FULTON Endura EDR 750 Nstallation, Operation And Maintenance Manual
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FULTON Endura EDR 750 Nstallation, Operation And Maintenance Manual

FULTON Endura EDR 750 Nstallation, Operation And Maintenance Manual

Condensing hydronic boilers 750,000 - 2,000,000 btu/hr featuring pure control
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Tender No. MET21-117 Design & Build RFP: Gas Heating Upgrade
The Tender Documents shall be amended and will become part of the Contract
Documents.
This addendum shall form an integral part of the Tender Documents.
1.
Design Consultant and Contractor shall be fully responsible in providing a
transport design plan that is acceptable to MRHA Project Manager and HNS BDG
Engineering. The Team shall provide back up materials on their determination of how
and what they intend to use to remove old boilers and heating system to be replaced
and to install new boilers from ground level temporary storage, shipping container or
like, at Alderney Manor to inside the penthouse mechanical boiler room.
Note, the roof shall not be used as a sitting staging area for craning of old and new
boilers and other heavy old and new equipment from ground into penthouse boiler room
and vice versa, unless there is an approved engineering structural assessment of the
roof with respect to the process that provides no detriment or undue risk to roof
structure and integrity. It is preferred by BDG and MRHA that a craned lift be continuous
from ground into penthouse and vice versa for all demolition and new craning of boilers
and equipment.
2.
The correct IOM manual for the new boilers follows this page and forms part of
this addendum.
The closing date and time remains the same.
Tender No. MET21-117
Metropolitan Regional Housing Authority
Replacement in Dartmouth
ADDENDUM NO. 5
July 27, 2021
Page 1 of 1
Design & Build RFP: Gas Heating Upgrade
Replacement in Dartmouth
Addendum #5 Page 1 of 105

