Gas pulse combustion hydronic heating boiler (84 pages)
Summary of Contents for FULTON Endura+ Series
Page 1
- - - - - - - - - - - - - - - - one or more patents of WHOLE VALUE Fulton Group N.A., Inc. Fulton Group N.A., Inc. CHECKED BY: ELEC. ENG: PROJECT NAME: (1) PLACE DEC.
Annual Maintenance and Inspection Schedule ........... 4-4 Removing an Existing Boiler ................2-33 O2 Compensation Measurement ................4-4 Assembly of Fulton Multi-Skid Systems............. 2-34 Removing, Inspecting and Cleaning Burner ............4-5 Relocating the EDR+ 6000 Panel Box to Opposite Side ........2-35 Inspecting the Pilot Ignition Assembly ..............
Code ANSI Z223.1/NFPA 54 latest edition, and the specific 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.
The Fulton Endura+ hot water boiler is an automatic, fuel-fired, ultra high- jurisdictional/professional codes and efficiency boiler. The boiler can either have combustion air ducted directly from regulations.
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 difficulty in the future. Correct...
Page 10
1;24 1Endura+ boilers may be operated up to 10,000 feet elevation, and up to 1,000 feet elevation at 80˚ F without de-rate. Consult your Fulton Representative for capacities at higher elevation. 2Applies to natural gas with a calorific value of 1,010 BTU per FT3.
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 Clearances and Serviceability TABLE 2 (CONT.) - SAFETY RELIEF VALVE INLET AND OUTLET SIZES Model Trim Pressure Inlet Size Outlet Size PSI (kPa) inch (mm) inch (mm) Adhere to the following for clearances and serviceability: EDR+ 4000 30 (206.84) 2 (50.8) 2 1/2 (63.5)
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 WARNING NOTEE: 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 All information in this manual is for connection.
Page 15
ENDURA+ BOILER PRIMARY - SECONDARY SINGLE DIMENSIONS ARE IN INCHES are proprietary and are the B. PALMER 4/11/2016 drawing may be covered by Fulton Group N.A., Inc TOLERANCES exclusive property of one or more patents of FRACTION & `1/8 BOILER PIPING DIAGRAM...
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 Meet Water Chemistry Requirements WARNING All information in this manual is for reference and guidance purposes, System water chemistry requirements are as follows: and does not substitute for required pH: Range of 8.5 - 10.5 professional training, conduct, and strict adherence to applicable ...
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 Line Gas Pressure Regulation Consult the regulator manufacturer for orifice selection. If two or more springs are available for a particular When inlet gas pressure exceeds the maximum on the outlet pressure in the desired range use the spring with boiler name plate, a line gas pressure regulator is required the lower range for better accuracy.
Page 21
ENDURA+ MULTIPLE BOILER GAS SUPPLY PIPING DIMENSIONS ARE IN INCHES are proprietary and are the B. PALMER 4/11/2016 drawing may be covered by Fulton Group N.A., Inc TOLERANCES exclusive property of one or more patents of 972 Centerville Road - - - -...
SECTION 2 EDRP-IOM-2019-0212 Components Requiring Ventilation to the Install Condensate Drain Trap Outdoors A condensate drain trap is intended for use with the Fulton Endura+ boiler. NOTEE: The port marked “AIR” on the SKP25 actuator cannot be used as as gas vent connection. Connecting a vent line to this port may cause operational issues.
Page 23
ENDURA+ SINGLE BOILER CONDENSATE DRAIN DIMENSIONS ARE IN INCHES /2016 10/5/2016 10/5/2016 B. PALMER 4/11/2016 are proprietary and are the Fulton Group N.A., Inc TOLERANCES drawing may be covered by exclusive property of 972 Centerville Road PLUG. FRACTION &...
Multiple Boilers Sharing A Common Drain Trap 6. All piping (Figure 12) must be CPVC, high-temperature silicone tubing, galvanized, or stainless steel, and be The multiple boiler condensate drain trap is Fulton Part Number free of leaks. Copper, carbon steel/iron pipe or PVC are not acceptable.
Page 26
11⅜" 1½" N.P.T. INLET 6½" 2¾" 2¾" FRONT VIEW RIGHT VIEW LEFT VIEW FIGURE 15 - FULTON PH NEUTRALIZING KIT MULTIPLE BOILER SINGLE BOILER ASSEMBLY ASSEMBLY TOP VI EW TOP VI EW TOP VI EW I SOMETRI C VI EW...
