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

Condensing hydronic boilers 750,000 - 2,000,000 btu/hr featuring pure control
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INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
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-230608

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Summary of Contents for FULTON Endura EDR

  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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-230608...

  • Page 3: Table Of Contents

    PARAMETER BACKUP ........................3 9 MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP ............2 17 PARAMETER RESTORE .......................3 10 Install pH Neutralization Kit ................2-21 Using the Fulton PURE Control™ Interface ............3-12 Venting Requirements ..................2-22 NAVIGATION ..........................3 12 Combustion Air Intake ..................2-23 Fulton PURE Control™...
  • Page 4 After All Repairs and Maintenance ..............4-9 Parts Diagrams ....................4-10 Troubleshooting ....................4-17 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. 2023...

  • Page 5: Introduction

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

  • Page 6: Overview

    Code ANSI Z223.1/NFPA 54 latest edition, and the speci 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 7: Installation

    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- red, ultra high- jurisdictional/professional codes and e ciency boiler. Combustion air supply may be ducted to the boiler from the 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 di culty in the future. Correct...
  • Page 10 An appliance adapter may be required. Standard natural gas con gurations only. Alternate or custom con gurations may have di erent Speci cations and dimensions are approximate and for reference only. Fulton practices continuous product requirements; always review the boiler nameplate before installation.

  • Page 11: Clearances And Serviceability

    INSTALLATION SECTION 2 EDR-PURE-IOM-230608 2. The discharge pipe must: Clearances and Serviceability » Not have a diameter less than the full area of Adhere to the following for clearances and serviceability: the valve outlet. » Be as short and straight as possible and so 1.

  • Page 12: Install Water Piping

    . Each must be designed to system speci cations. ƒ Install ltration in the common loop or per boiler to remove particulates if appropriate. A #4 or ner mesh size is required. © Fulton Group N.A., Inc. 2023...
  • Page 13 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 ow path for system water.  © Fulton Group N.A., Inc. 2023...
  • 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 ƒ Use a reverse return primary header to balance ow across the boilers. Where reverse return cannot be used, it is recommended to install a balancing valve per boiler. 2-10 © Fulton Group N.A., Inc. 2023...

  • Page 17: Meet Water Chemistry Requirements

    INSTALLATION SECTION 2 EDR-PURE-IOM-230608 Meet Water Chemistry Requirements WARNING All information in this manual is for System water chemistry requirements are as follows: reference and guidance purposes, and does not substitute for required ƒ pH: Range of 8.5 - 10.5 professional training, conduct, ƒ...

  • Page 18: Fill The Boiler With Water

    Servo Valve 6. When the boiler is installed at a higher level than baseboard radiation (if used), air elimination must be provided directly above the unit. FIGURE 8 TYPICAL GAS TRAIN VARIES BY SIZE/MODEL 2-12 © Fulton Group N.A., Inc. 2023...
  • Page 19 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 ƒ Line Gas Pressure Regulation When inlet gas pressure exceeds 28”W.C. (14”W.C. Canada), a line gas pressure regulator is required to step the gas pressure Measure down below maximum pressure. inlet supply gas pressure Proper selection and installation of a gas pressure regulator here is essential in providing conditions for e cient and reliable combustion.

  • Page 20: Gas Piping Installation

    2. Piping must be of the proper size to ensure adequate gas supply. It is typical for gas delivery piping to be up- sized one or several diameters larger than boiler gas inlet size. 2-14 © Fulton Group N.A., Inc. 2023...
  • Page 21 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 22 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 12 ENDURA MULTIPLE BOILER GAS SUPPLY PIPING 2-16 © Fulton Group N.A., Inc. 2023...

  • Page 23: Install Condensate Drain Trap

    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 24 4. The maximum capacity to attach per condensate drain kit   is 4,000,000 BTU/hr total.  5. Housekeeping pad required, minimum 4 inch (102 mm). FIGURE 13 CONDENSATE DRAIN PIPING FOR INDIVIDUAL ENDURA BOILER 2-18 © Fulton Group N.A., Inc. 2023...
  • Page 25 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 26 TOP VIEW (COVER NOT SHOWN) FIGURE 16 MULTIPLE BOILER CONDENSATE DRAIN TRAP 12 ½ 1½" N.P.T. OUTLET 1½" N.P.T. INLET 6 ½ LEFT VIEW FRONT VIEW RIGHT VIEW FIGURE 17 FULTON PH NEUTRALIZING KIT 2-20 © Fulton Group N.A., Inc. 2023...
  • Page 27 2. Connect kit downstream of Condensate Drain Trap. See Install pH Neutralization Kit 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 28: Venting Requirements

    5. If the maximum positive pressure loss is exceeded, the boiler may have to be de-rated or require the installation of draft accessories such as an engineered exhaust assist fan to prevent operational issues from 2-22 © Fulton Group N.A., Inc. 2023...