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  • Page 1 Metropolitan Regional Housing Authority Tender No. MET21-117 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth ADDENDUM NO. 5 July 27, 2021 The Tender Documents shall be amended and will become part of the Contract Documents. This addendum shall form an integral part of the Tender Documents. Design Consultant and Contractor shall be fully responsible in providing a transport design plan that is acceptable to MRHA Project Manager and HNS BDG Engineering.
  • Page 2 Endura (EDR) Condensing Hydronic Boilers 750,000 - 2,000,000 BTU/HR Featuring PURE Control™ Serial/ National Board Number Model Fulton Order Owner Site Name Date EDR-PURE-IOM-210617 Tender No. MET21-117 Addendum #5 Page 2 of 105 Design & Build RFP: Gas Heating Upgrade...
  • Page 3 Tender No. MET21-117 Addendum #5 Page 3 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 4 SIDE WALL VENT TERMINATION ....................2-31 SECONDARY PUMPS ........................3-16 Removing an Existing Boiler ................2-35 LEAD/LAG ...........................3-16 Assembly of Fulton Multi-Skid Systems............. 2-35 LEAD/LAG CONFIGURATION ......................3-16 Electrical Connections and Devices ..............2-37 PID CONTROL ..........................3-17 JUNCTION BOX LOCATIONS FOR FIELD WIRING ...............2-42 LOCAL PID ..........................3-17...
  • Page 5 Installation & Operation “Start-Up” Report ............5-5 Annual Maintenance Checklists ................5-7 Notes ........................5-17 Tender No. MET21-117 Addendum #5 Page 5 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 6 INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Tender No. MET21-117 Addendum #5 Page 6 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 7 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 8 INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Tender No. MET21-117 Addendum #5 Page 8 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 9 The Fulton Endura hot water boiler is an automatic, fuel-fired, ultra high- jurisdictional/professional codes and efficiency boiler. Combustion air supply may be ducted to the boiler from the regulations.
  • Page 10 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 11 FRONT VIEW RIGHT SIDE VIEW BACK VIEW FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER Tender No. MET21-117 Addendum #5 Page 11 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 12 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 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 13 ƒ Install filtration in the common loop or per boiler to remove particulates if appropriate. A #4 or finer mesh size is required. Tender No. MET21-117 Addendum #5 Page 13 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 14 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 WARNING ƒ Install bypass chemical feeder for corrosion inhibitor maintenance if appropriate. All information in this manual is for ƒ Install corrosion coupon holder to assess corrosion inhibitor performance if reference and guidance purposes, appropriate. and does not substitute for required professional training, conduct, ƒ...
  • Page 15 PROJECT MANAGER: written consent. THIRD ANGLE PROJECTION K.BOTTORFF 7/7/2014 1 OF 1 SHEET 1 OF 1 Tender No. MET21-117 Addendum #5 Page 15 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 16 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 17 Where reverse return cannot be used, it is recommended to install a balancing valve per boiler. Tender No. MET21-117 Addendum #5 Page 17 of 105 Design & Build RFP: Gas Heating Upgrade 2-10 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 18 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 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 ƒ pH: Range of 8.5 - 10.5 professional training, conduct, and strict adherence to applicable ƒ...
  • Page 19 FIGURE 8 - TYPICAL GAS TRAIN (VARIES BY SIZE/MODEL) Tender No. MET21-117 Addendum #5 Page 19 of 105 Design & Build RFP: Gas Heating Upgrade 2-12 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 20 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 Proper selection and installation of a gas pressure regulator is essential in providing conditions for efficient and reliable combustion. Adhere to the following guidelines when selecting and installing a gas pressure regulator: Measure inlet supply A sediment trap is recommended prior to the inlet of ƒ...
  • Page 21 The boiler cannot be used as a pipe anchor. Tender No. MET21-117 Addendum #5 Page 21 of 105 Design & Build RFP: Gas Heating Upgrade 2-14 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 22 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 TABLE 3 - SCH 40 PIPE NATURAL GAS CAPACITY Nominal Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. 14”wc pressure. Pipe Size Pressure drop of 0.5”wc. Equivalent length of pipe (feet) Inch (mm) Inch (mm) 90 Elb Feet...
  • Page 23 FIGURE 12 - ENDURA MULTIPLE BOILER GAS SUPPLY PIPING Tender No. MET21-117 Addendum #5 Page 23 of 105 Design & Build RFP: Gas Heating Upgrade 2-16 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 24 ƒ Multiple Boilers Sharing A Common Drain Trap Install Condensate Drain Trap The multiple boiler condensate drain trap is Fulton Part A condensate drain trap is intended for use with the Fulton Number 4-57-000440. The maximum number of units to Endura boiler.
  • Page 25 PROJECT NAME: Tender No. MET21-117 Addendum #5 Page 25 of 105 DRAWING NUMBER Design & Build RFP: Gas Heating Upgrade G-35-100002 APPROVED BY: 2-18 PROJECT MANAGER: 2/21/2014 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020 SHEET 1 OF 1...
