Gas pulse combustion hydronic heating boiler (84 pages)
Summary of Contents for FULTON Endura EDR-750
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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...
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...
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 be of the sealed combustion/direct vent 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...
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.
INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate. All information in this manual is for reference and guidance purposes, Install corrosion coupon holder to assess corrosion inhibitor performance if and does not substitute for required appropriate.
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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...
INSTALLATION SECTION 2 EDR-IOM-2019-0212 WARNING 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...
INSTALLATION SECTION 2 EDR-IOM-2019-0212 Inlet Gas Pressure If the level of pipe system cleanliness is unacceptable 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. ...
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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...
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.
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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 ...
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.
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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...
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”...
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. ...
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...
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.
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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®...
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.
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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.
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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...
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).
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.
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.
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.
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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.
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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...
` 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...
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` 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.
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.
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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.
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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.
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...
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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.
Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
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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.
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.
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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.
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.
20 mA water temperature: The setpoint valued assigned to a remote 20 mA 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.
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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.
Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
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 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.
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.
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).
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.
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.
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...
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.
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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...
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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.
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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.
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