FULTON ENDURA EXE-399 Quick Start Manual

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This Quick Start Guide is provided for use by a professional
installing contractor as reference instruction for the
installation and start-up of this boiler. This is not a substitute
for the Installation, Operation and Maintenance Manual
(IOM), required professional training and conduct, and strict
adherence to applicable jurisdictional codes and regulations.
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Failure to follow instructions, cautions and warnings in the
IOM may result in property damage, personal injury, or loss
FIRST
of life. Fulton assumes no responsibility for damage(s) of any
kind caused by inappropriate use of this Quick Start Guide
and/or failure to read the full IOM provided.
DIGITAL MANUAL
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Operation & Maintenance Manual
1. TRANSPORT
This boiler has a compact footprint, handle with care to avoid tipping, use caution
during movement and take turns slowly.
Do not run ratchet straps or cargo tie downs over top of the shipping box.
Move the boiler using a pallet jack from any side or a hand truck from the right hand
side only. The boiler may be laid down on the rear for transportation.
2. UNCRATING
Remove the cardboard shipping box, then remove the lag screws securing the
boiler base to the wooden shipping skid. Carefully remove the boiler from the
wooden shipping skid. Once the boiler is in position, the protective plastic may be
peeled off the cabinet surfaces.
3. PLACEMENT
This boiler is required to be installed on a level, rigid, non-combustible base. It may
be installed on a steel or concrete housekeeping pad or directly on the floor. Use
metal shims if necessary to ensure the boiler is level. Do not install on springs.
Ensure boiler components are protected from water and debris, and choose a
suitable location where room temperatures are above 32°F (0°C) and do not exceed
104°F (40°C). Models with rated capacity greater than 400,000 BTU/hr are not
permitted for installation in a closet or alcove.
4. CLEARANCES
FRONT REAR*
24 inch (610 mm) 12 inch (305 mm)
* 12 inch rear clearance is to combustibles and for maintenance, allow for 24inch rear
clearance to accommodate installation of the flue gas exhaust vent.
5. WATER CONNECTIONS
The upper water connection is the boiler supply (outlet). The lower water connection
is the boiler return (inlet). Field piping, fittings and ancillaries are not supplied with
the boiler. Install pipe hangers or supports so that the boiler is not supporting any
external piping load.
This boiler is for closed loop hot water heating (hydronic) service. It is not suitable
for use as a domestic water heater. Do not heat open loop water, such as used for
showers, sinks, pools, or washdown process directly through the boiler.
SUPPLY WATER
TEMPERATURE SENSOR
NOTE: INSTALL 5 TO 10 PIPE
DIAMETERS DOWNSTREAM
OF CLOSELY SPACED TEES
SAFETY
RELIEF
VALVE
P&T
GAUGE
#4 OR FINER
HEATING HOT MESH
WATER RETURN STRAINER
ENDURA XE Condensing Hydronic Boilers
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TOP SIDES
16 inch (406 mm) 0 inch (0 mm)
SYSTEM
(SECONDARY)
HEATING HOT
PUMP(S)
WATER SUPPLY
AIR & DIRT
REMOVAL
CLOSELY SPACED TEES
NOTE: ≤ 4 DIAMETERS
DEDICATED BOILER
(PRIMARY) PUMP
NOTE: PUMP INTO THE
BOILER RETURN (INLET)
EXPANSION TANK
NOTE: MUST BE INSTALLED ON THE
SUCTION SIDE OF THE SECONDARY PUMP(S)
AND PRE-CHARGED PRIOR TO FILLING SYSTEM
QUICK START GUIDE
APPLIES TO: EXE-399, EXE-500, EXE-650, EXE-750
Primary-Secondary Arrangements: A dedicated boiler (primary) pump must be
installed on the boiler return, pumping into the boiler. Install closely spaced tees a
maximum of 4 pipe diameters apart, or use a hydraulic separator.
Refer to the IOM for variable primary and modular (multiple boiler) arrangements.
A Safety Relief Valve (SRV), tee for SRV, and Pressure & Temperature (P&T) gauge
are provided in the boiler trim kit. Install the tee and SRV in the upright vertical
position on the boiler supply (outlet) piping. Do not isolate the boiler pressure vessel
from the SRV with any valves. Use a tee (not supplied) to install the P&T.
Installation of a properly selected expansion tank, strainer, air separator and air vent
is required. These ancillaries must be installed on the suction side of the system
(secondary) pump(s).
Water Systems: Install an automatic fill valve in the water fill line to the system and
set the valve to meet or exceed a minimum fill pressure of 12 psi at the boiler.
Water/Glycol Systems: Install a glycol feed system and set the fill pressure switch to
meet or exceed a minimum fill pressure of 30 psi at the boiler.
6. FILLING THE BOILER
Pre-charge the expansion tank per the manufacturer's instructions and begin filling
the hydronic system.
Open the boiler SRV to bleed air from the boiler vessel, leave SRV open until a
steady flow of water is observed. Eliminate air in system piping.
Using the P&T gauge on the boiler outlet, verify the system meets the minimum fill
pressure of 12 psi for water, and 30 psi for water/glycol.
7. FUEL GAS CONNECTION
To ensure adequate gas supply, size the field gas piping such that the inlet gas
pressure drop from static (boiler idle) to dynamic (boiler at high fire) does not exceed
15%. It is typical for gas delivery piping to be up-sized one or more diameters larger
than boiler gas inlet size.
The gas pipe and the fittings must be new and free of dirt or other deposits. Install a
test port, manual gas shutoff valve and union (not supplied) prior to the boiler. Install
pipe hangers or supports so that the boiler is not supporting any piping load. Refer
to the IOM for installation of gas vents to the outdoors.
Refer to the nameplate at the rear of the boiler for gas pressure requirements.
Where gas pressure exceeds the maximum listed on the nameplate, install an
appropriately selected line pressure regulator (not supplied) listed and labeled to
ANSI Z21.80/CSA 6.22 a minimum of 10 feet (3 m) of pipe away from the boiler.
Appliance regulators are not a substitution for line gas pressure regulators and
must not be used.
8. FUEL GAS LEAK TESTING
All gas piping connections must be checked for leaks before being placed into
service. Test with compressed air or inert gas if possible.
After completing pressure testing and obtaining any necessary approvals from the
Authority Having Jurisdiction (AHJ), introduce gas service and purge gas piping in
accordance with local codes. Do not purge into a confined space or where fuel gas
can accumulate.
The boiler gas train has been factory leak tested, however, fittings may loosen
during shipping or installation. After field gas piping is completed and before wiring
installation is started, all piping connections (factory and field) must be carefully
checked for gas leaks. Use a soap and water solution or combustible gas detector.
Detection must not exceed Level 1 (500 ppm).
9. FLUE GAS CONDENSATE DRAIN
A condensate drain trap is provided with the boiler and must be installed as
shown. A condensate pH Neutralizer is optional, but may be required by the AHJ.
Condensate drain lines and fittings (not supplied) must be PVC, CPVC, stainless
steel or silicone tube. Do not use copper or steel/iron pipe, these materials are not
suitable. Maintain a minimum downward pitch toward the floor drain of 1 inch (25
mm) for every 12 feet (3.7 m).
CONDENSATE TRAP
(REQUIRED)
CONTINUED ON PAGE 2
PH NEUTRALIZATION
(OPTIONAL)
1