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FULTON Endura Installation, Operation And Maintenance Manual
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FULTON Endura Installation, Operation And Maintenance Manual

Condensing hydronic boilers
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INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
Endura (EDR)
Condensing Hydronic Boilers
750,000 - 2,000,000 BTU/HR
with SOLA Control
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
EDR-SOLA-IOM-2022-0216

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Summary of Contents for FULTON Endura

  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Endura (EDR) Condensing Hydronic Boilers 750,000 - 2,000,000 BTU/HR with SOLA Control Serial/ National Board Number Model Fulton Order Owner Site Name Date EDR-SOLA-IOM-2022-0216...
  • Page 3 Weekly Maintenance Schedule ................4-4 Removing an Existing Boiler ................2-34 Monthly Maintenance Schedule ................4-4 Assembly of Fulton Multi-Skid Systems............. 2-35 Procedure for Inspecting the Air Inlet Filter ............4-4 Electrical Connections and Devices ..............2-36 Annual Maintenance Schedule ................4-5 JUNCTION BOX LOCATIONS FOR FIELD WIRING ...............2-41...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS EDR-SOLA-IOM-2022-0216 Service Pre-Commissioning Installation Checklist ............5-3 Installation & Operation “Start-Up” Report ............5-5 Annual Maintenance Checklists ................5-7 Notes ........................5-17 © Fulton Group N.A., Inc. 2022...
  • Page 5 INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 6 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 INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 8 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 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 *Standard configurations may be available as an option; please consult factory. Note: All dimensions are approximate and are subject to change without notice. TOP VIEW FRONT VIEW RIGHT SIDE VIEW BACK VIEW FIGURE 1 - VIEWS OF ENDURA HYDRONIC BOILER © Fulton Group N.A., Inc. 2022...
  • Page 11 1 (25.4) components, on the Endura skid. Install Boiler Trim Each Endura boiler is supplied with a safety relief valve sized in accordance with ASME requirements. Adhere to the following installation requirements: 1. The safety relief valve (Figure 2) must: Note: Valve is »...
  • Page 12 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. 2022...
  • Page 13 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 ƒ Install bypass chemical feeder for corrosion inhibitor maintenance if WARNING 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 14 Note: Sample piping layout (P&ID) is a general representation of system installation. Good practice should be used in system    design, including but not limited to adequate pipe/valve sizing and natural flow path for system water.  © Fulton Group N.A., Inc. 2022...
  • Page 15 REVISION DESCRIPTION CHECKED B.O.M. MECH. ENG ELEC. ENG APPROVED HEATING HOT REVISION HISTORY WATER SUPPLY SYSTEM (SECONDARY) PUMP FULTON ENDURA CONDENSING HYDRONIC BOILER AIR REMOVAL SUPPLY WATER TEMPERATURE SENSOR EXPANSION TANK CLOSELY SPACED TEES (<4 DIAMETERS) SEE NOTE 4 BOILER...
  • Page 16 Where using closely spaced tees, separate by four pipe diameters or less. ƒ Install the dedicated boiler circulator on the inlet side of the Endura boiler, pumping into the return connection. Select pump(s) with sufficient total dynamic head for the pressure drop of the loop at design flow. See Figure 3 for the boiler water pressure drop.
  • Page 17 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 ƒ Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2 mpy. WARNING Due to changing environmental restrictions a non-heavy metal ALL ORGANIC inhibitor is recommended which is designed for multi metal All information in this manual is for reference and guidance purposes, systems including ferrous metals and yellow metals such as copper and and does not substitute for required...
  • Page 18 Note: Measure Inlet gas pressure here Main Gas Valve (see Figure 26) Lockup Regulator with Integral Vent Limiter Ignition Enrichment Regulator FIGURE 8 - TYPICAL GAS TRAIN (VARIES BY SIZE/MODEL) with Integral Vent Limiter 2-12 © Fulton Group N.A., Inc. 2022...
  • Page 19 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 ƒ Inlet Gas Pressure ƒ A line pressure regulator listed and labeled to ANSI Z21.80/CSA 6.22 is recommended. Lock-up is defined Adhere to the following: as an outlet pressure not more than 150% or 5” W.C., whichever is greater, above the setpoint after ƒ...