  • Page 26 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 DETAIL A HEADER MUST BE AT FLOOR (NOT PAD) HEIGHT Figure Notes: 0.25” (U.S.) tapping 1. Header must be slightly pitched toward the drain. provided for water connection to 2. Header material must be CPVC, galvanized steel, or maintain water seal.
  • Page 27 1½" N.P.T. INLET 6 ½ LEFT VIEW FRONT VIEW RIGHT VIEW FIGURE 17 - FULTON PH NEUTRALIZING KIT Tender No. MET21-117 Addendum #5 Page 27 of 105 Design & Build RFP: Gas Heating Upgrade 2-20 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 28 2. Connect kit downstream of Condensate Drain Trap. See Figure 18. The pH Neutralization Kit is a Fulton-provided kit designed to 3. Pipe outlet to appropriate drain. It is acceptable to use bring the pH level of the boiler’s condensate to a more neutral PVC or CPVC on the outlet to drain.
  • Page 29 Tender No. MET21-117 Addendum #5 Page 29 of 105 Design & Build RFP: Gas Heating Upgrade 2-22 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 30 7. Site specific conditions not addressed in this manual may require CAUTION additional precautions or design considerations. Consult your local Fulton Representative and venting supplier for recommendations. Ensure there is not a negative pressure in the boiler room.
  • Page 31 1 in2 per 3,000 BTU/hr of the total input capacity of the combined burners located in the boiler room. See Table 6. Tender No. MET21-117 Addendum #5 Page 31 of 105 Design & Build RFP: Gas Heating Upgrade 2-24 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 32 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 WARNING 5. For multiple boiler installations, multiply the number of boilers by required net free area per boiler. All information in this manual is for reference and guidance purposes, TABLE 6 - MAKE-UP AIR VENTILATION OPENINGS and does not substitute for required Boiler Input Two Openings Min.
  • Page 33 For installation using a barometric damper, verify the air openings meet the Tender No. MET21-117 Addendum #5 Page 33 of 105 Design & Build RFP: Gas Heating Upgrade 2-26 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 34 Table 6, and a spill switch and a CO2 detector are installed and interlocked with the boiler(s). Barometric dampers must never be Fulton accepts no liability for installation used in a positive pressure (Category IV) exhaust or ducted combustion air of any venting, including the selection of application.
  • Page 35 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 WARNING TABLE 8 - FULTON PART NUMBERS FOR FLUE GAS EXHAUST ADAPTERS Fulton accepts no liability for installation Part/Catalog Number Stack of any venting, including the selection of Manufacturer Line Material venting materials. Maximum allowable EDR-750-1500...
  • Page 36 JOB NUMBER: DESCRIPTION: The items shown in UNLESS OTHERWISE NOTED: drawings are this drawing may be this drawing may be The Fulton Companies M.BERWALD 9/23/2014 10/9/2014 DIMENSIONS ARE IN INCHES ENDURA PVC EXHAUST VENTING TOLERANCES ON covered by one or...
  • Page 37 3. To prevent the possible re-circulation of flue gases, the vent designer Tender No. MET21-117 Addendum #5 Page 37 of 105 Design & Build RFP: Gas Heating Upgrade 2-30 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 38 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 must take into consideration such things as prevailing 2. Secure the outside flange to the wall with nails or winds, eddy zones, building configurations, etc. Adverse screws, and seal with adhesive material. conditions effect operation reliability and durability of the boiler(s).
  • Page 39 LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT FIGURE 22 - ROOF PENETRATION DETAILS Tender No. MET21-117 Addendum #5 Page 39 of 105 Design & Build RFP: Gas Heating Upgrade 2-32 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 40 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 FLUE GAS EXHAUST TERMINATION (RAIN CAP NOT REQUIRED) STORM COLLAR (FOR DOUBLE WALL) TYPICAL ROOF PENETRATION COMBUSTION AIR FROM THE ROOM ( SUGGESTED INSTALLATION CONFIGURATIONS ) NOTES: 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 3) INSTALL SUPPORT STRAPS AT 5 FT (152 CM) HORIZONTAL...
  • Page 41 LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT FIGURE 24 - SIDEWALL PENETRATIONS DETAIL Tender No. MET21-117 Addendum #5 Page 41 of 105 Design & Build RFP: Gas Heating Upgrade 2-34 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 42 When an existing boiler is removed from a common venting Adhere to the following for multi-skid engineered systems: system, the common venting system is likely to be too large for 1. Refer to the Fulton mechanical/electrical drawings proper venting of the appliances remaining connected to it. during assembly.
  • Page 43 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. 9. If a header is supplied, mount the header as shown in the mechanical drawing.
  • Page 44 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 WARNING Electrical Connections and Devices All information in this manual is for reference and guidance purposes, The boiler is designed to operate within the following limits at the connection and does not substitute for required terminals: professional training, conduct, and strict adherence to applicable jurisdictional/ AC power supplied is within +/- 5% of the boiler rated voltage with the...
