FULTON Endura EDR-750 Installation And Operation Manual
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FULTON Endura EDR-750 Installation And Operation Manual

Condensing hydronic boilers 750,000 - 2,000,000 btu/hr
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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

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  • Page 1 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...

  • Page 3: Table Of Contents

    Replacing Gas Valve Internal Filter ............... 4-4 Removing an Existing Boiler ................2-33 Removing and Cleaning Burner Assembly ............4-5 Assembly of Fulton Multi-Skid Systems............. 2-34 Verification of Ignition Gap .................. 4-6 Electrical Connections and Devices ..............2-35 After All Repairs and Maintenance ..............4-7 JUNCTION BOX LOCATIONS FOR FIELD WIRING ...............2-40...
  • Page 4 TABLE OF CONTENTS EDR-IOM-2019-0212 © Fulton Group N.A., Inc. 2019...

  • Page 5: Introduction

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

  • Page 6: Overview

    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.

  • Page 7: Installation

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

  • Page 8: Product Overview

    The Fulton Endura hot water boiler is an automatic, fuel-fired, ultra high- jurisdictional/professional codes and efficiency 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 difficulty in the future. Correct...
  • Page 10 1848 3128 3210 Note: All dimensions are approximate and are subject to change without notice. 1419 1456 TOP VIEW FRONT VIEW RIGHT SIDE VIEW BACK VIEW FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER © Fulton Group N.A., Inc. 2019...

  • Page 11: Clearances And Serviceability

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 Clearances and Serviceability 2. The discharge pipe must: » Not have a diameter less than the full area of Adhere to the following for clearances and serviceability: the valve outlet. » Be as short and straight as possible and so 1.

  • Page 12: Install Water Piping

    The lower water connection on the rear of the boiler is the inlet connection. ƒ Install filtration in the common loop or per boiler to remove particulates if appropriate. A #4 or finer mesh size is required. © Fulton Group N.A., Inc. 2019...

  • Page 13: Variable Primary Piping Arrangement

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING ƒ Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate. All information in this manual is for reference and guidance purposes, ƒ Install corrosion coupon holder to assess corrosion inhibitor performance if and does not substitute for required appropriate.
  • Page 14 DRAWING NUMBER SURFACE FINISH G-35-100005 except with prior 250 MICRO-INCHES B.O.M. REVIEW APPROVED BY: PROJECT MANAGER: written consent. THIRD ANGLE PROJECTION K.BOTTORFF 7/7/2014 1 OF 1 SHEET 1 OF 1 © Fulton Group N.A., Inc. 2019...
  • Page 15 UNLESS OTHERWISE NOTED: MECH. ENG: JOB NUMBER: DESCRIPTION: CALLOUTS & DESCRIPTION. M.E.B. 1/20/15 2/2/15 1/30/15 this drawing may be The Fulton Companies drawings are M.BERWALD 1/20/2015 2/2/2015 DIMENSIONS ARE IN INCHES ENDURA BOILER PRIMARY - SECONDARY TOLERANCES ON covered by one or...

  • Page 16: Primary-Secondary Piping Arrangement

    Meet Water Chemistry Requirements System water chemistry requirements are as follows: ƒ pH: Range of 8.5 - 10.5 ƒ Oxygen: Less than 250 ppb (operating condition) ƒ Total Iron/Copper: Less than 5 ppm 2-10 © Fulton Group N.A., Inc. 2019...

  • Page 17: Prevent Oxygen Contamination

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING ƒ Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2 mpy. Due to changing environmental restrictions a non-heavy metal ALL All information in this manual is for ORGANIC inhibitor is recommended which is designed for multi metal reference and guidance purposes, systems including ferrous metals and yellow metals such as copper and and does not substitute for required...

  • Page 18: Eliminate System Air

    9/24/2014 (3) PLACE DEC. 0.005 INITIAL RELEASE permit their use except ANGLE 0.5 DEG DRAWING NUMBER © Fulton Group N.A., Inc. 2019 with prior written consent. SURFACE FINISH G-35-100009 REVISION DESCRIPTION B.O.M. ELEC. ENG MECH. ENG CHECKED APPROVED B.O.M. REVIEW...