  • Page 20 10 linear feet of pipe between the REFER TO THE INSTALLATI INFORMATION REGARDING regulator outlet and boiler fuel train inlet. AND OTHER INSTALLATION FIGURE 10 - ENDURA SINGLE BOILER GAS SUPPLY PIPING 2-14 © Fulton Group N.A., Inc. 2022...
  • Page 21 3. The line regulator should be installed with a  minimum of 10 linear feet of pipe between the regulator outlet and boiler fuel train inlet. FIGURE 11 - ENDURA MULTIPLE BOILER GAS SUPPLY PIPING 2-15 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 22 ƒ Components Requiring Ventilation to the Install Condensate Drain Trap Outdoors A condensate drain trap is intended for use with the Fulton The following do not require ventilation to the outdoors, as Endura boiler. there is a vent limiter in use: ƒ...
  • Page 23 4. The maximum capacity to attach per condensate drain kit   is 4 MMBH total.  5. Housekeeping pad required, minimum 4 inch (102 mm). FIGURE 13 - CONDENSATE DRAIN PIPING FOR INDIVIDUAL ENDURA BOILER 2-17 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 24 6. The maximum capacity to attach per multiple boiler condensate drain trap is 12 MMBH total. 7. Housekeeping pad required, minimum 4 inch (102 mm). DETAIL A CONDENSATE DRAIN KIT FIGURE 14 - CONDENSATE DRAIN PIPING FOR MULTIPLE ENDURA BOILERS 2-18 © Fulton Group N.A., Inc. 2022...
  • Page 25 Adhere to the following for installation: 1.5 inch (38.1 mm) drain connection on the drain tank 1. The Fulton Endura boiler 1 inch (25.4 mm) condensate must be the highest point prior to going to the drain. drain will be connected to the 1 inch (25.4 mm) inlet Failure to keep drain piping lower than this point will on the drain trap.
  • 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 I SOMETRI C VI EW I SOMETRI C VI EW FRONT VI EW...
  • Page 27 All information in this manual is for reference and guidance purposes, The pH Neutralization Kit is a Fulton-provided kit designed to bring the pH level and does not substitute for required of the boiler’s condensate to a more neutral level. It is not a replacement or professional training, conduct, and strict alternative for the Condensate Drain Trap.
  • Page 28 6. Adhere to local and jurisdictional codes and regulations, which may differ from recommendations and diagrams contained in this manual. 7. Site specific conditions not addressed in this manual may require additional precautions or design considerations. Consult your local Fulton Representative and venting supplier for recommendations. –...
  • Page 29 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 WARNING direction, nearby mechanical equipment and other design considerations as detailed in this manual. Some recommendations: All information in this manual is for reference and guidance purposes, ƒ Avoid sharp turns, boot tees, bullhead tees, back-to-back 90 and does not substitute for required degree elbows, and short radius elbows.
  • Page 30 9. Where mechanical combustion air supply systems are used, such as a combustion air supply fan or a motorized louver, they must be interlocked with the boiler control panel to prove operation prior to burner ignition 2-24 © Fulton Group N.A., Inc. 2022...
  • Page 31 Where manual louvers are used, ensure they are fully open prior to operating the boiler(s). Fulton accepts no liability for installation of any venting, including the selection of 10. A 90˚ elbow is recommended on the air inlet to prevent debris falling into venting materials.
  • Page 32 A 45° REDUCING TEE OR ELBOW IN THE DI IS RECOMMENDED. STRAIGHT OR 90° TEES USED. DO NOT USE BOOT TEES OR BULL HEAD TE ENDURA BOILERS CANNOT BE COMMON VE FIGURE 20 - ENDURA COMMON EXHAUST VENTING; TYPICAL INSTALLATION GUIDELINES 2-26 © Fulton Group N.A., Inc. 2022...
  • Page 33 Any venting material supplied for the Endura boiler must be AL29-4C or 316L/444 SS, listed and labeled to UL 1738, and guaranteed appropriate for the application by the manufacturer and supplier of the venting. It is also acceptable to vent as Category II condensing, negative pressure, for which an upsized diameter is typically required.
  • Page 34 230° F 200° F 158° F Stack Limit (130° C) (130° C) (110° C) (93° C) (70° 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 35 PIPE RETAINING CLAMP, TYPICAL EACH SIDE It is possible to combine the air intake and/or exhaust venting of multiple Endura boilers. The pressure drop across END VIEW the entire common system, the combined total of both air 3½ INCH OR intake and exhaust, must comply with the draft pressure 4.35 CM AIR GAP...