  • Page 45 NOTE: ALWAYS REFER TO THE SCHEMATIC INSIDE YOUR BOILER FOR THE PRINT SPECIFIC TO YOUR BOILER Tender No. MET21-117 Addendum #5 Page 45 of 105 Design & Build RFP: Gas Heating Upgrade 2-38 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 46 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 from 123 from 123 TB2- X3.04.3 X3.04.2 SAFETY LOOP X3.04.5 X3.04.1 CVM(OC1) X3.02.2 X20.5 AIR SWITCH from 140 X3.02.1 X10.2 X20.4 from 139 TB2- X3.04.4 X10.3 X20.3 from 141 X10.4 CR16 X20.2 from 142 X5.01.2 X8.04.1 X10.1 from 123 LOW GAS...
  • Page 47 (NOTES 1,6) EDR 750-2000 PURE CONTROL REFERENCE ONLY FIELD CONNECTIONS POWER OPEN, POWER CLOSED TB4- Tender No. MET21-117 Addendum #5 Page 47 of 105 Design & Build RFP: Gas Heating Upgrade 2-40 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 48 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 SAFETY AND LWCO CONTROL RELAY RELAY DC POWER RAIL SUPPLY CONTROLS FUSE EXPANSION MODULES BLOWER FUSE CUSTOMER FIELD CONNECTIONS BURNER MANAGEMENT FIGURE 25 - ELECTRICAL CONTROLS LAYOUT (REFERENCE ONLY, LAYOUT MAY VARY) Tender No. MET21-117 Addendum #5 Page 48 of 105 Design &...
  • Page 49 (FLA) of external devices wired to the boiler power circuit cannot exceed 1A. ` LEAD/LAG INTEGRATED SEQUENCING WIRING 1. The Fulton PURE Control™ includes integrated sequencing capabilities. When utilized, the boiler control system will automatically stage boilers and operate burner firing rates in parallel as necessary to FIGURE 27 - ETHERNET-IP FIELD WIRING FOR 2-45-315010 maintain a hydronic setpoint.
  • Page 50 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 8. Also available as an alternative option from the factory 8. If the System Supply value becomes unavailable across is a 5-port 24VDC Ethernet switch that may be field DIN the Universal Data system, boilers configured for Lead/ rail mounted inside of the boiler cabinet.
  • Page 51 4. Can be modulated only if system pump feature is not used. A 0-10 VDC output is provided. Tender No. MET21-117 Addendum #5 Page 51 of 105 Design & Build RFP: Gas Heating Upgrade 2-44 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 52 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 ` ALTERNATE COMMUNICATION PROTOCOL GATEWAY ` BOILER STATUS CONTACT Reference the Protonode Start-Up Guide for for BACnet A dry contact is provided for remote monitoring of boiler protocol. status. When the main gas valve is enabled, the contact is closed.
  • Page 53 INSTALLATION SECTION 2 EDR-PURE-IOM-210617 PAGE LEFT INTENTIONALLY BLANK Tender No. MET21-117 Addendum #5 Page 53 of 105 Design & Build RFP: Gas Heating Upgrade 2-46 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 54 OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Tender No. MET21-117 Addendum #5 Page 54 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 55 (fill) valve set pressure. No more water should be entering the system. Close the shutoff valve on the cold-water fill line. Tender No. MET21-117 Addendum #5 Page 55 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 56 4. The Fulton factory Test Fire Report should be used as a point of reference authorization specific to the Endura in commissioning settings for the boilers in the field, however a factory product line for guidance.
  • Page 57 It is possible to return to the main menu at any time by Commissioning/Start up by a non- repeatedly pressing ESC (Escape). See Figure 27. Fulton authorized person will void the product warranty. FIGURE 27 - SIEMENS AZL DISPLAY...
  • Page 58 OPERATION SECTION 3 EDR-PURE-IOM-210617 Tender No. MET21-117 Addendum #5 Page 58 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 59 ƒ Adjusting Fuel/Air Curve NOTE: 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 60 OPERATION SECTION 3 EDR-PURE-IOM-210617 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. –...
  • Page 61 The output will no longer flash, oP: will be displayed on the left solid and the operating percentage will be displayed on the right. Tender No. MET21-117 Addendum #5 Page 61 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 62 OPERATION SECTION 3 EDR-PURE-IOM-210617 ƒ 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 63 For troubleshooting, go to error code 137 to view diagnostic code. Tender No. MET21-117 Addendum #5 Page 63 of 105 Design & Build RFP: Gas Heating Upgrade 3-10 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 64 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 65 Tap the “back” button to return to category navigation. Tender No. MET21-117 Addendum #5 Page 65 of 105 Design & Build RFP: Gas Heating Upgrade 3-12 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 66 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 67 The Anti-Cycle Timer, if used, will prevent the burner from firing for a minimum amount of time between cycles Tender No. MET21-117 Addendum #5 Page 67 of 105 Design & Build RFP: Gas Heating Upgrade 3-14 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 68 No Access a history of preventative maintenance and repairs. Tapping “View Entry” Fulton document should substitute will expand detail on a previous record. Add a record of service by tapping “New for full review of documentation Entry”...
  • Page 69 , and how quickly the burner(s) ramp up to meet setpoint. A passive setting will provide more damped setpoint response. Tender No. MET21-117 Addendum #5 Page 69 of 105 Design & Build RFP: Gas Heating Upgrade 3-16 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 70 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.
