FULTON Endura EDR-1000 User manual

INSTALLATION AND
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
EDR-IOM-2014-0318

Questions? Please Contact Your Local Manufacturer’s Representative
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
InstallWater Piping.............................................................................................. 2-6
MeetWater Chemistry Requirements.................................................................. 2-7
PREVENT OXYGEN CONTAMINATION..........................................................................................28
ELIMINATE SYSTEM AIR ..............................................................................................................29
Fill the BoilerWith Water ..................................................................................... 2-9
Install Gas Piping.................................................................................................. 2-9
COMPONENTS REQUIRINGVENTILATIONTOTHE OUTDOORS.................................................210
Install Condensate Drain.................................................................................... 2-11
SINGLE BOILER DRAINTRAP.....................................................................................................211
MULTIPLE BOILERS SHARING A COMMON DRAINTRAP .........................................................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
ExhaustVenting ................................................................................................. 2-17
COMMONVENTING LAYOUTS FOR ENDURA.............................................................................218
VENTINGTERMINATIONS..........................................................................................................219
WALL THIMBLE INSTALLATION.................................................................................................220
HORIZONTAL VENTTERMINATION............................................................................................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
CommissionThe Boiler......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION.................................................................................33
CommissionThe Boiler: Dungs Zero Governing GasValve................................... 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 ANDVERIFYING CHANGE..................................................310
REVIEWING STATISTICS.............................................................................................................312
ACCESSING LOCKOUT HISTORY .................................................................................................313
SOLA DIAGNOSTICS...................................................................................................................315
PerformTest of LowWater Cut O ..................................................................... 3-16
PerformTest of Limit Controls ........................................................................... 3-17
PerformTest of Low Gas Pressure Switch .......................................................... 3-17
PerformTest 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
StandardWarranty for Fulton Endura Hydronic Boilers....................................... 5-3
Parts ..................................................................................................................... 5-5

© The Fulton Companies 2014
TABLE OF CONTENTS EDR-IOM-2014-0318
0-2

Questions? Please Contact Your Local Manufacturer’s Representative 1-1
INTRODUCTION
INTRODUCTION
1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2014
INTRODUCTION EDR-IOM-2014-0318 SECTION 1
1-2
Overview
Prior to shipment, the following inspections and tests are
made to ensure the highest standards of manufacturing for
our customers:
Material inspections
Manufacturing process inspections
American Society of Mechanical Engineers (ASME)
welding inspection
ASME hydrostatic test inspection
Electrical components inspection
Operating test
Final engineering inspection
Crating inspection
This manual is provided as a guide to the correct operation
and maintenance of your Fulton equipment, and should be
read in its entirety and be made permanently available to the
sta responsible for the operation of the boiler. It should not,
however, be considered as a complete code of practice, nor
should it replace existing codes or standards which may be
applicable. Fulton reserves the right to change any part of
this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment
can be hazardous and requires trained, qualied installers
and service personnel. Trained personnel are responsible
for the installation, operation, and maintenance of this
product, and for the safety assurance of installation,
operation, and maintenance processes. Do not install,
operate, service or repair any component of this
equipment unless you are qualied and fully understand
all requirements and procedures. Trained personnel
refers to those who have completed Fulton Service School
training specic to this product.
When working on this equipment, observe all warnings,
cautions, and notes in literature, on stickers and labels, and
any additional safety precautions that apply. Follow all safety
codes and wear appropriate safety protection. Follow all
jurisdictional codes and consult any jurisdictional authorities
prior to installation.
Warnings & Cautions
WARNINGS and CAUTIONS appear in various chapters of this
manual. It is critical that all personnel read and adhere to all
information contained in WARNINGS and CAUTIONS.
WARNINGS must be observed to prevent serious injury
or death to personnel.
CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
eectiveness.
All Warnings and Cautions are for reference and guidance
purposes, and do not substitute for required professional
training, conduct, and strict adherence to applicable
jurisdictional/professional codes or regulations.
Disclaimers and Local Codes
Installation of the equipment shall conform to all the
requirements or all national, state and local codes established
by the authorities having jurisdiction or, in the absence
of such requirements, in the US to the National Fuel Gas
Code ANSI Z223.1/NFPA 54 latest edition, and the specic
instructions in this manual. Authorities having jurisdiction
should be consulted prior to installation.
When required by local codes, the installation must conform
to the American Society of Mechanical Engineers Safety Code
for Controls and Safety Devices for Automatically Fired Boilers
(ASME CSD-1).
The boiler heat exchanger is manufactured and stamped
in accordance with ASME Boiler and Pressure Vessel Code,
Section IV for a maximum allowable working pressure
and operating temperature of 160 psig and 210 F (99 C)
respectively.