  • Page 19: Inlet Gas Pressure

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 ƒ Inlet Gas Pressure If the level of pipe system cleanliness is unacceptable ƒ or unknown, it is recommended that a gas filter be Adhere to the following: installed prior to the regulator. Static inlet gas pressure: Measure while boiler is idle. ƒ...
  • Page 20 The corporation does  2 DEG. not permit their use DRAWING NUMBER G-35-100007 except with prior B.O.M. REVIEW APPROVED BY: PROJECT MANAGER: written consent. 2-14 THIRD ANGLE PROJECTION 9/25/2014 1 OF 1 SHEET 1 OF 1 © Fulton Group N.A., Inc. 2019...
  • Page 21 DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: UNLESS OTHERWISE NOTED: drawings are this drawing may be The Fulton Companies M.BERWALD 7/25/2014 9/25/2014 DIMENSIONS ARE IN INCHES ENDURA MULTIPLE BOILER GAS SUPPLY 3. The line regulator should be installed with a...

  • Page 22: Components Requiring Ventilation To The Outdoors

    ƒ Multiple Boilers Sharing A Common Drain Trap The multiple boiler condensate drain trap is Fulton Part Num- A condensate drain trap is intended for use with the Fulton ber 4-57-000440. The maximum number of units to attach per Endura boiler.
  • Page 23 BOILER CHECKED BY: ELEC. ENG: PROJECT NAME: (2) PLACE DEC.  Fulton Companies. UPDATED CONNECTION FOR CONDENSATE A.A. The Fulton Companies. 3/3/2014 (3) PLACE DEC.  .005 The corporation does DRAIN. M.E.B. 9/10/14 9/10/14 9/10/14 9/11/14 ANGLES ...
  • Page 24 (25.4 mm) for the header piping. DETAIL A 6. The maximum capacity to attach per multiple boiler CONDENSATE condensate drain trap is 12 MMBH total. DRAIN KIT 7. Housekeeping pad required, minimum 4 inch (102 mm). 2-18 © Fulton Group N.A., Inc. 2019...

  • Page 25: Install Ph Neutralization Kit

    7. Connect the 1.5 inch (38.1 mm) drain outlet to an appropriate waste line following applicable codes. The 1. The Fulton Endura boiler 1 inch (25.4 mm) condensate 1.5 inch (38.1 mm) drain connection on the drain tank drain will be connected to the 1 inch (25.4 mm) inlet must be the highest point prior to going to the drain.
  • Page 26 1½" N.P.T. OUTLET 1½" N.P.T. INLET 6 ½ LEFT VIEW FRONT VIEW RIGHT VIEW FIGURE 17 - FULTON PH NEUTRALIZING KIT MULTIPLE BOILER SINGLE BOILER ASSEMBLY ASSEMBLY TOP VI EW TOP VI EW TOP VI EW I SOMETRI C VI EW...

  • Page 27: Venting Requirements

    4. Check condensate pH periodically. CAUTION An uninterruptible water supply is required NOTEE: Replacement bags are available from your Fulton local representative. – for the multiple boiler condensate trap The medium in the container will neutralize the condensate of 12 MM Btu’s for and shall be connected to the ¼”...

  • Page 28: Combustion Air Intake

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING 7. Site specific conditions not addressed in this manual may require additional precautions or design considerations. Consult your local Fulton Do not terminate venting into an Representative and venting supplier for recommendations. enclosed area. –...

  • Page 29: Combustion Air Supply From The Boiler Room

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING perchlorethylene, halogenated compounds) in the combustion air supply to the boiler will cause damage or failure to the heat exchanger and/ All information in this manual is for or burner, and is not covered under warranty. High-risk situations for reference and guidance purposes, particulate matter to be in the air include construction and maintenance and does not substitute for required...

  • Page 30: Air Piped From Outside Boiler Room

    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. 2-24 © Fulton Group N.A., Inc. 2019...

  • Page 31: Air Filter

    All Schedule 40 PVC pipe, fittings, primer and cement must conform to American National Standard Institute and the Fulton accepts no liability for installation American Society for Testing and Materials (ANSI/ASTM standards) per pipe of any venting, including the selection of manufacturer’s requirements.
  • Page 32 2-26 This design and The items shown in DRAWN BY: MECH. ENG: JOB NUMBER: DESCRIPTION: UNLESS OTHERWISE NOTED: © Fulton Group N.A., Inc. 2019 drawings are this drawing may be The Fulton Companies M.BERWALD 7/2/2014 7/25/2014 DIMENSIONS ARE IN INCHES...
  • Page 33 230° F 200° F 200° F Stack Limit (130° C) (130° C) (110° C) (93° C) (93° C) Setting TABLE 8 - FULTON PART NUMBERS FOR FLUE GAS EXHAUST ADAPTERS Part/Catalog Number Stack Manufacturer Line Material EDR-750-1500 EDR-2000 M&G DuraVent® FasNSeal®...