  • Page 71 Tap the “Next Curve” button to navigate through data types. Tender No. MET21-117 Addendum #5 Page 71 of 105 Design & Build RFP: Gas Heating Upgrade 3-18 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 72 Loss of power without Non-Fulton product information an operational battery will result in lost program settings. is for reference purposes only. No Fulton document should substitute ` SENSOR STATUS for full review of documentation available from the component An overview of boiler and auxiliary sensor status is available on this screen.
  • Page 73 1. With the boiler running turn down the high gas pressure switch until a lock out is annunciated. 2. Return the switch to normal setting, re-start the boiler. Tender No. MET21-117 Addendum #5 Page 73 of 105 Design & Build RFP: Gas Heating Upgrade 3-20 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 74 MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Tender No. MET21-117 Addendum #5 Page 74 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 75 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 76 MAINTENANCE SECTION 4 EDR-PURE-IOM-210617 Tool List To complete routine preventative maintenance or repairs, certain tools and supplies will be required that are not provided with the boiler. The qualified service technician should be prepared with the following tools and supplies. Digital Multimeter (DMM) with True RMS ƒ...
  • Page 77 Operating the burner with the combustion air 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. In order to meet warranty conditions, ensure all appropriate maintenance 3.
  • Page 78 2. Replace the combustion air filter with a new filter of the same Fulton part number (type, size and style). Never use open flame or other sources of ignition to check for gas leaks.
  • Page 79 7. Remove the (8) bolts and washers on burner flange. – NOTE: Due to unique hardware specifications, alternate hardware must not be substituted. If hardware is lost or damaged, contact your Fulton representative for replacement. Tender No. MET21-117 Addendum #5 Page 79 of 105 Design &...
  • Page 80 12. If any burner damage is detected, contact your Fulton Representative. Reassemble as follows: 1. Reassemble in reverse order. 2. Replace with a new O-ring and apply Superolube lubricant (Fulton Part number 2-12-000661). Ensure O-ring is positioned properly between premix elbow and fan transition.
  • Page 81 3. Install the ignitor on the burner flange: Apply anti-seize compound to ignitor screws and tighten in place using a torque-rated screwdriver to 8 inch-pounds. Use only a new gasket assembly, Fulton part number 2-12- 001261. 4. Remove the sight glass, flame scanner, and heat block. Position a light to shine into the combustion chamber through the sight glass as required.
  • Page 82 MAINTENANCE SECTION 4 EDR-PURE-IOM-210617 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 verifi cation. Make adjustments as necesary. 3. Complete the “Installation and Operation Report” for Endura boilers and retain in the boiler’s maintenance records. –...
  • Page 83 If calibrated flow meters are not available, flow rate can be approximated by calculation by observing the delta-T across the boiler heat exchanger at a given firing rate. See the Fulton “Calculating Flow Rate” Engineering Guide for more details. High Back Pressure Switch...
  • Page 84 CHECK Boiler Excessively Cycling Controller/Software Consult Fulton technical support to verify the latest software version is installed on the PURE Control. Verify boiler is configured for automatic operation. Verify temperature setpoint and on/off hysteresis settings are appropriate at each boiler. A tighter hysteresis band will increase cycling, relax (increase) this band to reduce cycling.
  • Page 85 If a “Version Mismatch: UniLogic/UniStream Firmware" screen is prompted while performing the program update, continue performing the update as outlined in Section 4 of the PURE Controls Addendum. If further issues are experienced, contact Fulton technical support No SD Card Error Controller/Settings Install/Replace SD card with a capacity of 4GB or larger.
  • Page 86 SERVICE DOCUMENTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Tender No. MET21-117 Addendum #5 Page 86 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 87 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 PAGE INTENTIONALLY LEFT BLANK Tender No. MET21-117 Addendum #5 Page 87 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 88 Gas regulators installed minimum 10 feet of pipe from the boilers? SITE SIGN-OFF DATE: PRINT NAME TITLE: When complete, return a copy to your Fulton Representative and/or the service organization performing commissioning (“start-up”) services. Tender No. MET21-117 Addendum #5 Page 88 of 105 Design & Build RFP: Gas Heating Upgrade Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 89 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 PAGE INTENTIONALLY LEFT BLANK Tender No. MET21-117 Addendum #5 Page 89 of 105 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 90 “START-UP” REPORT NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. WARRANTY COVERAGE IS VALID ONLY IF THIS FORM IS SUCCESSFULLY COMPLETED AND RETURNED TO FULTON WITHIN TWELVE WEEKS OF START-UP. DATE FULTON REP.
  • Page 91 P-161 Total Faults P-162 Operating Hours P-166 Number of Startups When complete, please keep this form with the boiler, store a record copy in a safe location, and return a copy to Fulton: The Fulton Companies ATTN: FHS Service Coordinator...