Questions? Please Contact Your Local Manufacturer’s Representative 2-1
INSTALLATION
INTRODUCTION
1
INSTALLATION
2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2014
2-2
INSTALLATION EDR-IOM-2014-0318 SECTION 2
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
4 CAUTION
This boiler is certied for indoor
installation only. This boiler may not
be eld retrotted.
This boiler is not designed for use in
systems where water is continuously
replenished. The warranty is valid for
closed loop systems only.
Fulton cannot be held responsible
for the selection, engineering,
installation, or sizing of any
additional equipment or components
of the hydronic heating system.
Product Overview
Prior to the performance of installation, operation, or maintenance procedures,
personnel should become familiar with the equipment (Table 1 and Figure 1) and
its components.
The Fulton Endura hot water boiler is an automatic, fuel-red, ultra high-
eciency boiler. The boiler can either be of the sealed combustion/direct vent
type or utilize conventional combustion air intake and ue methods.
The boiler is capable of sidewall venting when the appropriate venting materials
are used, and when permitted by local code requirements.
The Fulton Endura boiler is ETL-certied to Underwriters Laboratories (UL) Edition
7 UL Standard for Safety Commercial-Industrial Gas Heating Equipment, and
bears the H stamp. The boiler heat exchanger is manufactured and stamped in
accordance with American Society of Mechanical Engineers (ASME) Boiler and
Pressure Vessel Code, Section IV for a maximum allowable working pressure
and temperature of 160 psi and 210 F (99 C) respectively. All Endura boilers are
hydrostatically tested, test red and shipped as a complete packaged unit.
Fuel, water and electrical connections are similar to other boilers of this type.
Please be aware of which burner and control conguration has been designed
specically for your application.
This Endura boiler is to be installed as part of a hydronic heating system. A
qualied engineer must be consulted for the selection of the equipment and
components of the heating system. Various system conditions can result in
incorrect heat distribution to users of the heating system.
Each Endura Boiler is supplied with the following:
Integrated combustion supervision and temperature operating control
Operating and high temperature probe(s) in pressure vessel
Low water probe(s) in pressure vessel
ASME safety relief valve
Installation and Operation Manual
Test re report
Wiring diagram
Temperature and pressure (T&P) gauge
1 can touch up paint
The customer should examine the equipment for any damage. It is the
responsibility of the installer to ensure all parts supplied with the equipment are
tted in a correct and safe manner.

Questions? Please Contact Your Local Manufacturer’s Representative 2-3
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Competent personnel in accordance
with all applicable local codes
should carry out the installation
of the Fulton equipment. All state
and jurisdictional codes beyond the
scope of the applicable ASME Boiler
and Pressure Vessel Codes, for its
corresponding classication, should
be followed in all cases. Jurisdictional
authorities must be consulted prior to
installation.
A competent rigger experienced in
handling heavy equipment should
handle rigging your equipment into
position.
The equipment must be installed on a
non-combustible surface.
Failure to provide required and
safe access to the equipment
could impede commissioning and
maintenance. Service technicians
are instructed not to commence
commissioning if hazardous
conditions exist.
Failure to provide proper minimum
clearances between equipment and
combustible materials may result in
re.
4 CAUTION
Do not allow weight to bear on
equipment components to prevent
damage.
Do not use to directly heat swimming
pool.
Placement & Rigging
Proper placement of your Fulton product is essential. Attention paid to
the following points will save a great deal of diculty in the future. Correct
placement is the rst step to trouble-free installation, operation, and
maintenance.
Adhere to the following for placement and rigging:
1. Check building specications for permissible oor loading. Use Table 1 for
unit reference.
2. Conform to all the requirements of all national, state and local codes
established by the authorities having jurisdiction and/or the U.S. to the
National Fuel Gas Code, latest edition. Authorities having jurisdiction
should be consulted before installations are made. Where required by local
codes, the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically
Fired Boilers (ASME CSD-1).
3. Since an external electrical source is utilized, the boiler, when installed,
must be electrically ground in accordance with the National Electric Code,
American National Standards Institute (ANSI) National Fire Protection
Association (NFPA) 70, latest edition.
4. Standard Endura boilers are certied for indoor installation only.
5. Install so that all system components are protected from water (dripping,
spraying, rain, etc.) and debris (dry wall dust, insulation particles, etc.)
during boiler operation and service.
6. Install on a level, non-combustible surface in the vertical position. Concrete
is strongly recommended. The surface must be elevated a minimum of 4”
(102 mm) above the oor.
7. Provide combustion and ventilation air in accordance with applicable
provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section
5.3, Air for Combustion and Ventilation.
8. Locate the boiler so that the air supply and exhaust piping between the
boiler and outside wall/roof are within the maximum lengths for horizontal
or vertical venting if sealed combustion will be used. See Clearances and
Serviceability section of this manual.
Clearances and Serviceability
Adhere to the following for clearances and serviceability:
1. All local and national codes (NFPA, ANSI, UL, CSA, ASME) must be
followed for proper clearances and serviceability for your boiler or heater.
Authorities having jurisdiction should be consulted before installations are
made.
2. Appropriate front, back, side and top clearances must be maintained