  • Page 29: Combustion Air Intake

    7. Site speci c 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 30 1 in per 3,000 BTU/hr of the total input capacity of the combined burners located in the boiler room. See Table 6. 2-24 © Fulton Group N.A., Inc. 2023...
  • Page 31 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 32 II) exhaust vent, the design must prevent ue gas condensate from draining down the outside of the stack or dripping into the space. For installation using a barometric damper, verify the air openings meet the 2-26 © Fulton Group N.A., Inc. 2023...
  • Page 33 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 34 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 EDR-2000 ue gas operating temperatures may M&G DuraVent®...
  • Page 35 COMMON EXHAUST HEADER (SEE NOTES 4,5,6) ECCENTRIC INCREASER SWEEPING 90° ELBOW (SEE NOTE 8) 45° REDUCING TEE FULTON ENDURA (SEE NOTE 7) HYDRONIC CONDENSING BOILER NOTES: THIS IS A TYPICAL ARRANGEMENT FOR REF PURPOSES ONLY. ACTUAL INSTALLATIONS ALTERNATE OR ADDITIONAL COMPONENTS SHOWN FOR CLARITY.
  • Page 36 (See Figures 22, 23 and 24). The air space clearances should be observed to joists, studs, sub oors, plywood, drywall or plaster enclosures, insulating sheathing, rafters, roo ng, and any other material classed as combustible. 2-30 © Fulton Group N.A., Inc. 2023...
  • Page 37 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 3. To prevent the possible re-circulation of ue gases, 3. Install the inside ange to the inside wall, secure with the vent designer must take into consideration such nails or screws, and seal with adhesive material. things as prevailing winds, eddy zones, building con gurations, etc.
  • Page 38 BOILER 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 2-32 © Fulton Group N.A., Inc. 2023...
  • Page 39 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 40 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 2-34 © Fulton Group N.A., Inc. 2023...
  • Page 41 Adhere to the following for multi-skid engineered systems: proper venting of the appliances remaining connected to it. 1. Refer to the Fulton mechanical/electrical drawings At the time of removal of an existing boiler, while the other during assembly.
  • Page 42 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 43 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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/ ƒ...
  • Page 44 119 to 124,132 to 124 LWCP1 LWCP2 EDR 750 2000 PURE CONTROL REFERENCE ONLY ELECTRICAL SCHEMATIC DIAGRAM NOTE: ALWAYS REFER TO THE SCHEMATIC INSIDE YOUR BOILER FOR THE PRINT SPECIFIC TO YOUR BOILER 2-38 © Fulton Group N.A., Inc. 2023...
  • Page 45 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 46 VALVE TYPE OPEN CLOSED ISOLATION VALVE POWER CLOSED, SPRING OPEN SUPPLY VOLTAGE POWER OPEN, SPRING CLOSED (NOTES 1,6) CR07 POWER OPEN, POWER CLOSED TB4- EDR 750 2000 PURE CONTROL REFERENCE ONLY FIELD CONNECTIONS 2-40 © Fulton Group N.A., Inc. 2023...
  • Page 47 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 SAFETY AND LWCO CONTROL RELAY DC POWER RELAY RAIL SUPPLY CONTROLS FUSE EXPANSION MODULES BLOWER FUSE CUSTOMER FIELD CONNECTIONS BURNER MANAGEMENT FIGURE 25 ELECTRICAL CONTROLS LAYOUT REFERENCE ONLY, LAYOUT MAY VARY 2-41 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 48 (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 ring rates in parallel as necessary to FIGURE 27 ETHERNET IP FIELD WIRING FOR 2 45 315010 maintain a hydronic setpoint.
  • Page 49 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 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 eld DIN the Universal Data system, boilers con gured for Lead/ rail mounted inside of the boiler cabinet.
  • Page 50 Control™ User Manual for complete instructions. 3. The pump contact has a maximum rating of 6 Amps at 120 VAC. 4. Can be modulated only if system pump feature is not used. A 0-10 VDC output is provided. 2-44 © Fulton Group N.A., Inc. 2023...
  • Page 51 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 ` 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 52 INSTALLATION SECTION 2 EDR-PURE-IOM-230608 PAGE LEFT INTENTIONALLY BLANK 2-46 © Fulton Group N.A., Inc. 2023...
  • Page 53 OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 54 6. Check temperature/pressure indicator reading, which should equal the pressure-reducing ( ll) valve set pressure. No more water should be entering the system. Close the shuto valve on the cold-water ll line. © Fulton Group N.A., Inc. 2023...
  • Page 55 4. The Fulton factory Test Fire Report should be used as a point of reference authorization speci c to the Endura in commissioning settings for the boilers in the eld, however a factory product line for guidance.
  • Page 56 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 57 OPERATION SECTION 3 EDR-PURE-IOM-230608 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 58 NOTE: Fulton Endura boilers are factory test red and pre-programmed with values in the fuel/air curve (P0-ignition to P9-high re). With the burner on, follow the below steps for making eld changes to the fuel/air curve points. A calibrated ue gas analyzer is required to complete these steps and must be properly inserted into the boiler ue exhaust vent while making changes to the fuel/air curve points.
  • Page 59 OPERATION SECTION 3 EDR-PURE-IOM-230608 1) Con rm position of the fuel selection switch where applicable. 2) Enter the password and parameter “400” will ash. 3) Press the enter (i/reset) button 2 times. a. “P1” will ash and the curve point will be displayed. –...
  • Page 60 5) Press and hold the – and + for 3 seconds to return to automatic mode. a. The output will no longer ash, oP: will be displayed on the left solid and the operating percentage will be displayed on the right. © Fulton Group N.A., Inc. 2023...
  • Page 61 OPERATION SECTION 3 EDR-PURE-IOM-230608 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 62 – NOTE: If an error occurs during the Restore process, a negative value is displayed. For troubleshooting, go to error code 137 to view diagnostic code. 3-10 © Fulton Group N.A., Inc. 2023...
  • Page 63 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 64 OPERATION SECTION 3 EDR-PURE-IOM-230608 WARNING Using the Fulton PURE Control™ Interface All information in this manual is for Reference the Hydronic PURE Control™ User Manual for detailed instructions reference and guidance purposes, on the controls system. The boiler control system features an integrated color...
  • Page 65 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 66: Fulton Pure Control™ Menu Screen Functions