  • Page 92 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY BOILER NB/SERIAL # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE Burner head cleaned (30-72.5 psi air only) COMPLETE...
  • Page 93 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. Tender No. MET21-117 Addendum #5 Page 93 of 105 Design &...
  • Page 94 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY BOILER NB/SERIAL # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE Burner head cleaned (30-72.5 psi air only) COMPLETE...
  • Page 95 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. Tender No. MET21-117 Addendum #5 Page 95 of 105 Design &...
  • Page 96 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY BOILER NB/SERIAL # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE Burner head cleaned (30-72.5 psi air only) COMPLETE...
  • Page 97 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. Tender No. MET21-117 Addendum #5 Page 97 of 105 Design &...
  • Page 98 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY BOILER NB/SERIAL # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE Burner head cleaned (30-72.5 psi air only) COMPLETE...
  • Page 99 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. Tender No. MET21-117 Addendum #5 Page 99 of 105 Design &...
  • Page 100 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID EDR CERTIFICATE OF REGISTRATION. DATE TECH CERTIFICATE # TECHNICIAN BOILER MODEL TECH. COMPANY BOILER NB/SERIAL # ANNUAL MAINTENANCE: Burner head removed and visually inspected COMPLETE Burner head cleaned (30-72.5 psi air only) COMPLETE...
  • Page 101 Installation, Operation, and Maintenance Manual must be produced for warranty consideration. Please use photocopies or consult your local Fulton Representative for additional copies of this form. Tender No. MET21-117 Addendum #5 Page 101 of 105 Design &...
  • Page 102 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 NOTES Tender No. MET21-117 Addendum #5 Page 102 of 105 Design & Build RFP: Gas Heating Upgrade 5-17 Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 103 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 NOTES Tender No. MET21-117 Addendum #5 Page 103 of 105 Design & Build RFP: Gas Heating Upgrade 5-18 Replacement in Dartmouth © Fulton Group N.A., Inc. 2020...
  • Page 104 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-210617 NOTES Tender No. MET21-117 Addendum #5 Page 104 of 105 Design & Build RFP: Gas Heating Upgrade 5-19 Questions? Please Contact Your Local Manufacturer’s Representative Replacement in Dartmouth...
  • Page 105 Fulton Group N.A., Inc. Fulton Steam Solutions, 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.
  • Page 106 Metropolitan Regional Housing Authority Tender No. MET21-117 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth ADDENDUM NO. 4 July 27, 2021 The Tender Documents shall be amended and will become part of the Contract Documents. This addendum shall form an integral part of the Tender Documents. The closing date and time has changed.
  • Page 107 Documents. This addendum shall form an integral part of the Tender Documents. PART 1 1. Client-supplied boilers are not Lochinvar FB 1501, but shall be Fulton Endura EDR-1500. 2. Fulton Endura EDR-1500 Specs (marked up) from supplier Enviroair. See specs attached.
  • Page 108 Shop drawings shall be approved by Team and Supplier, not BDG or Project Manager,” 7. IOM Manual for Fulton Endura boiler is provided. (Design & Build Team is responsible for accuracy of and for all information required to design and install for these client-supplied boilers.)
  • Page 109 Tender No. MET21-117 ADDENDUM #3 Page 3 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 110 Tender No. MET21-117 ADDENDUM #3 Page 4 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 111 Tender No. MET21-117 ADDENDUM #3 Page 5 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 112 Tender No. MET21-117 ADDENDUM #3 Page 6 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 113 Tender No. MET21-117 ADDENDUM #3 Page 7 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 114 Tender No. MET21-117 ADDENDUM #3 Page 8 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 115 Tender No. MET21-117 ADDENDUM #3 Page 9 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 116 Tender No. MET21-117 ADDENDUM #3 Page 10 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 117 Tender No. MET21-117 ADDENDUM #3 Page 11 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 118 Tender No. MET21-117 ADDENDUM #3 Page 12 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 119 Tender No. MET21-117 ADDENDUM #3 Page 13 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 120 Tender No. MET21-117 ADDENDUM #3 Page 14 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 121 Tender No. MET21-117 ADDENDUM #3 Page 15 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 122 Tender No. MET21-117 ADDENDUM #3 Page 16 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 123 Tender No. MET21-117 ADDENDUM #3 Page 17 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 124 Tender No. MET21-117 ADDENDUM #3 Page 18 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 125 Tender No. MET21-117 ADDENDUM #3 Page 19 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 126 Tender No. MET21-117 ADDENDUM #3 Page 20 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 127 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 Tender No. MET21-117 ADDENDUM #3 Page 21 of 88 Design & Build RFP: Gas Heating Upgrade EDR-IOM-2014-0318...
  • Page 128 Tender No. MET21-117 ADDENDUM #3 Page 22 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...