© The Fulton Companies 2014
INSTALLATION EDR-IOM-2014-0318 SECTION 2
2-4
TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS
FIGURE 1  VIEWS OF ENDURA HYDRONIC BOILER
Alternate gas pressure arrangements may apply. Please verify gas pressure ratings for your boiler by viewing the boiler name plate.
Typical 120 VAC controls allow for a +10% and a -15% voltage uctuation. Voltages lower than 120 V can result in slightly decreased available output.
*Standard congurations. Alternate voltages may be available as an option; please consult factory.
Note: All dimensions are approximate and are subject to change without notice.
MODEL EDR 1000 1500 2000
Input Million BTU/Hr
kW
1.0
293
1.5
411
2.0
549
Fuel Cons. @ rated cap. (Nat. Gas)
FT3/Hr
M3/Hr
1000
28.32
1500
42.5
2000
56.7
Output at AHRI Test Condition
BHP
KCal/h
28.4
239,396
41.9
353,424
56
472,240
Electrical Req. (Amps)*
120V, 60Hz, 1 Phase 10 20 20
Water Content Gal
Liters
50
189
104
394
102
386
Dry Weight LBS
KG
1430
649
2260
1025
2360
1071
Operating Weight LBS
KG
1848
838
3128
1419
3210
1456
MODEL EDR 1000 1500 2000
A. Boiler Width IN
CM
28
72
33.9
86
33.9
86
B. Overall Boiler Height IN
CM
68
172.7
80
203.2
80
203.2
C. Overall Boiler Depth IN
CM
49.75
126.4
60.6
153.8
60.6
153.8
D. Flue Outlet Diameter IN
CM
6
15.2
6
15.2
8
15.2
E. Water Inlet/Outlet Diameter IN
CM
2
5.08
4
10.2
4
10.2
F. Min. Clearance (top) IN
CM
18
46
18
46
18
46
G. Air Inlet Diameter (top access) IN
CM
6
15.25
8
20.3
8
20.3
Min. Clearance (sides) IN
CM
1
2.5
1
2.5
1
2.5
FRONT VIEW RIGHT SIDE VIEW BACK VIEW
TOP VIEW
B
D
E
G
E
C
F
A