  • Page 36 BOILER APPLIANCE ADAPTER CONSULT FLUE MFG FOR SELECTION REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER CONDENSATE TRAP LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT FIGURE 22 - ROOF PENETRATION DETAILS 2-30 © Fulton Group N.A., Inc. 2022...
  • Page 37 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 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 38 REFERENCE TABLE 1 FOR FLUE GAS STACK DIAMETER FLUE GAS EXHAUST TERMINATION VELOCITY CONE FOR VAPOR PLUME MITIGATION AWAY FROM BUILDING CONDENSATE TRAP LEVEL HOUSEKEEPING PAD MIN 4 INCH (102 CM) HEIGHT FIGURE 24 - SIDEWALL PENETRATIONS DETAIL 2-32 © Fulton Group N.A., Inc. 2022...
  • Page 39 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 ƒ Venting Terminations 3. Install the inside flange to the inside wall, secure with nails or screws, and seal with adhesive material. Adhere to National Fuel Gas Code (ANSI Z223.1) and the 4. Pass the vent pipe through the thimble from the following for installation: outside and join to the rest of the vent system.
  • Page 40 Flue should be directed away from surfaces, if possible. (FLA) of external devices wired to the Endura boiler power circuit cannot exceed Removing an Existing Boiler When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
  • Page 41 Assembly of Fulton Multi-Skid Systems professional codes and regulations. Adhere to the following for multi-skid engineered systems: 1. Refer to the Fulton mechanical/electrical drawings during assembly. 2. Ensure that equipment orientation allows for operation interface and maintenance. 3. Align the skids as shown on the drawings ensuring that skid fasteners (skid joint angles) are matched.
  • Page 42 Do not run Building Management System (BMS) or any other communication wiring into the high voltage box. The Endura cabinet has removable panels to facilitate access. Do not run conduit through or over access panels. Adhere to the following when making electrical connections: 1.
  • Page 43 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 EDR 750 - 2000 REFERENCE ONLY ELECTRICAL SCHEMATIC DIAGRAM 2-37 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 44 LR RELAY SETTINGS TIME RANGE TIME MODE (BOTTOM) (TOP) (MIDDLE) B/Bi SIZE REFERENCE CHART J-FUSE (BM) BOILER SIZE EDR 750-1000 10A (2-45-000267) EDR 1500-2000 25A (2-45-000278) EDR 750 -2000 REFERENCE ONLY ELECTRICAL SCHEMATIC DIAGRAM (CONTINUED) 2-38 © Fulton Group N.A., Inc. 2022...
  • Page 45 INSTALLATION SECTION 2 EDR-SOLA-IOM-2022-0216 MODSYNC ISOLATION VALVE OPTIONAL DEVICES AND PUMP INTEGRATION OPTIONAL COMPONENTS EDR 750-2000 REFERENCE ONLY ELECTRICAL SCHEMATIC DIAGRAM (CONTINUED) 2-39 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 46 EDR-SOLA-IOM-2022-0216 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 2-40 © Fulton Group N.A., Inc. 2022...
  • Page 47 The rating of each external device contact is the maximum primary loop. allowable amperage of the contact. The total Full Load Amps (FLA) of external devices wired to the Endura boiler power 4. The sensor monitors hydronic loop temperature in circuit cannot exceed 1A.
  • Page 48 ` AUXILIARY SAFETY INTERLOCK FOR EXTERNAL DEVICE and field wired to the MASTER boiler. 1. When the Endura boiler receives a call for heat, the 2. An outdoor air temperature sensor kit is not required if startup sequence first checks for a completed LCI circuit.
  • Page 49 ` BURNER FIRE RATE OUTPUT 2-45-880360) wired to the REMOTE setting of the three 1. Fulton SOLA J10 plug terminals 4, 5, and 6 may be used position control switch, rated for 5 Amps maximum. A for either 4-20 mA or 0-10 VDC burner fire rate output.
  • Page 50 A dry contact is provided for remote monitoring of boiler status. When the main gas valve is enabled, the contact is closed. This requires a 120 VAC relay (P/N 2-45-880360), rated for 5 Amps maximum. 2-44 © Fulton Group N.A., Inc. 2022...
  • Page 51 OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 52 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. 2022...
  • Page 53 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 54 Commissioning/Start up by a non- Fulton authorized person will void the 2. Turn the boiler on and ensure that there is a call for heat. If the unit does product warranty.
  • Page 55 WARNING combustion throughout the range. Once combustion setup is completed at low and high fire, perform the following steps a minimum of ten times Non-Fulton product information is for reference purposes only. No Fulton to verify O2 repeatability: document should substitute for full Ramp the boiler from low fire RPM to high fire RPM.
  • Page 56 15. Once combustion is verified with a combustion analyzer place the control back into automatic mode and check all boiler safeties. FIGURE 29 - ENRICHMENT TEST BUTTON     © Fulton Group N.A., Inc. 2022...