  • Page 129: 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 130 TABLE OF CONTENTS EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 24 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 131: Introduction

    INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Tender No. MET21-117 ADDENDUM #3 Page 25 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 132: 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 133: Installation

    INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Tender No. MET21-117 ADDENDUM #3 Page 27 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 134: 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 135: 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 136 TOP VIEW FRONT VIEW RIGHT SIDE VIEW BACK VIEW FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER Tender No. MET21-117 ADDENDUM #3 Page 30 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 137: Install Boiler Trim

    INSTALLATION SECTION 2 EDR-IOM-2014-0318  (Figure 1). This will allow access around the equipment NOTE: Each boiler is equipped with a pressure- to facilitate maintenance and a safe work environment. temperature gauge to be installed in the outlet piping An 1 inch (25.4 mm) side clearance is acceptable section of the boiler.

  • Page 138: 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 139: 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 140: Prevent Oxygen Contamination

    6. At a minimum, the hydronic fl uid should be checked for glycol concentration and pH once a year. Tender No. MET21-117 ADDENDUM #3 Page 34 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 141: 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 142: 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 143: 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 144 Detail A  The maximum capacity to attach per condensate drain kit is 12 MMBH total. Tender No. MET21-117 ADDENDUM #3 Page 38 of 88 Design & Build RFP: Gas Heating Upgrade 2-12 Replacement in Dartmouth © The Fulton Companies 2014...
  • Page 145 ----- ----- ----- 41200 33660 29128 FIGURE 5 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP) Tender No. MET21-117 ADDENDUM #3 Page 39 of 88 Design & Build RFP: Gas Heating Upgrade 2-13 Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 146: 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 147: 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 148: Combustion Air Supply From The Boiler Room

    See Table 6. 1. The combustion air supply can be piped directly to the Tender No. MET21-117 ADDENDUM #3 Page 42 of 88 Design & Build RFP: Gas Heating Upgrade 2-16 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 149: 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 150: Common Venting Layouts For Endura

    COMMON HEADER: 1. Precautions must be taken to ensure the prevention of fl ue gases from Tender No. MET21-117 ADDENDUM #3 Page 44 of 88 Design & Build RFP: Gas Heating Upgrade 2-18 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 151: 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 152: Wall Thimble Installation

    FIGURE 7 - WALL THIMBLE INSTALLATION Tender No. MET21-117 ADDENDUM #3 Page 46 of 88 Design & Build RFP: Gas Heating Upgrade 2-20 Replacement in Dartmouth © The Fulton Companies 2014...
  • Page 153 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 154 48 IN. / 122 CM. MAINTAIN MINIMUM 9"/22.86 CM AIR SPACE WALL PENETRATION CLEARANCES TO COMBUSTABLES, WIRES AND INSULATION Tender No. MET21-117 ADDENDUM #3 Page 48 of 88 Design & Build RFP: Gas Heating Upgrade 2-22 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 155: 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 156: Electrical Connections