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
2-5
(Figure 1). This will allow access around the equipment
to facilitate maintenance and a safe work environment.
An 1 inch (25.4 mm) side clearance is acceptable
between any number of boilers. Custom congurations
may not allow 1 inch (25.4 mm) side clearance.
Although a 1 inch (25.4 mm) side clearance is permitted,
allowing 24 inches (610 mm) will facilitate and expedite
maintenance and any advanced troubleshooting.
NOTE:Side panels are latched; however, maintenance
and service does not require boiler access through side
panels. All maintenance and service can be performed
from front, rear, and top of boiler.
3. Ensure all labels on the boiler will be fully visible for
maintenance and inspection.
4. Do not place any boiler room accessories, or other
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:
» Be connected to the coupling located in the
top of the boiler.
» Be installed in the vertical position.
NOTE:Safety relief valve size is determined by trim
pressure and is supplied in the trim kit along with
appropriate bushing, inlet and outlet sizes. See Table 2.
Standard trim pressure is 60 PSIG.
2. The discharge pipe must:
» Not have a diameter less than the full area of
the valve outlet.
» Be as short and straight as possible and so
arranged as to avoid undue stress on the valve.
» Be supported by means other than the safety
valve itself.
» Be piped to avoid danger of scalding
personnel.
NOTE:Each boiler is equipped with a pressure-
temperature gauge to be installed in the outlet piping
section of the boiler. Gauge must not be isolated from
the boiler by any valve.
TABLE 2  SAFETY RELIEF VALVE INLET AND OUTLET SIZES
Model Trim Pressure
PSI (kPa)
Inlet Size
inch (mm)
Outlet Size
inch (mm)
EDR-1000 30 (206.84)
through
160 (1103.16)
3/4 (19.05) 1 (25.4)
EDR-1500 30 (206.84) 1 (25.4) 1 1/4 (31.75)
60 (413.69) 3/4 (19.05) 1 (25.4)
100 (689.48) 3/4 (19.05) 1 (25.4)
125 (861.84) 3/4 (19.05) 1 (25.4)
160 (1103.16) 3/4 (19.05) 1 (25.4)
EDR-2000 30 (206.84) 1 1/4 (31.75) 1 1/2 (38.1)
60 (413.69) 1 (25.4) 1 1/4 (31.75)
100 (689.48) 3/4 (19.05) 1 (25.4)
125 (861.84) 3/4 (19.05) 1 (25.4)
160 (1103.16) 3/4 (19.05) 1 (25.4)
Note: Valve is
shipped loose
and must be
installed by the
contractor.
FIGURE 2  SAFETY VALVE LOCATION

© The Fulton Companies 2014
2-6
INSTALLATION EDR-IOM-2014-0318 SECTION 2
Install Water Piping
All water supplies contain some solids, dissolved gases or dissolved minerals.
These may cause corrosion, deposition and/or fouling of equipment. To prevent
these contaminants from impacting boiler performance, valve operation and
general pipe longevity, each location must be analyzed and treated accordingly.
Adhere to the following for water piping installation (See Figure 3):
1. Isolation valves are recommended on both water connections for ease of
service.
2. Install piping so that the boiler is not supporting any additional piping.
3. Install manual purging valves in all loops and zones. Install a pressure-
reducing (automatic ll) valve in the cold water ll line to the boiler system.
Check that the proposed operation of zone valves, zone circulator(s) and
diverting valves will not isolate air separator(s) and/ or expansion tank(s)
from the boiler. Clearance from hot water pipes to combustibles must be at
least 6 inches (152 mm).
4. When used in conjunction with a refrigeration system, install the boiler
so that the chilled medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from entering the
boiler. If the boilers are connected to heating coils (located in air handling
units where they may be exposed to refrigerated air circulation) such
boiler piping systems must be equipped with ow control valves or other
automatic means to prevent gravity circulation of the boiler water during
the cooling cycle.
5. Include the following in the mechanical equipment in the hydronic
heating system:
»An automatic pressure activated water make up valve with back
ow preventer. It must be set to maintain required Net Positive
Suction Head (NPSH) for re-circulating pumps, a positive system
pressure at the highest point of at least 5-10 PSIG, and make up
water valve should be designed to add water to the system at the
outlet of the boiler and should not be fed directly into the boiler.
»Air removal equipment, including an air separator and automatic
breather valves, along with a functioning expansion tank . Each
must be designed to system specications.
NOTE:The upper water connection on the back of the boiler is the outlet
connection. The lower water connection on the rear of the boiler is the inlet
connection.
NOTE:The Fulton Endura boiler does not require a primary/secondary ow
piping system. Although primary/secondary is an acceptable conguration,
the boiler does not have a minimum return water temperature requirement
and the heat exchanger will not be harmed by low ow or zero ow
conditions. See Figure 3 for a sample piping layout.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
The discharge from the safety relief
valve must be arranged to ensure
no danger of scalding personnel, or
equipment damage.
Provisions must be made to properly
pipe the safety relief discharge
away from the boiler to the point of
discharge.
No shuto of any kind shall be placed
between the safety relief valve
and the boiler, or in the discharge
pipe between the valve and the
atmosphere. Doing so may cause an
explosion from overpressure.
The hydronic system should never be
ushed while the boiler is attached
to the system since the debris could
accumulate in the boiler and block
water from passing through the heat
exchanger.

