FULTON EDR-1000 Installation And Operation Manual
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FULTON EDR-1000 Installation And Operation Manual

Endura series (edr) condensing hydronic boilers 1,000,000 - 2,000,000 btu/hr
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INSTALLATION AND

OPERATION MANUAL

Endura (EDR)
Condensing Hydronic Boilers
1,000,000 - 2,000,000 BTU/HR
Serial/ National
Board Number
Model
Fulton Order
Sold To
Job Name
Date
EDR-IOM-2014-0318

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Summary of Contents for FULTON EDR-1000

  • Page 1: Operation Manual

    INSTALLATION AND OPERATION MANUAL Endura (EDR) Condensing Hydronic Boilers 1,000,000 - 2,000,000 BTU/HR Serial/ National Board Number Model Fulton Order Sold To Job Name Date EDR-IOM-2014-0318...

  • Page 3: Table Of Contents

    HORIZONTAL VENT TERMINATION ....................2-23 Warranty & Parts Removing an Existing Boiler ................2-23 Electrical Connections ..................2-24 Standard Warranty for Fulton Endura Hydronic Boilers ........5-3 Assembly of Fulton Multi-Skid Systems............. 2-25 Parts ........................5-5 Operation Perform Pre-Start-Up Inspection ................. 3-2 Fill and Purge the System..................
  • Page 4 TABLE OF CONTENTS EDR-IOM-2014-0318 © The Fulton Companies 2014...

  • Page 5: Introduction

    INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 6: Overview

    Code ANSI Z223.1/NFPA 54 latest edition, and the specifi c should it replace existing codes or standards which may be instructions in this manual. Authorities having jurisdiction applicable. Fulton reserves the right to change any part of should be consulted prior to installation. this installation, operation and maintenance manual.

  • Page 7: Installation

    INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 8: Product Overview

    The Fulton Endura hot water boiler is an automatic, fuel-fi red, ultra high- jurisdictional/professional codes and effi ciency boiler. The boiler can either be of the sealed combustion/direct vent regulations.

  • Page 9: Placement & Rigging

    Placement & Rigging WARNING All information in this manual is for Proper placement of your Fulton product is essential. Attention paid to reference and guidance purposes, the following points will save a great deal of diffi culty in the future. Correct...
  • Page 10 *Standard confi gurations. Alternate voltages may be available as an option; please consult factory. Note: All dimensions are approximate and are subject to change without notice. TOP VIEW FRONT VIEW RIGHT SIDE VIEW BACK VIEW FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER © The Fulton Companies 2014...

  • Page 11: Install Boiler Trim

    Trim Pressure Inlet Size Outlet Size maintenance and any advanced troubleshooting. PSI (kPa) inch (mm) inch (mm) EDR-1000 30 (206.84) 3/4 (19.05) 1 (25.4)  NOTE: Side panels are latched; however, maintenance through and service does not require boiler access through side 160 (1103.16)

  • Page 12: Install Water Piping

     NOTE: The Fulton Endura boiler does not require a primary/secondary fl ow piping system. Although primary/secondary is an acceptable confi guration, the boiler does not have a minimum return water temperature requirement and the heat exchanger will not be harmed by low fl ow or zero fl ow conditions.

  • Page 13: Meet Water Chemistry Requirements

    INSTALLATION SECTION 2 EDR-IOM-2014-0318 WARNING 6. Install fi ltration to remove particulates if appropriate. A #10 mesh size is suggested. All information in this manual is for reference and guidance purposes, 7. Install bypass chemical feeder for corrosion inhibitor maintenance if and does not substitute for required appropriate.

  • Page 14: Prevent Oxygen Contamination

     Eliminate fi ttings wherever possible hydronic systems. Do not use automotive glycol.  Use air elimination devices in system piping 6. At a minimum, the hydronic fl uid should be checked for glycol concentration and pH once a year. © The Fulton Companies 2014...

  • Page 15: Eliminate System Air

    INSTALLATION SECTION 2 EDR-IOM-2014-0318  Eliminate System Air CAUTION Care needs to be taken to eliminate  NOTE: There are no built-in boiler air eliminating features. oxygen from the water system, as excess oxygen in the system will Adhere to the following for air elimination: reduce the life of any boiler.

  • Page 16: Components Requiring Ventilation To The Outdoors

     A parts kit must be ordered from your Fulton manufacturer’s representative for plumbing the vent lines outside the cabinet. Improper plumbing will cause the cabinet to lose its sealing, which can lead to improper combustion and bypassing of the air fi lter.