  • Page 34: Common Venting Layouts For Endura

    WIDTH TO VARY WITH DIAMETER “A” COLLAR WALL THICKNESS with other equipment. Examples include steam boilers, water heaters, generators, and other types of Fulton VARIABLE equipment. (MIN. 3 ¼ IN) – (MAX. 20 INCHES) (MIN. 8,255 CM – MAX. 50,8 CM) FIGURE 21- WALL THIMBLE INSTALLATION 3.
  • Page 35 INSTALLATION SECTION 2 EDR-IOM-2019-0212 FIGURE 22 - 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 36 (645 MM PER 1.17 KW) CONSULT FLUE MFG FOR SELECTION REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER CONDENSATE TRAP 12 INCH (305 MM) LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT 2-30 © Fulton Group N.A., Inc. 2019...
  • Page 37 INSTALLATION SECTION 2 EDR-IOM-2019-0212 FIGURE 24 - SIDEWALL PENETRATIONS DETAIL TYPICAL SIDE WALL PENETRATIONS WALL TERMINATIONS DETAIL VIEW ( SUGGESTED INSTALLATION CONFIGURATIONS ) 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...

  • Page 38: Venting Terminations

    Minimum wall thickness through which vent system may be installed is 3.25 inches (8.26 9. Fulton does not recommend the use of rain caps on the cm). Maximum wall thickness through which vent flue termination. Rain caps contribute to ice buildup, system may be installed is 20 inches (50.8 cm).

  • Page 39: Removing An Existing Boiler

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING 4. Do not terminate below operable windows and building openings unless exception is granted by the authority having jurisdiction. All information in this manual is for 5. The vent terminations must be at least 4 ft (1.22 m) horizontally from reference and guidance purposes, electric meters, gas meters, regulators, and relief equipment.

  • Page 40: Assembly Of Fulton Multi-Skid Systems

    Adhere to the following for multi-skid engineered systems: WARNING 1. Refer to the Fulton mechanical/electrical drawings during assembly. The rating of each external device contact 2. Ensure that equipment orientation allows for operation interface and is the maximum allowable amperage of maintenance.

  • Page 41: Electrical Connections And Devices

    INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING 9. If a header is supplied, mount the header as shown in the mechanical drawing. All information in this manual is for reference and guidance purposes, – NOTEE: For piping supplied in sections, make up and connect hand tight until all and does not substitute for required sections are in place to ensure sections align properly.
  • Page 42 R.A.S. 05-17-2017 ANGLES 2 DEG. 9/14/2017 9/15/2017 2-36 SURFACE FINISH written consent. B.O.M. REVIEW APPROVED BY: REVISION DESCRIPTION B.O.M. ELEC. ENG MECH. ENG CHECKED APPROVED 250 MICRO-INCHES © Fulton Group N.A., Inc. 2019 THIRD ANGLE PROJECTION REVISION HISTORY...
  • Page 43 The exclusive property of The ECR 2015-811 R.A.S. 10-24-2017 10/24/2017 10/24/2017 FRACTIONS 1/16 Fulton Companies. The Fulton Companies. CHECKED BY: ELEC. ENG: PROJECT NAME: (2) PLACE DEC. A.K. D.F. MOVED MODSYNC CONNECTION corporation does not permit 3/20/13 (3) PLACE DEC.
  • Page 44 Pulaski, New York USA 13142 EDR 750-2000 WITH OPTIONS SHOWN ELEC. ENG: PROJECT NAME: 3/20/13 EDR 750-2000 REFERENCE ELECTRICAL SCHEMATIC DIAGRAM (CONTINUED) DRAWING NUMBER E53-10001 APPROVED BY: PROJECT MANAGER: 3/20/13 SHEET 1 OF 2 2-38 © Fulton Group N.A., Inc. 2019...
  • Page 45 Fulton SOLA FULTON SOLA Notes: See Reference Eletrical Schematic Diagrams for field wiring connections. Refrence the R7910A SOLA HC (Hydronic Control) manual for additional information. FIGURE 25 - FULTON SOLA PIN LAYOUT 2-39 Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 46: Junction Box Locations For Field Wiring

    ` LEAD/LAG INTEGRATED SEQUENCING WIRING 5. It is field installed downstream of the boilers in the 1. The Fulton SOLA includes integrated sequencing common supply water header. The well must be directly capabilities. When utilized, the boiler control system will...
  • Page 47 ` BURNER FIRE RATE OUTPUT or spring-open / power-close. 1. Fulton SOLA J10 plug terminals 4, 5, and 6 may be used 2. A motorized isolation valve is used in variable primary for either 4-20 mA or 0-10 VDC burner fire rate output.
  • Page 48 1. This hydronic boiler in the standard configuration for 5 Amps maximum. includes one factory installed low water cut off (LWCO) device in compliance with CSD-1. Some authorities having jurisdiction (AHJ) may require the use of a 2nd (auxiliary) LWCO. 2-42 © Fulton Group N.A., Inc. 2019...

