INSTALLATION AND OPERATION MANUAL Endura (EDR) Condensing Hydronic Boilers 1,000,000 - 2,000,000 BTU/HR Serial/ National Board Number Model Fulton Order Sold To Job Name Date EDR-IOM-2014-0318
TABLE OF CONTENTS EDR-IOM-2014-0318 Introduction 1-1 Overview .............................................................................................................. 1-2 Warnings & Cautions............................................................................................ 1-2 Disclaimers and Local Codes ................................................................................ 1-2 SYSTEM DESIGN AND BOILER OPERATION ..................................................................
TABLE OF CONTENTS 0-2 EDR-IOM-2014-0318 © The Fulton Companies 2014
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative 1 2 3 4 5 1-1
INTRODUCTION EDR-IOM-2014-0318 SECTION 1 Overview Warnings & Cautions Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers: 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. Material inspections WARNINGS must be observed to prevent serious injury or death to personnel.
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative 1 2 3 4 5 2-1
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. 4 CAUTION This boiler is certified for indoor installation only. This boiler may not be field retrofitted. This boiler is not designed for use in systems where water is continuously replenished. The warranty is valid for closed loop systems only.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 Placement & Rigging Proper placement of your Fulton product is essential. Attention paid to the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble-free installation, operation, and maintenance. Adhere to the following for placement and rigging: 1. Check building specifications for permissible floor loading. Use Table 1 for unit reference. 2.
INSTALLATION SECTION 2 EDR-IOM-2014-0318 TABLE 1 - BOILER DIMENSIONS AND OPERATING REQUIREMENTS 1000 1500 2000 MODEL EDR 1.0 293 1.5 411 2.0 549 A. Boiler Width 1000 28.32 1500 42.5 2000 56.7 28.4 239,396 41.9 353,424 56 472,240 10 20 Gal Liters 50 189 LBS KG LBS KG MODEL EDR Input Million BTU/Hr kW Fuel Cons. @ rated cap. (Nat. Gas) FT3/Hr M3/Hr Output at AHRI Test Condition BHP KCal/h Electrical Req.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 (Figure 1). This will allow access around the equipment to facilitate maintenance and a safe work environment. An 1 inch (25.4 mm) side clearance is acceptable between any number of boilers. Custom configurations may not allow 1 inch (25.4 mm) side clearance. Although a 1 inch (25.4 mm) side clearance is permitted, allowing 24 inches (610 mm) will facilitate and expedite maintenance and any advanced troubleshooting.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. The discharge from the safety relief valve must be arranged to ensure no danger of scalding personnel, or equipment damage. Provisions must be made to properly pipe the safety relief discharge away from the boiler to the point of discharge.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 6. Install filtration to remove particulates if appropriate. A #10 mesh size is suggested. 7. Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate. 8. Install corrosion coupon holder to assess corrosion inhibitor performance if appropriate. 9. Before installing a Endura boiler into a hydronic loop, be sure that the system piping and any other components of the system are clean and free of debris and any foreign matter.
INSTALLATION EDR-IOM-2014-0318 SECTION 2 AIR SEPARATOR MAKE UP WATER SYSTEM SUPPLY WATER MOTORIZED ISOLATION VALVE (OPTIONAL) SYSTEM PUMPS AND VALVES AS DETERMINED APPROPRIATE BY OTHERS EXPANSION TANK AIR SEPARATOR AND EXPANSION TANK AS DETERMINED APPROPRIATE BY OTHERS SYSTEM RETURN WATER FIGURE 3 - SAMPLE PIPING LAYOUT Note: Sample piping layout (P&ID) is a general representation of system installation.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 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.
INSTALLATION ! EDR-IOM-2014-0318 (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.). 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. SECTION 2 5.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 For every ten feet of pipe run, increase the pipe size one diameter. Protect the vent termination from water, dust and insects. Install Condensate Drain A condensate drain kit is intended for use with the Fulton Endura boiler.
INSTALLATION EDR-IOM-2014-0318 SECTION 2 FIGURE 4 - CONDENSATE DRAIN PIPING FOR ENDURA BOILERS Detail A Condensate Drain Kit REAR VIEW Figure 4 Notes: 0.25” (U.S.) TAPPING PROVIDED FOR WATER CONNECTION TO MAINTAIN WATER SEAL Header must be level or slightly pitched toward the drain. Header material to be galvanized steel or 316L stainless. Header should be taken to the lowest point possible and maintain a minimum 5.5 inch (14.2 cm) drop from 1.5 inch (38.1 mm) condensate drain kit/trap outlet.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 TABLE 3 - NOMINAL PIPE SIZE Nominal Pipe Size ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. Pressure drop of 0.5”wc/Equivalent length of pipe (feet) Inch (mm) Inch (mm) 90 Elb Feet (meter) Tee Feet (meter) 20 40 60 80 100 150 200 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.