    OPERATION SECTION 3 EDR-PURE-IOM-230608 WARNING Fulton PURE Control™ Menu Screen Functions All information in this manual is for reference and guidance purposes, ƒ Boiler Control and does not substitute for required professional training, conduct, General individual boiler and ancillary functionality is accessed through this and strict adherence to applicable category.

  • Page 67: Boiler History

    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 68: Secondary Pumps

    Lead stop is how far above setpoint before the lead boiler turns o . ƒ The aggressive-passive slider determines how quickly lag boilers are enabled, , and how quickly the burner(s) ramp up to meet setpoint. A passive setting will provide more damped setpoint response. 3-16 © Fulton Group N.A., Inc. 2023...

  • Page 69: Pid Control

    No The boiler can be locked to low re 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...

  • Page 70: Setpoint

    Outdoor Reset screen in Setpoint. ƒ Trending Trending data is continuously recorded by the control and can be enabled or disabled by the operator. Tap the “Next Curve” button to navigate through data types. 3-18 © Fulton Group N.A., Inc. 2023...

  • Page 71: Admin

    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 72: Commissioning Mode

    Test the high gas pressure switch as follows: 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. 3-20 © Fulton Group N.A., Inc. 2023...

  • Page 73: Maintenance

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

  • Page 74: General

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

  • Page 75: Tool List

    Loctite® C5-A Copper Anti-Seize or Equivalent be completed by trained personnel. Appropriate training and instructions ƒ Hercules® Megaloc® Thread Sealant or Equivalent are available from the Fulton Service ƒ Portable Shop Vacuum Department at (315) 298-5121 or your local Fulton Heating Solutions ƒ...

