dungs gas lter is clean (blue). See page 4-4 in the Manual

1. Verify the transformer ground; the connection point should be to bare metal and free of paint or powder coat with an appropriately sized star washer installed.

2. Conrm the wiring harness and connections for 120VAC power and between the blower and SOLA base.

Rates) without exceeding approved ranges.

2. Verify that the 3-Position Damper is ‘closed’ perpendicular to the air intake pipe when the unit is o, and adjusts to the appropriate 25-30 degree range during light o.

3. Conrm that the correct ignitor for the burner is installed with the bridge, proper oset, and proper gaping. See page 4-5 in the Manual.

4. Verify that the ignition transformer has power and the Ignitor is sparking.

5. Verify Gas pressure (Incoming to the Dungs lockup regulator >4”WC at high re, Incoming to Dungs MBC gas valve >3”WC at high re)

6. Verify that solenoid on the enrichment gas train is actuated during light o and an appropriate amount of gas pressure is seen (1.0 to 3.5”WC)

Flame lost in run - Lockout 108

Waiting for Safety Data Verication - Lockout 2

Flame detected out of sequence - Lockout 105

7. Verify Venting Pressures and Congurations. See page 2-21 in the manual for acceptable ranges and installation.

8. Increase the MBC Dungs Valve Oset up to 1 full turn positive.

9. Pull the burner. Inspect for dirt/dust that could cause it to clog and any other physical issue.

Boiler / Maintenance Items 1. Verify Gas pressure (Incoming to the Dungs lockup regulator >4”WC at high

re, Incoming to Dungs MBC gas valve >3”WC at high re)

2. Verify Combustion at low and High Fire. See Tables 9 and 10 on page 3-7 of the manual for acceptable ranges.

3. Verify Venting Pressures and Congurations. See page 2-21 in the manual for acceptable ranges and installation.

4. Pull the burner. Inspect for dirt/dust that could cause it to clog and any other physical issue.

Controller / Settings ** Safety Data or Settings have changed and require verication

From the Conguration Menu Select ‘Verication’ in the bottom right corner. Press Begin (Login Required) and follow the prompts. Final step will be to press/hold the reset button on the SOLA base for 2-3 seconds.

Boiler / Maintenance Items 1. Verify wiring and connection between SOLA base, UV Scanner, and

associated terminal blocks.

2. Cover or block the sight glass to prevent light from the room from being picked up by the sensor.

Questions? Please Contact Your Local Manufacturer’s Representative

3. Remove and visually inspect the UV sensor, When looking at the eye sensor should not blink or light up. Note that overhead lights etc.… will trigger the sensor.

4. Swap sensors with a known good unit to see if the issue follows, or replace with new sensor.

4-11

No part of this Installation, Operation, and Maintenance manual

may be reproduced in any form or by any means without

permission in writing from Fulton Group N.A., Inc.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of Fulton Group N.A., Inc., a global manufacturer of steam,

hot water and thermal uid heat transfer systems.

Fulton Heating Solutions

6288 Running Ridge Road, Syracuse, NY 13212 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

EDR-IOM-2019-0212

FULTON Endura EDR-750, Endura EDR-1000, Endura EDR-1500, Endura EDR-2000 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual