Fulton Endura (EDR) Condensing Hydronic Boiler - Manual (Page 3)

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EDR-IOM-2014-0318
TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Product Overview ................................................................................................. 2-2
Placement & Rigging ........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-3
Install Boiler Trim ................................................................................................. 2-5
Install Water Piping .............................................................................................. 2-6
Meet Water Chemistry Requirements .................................................................. 2-7
PREVENT OXYGEN CONTAMINATION ..........................................................................................2-8
ELIMINATE SYSTEM AIR ..............................................................................................................2-9
Fill the Boiler With Water ..................................................................................... 2-9
Install Gas Piping .................................................................................................. 2-9
COMPONENTS REQUIRING VENTILATION TO THE OUTDOORS .................................................2-10
Install Condensate Drain .................................................................................... 2-11
SINGLE BOILER DRAIN TRAP .....................................................................................................2-11
MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP .........................................................2-11
Install pH Neutralization Kit ............................................................................... 2-14
Venting ............................................................................................................... 2-15
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................2-16
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................2-16
Air Filter .............................................................................................................. 2-17
Exhaust Venting ................................................................................................. 2-17
COMMON VENTING LAYOUTS FOR ENDURA .............................................................................2-18
VENTING TERMINATIONS ..........................................................................................................2-19
WALL THIMBLE INSTALLATION .................................................................................................2-20
HORIZONTAL VENT TERMINATION ............................................................................................2-23
Removing an Existing Boiler ............................................................................. 2-23
Electrical Connections ....................................................................................... 2-24
Assembly of Fulton Multi-Skid Systems............................................................. 2-25
Operation 3-1
Perform Pre-Start-Up Inspection ......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
Commission The Boiler ......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION .................................................................................3-3
Commission The Boiler: Dungs Zero Governing Gas Valve ................................... 3-3
TURNDOWN .................................................................................................................................3-6
SOLA Hydronic Controller for Endura ................................................................... 3-7
STATUS SUMMARY SCREEN.........................................................................................................3-7
CENTRAL HEAT OPERATION SCREEN ...........................................................................................3-7
CENTRAL HEAT OPERATION - FIRING RATE SCREEN ...................................................................3-8
CENTRAL HEAT OPERATION - SETPOINT SCREEN .......................................................................3-9
CENTRAL HEAT CONFIGURATION – SETPOINT SCREEN .............................................................3-9
CENTRAL HEAT CONFIGURATION – MODULATION SCREEN ......................................................3-9
CHANGING HIGH LIMIT SETPOINT AND VERIFYING CHANGE ..................................................3-10
REVIEWING STATISTICS .............................................................................................................3-12
ACCESSING LOCKOUT HISTORY .................................................................................................3-13
SOLA DIAGNOSTICS ...................................................................................................................3-15
Perform Test of Low Water Cut Off ..................................................................... 3-16
Perform Test of Limit Controls ........................................................................... 3-17
Perform Test of Low Gas Pressure Switch .......................................................... 3-17
Perform Test of High Gas Pressure Switch .......................................................... 3-17
General Operation of the Boiler ......................................................................... 3-17
Maintenance 4-1
General ................................................................................................................. 4-2
Daily Maintenance and Inspection Schedule ...................................................... 4-2
Weekly Maintenance and Inspection Schedule .................................................. 4-2
Monthly Maintenance and Inspection Schedule ................................................. 4-2
Procedure for Cleaning the Air Inlet Filter .......................................................... 4-3
Annual Maintenance and Inspection Schedule ................................................... 4-3
Removing and Cleaning Burner Assembly .......................................................... 4-4
After All Repairs and Maintenance ...................................................................... 4-5
Troubleshooting ................................................................................................... 4-5
Warranty & Parts 5-1
Standard Warranty for Fulton Endura Hydronic Boilers ....................................... 5-3
Parts ..................................................................................................................... 5-5