  • Page 17: Install Condensate Drain

    Install Condensate Drain and does not substitute for required professional training, conduct, and strict adherence to applicable A condensate drain kit is intended for use with the Fulton Endura boiler. jurisdictional/professional codes and regulations.  Single Boiler Drain Trap If the water supply must be The condensate drain kit is Fulton Part Number 4-57-005500.
  • Page 18  For multiple boiler installation, maintain and minimum pipe size of 1 inch (25.4 mm) for the header piping. Detail A  The maximum capacity to attach per condensate drain kit is 12 MMBH total. 2-12 © The Fulton Companies 2014...
  • Page 19 10.10 (3.07) 23.60 (7.19) ----- ----- ----- ----- 20200 16503 12766 8 (203.2) 7.98 (202.69) 13.30 (4.05) 29.10 (8.86) ----- ----- ----- ----- 41200 33660 29128 FIGURE 5 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP) 2-13 Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 20: Install Ph Neutralization Kit

    The header must be at least 5.5 inches (14.2 cm) below the condensate outlet of the The pH Neutralization Kit is a Fulton-provided kit designed to individual boiler, and must remain fl ooded - achieved bring the pH level of the boiler’s condensate to a neutral level.

  • Page 21: Venting

    INSTALLATION SECTION 2 EDR-IOM-2014-0318  NOTE: Replacement bags are available from your Fulton local WARNING representative. The medium in the container will neutralize the condensate All information in this manual is for of 12 MM Btu’s for approximately 6 months.

  • Page 22: Combustion Air Supply From The Boiler Room

    High-risk situations for particulate matter to be in the air include construction Adhere to the following for installation: and maintenance activities. See Table 6. 1. The combustion air supply can be piped directly to the 2-16 © The Fulton Companies 2014...

  • Page 23: Air Filter

    INSTALLATION SECTION 2 EDR-IOM-2014-0318 air inlet of the boiler. WARNING 2. The air intake must be piped out of the building if the boiler room contains Cements for plastic pipe are contaminated air. fl ammable liquids and should be kept away from all sources of 3.

  • Page 24: Common Venting Layouts For Endura

    Never use open fl ame or smoke from a cigarette, cigar, or pipe as a testing *PVC, CPVC and polypropylene are approved for EDR-1000 only. method during boiler installation, 5. The condensate connection on the boiler should be piped into the stack operation, or maintenance.

  • Page 25: Venting Terminations

    INSTALLATION SECTION 2 EDR-IOM-2014-0318 traveling back through idle boilers (fl ue gas recirculation, FGR). Looking WARNING at the condition of all boilers on at high fi re condition will facilitate the The exhaust vent installer should be selection of the diameter of the stack that is appropriate; however there is familiar with Federal Codes as well still a risk of FGR that needs to be managed.

  • Page 26: Wall Thimble Installation

    (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. FIGURE 7 - WALL THIMBLE INSTALLATION 2-20 © The Fulton Companies 2014...
  • Page 27 INSTALLATION SECTION 2 EDR-IOM-2014-0318 FIGURE 8 - ROOF PENETRATION DETAILS 4FT 3 IN ( 130 CM ) NOTE: AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPARATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS. MIN 4FT / 122 CM ABOVE AIR INTAKE PIPING SCREENED INLET...
  • Page 28 LOCATE INTAKE WALL PENETRATION RECIRCULATION DURING DIFFERENT WIND CONDITIONS UPWIND OF EXHAUST PIPING NOTE: AIR INTAKE 48 IN. / 122 CM. MAINTAIN MINIMUM 9"/22.86 CM AIR SPACE WALL PENETRATION CLEARANCES TO COMBUSTABLES, WIRES AND INSULATION 2-22 © The Fulton Companies 2014...

  • Page 29: Horizontal Vent Termination

    8. To prevent the possible re-circulation of fl ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building confi gurations, etc. Fulton cannot be held responsible for the eff ects such adverse conditions may have on the operation of the boilers.

  • Page 30: Electrical Connections

    20A and the units will draw 15A (8A for EDR-1000) on a regular basis, with the fan at maximum speed. A connection box has been provided on the back of the unit for high and low 2-24 ©...

  • Page 31: Assembly Of Fulton Multi-Skid Systems

    9. If a header is supplied, mount the header as shown in Adhere to the following for multi-skid engineered systems: the mechanical drawing. 1. Refer to the Fulton mechanical/electrical drawings  NOTE: For piping supplied in sections, make up and during assembly.
  • Page 32 INSTALLATION SECTION 2 EDR-IOM-2014-0318 38, 44, 45 EXAMPLE ELECTRICAL SCHEMATIC DIAGRAM 2-26 © The Fulton Companies 2014...
  • Page 33 INSTALLATION SECTION 2 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.
  • Page 34 INSTALLATION SECTION 2 EDR-IOM-2014-0318 2-28 © The Fulton Companies 2014...

  • Page 35: Operation

    OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 36: Perform Pre-Start-Up Inspection

    When only water is discharged from all vents, the initial purging is complete. 5. With the gas shutoff valve closed, turn on power to the boiler and operate © The Fulton Companies 2014...