  • Page 57 OPERATION SECTION 3 EDR-SOLA-IOM-2022-0216 – NOTE: The boiler is factory-configured for standard natural gas. Contact your WARNING authorized service organization for conversion to HD5 propane. All information in this manual is for reference and guidance purposes, TABLE 9 - METAL MESH BURNERS: VERIFICATION OF NATURAL GAS COMBUSTION and does not substitute for required Light Off Low Fire...
  • Page 58 Use a calibrated gas flow meter (not supplied) to measure burner input rates. Consult your local manufacturer’s representative or service organization with factory authorization specific to the Endura product line for guidance. © Fulton Group N.A., Inc. 2022...
  • Page 59 Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.
  • Page 60 In this screen (Figure 34) the Setpoint can be changed. Press the up and down arrow or press Clear and enter the desired Setpoint. Then press OK. FIGURE 33 - CENTRAL HEAT OPERATION - FIRING RATE SCREEN 3-10 © Fulton Group N.A., Inc. 2022...
  • Page 61 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 62 See Table 11 for factory recommended values, field adjustment outside of these values may be required for optimal response performance. 3-12 © Fulton Group N.A., Inc. 2022...
  • Page 63 This change will require Verification. Verify jurisdictional/professional codes and as follows: 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 64 4. If there are no more changes the control will ask for a reset (Figure 40). This can be done by pressing the reset button on the front of the Sola control (the base) for 1 to 2 seconds. FIGURE 41 - RESET VERIFICATION SCREEN 3-14 © Fulton Group N.A., Inc. 2022...
  • Page 65 Clear All. This is not recommended. professional training, conduct, and strict adherence to applicable 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.
  • Page 66 Unapproved modifications may cause injury, equipment damage, and FIGURE 44 - VIEWING LOCKOUT will void the warranty. FIGURE 45 - CLEARING LOCKOUT FIGURE 46 - LOCKOUT INFORMATION 3-16 © Fulton Group N.A., Inc. 2022...
  • Page 67 OPERATION SECTION 3 EDR-SOLA-IOM-2022-0216 ƒ SOLA Diagnostics WARNING From the Status Summary screen (Figure 47), press Diagnostics. 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.
  • Page 68 FIGURE 49 - DIGITAL I/O Pressing Analog I/O will place you into the Analog I/O screen (Figure 50). Specific information on temperature, firing rate, flame signal and fan speed may be viewed. FIGURE 50 - ANALOG I/O 3-18 © Fulton Group N.A., Inc. 2022...
  • Page 69 The screen shots and information in this section will help you configure various service or repair this equipment unless options available on the Endura boiler. For further information on installation you (they) fully understand all applicable requirements refer to the electrical portion in the Installation section.
  • Page 70 Detection Time: The amount of time that must expire, after the interstage delay time has expired, before a boiler is added. ƒ Error Threshold: A stage is added when the error becomes excessive based on degrees away from set point. FIGURE 53- ADD STAGE 3-20 © Fulton Group N.A., Inc. 2022...
  • Page 71 Detection Time: The amount of time that must expire, after the interstage regulations. delay time has expired, before a boiler is added. Non-Fulton product information is for ƒ Error Threshold: A stage is added when the error becomes excessive based reference purposes only.
  • Page 72 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 3-22 © Fulton Group N.A., Inc. 2022...
  • Page 73 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 74 Select configure and scroll to and select the sensor configuration. The row labeled “*S2 (J8-6) Sensor (4-20mA remote)” needs to be set on 4-20mA as shown in Figure 60. FIGURE 60 - REMOTE 4-20MA SENSOR CONFIGURATION 3-24 © Fulton Group N.A., Inc. 2022...
  • Page 75 Off Hysteresis: The differential above setpoint when the boiler is turned off. regulations. ƒ On Hysteresis: The differential from setpoint when the boiler is turned on. Non-Fulton product information is for ƒ 4 mA water temperature: The setpoint valued assigned to a remote 4 mA reference purposes only. No Fulton...
  • Page 76 Starting from the status screen tap configure and then scroll to and select sensor configuration. The outdoor temperature source needs to be assigned to EnviraCOM outdoor sensor. Ensure values are as indicated in Figure 64. 3-26 © Fulton Group N.A., Inc. 2022...