  • Page 76: Monthly Maintenance Schedule

    NOTE: Operating the burner with the combustion air lter removed will void the burner warranty. A clean lter 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 77: Annual Maintenance Schedule

    2. Replace the combustion air lter with a new lter of the same Fulton part number (type, size and style). Never use open ame or other sources of ignition to check for gas leaks.

  • Page 78: Removing And Cleaning The Flame Rod

    7. Remove the (8) nuts and washers on burner ange. – NOTE: Due to unique hardware speci cations, alternate hardware must not be substituted. If hardware is lost or damaged, contact your Fulton representative for replacement. © Fulton Group N.A., Inc. 2023...
  • Page 79 A vacuum may be used at the air/gas inlet to assist in removing particulate matter. CAUTION 12. If any burner damage is detected, contact your Fulton Representative. Reassemble in reverse order as follows: Use caution when using any cleaning solutions.

  • Page 80: Veri Cation Of Ignition Gap

    3. Install the ignitor on the burner ange: 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 P/N 2-12-001261. 4. Remove the sight glass, ame scanner, and heat block. Position a light to shine into the combustion chamber through the sight glass as required.

  • Page 81: After All Repairs And Maintenance

    MAINTENANCE SECTION 4 EDR-PURE-IOM-230608 WARNING After All Repairs and Maintenance All information in this manual is for 1. Perform all Safety Checks as described in the Operation section. reference and guidance purposes, and does not substitute for required 2. Fire the boiler and perform a full combustion veri cation. Make professional training, conduct, adjustments as necesary.

  • Page 82: Parts Diagrams

    STAINLESS STEEL PT100 SENSOR, HEX14, 1/4"NPT, 9.5 X 45MM 2-50-315302 BRASS PT100 SENSOR, HEX14, 1/4"NPT, 9.5 X 45MM 5-11-000018 18" LONG HIGH VOLTAGE IGNITION CABLE WITH 1/4" FEMALE CONNECTIONS FIGURE 29 INSTRUMENTATION AND DEVICES EDR 750/1000 4-10 © Fulton Group N.A., Inc. 2023...
  • Page 83 MAINTENANCE SECTION 4 EDR-PURE-IOM-230608 ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 2-12-315004 1/4" X 1/8" ID FLEXIBLE NEOPRENE TUBING 2-40-000294 HIGH LIMIT AQUASTAT WITH MANUAL RESET (100-200F) 2-20-000023 3" WATER LEVEL PROBE 2-40-000976 TRANSFORMER 120V 50 / 60 Hz 15.6KVPK SECONDARY 28 MA 2-22-000048 1/4"...
  • Page 84 1" X 2 1/2" - NPT SCH 40 NIPPLE 2-35-001430 1" X 9" - NPT SCH 40 NIPPLE 2-35-001555 1" X 12" - NPT SCH 40 NIPPLE FIGURE 31 GAS TRAIN EDR 750/1000 4-12 © Fulton Group N.A., Inc. 2023...
  • Page 85 MAINTENANCE SECTION 4 EDR-PURE-IOM-230608 ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 2-22-000215 #8 USS FLAT WASHER - ZINC PLATED 2-35-001230 1/4" BRASS SQUARE HEAD PLUG 2-22-000294 8-32 STOP NUT - NYLON INSERT - STEEL 2-35-001362 1 1/2" X 16" - NPT SCH 40 NIPPLE 2-22-315013 #8-32 X 1/2"...
  • Page 86 SINGLE CIRCUIT, 65A TERMINAL BLOCK (18GA. - 6GA.) 5-10-081590 PURE ELECTRICAL BACK PANEL 2-45-000517 750/1000 PURE 15 AMP CUBE FUSE TCF15 2-45-000535 1500/2000 PURE 25 AMP CUBE FUSE TCF25 FIGURE 33 ELECTRICAL CONTROLS EDR 750 TO 2000 4-14 © Fulton Group N.A., Inc. 2023...
  • Page 87 MAINTENANCE SECTION 4 EDR-PURE-IOM-230608 PART PART ITEM DESCRIPTION QTY U.O.M. ITEM DESCRIPTION QTY U.O.M. NUMBER NUMBER 2-10-000012 1/4" OD X .17 ID BLACK NYLON TUBING 2-22-420023 M5 X 0.8MM X 20MM LG. CLASS 12.9 SOCKET HEAD CAP 2-12-000012 3/4" NPT SIGHT OBSERVATION PORT SCREW 2-12-000236 4 3/4"...
  • Page 88 18" LONG HIGH VOLTAGE IGNITION CABLE 2-22-000467 5/16-18 X 1 1/4" HHCS, SAE GR. 5 BOLT 5-20-072000 ENDURA EDR-1500 / EDR-2000 DIRECT SPARK IGNITION 2-22-315013 #8-32 X 1/2" SOCKET HEAD CAP SCREW 5-20-C71590 ENDURA 1500K / 2000K MACHINED BLOWER TRANSITION 2-22-420002 M8-1.25 x 12mm CLASS 10.9 BUTTON HEAD CAP SCREW...