  • Page 37: Commission The Boiler

    OPERATION SECTION 3 EDR-IOM-2014-0318 the circulator. Circulate the system water for approximately 30 minutes to WARNING move all air to the automatic air separation point. Do not attempt to start the boiler for 6. Check temperature/pressure indicator reading, which should equal the any testing before fi lling and purging pressure-reducing (fi ll) valve set pressure.
  • Page 38 Proper set up of the Ignition Enrichment gas is crucial to the “light-off ” of the boiler and requires verifi cation in the fi eld during initial commissioning. Fulton recommends the Ignition Enrichment setting is verifi ed during the yearly preventative maintenance.
  • Page 39 OPERATION SECTION 3 EDR-IOM-2014-0318 WARNING Non-Fulton product information is for SOLA “manual fi ring rate” screen (Figure 14). reference purposes only. No Fulton document should substitute for full 10. Connect an inches of water column measuring device (i.e., manometer) to review of documentation available the Enrichment gas valve test port (Figure 10).

  • Page 40: Turndown

     Turndown EDR-1500 and EDR-2000 boilers leave the factory with a default setting of 5:1 turndown; however, 8:1 may be allowable if site conditions permit. EDR-1000 boilers have a default setting of 10:1 turndown. Please consult a factory-trained representative for guidance.

  • Page 41: Sola Hydronic Controller For Endura

    OPERATION SECTION 3 EDR-IOM-2014-0318 SOLA Hydronic Controller for Endura WARNING All information in this manual is for The screen shots and information in this section will help you navigate through reference and guidance purposes, display parameters that would be used for initial startup. and does not substitute for required professional training, conduct, and strict adherence to applicable...

  • Page 42: Central Heat Operation - Firing Rate Screen

     NOTE: If the boiler is not placed back in automatic mode following maintenance, the boiler will not operate properly. Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

  • Page 43: Central Heat Operation - Setpoint Screen

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

  • Page 44: Changing High Limit Setpoint And Verifying Change

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

  • Page 45: Section 3 Operation

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

  • Page 46: Reviewing Statistics

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

  • Page 47: Accessing Lockout History

    Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
  • Page 48 Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

  • Page 49: Sola Diagnostics

    SECTION 3 EDR-IOM-2014-0318  SOLA Diagnostics WARNING From the Status Summary screen (Figure 28), press Diagnostics. 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.

  • Page 50: Perform Test Of Low Water Cut Off

    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. 3-16 © The Fulton Companies 2014...

  • Page 51: Perform Test Of Limit Controls

    OPERATION SECTION 3 EDR-IOM-2014-0318 Perform Test of Limit Controls WARNING Do not operate, or allow others to operate, Fire the boiler and test the high limit control as follows: service or repair this equipment unless you (they) fully understand all applicable 1.
  • Page 52 OPERATION SECTION 3 EDR-IOM-2014-0318 3-18 © The Fulton Companies 2014...

  • Page 53: Maintenance

    MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 54: General

    Daily, Weekly and Monthly Maintenance and Inspection (Fulton considers the regulations. following to be good practice for any boiler, and is applicable to the full line of Endura boilers). It is also good practice for any boiler installation to perform...

  • Page 55: Procedure For Cleaning The Air Inlet Filter

    Consult Fulton Heating Solutions immediately if there is a and strict adherence to applicable concern. jurisdictional/professional codes and 4.

  • Page 56: Removing And Cleaning Burner Assembly

    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 Sales Representative. © The Fulton Companies 2014...

  • Page 57: After All Repairs And Maintenance

    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 fl ange studs and retorque to 23 ft-lbs.
  • Page 58 If UV scanner does not detect the fl ame during the Iden fy and correct. 4-second trial-for-igni on period, the gas valve and spark igni on are de-energized. At this me a safety lockout occurs. © The Fulton Companies 2014...

  • Page 59: Section 4 Maintenance

    MAINTENANCE SECTION 4 EDR-IOM-2014-0318 PROBLEM CAUSE CHECK Main fl ame fails Ignition issue 1. Visually verify spark. 2. Replace igniter or transformer, as needed. Gas valve not set properly Verify the last elbow gas pressure matches the start up report. Enrichment issue Verify the pressure of the regulator matches the report.
  • Page 60 MAINTENANCE SECTION 4 EDR-IOM-2014-0318 © The Fulton Companies 2014...

  • Page 61: Warranty & Parts

    WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 62 WARRANTY & PARTS SECTION 5 EDR-IOM-2014-0318 © The Fulton Companies 2014...

  • Page 63: Standard Warranty For Fulton Endura Hydronic Boilers

    Fulton will repair or replace any part of the Endura boiler found to be defective in workmanship or material within 18 months of shipment from the factory or 12 months from start up (whichever comes fi rst). Fulton shall be notifi ed in writing as soon as any defect becomes apparent. Defective parts must be returned to Fulton for evaluation and warranty consideration.
  • Page 64 PAGE INTENTIONALLY LEFT BLANK...

  • Page 65: Parts

    Fulton Companies. When ordering replacement parts, please have recommended for this equipment. the model number and serial/National Board number of your Fulton boiler ready. Use of non-factory authorized parts may jeopardize safety and system...
  • Page 66 WARRANTY & PARTS SECTION 5 EDR-IOM-2014-0318 © The Fulton Companies 2014...
  • Page 68 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 fl uid heat transfer systems.

This manual is also suitable for:

Edr-1500Edr-2000

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