INSTALLATION SECTION 2 EDR-IOM-2014-0318 30 3/8 [771] 3 13/16 [97] (TYP.) 12 1/2 [318] TOP VIEW 1 3 10 3/4 [273] 11 1/4 [286] 4 3 2 1" NPT CONNECTION TO BOILER 1 1/2" PLASTIC FITTING CONNECTION TO DRAIN ISOMETRIC VIEW 1. Neutralizer Kit with Magnesium Oxide 2. Condensate Drain Kit Assembly 3. 1 1/2” by 3” NPT Stainless or Galvanized Nipple 4.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 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.
INSTALLATION EDR-IOM-2014-0318 SECTION 2 to turn around) 13. In Canada, for recommended practice, refer to CSAB1. Never direct flue stacks in a downward direction. Combustion Air Supply From the Boiler Room TABLE 4 - GENERAL VENTING REQUIREMENTS Endura Model Number EDR-1000 EDR-1500 EDR-2000 Maximum Negative Draft -0.04”W.C. -0.04 “ W.C. -0.04 “ W.C. Maximum Positive Draft +1.50 “ W.C. +1.50 “ W.C. +1.50 “ W.C. 7.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 air inlet of the boiler. 2. The air intake must be piped out of the building if the boiler room contains contaminated air. 3. Air Intake pipes and fittings shall be Schedule 40 PVC pipe or galvanized steel. All Schedule 40 PVC pipe, fittings, 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. 4.
INSTALLATION ! WARNING Do not terminate venting into an enclosed area. Never use open flame 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. EDR-IOM-2014-0318 SECTION 2 Venting Material* Max.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 traveling back through idle boilers (flue gas recirculation, FGR). Looking at the condition of all boilers on at high fire condition will facilitate the selection of the diameter of the stack that is appropriate; however there is still a risk of FGR that needs to be managed. Options to consider for this management include the following: Mechanical draft assist systems (exhaust fans).
INSTALLATION ! EDR-IOM-2014-0318 SECTION 2 WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations. Wall Thimble Installation Adhere to the following for installation (see Figure 7): 1. The thimble is inserted through the wall from the outside. 2.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 FIGURE 8 - ROOF PENETRATION DETAILS 4FT 3 IN ( 130 CM ) MIN 4FT / 122 CM ABOVE AIR INTAKE PIPING NOTE: AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS. SCREENED INLET EXHAUST STACK IS DOWNWIND OF AIR INTAKE OPENING IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN. ) ABOVE THIS NORMALLY EXPECTED LEVEL.
INSTALLATION SECTION 2 EDR-IOM-2014-0318 FIGURE 9 - WALL PENETRATION DETAILS MIN. / MAX. WALL THICKNESS ( 3 1/4 IN. - 20 IN. ) ( 8.255 CM - 50.
SECTION 2 EDR-IOM-2014-0318 Horizontal Vent Termination Adhere to the following for installation: NOTE: The vent termination is joined to the vent pipe outside the wall. Use the same joining procedures for vent pipe and fittings. ! INSTALLATION 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. 1.
INSTALLATION ! 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.
SECTION 2 INSTALLATION EDR-IOM-2014-0318 voltage wiring. Do not run Building Management System (BMS) wiring into the same box as the power. 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.
INSTALLATION EDR-IOM-2014-0318 SECTION 2 6 5 33 38, 44, 45 EXAMPLE ELECTRICAL SCHEMATIC DIAGRAM 2-26 © The Fulton Companies 2014
SECTION 2 1 3 2 7 INSTALLATION EDR-IOM-2014-0318 NOTES: 1. ( ) DENOTES FIELD WIRING BY OTHERS.. 2. TERMINAL BLOCK(S) LOCATED IN CUSTOMER CONNECTION JUNCTION BOX. 3. PB1 AND PB2 ARE COMBINATION PILOT LIGHT - PUSH BUTTON ASSEMBLIES. 4. LOW WATER TEST; PRESS AND HOLD PB2 FOR 3 SECONDS. MOMENTARILY PRESS PB2 TO RESET, OR WAIT 30 SECONDS FOR AUTO RESET. 5. ( ) INDICATES COMPONENTS INSTALLED IN PANEL BOX. 6. REMOVE FACTORY INSTALLED JUMPER FOR E-STOP CONNECTION. 7.
INSTALLATION 2-28 EDR-IOM-2014-0318 SECTION 2 © The Fulton Companies 2014
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative 1 2 3 4 5 3-1
OPERATION ! 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 fire 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.
SECTION 3 OPERATION EDR-IOM-2014-0318 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 (fill) valve set pressure. No more water should be entering the system. Close the shutoff valve on the cold-water fill line. 7. Visually inspect all pipe joints and equipment connections for leaks.
OPERATION ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer. 4 EDR-IOM-2014-0318 SECTION 3 NOTE: Perform the following steps for field commissioning with the Dungs Gas Valve (Figure 10). NOTE: A combustion analyzer will be required when making changes to the Dungs valve settings. 1.
SECTION 3 OPERATION EDR-IOM-2014-0318 ! SOLA “manual firing rate” screen (Figure 14). 10. Connect an inches of water column measuring device (i.e., manometer) to the Enrichment gas valve test port (Figure 10). Insert combustion analyzer probe into the flue gas outlet port. 11. Open the front access door and locate the Enrichment test button located at the top of the electrical box.