  • Page 89: Troubleshooting

    EDR-PURE-IOM-230608 Troubleshooting Use the following table as a guide to troubleshooting your boiler. For further support, record the boiler National Board #, Error Code, Diagnostic Code, and Phase of the alarm occurrence(s) and contact your local Fulton Representative. PROBLEM CAUSE...
  • Page 90 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 con gured for automatic operation. Verify temperature setpoint and on/o hysteresis settings are appropriate at each boiler. A tighter hysteresis band will increase cycling, relax (increase) this band to reduce cycling.
  • Page 91 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 92 Verify manifold pressure and air damper combustion settings are su cient at all points to satisfy minimum air switch pressure. Electrical/Wiring Verify wiring to/from the Air Switch, ensure terminals are tight and wires are secure. 4-20 © Fulton Group N.A., Inc. 2023...

  • Page 93: Service

    SERVICE DOCUMENTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 94 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 PAGE INTENTIONALLY LEFT BLANK © Fulton Group N.A., Inc. 2023...

  • Page 95: 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 96 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 PAGE INTENTIONALLY LEFT BLANK © Fulton Group N.A., Inc. 2023...

  • Page 97: Installation & Operation "Start-Up" Report

    NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 98 * Use only a Slack Tube Manometer or equivalent. The use of a digital manometer is not recommended. When complete, please keep this form with the boiler, store a record copy in a safe location, and return a copy to Fulton: Fulton Phone: (315) 298-5121 •...

  • Page 99: Annual Maintenance Checklists

    SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 ENDURA (EDR) ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 (air only)
  • Page 100 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. 2023-0607-EDR-PURE-MX-FORM.PDF © Fulton Group N.A., Inc. 2023...
  • Page 101 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 ENDURA (EDR) ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 (air only)
  • Page 102 When complete, please keep this form with the boiler and store a record copy in a safe location. Accurate and complete combustion and maintenance records detailing compliance with the 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. 2023-0607-EDR-PURE-MX-FORM.PDF 5-10...
  • Page 103 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 ENDURA (EDR) ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 (air only)
  • Page 104 When complete, please keep this form with the boiler and store a record copy in a safe location. Accurate and complete combustion and maintenance records detailing compliance with the 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. 2023-0607-EDR-PURE-MX-FORM.PDF 5-12...
  • Page 105 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 ENDURA (EDR) ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 (air only)
  • Page 106 When complete, please keep this form with the boiler and store a record copy in a safe location. Accurate and complete combustion and maintenance records detailing compliance with the 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. 2023-0607-EDR-PURE-MX-FORM.PDF 5-14...
  • Page 107 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 ENDURA (EDR) ANNUAL MAINTENANCE CHECKLIST NOTE: TO BE COMPLETED BY A FACTORY AUTHORIZED TECHNICIAN HOLDING A VALID ENDURA (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 (air only)
  • Page 108 When complete, please keep this form with the boiler and store a record copy in a safe location. Accurate and complete combustion and maintenance records detailing compliance with the 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. 2023-0607-EDR-PURE-MX-FORM.PDF 5-16...

  • Page 109: Notes

    SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 NOTES 5-17 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 110 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 NOTES 5-18 © Fulton Group N.A., Inc. 2023...
  • Page 111 SERVICE DOCUMENTS SECTION 5 EDR-PURE-IOM-230608 NOTES 5-19 Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 112 Fulton Group N.A., Inc. Fulton Thermal Corporation is part of Fulton Group N.A., Inc., a global manufacturer of steam, hot water and thermal uid heat transfer systems. Fulton Steam Solutions, Inc. & Fulton Heating Solutions, Inc.

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