  • Page 77 “enable”. Refer to Figure 65 for jurisdictional/professional codes and factory default settings: 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 78 For a standalone boiler application warm weather shutdown must be configured through a different screen. This screen can be found by selecting configure from the boiler status screen. Scroll to and select warm weather shutdown configuration and follow similar steps as above. 3-28 © Fulton Group N.A., Inc. 2022...
  • Page 79 Stack limit must not exceed exhaust material temperature jurisdictional/professional codes and limitations. See Table 7. 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 80 Any one of the available pump outputs A through C can be used to do so. For Endura boilers equipped with an isolation valve control relay, choose the pump output wired to this relay. From this screen select Auto for pump control and either pump A, B, or C for pump output.
  • Page 81 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 72 - ADVANCED PUMP CONFIGURATION SCREEN ƒ...
  • Page 82 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. 3-32 © Fulton Group N.A., Inc. 2022...
  • Page 83 3. Reset the Low Water condition by pressing the Low Water reset button and Non-Fulton product information is for reset the Sola control. Boiler should start the Call for Heat sequence again. reference purposes only. No Fulton document may substitute for full 4.
  • Page 84 Endura boilers should be operated and controlled so the boiler and does not substitute for required cycles less than 12,000 times per year. Endura boilers should be operated and professional training, conduct, and strict adherence to applicable...
  • Page 85 MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 86 Daily, Weekly and Monthly Maintenance and Inspection are considered good jurisdictional/professional codes and practice for any boiler, and are applicable to the full line of Endura boilers. It is regulations. also good practice for any boiler installation to perform a thorough review of the overall system on a regular basis, and after any maintenance procedures.
  • Page 87 MAINTENANCE SECTION 4 EDR-SOLA-IOM-2022-0216 WARNING Tool List All information in this manual is for To complete routine preventative maintenance or repairs, certain tools and reference and guidance purposes, supplies will be required that are not provided with the boiler. The qualified and does not substitute for required service technician should be prepared with the following tools and supplies.
  • Page 88 NOTE: 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. 3. Return the filter to its original position in the slot.
  • Page 89 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 90 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 91 NOTE: Due to unique hardware specifications, alternate hardware must not be Use caution when using any cleaning substituted. If hardware is lost or damaged, contact your Fulton representative for solutions. Refer to local regulations for replacement. proper cleaning solution disposal.
  • Page 92 MAINTENANCE SECTION 4 EDR-SOLA-IOM-2022-0216 WARNING 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. Personnel performing burner assembly maintenance must wear ƒ O-ring for EDR-750/1000 is Fulton Part Number 2-12-000236 appropriate respiratory protection.
  • Page 93 6. Visually verify the ignition position relative to the 3. Complete the “Installation and Operation Report” for burner head. Endura boilers and retain in the boiler’s maintenance records. ƒ The negative electrode must not be touching or resting on the burner head.
  • Page 94 2-40-000332 THERMISTOR TEMP. SENSOR DUAL ELEMENT 2-40-000976 TRANSFORMER 120V 50 / 60 Hz 15.6KVPK SECONDARY 28 MA 2-40-071000 ENDURA 750K / 1000K METAL MESH BURNER HEAD 2-45-000093 FEMALE NYLON EXPANDED INSULATED SPLICE 2-45-000423 FEMALE NYLON EXPANDED INSULATED CONNECTOR, 16-14 AWG...
  • Page 95 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 3" WATER LEVEL PROBE 2-20-000137...
  • Page 96 Verify ILK circuit input at SOLA base including Limit String and Auxiliary Safeties (pin J5-1) Connections Controller / Settings Check the Alarm History to determine what triggered the fault Details >> History >> Lockouts >> Select the desired lockout to see the ‘First out’ 4-12 © Fulton Group N.A., Inc. 2022...
  • Page 97 14. Pull the burner. Inspect for dirt/dust that could cause it to clog and any other physical issue. Clean with compressed air only if necessary. 15. If the issue persists after thoroughly completing all of the above steps, contact your Fulton Representative for upgrade kit # 7-53-070000.
  • Page 98 Note that overhead lights will trigger the sensor. 4. Swap sensors with a known good unit to see if the issue follows, or replace with new sensor. 4-14 © Fulton Group N.A., Inc. 2022...