    A connection box has been provided on the back of the unit for high and low Tender No. MET21-117 ADDENDUM #3 Page 50 of 88 Design & Build RFP: Gas Heating Upgrade 2-24 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 157: 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 158 INSTALLATION SECTION 2 EDR-IOM-2014-0318 38, 44, 45 EXAMPLE ELECTRICAL SCHEMATIC DIAGRAM Tender No. MET21-117 ADDENDUM #3 Page 52 of 88 Design & Build RFP: Gas Heating Upgrade 2-26 Replacement in Dartmouth © The Fulton Companies 2014...
  • Page 159 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 160 INSTALLATION SECTION 2 EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 54 of 88 Design & Build RFP: Gas Heating Upgrade 2-28 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 161: Operation

    OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Tender No. MET21-117 ADDENDUM #3 Page 55 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 162: Perform Pre-Start-Up Inspection

    5. With the gas shutoff valve closed, turn on power to the boiler and operate Tender No. MET21-117 ADDENDUM #3 Page 56 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 163: 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 164 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 165 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 166: Turndown

    13. Once combustion is checked and verifi ed with a combustion analyzer place the control back into automatic mode and check all boiler safeties. Non-Fulton product information is for TABLE 8 - VERIFICATION OF IGNITION ENRICHMENT reference purposes only. No Fulton...

  • Page 167: 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 168: 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 169: 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 170: 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 171 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 172: 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 173: 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 174 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 175: 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 176: Perform Test Of Low Water Cut Off

    Sola control. Boiler should start the Call for Heat sequence again. 4. Perform appropriate test for any secondary Low Water controls. Tender No. MET21-117 ADDENDUM #3 Page 70 of 88 Design & Build RFP: Gas Heating Upgrade 3-16 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 177: 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 178 OPERATION SECTION 3 EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 72 of 88 Design & Build RFP: Gas Heating Upgrade 3-18 Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 179: Maintenance

    MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Tender No. MET21-117 ADDENDUM #3 Page 73 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...

  • Page 180: 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 181: 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 182: 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. Tender No. MET21-117 ADDENDUM #3 Page 76 of 88 Design &...

  • Page 183: 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 184 4-second trial-for-igni on period, the gas valve and spark igni on are de-energized. At this me a safety lockout occurs. Tender No. MET21-117 ADDENDUM #3 Page 78 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...
  • Page 185 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 186 MAINTENANCE SECTION 4 EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 80 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 187: Warranty & Parts

    WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Tender No. MET21-117 ADDENDUM #3 Page 81 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 188 WARRANTY & PARTS SECTION 5 EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 82 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...

  • Page 189: 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 190 PAGE INTENTIONALLY LEFT BLANK Tender No. MET21-117 ADDENDUM #3 Page 84 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...

  • Page 191: 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 192 WARRANTY & PARTS SECTION 5 EDR-IOM-2014-0318 Tender No. MET21-117 ADDENDUM #3 Page 86 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth © The Fulton Companies 2014...
  • Page 193 Tender No. MET21-117 ADDENDUM #3 Page 87 of 88 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth...
  • Page 194 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.
  • Page 195 Metropolitan Regional Housing Authority Tender No. MET21-117 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth ADDENDUM NO. 2 July 13, 2021 The Tender Documents shall be amended and will become part of the Contract Documents. This addendum shall form an integral part of the Tender Documents. Clarification: The closing date and time has changed.
  • Page 196 Metropolitan Regional Housing Authority Tender No. MET21-117 Design & Build RFP: Gas Heating Upgrade Replacement in Dartmouth ADDENDUM NO. 1 June 30, 2021 The Tender Documents shall be amended and will become part of the Contract Documents. This addendum shall form an integral part of the Tender Documents. Clarification: The boilers will be owner supplied for installation under this contract.

This manual is also suitable for:

Endura edr 1000Endura edr 1500Endura edr 2000

Table of Contents