  • Page 49: Operation

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

  • Page 50: Perform Pre-Start-Up Inspection

    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. © Fulton Group N.A., Inc. 2019...

  • Page 51: Commission The Boiler

    3. Performance factors affected may include but are not limited to input/ output ratings, efficiency, 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 field, however a factory certified service technician should account for all site conditions when finalizing operational settings.
  • Page 52 Commissioning/Start up by a non- NOTEE: A properly calibrated combustion analyzer will be required when making – Fulton authorized person will void the changes to the valve settings. product warranty. 1. Follow the steps in the SOLA Hydronic Controller section of this manual Please read these instructions and to access the parameters to run the boiler in manual mode.
  • Page 53 – of the boiler and requires verification in the field during initial commissioning. Fulton recommends the Ignition enrichment setting is verified during the yearly preventative maintenance. 10. Once final field combustion is completed at low and high fire, the ignition enrichment setting requires verification.
  • Page 54 13. The enrichment gas regulator (Figure 27) may be used to increase or REVISION HISTORY decrease the valve outlet pressure as required. 14. Once combustion is verified with a combustion analyzer place the control back into automatic mode and check all boiler safeties. © Fulton Group N.A., Inc. 2019...

  • Page 55: Turndown

    OPERATION SECTION 3 EDR-IOM-2019-0212 WARNING – NOTEE: The boiler is factory-configured for standard natural gas. Contact your authorized service organization for conversion to HD5 propane. All information in this manual is for reference and guidance purposes, TABLE 9 - METAL MESH BURNERSE: VERIFICATION OF NATURAL GAS COMBUSTION and does not substitute for required Light Off Low Fire...

  • Page 56: Sola Hydronic Controller - General Operation

    (to be able to run the boiler anywhere in the firing range) you would press the yellow block next to Firing Rate. Pressing Firing Rate © Fulton Group N.A., Inc. 2019...
  • Page 57 If the boiler is not placed back in automatic mode following maintenance, jurisdictional/professional codes and the boiler will not operate properly. 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.

  • Page 58: Central Heat Operation - Setpoint Screen

    FIGURE 35 - CENTRAL HEAT CONFIGURATION - SETPOINT SCREEN ƒ Central Heat Configuration – Modulation Screen By pressing the black arrow on the top of the page you will be able to move from 3-10 © Fulton Group N.A., Inc. 2019...

  • Page 59: Central Heat Configuration - Modulation Screen

    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 60 **Pumps, PLC or ModSync panels may require lower ambient temperatures or additional cooling. 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 © Fulton Group N.A., Inc. 2019...

  • Page 61: 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 62: Accessing Lockout History

    (Figure 45). Time and date stamp of the last fifteen lockouts is displayed. Pressing Clear Lockout will clear the current lockout. By pressing the specific lockout more information on the lockout will be displayed (Figure 46). 3-14 © Fulton Group N.A., Inc. 2019...
  • Page 63 OPERATION SECTION 3 EDR-IOM-2019-0212 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.

  • Page 64: Sola Diagnostics

    A green light next to the input indicates the control’s input is made or satisfied. A gray circle indicates the input is not satisfied. This is a helpful trouble shooting screen. 3-16 © Fulton Group N.A., Inc. 2019...

  • Page 65: Lead/Lag Integrated Sequencing

    OPERATION SECTION 3 EDR-IOM-2019-0212 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. Check daily that the equipment area is free and clear of any combustible materials, including flammable vapors and liquids.
  • Page 66 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: 3-18 © Fulton Group N.A., Inc. 2019...
  • Page 67 ƒ and strict adherence to applicable on degrees away from set point. 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 53- ADD STAGE From the Lead Lag Master Configuration screen Select the box labeled Advanced Settings in the bottom right hand corner.
  • Page 68 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 © Fulton Group N.A., Inc. 2019...

  • Page 69: Domestic Hot Water (Dhw) Temperature Sensor

    All boilers in the lead lag boiler plant have to be firing prior to any jurisdictional/professional codes and boiler operating above 40% fan speed. 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.