  • Page 99: Service

    SERVICE DOCUMENTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 100 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 PAGE INTENTIONALLY LEFT BLANK © Fulton Group N.A., Inc. 2022...

  • Page 101: Pre-Commissioning Installation Checklist

    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. Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 102 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 PAGE INTENTIONALLY LEFT BLANK © Fulton Group N.A., Inc. 2022...

  • Page 103: Installation & Operation "Start-Up" Report

    “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 104 Burner Cycles Burner Hours Controller Cycles Controller Hours 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 972 Centerville Road Pulaski, New York 13142 Phone: (315) 298-5121 •...

  • Page 105: Annual Maintenance Checklists

    SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 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 106 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. © Fulton Group N.A., Inc. 2022...
  • Page 107 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 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 108 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. 5-10 © Fulton Group N.A., Inc. 2022...
  • Page 109 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 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 110 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. 5-12 © Fulton Group N.A., Inc. 2022...
  • Page 111 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 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 112 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. 5-14 © Fulton Group N.A., Inc. 2022...
  • Page 113 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 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 114 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. 5-16 © Fulton Group N.A., Inc. 2022...

  • Page 115: Notes

    SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 NOTES 5-17 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 116 SERVICE DOCUMENTS SECTION 5 EDR-SOLA-IOM-2022-0216 NOTES 5-18 © Fulton Group N.A., Inc. 2022...
  • Page 117 PAGE INTENTIONALLY LEFT BLANK...
  • Page 118 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.

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