NOTEE: Replacement bags are available from your Fulton local representative. The medium in the container will neutralize the condensate of 12 MMBH for approximately 6 months. (Fulton Part No. 2-30-001580)
Never use open flame or smoke from a cigarette, cigar, or pipe as a testing 7. Site specific conditions not addressed in this manual may require additional precautions or design considerations. Consult your local Fulton method during boiler installation, Representative and venting supplier for recommendations.
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 WARNING 3. It is essential that only fresh air is allowed to enter the combustion All information in this manual is for air system. Foreign substances, such as combustible volatiles in the reference and guidance purposes, combustion system can create hazardous conditions.
4. Ensure the boiler room air is maintained at a dew point temperature below the temperature of combustion air. Failure to provide adequate ventilation or control dew point temperature may increase maintenance or damage boiler Fulton accepts no liability for installation components. of any venting, including the selection of venting materials.
Page 33
(UL1738) (UL 1738) Maximum 600° F 550° F 230° F Flue Gas (315° C) (287° C) (110° C) Temperature TABLE 8 - FULTON APPROVED FLUE GAS VENTING ADAPTERS* Manufacturer Line Material Part/Catalog Number EDR+2500/3000 EDR+6000 810013180 810013438 M&G DuraVent® FasNSeal®...
2. Endura+ boilers are not approved for combined venting with other equipment such as steam boilers, No boilers on, pre-purge and ignition water heaters, generators, and other types of Fulton equipment. 4. Consider the natural draft effects associated with vertical exhaust vent rise. Over-draft control accessories, 3.
Page 35
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 FIGURE 18 - ROOF PENETRATION DETAILS FLUE GAS EXHAUST TERMINATION (RAIN CAP NOT REQUIRED) MIN 4 FT (122 CM) EXHAUST STACK IS DOWNWIND STORM COLLAR OF AIR INTAKE OPENING (FOR DOUBLE WALL) CAUTION: SEPARATE AIR INTAKE AND EXHAUST TERMINATIONS AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION (FGR) DURING DIFFERENT WIND CONDITIONS.
Page 37
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 FIGURE 20 - SIDEWALL PENETRATION DETAIL TYPICAL SIDE WALL PENETRATIONS ( SUGGESTED INSTALLATION CONFIGURATIONS ) WALL TERMINATIONS DETAIL VIEW NOTES: FLUE GAS EXHAUST TERMINATION 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 EXHAUST STACK IS DOWNWIND...
10 feet of the swirling high winds may be present. vent. 9. Fulton does not recommend the use of rain caps on the 2. When installing inlet and exhaust terminations above flue termination. Rains caps contribute to ice buildup,...
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 WARNING 2. The termination of the vent system must be at least 12 inches (30.48 cm) above the finished grade, or at least 12 inches (30.48 cm) above normal All information in this manual is for snow accumulation level (for applicable geographical areas).
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.
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. All information in this manual is for reference and guidance purposes, 9.
Page 43
The one or more patents of The R.A.S. 8/22/2017 9/6/2017 8/22/2017 8/22/2017 9/18/2017 9/9/2017 ` 1/16 FRACTIONS Fulton Companies. The Fulton Companies. CHECKED BY: ` .01 (2) PLACE DEC. S.M. A.M.K. P.E.K. B.M.P. B.A.S. corporation does not permit (3) PLACE DEC.
Page 45
TOLERANCES drawing may be covered by exclusive property of FRACTION & one or more patents of WHOLE VALUE Fulton Group N.A., Inc. CHECKED BY: ELEC. ENG: PROJECT NAME: Fulton Group N.A., Inc. (1) PLACE DEC. 0.03 The corporation does not (2) PLACE DEC.
Page 47
INSTALLATION SECTION 2 EDRP-IOM-2019-0212 ` OUTDOOR AIR TEMPERATURE SENSOR KIT duty plus one backup, with automation rotation. The pumps cannot be powered directly through the boiler 1. If outdoor air temperature reset capabilities are to panel; a variable speed drive (not provided) is required. be utilized, an outdoor air temperature sensor kit is required and field wired to a boiler.
Authorization. The commissioning agency must successfully complete and 30 psi is required at the boiler outlet. 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 CAUTION must be produced for warranty consideration.