OPERATION ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer. This boiler is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand. EDR-IOM-2014-0318 SECTION 3 13. Once combustion is checked and verified with a combustion analyzer place the control back into automatic mode and check all boiler safeties.
SECTION 3 OPERATION EDR-IOM-2014-0318 SOLA Hydronic Controller for Endura The screen shots and information in this section will help you navigate through display parameters that would be used for initial startup. ! 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.
OPERATION ! 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. Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION EDR-IOM-2014-0318 Central Heat Operation - Setpoint Screen In this screen (Figure 15) the Setpoint can be changed. Press the up and down arrow or press Clear and enter the desired Setpoint. Then press OK. ! 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.
OPERATION ! 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. EDR-IOM-2014-0318 SECTION 3 the previous Setpoint screen to the Modulation Screen (Figure 17). This screen provides access to the PID (Proportional, Integral and Derivative) of the control. The sola password is also required to change these parameters.
SECTION 3 OPERATION EDR-IOM-2014-0318 ! 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. 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 19 - VERIFICATION PROCEDURE 2.
OPERATION ! EDR-IOM-2014-0318 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION EDR-IOM-2014-0318 4 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
OPERATION 4 EDR-IOM-2014-0318 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION EDR-IOM-2014-0318 4 SOLA Diagnostics From the Status Summary screen (Figure 28), press Diagnostics. 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.
OPERATION ! EDR-IOM-2014-0318 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 qualified 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.
SECTION 3 OPERATION EDR-IOM-2014-0318 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 off temperature to normal level, typically 10-20 degrees above set point.
OPERATION 3-18 EDR-IOM-2014-0318 SECTION 3 © The Fulton Companies 2014
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative 1 2 3 4 5 4-1
MAINTENANCE ! 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. 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.
SECTION 4 MAINTENANCE EDR-IOM-2014-0318 2. Test operating temperature control by reducing temperature setting as necessary to check burner operation. 3. Check flue 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. 5.
MAINTENANCE ! WARNING Personnel performing burner assembly maintenance must wear appropriate respiratory protection. Failure to do so may result in the inhalation of refractory ceramic fibers. 4 CAUTION 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. EDR-IOM-2014-0318 SECTION 4 accessed via the top removable panel. 7.
SECTION 4 EDR-IOM-2014-0318 MAINTENANCE 13. Reassemble in reverse order. Apply anti-seize to ignitor screws prior to reassembly. Be sure to use new gaskets for reassembly. 14. Ensure o-ring is positioned properly between premix elbow and burner transition. Clean and apply o-ring lubricant, as necessary. 15. Apply belleville washers so that they crown in middle; do not use nuts or washers that are not provided by Fulton. 16. Apply anti-seize to burner flange studs and retorque to 23 ft-lbs. 17.
MAINTENANCE EDR-IOM-2014-0318 SECTION 4 PROBLEM CAUSE CHECK Control does not illuminate 24 VAC Power Supply Check fuse or circuit breaker. Reset or replace as necessary. Fan will not start High temperature is tripped 1. Check sensor wiring connector. 2. Check resistance. 3. Replace sensor if faulty. Low gas is tripped 1. Reset switch, making sure to listen for audible click. 2. Replace switch if setting is below actual pressure. High gas is tripped 1.
SECTION 4 MAINTENANCE EDR-IOM-2014-0318 PROBLEM CAUSE CHECK Main flame fails Ignition issue 1. Visually verify spark. 2. Replace igniter or transformer, as needed. Gas valve not set properly Verify the last elbow gas pressure matches the start up report. Enrichment issue Verify the pressure of the regulator matches the report. Flame detector failure 1. Visually verify the flame through the sight glass. 2. Remove flame detector and visually verify the flame through the scanner tube. 3.
MAINTENANCE 4-8 EDR-IOM-2014-0318 SECTION 4 © The Fulton Companies 2014
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative 1 2 3 4 5 5-1
WARRANTY & PARTS 5-2 EDR-IOM-2014-0318 SECTION 5 © The Fulton Companies 2014
SECTION 5 EDR-IOM-2014-0318 WARRANTY & PARTS Standard Warranty for Fulton Endura Hydronic Boilers TEN 10 YEAR THERMAL SHOCK WARRANTY The Endura pressure vessel is warranted against failure due to thermal shock for ten (10) years, provided the boiler is installed, controlled, operated and maintained in accordance with the Installation, Operation and Maintenance Manual. This warranty does not cover damage due to corrosion, scaling, sooting and/or improper installation, operation and maintenance.
PAGE INTENTIONALLY LEFT BLANK
SECTION 5 EDR-IOM-2014-0318 Parts Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial/National Board number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherence with warranty requirements. Contact Fulton Companies at (315) 298-5121 for further information.
WARRANTY & PARTS 5-6 EDR-IOM-2014-0318 SECTION 5 © The Fulton Companies 2014
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.