  • Page 70: Remote 4-20 Ma Signal For Setpoint

    From the configuration screen scroll to and select lead lag master configuration and select the box labeled advanced settings in the bottom right hand corner. Using the left and right arrow keys scroll 3-22 © Fulton Group N.A., Inc. 2019...

  • Page 71: Supply Header Temperature Sensor

    20 mA water temperature: The setpoint valued assigned to a remote 20 mA ƒ signal 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 72: Outdoor Air Temperature Sensor

    For a lead/lag boiler plant this must be done through the lead lag master configuration. Return to the configuration screen and scroll to and select lead lag master configuration. Select the box in the bottom right 3-24 © Fulton Group N.A., Inc. 2019...
  • Page 73 Non-Fulton product information is for reference purposes only. No Fulton FIGURE 64 - OUTDOOR AIR SENSOR CONFIGURATION document may substitute for full review of documentation available hand corner labeled advanced settings.
  • Page 74 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 © Fulton Group N.A., Inc. 2019...

  • Page 75: Stack Limit

    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 76: Motorized Isolation Valve Set Up

    Next tap the advanced box in the bottom right hand corner of the pump configuration 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 © Fulton Group N.A., Inc. 2019...

  • Page 77: Enabling Burner Fire Rate Output

    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 78 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. 3-30 © Fulton Group N.A., Inc. 2019...

  • Page 79: Perform Test Of Low Water Cut Off

    OPERATION SECTION 3 EDR-IOM-2019-0212 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.
  • Page 80 PAGE INTENTIONALLY LEFT BLANK...

  • Page 81: Maintenance

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

  • Page 82: General

    Appropriate training and instructions essential for the efficient and reliable operation of this boiler. If an adjustment are available from the Fulton Service to the combustion is necessary, the flue gas composition should be checked Department at (315) 298-5121 or with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions.

  • Page 83: Procedure For Inspecting The Air Inlet Filter

    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 filter with a new filter of the same Fulton part number (type, size and style).

  • Page 84: Replacing Gas Valve Internal Filter

    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 flue gas leakage and cause damage to the studs. Follow proper safety precautions when using a ladder.

  • Page 85: Removing And Cleaning Burner Assembly

    – 2. Removes screws 1 and 2. hardware must not be substituted. If hardware is lost or damaged, contact your Fulton representative for 3. Replace filter insert 3. replacement. 4. Replace screws 1 and 2 and verify torque to 22 inch-lbs.

  • Page 86: Verification Of Ignition Gap

    072000 (metal woven mesh burners only). inlet to assist in removing particulate matter. 1. Remove ignition electrode assembly (ignitor). Visually 12. If any burner damage is detected, contact your Fulton check that the insulators are clean. Representative. 2. For re-installation or installation of a new ignitor, verify...

  • Page 87: After All Repairs And Maintenance

    MAINTENANCE SECTION 4 EDR-IOM-2019-0212 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 verification. Make adjustments as necesary. 3. Complete the “Installation and Operation Report” for Endura boilers and retain in the boiler’s maintenance records.
  • Page 88 MOLEX CONNECTOR - 4 CIRCUITS - DUAL ROW MINI FIT 2-45-000999 16 AWG WIRE 2-45-001027 HONEYWELL HEAT BLOCK ( 136733 ) 5-11-000018 18" LONG HIGH VOLTAGE IGNITION CABLE WITH 1/4" FEMALE CONNECTIONS FIGURE 77 - EDR 750/1000 BURNER ASSEMBLY © Fulton Group N.A., Inc. 2019...
  • Page 89 MAINTENANCE SECTION 4 EDR-IOM-2019-0212 BILL OF MATERIAL ITEM PART NUMBER DESCRIPTION U.O.M. 2-10-071520 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 2-12-000012 3/4" NPT SIGHT OBSERVATION PORT 2-12-001260 ENDURA 1500K / 2000K BURNER GASKET, GRAFTECH GRAFOIL GTB 2-20-000023...

  • Page 90: Troubleshooting

    1. Pull and Clean the Burner with compressed air (requires burner gaskets) Maintenance Items 2. Check for blockages or obstructions in the Air Intake or Exhaust venting. 3. Verify that the 3-position damper is opening AND closing to the appropriate positions. 4-10 © Fulton Group N.A., Inc. 2019...
  • Page 91 MAINTENANCE SECTION 4 EDR-IOM-2019-0212 PROBLEM CAUSE CHECK Flame lost early in run - Power / Wiring/ 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 Lockout 107 Connections washer installed.
  • Page 92 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.

This manual is also suitable for:

Endura edr-1000Endura edr-1500Endura edr-2000

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