SECTION 3 EDRP-IOM-2019-0212 WARNING 5. The Fulton factory Test Fire Report should be used as a point of reference in commissioning settings for the boilers in the field, however a factory certified service technician should account for all site conditions when Non-Fulton product information is for finalizing operational settings.
Page 53
OPERATION SECTION 3 EDRP-IOM-2019-0212 FIGURE 24 - SIEME S AZL DISPLAY Questions? Please Contact Your Local Manufacturer’s Representative...
Adjusting Fuel/Air Curve OTEE: Fulton Endura+ boilers are factory test fired and pre-programmed with values in the fuel/air curve (P0-ignition to P9-high fire). With the burner on, follow the below steps for making field changes to the fuel/air curve points. A calibrated flue gas analyzer is required to complete these steps and must be properly inserted into the boiler flue exhaust vent while making changes to the fuel/air curve points.
Page 55
OPERATION SECTION 3 EDRP-IOM-2019-0212 1) Confirm position of the fuel selection switch where applicable. 2) Enter the password and parameter “400” will flash. 3) Press the enter (i/reset) button 2 times. a. “P1” will flash and the curve point will be displayed. ...
OPERATION SECTION 3 EDRP-IOM-2019-0212 Parameter Backup 1. Press and hold “F” and “A” until Code is displayed. a. Then enter unit national board number press enter once complete. 2. “400: Set” will be displayed a. Press the”-“arrow three times until “000: Int” is displayed.
Page 59
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 61
Returns to the parent category. jurisdictional/professional codes and regulations. Tap to display information based on the screen currently selected. Non-Fulton product information is for reference purposes only. No Fulton Green: No alarm condition. Tap to document may substitute for full see Alarm History.
Page 63
` BOILER HISTORY Non-Fulton product information is for reference purposes only. No Various data points of operational history are summarized on this screen. Fulton document should substitute for full review of documentation ` ALARM HISTORY available from the component manufacturer.
No The boiler can be locked to low fire rate after ignition for a set period of time. This Fulton document should substitute period of time can be enabled/disabled and adjusted on this screen. for full review of documentation available from the component manufacturer.
Non-Fulton product information is for reference purposes only. No ` SYSTEM CONFIGURATION Fulton document should substitute for full review of documentation The System Configuration screen is used for saving (backup) and loading of available from the component program settings.
All maintenance procedures should be completed by trained personnel. Weekly Maintenance and Inspection Schedule Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or Weekly maintenance and inspection must include the following: your local Fulton Heating Solutions Representative.
OOEE: Operating the burner with the combustion air inlet filter removed will void the burner warranty. A clean filter of the same Fulton part number (type, size and style) must be installed while the boiler is in operation. 3. Return the filter to its original position in the slot, verify orientation.
1. Inspect the fuel train, burner and control panel to be sure components are fibers. free of debris and are properly attached to the boiler. 2. Replace the combustion air inlet filter with a new filter of the same Fulton part number (type, size and style). CAUTION 3.
1. A burner maintenance parts kit is required to complete the following the boiler. Failure to properly torque steps. Contact your Fulton representative to purchase this parts kit before hardware may result in PERSONAL proceeding, please have your National Board number ready to expedite INJURY, DEATH, or property damage.
Page 74
THE O2 COMPENSATION READOUT IS NOT A REPLACEMENT FOR A or genuine Fulton replacement hardware. Tighten in a star pattern. CALIBRATED FLUE GAS ANALYZER. EDR+2500/3000 Only: Verify torque to 23 ft-lbs.
1/16” (1.588 mm), adjust if needed. 6. Inspect that the insulation block around the pilot when installed has not lost structural integrity. Replace with original Fulton part if needed. 7. Reinstall the pilot ignition assembly per the instructions detailed in Removing, Inspecting, and Cleaning Burner.
Page 77
DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: UNLESS OTHERWISE NOTED The items shown in this EDR+ 6000 CONDENS INITIAL RELEASE TO FULTON PART NUMBER; DIMENSIONS ARE IN INCHES are proprietary and are the B. PALMER 6/26/2017 P.E.K. 7/11/2017 FIGURE 26 - EDR+ 4000-6000 BUR ER ASSEMBLY...
Page 79
MAINTENANCE SECTION 4 EDRP-IOM-2019-0212 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. Flame detector failure 1.
Page 82
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 fluid heat transfer systems.