Questions? Please Contact Your Local Manufacturer’s Representative 2-7
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Ensure all labels on the boiler are
legible. All connections and safety
devices, both mechanical and
electrical, must be kept clean, with
ease of access for inspection, use and
maintenance.
Do not store or use gasoline or other
ammable vapors and liquids or
corrosive materials in the vicinity of
this or any other appliances.
6. Install ltration to remove particulates if appropriate. A #10 mesh size is
suggested.
7. Install bypass chemical feeder for corrosion inhibitor maintenance if
appropriate.
8. Install corrosion coupon holder to assess corrosion inhibitor performance if
appropriate.
9. Before installing a Endura boiler into a hydronic loop, be sure that the
system piping and any other components of the system are clean and free
of debris and any foreign matter. The hydronic system must be completely
ushed prior to installing the boiler itself.
NOTE:Although motorized isolation valves are not required in a primary
only arrangement , they can help ensure system eectiveness. Proper
control strategy must be used to ensure ow paths in the hydronic loop and
residual heat in pressure vessel can be adequately dispersed when a boiler
is disabled.
Meet Water Chemistry Requirements
System water chemistry requirements are as follows:
pH: Range of 8.5 - 10.5
Oxygen: Less than 250 ppb (operating condition)
Total Iron/Copper: Less than 5 ppm
Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2 mpy.
Due to changing environmental restrictions a non-heavy metal ALL
ORGANIC inhibitor is recommended which is designed for multi metal
systems including ferrous metals and yellow metals such as copper and
brass.
Chloride: Less than 200 ppm
Adhere to the following:
1. Refer to your water conditioning or chemical treatment supplier for
analysis and recommendations for proper system conditions.
2. Follow a program with appropriate monitoring and maintenance of system
water conditions as provided by your water conditioning or chemical
treatment supplier.
3. If RO/DI water is used as a source for hydronic loop water or makeup water,
it must be neutralized to a pH of 8.5 - 10.5 prior to entering the boiler.
Failure to neutralize the RO/DI water will void the pressure vessel warranty
and may cause high general corrosion rates.
The system must have an automatic pH controller to monitor and log the
levels. This must be independent of other chemical feed systems.

© The Fulton Companies 2014
INSTALLATION EDR-IOM-2014-0318 SECTION 2
2-8
FIGURE 3  SAMPLE PIPING LAYOUT
MOTORIZED
ISOLATION VALVE
(OPTIONAL)
SYSTEM
RETURN WATER
AIR
SEPARATOR
MAKE UP
WATER
AIR SEPARATOR AND EXPANSION
TANK AS DETERMINED
APPROPRIATE BY OTHERS
SYSTEM PUMPS AND VALVES
AS DETERMINED
APPROPRIATE BY OTHERS
EXPANSION
TANK
SYSTEM
SUPPLY
WATER
Makeup water pH range must be 7.5 - 8.8; the boiler
water must be maintained within pH range of 8.5 -
10.5.
4. Operate the boiler in a closed-loop system using water
or water/glycol (not requiring a make-up water supply).
A large amount of improperly treated make-up water
can cause premature failure of the heat exchanger
resulting from scale build up. Scale build up will reduce
the eciency and useful life of the boiler and is not
covered under warranty.
5. For freeze protection an inhibited propylene glycol
is recommended. Only use mixtures formulated for
hydronic systems. Do not use automotive glycol.
6. At a minimum, the hydronic uid should be checked for
glycol concentration and pH once a year.
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.
Prevent Oxygen Contamination
There are several ways to prevent boiler water oxygen
contamination:
Minimize system leaks to minimize make up water
requirement
Do not use open tanks or ttings
Do not use oxygen permeable materials anywhere in
the water system
Repair leaks in the system quickly
Eliminate ttings wherever possible
Use air elimination devices in system piping

Questions? Please Contact Your Local Manufacturer’s Representative 2-9
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
4 CAUTION
Care needs to be taken to eliminate
oxygen from the water system, as
excess oxygen in the system will
reduce the life of any boiler. The
boiler warranty does not cover heat
exchanger replacement due to oxygen
contamination of boiler water.
Heat exchanger failure due to
inappropriate water quality, foreign
matter or debris damage is not covered
under the warranty.
If the piping system attached to this
unit will be chemically cleaned, the
boiler must be disconnected from the
system and a bypass installed so that
the chemical cleaning solution does
not circulate through the boiler.
Eliminate System Air
NOTE:There are no built-in boiler air eliminating features.
Adhere to the following for air elimination:
1. The installation of an air separator and air eliminator (air vent) is required.
2. To prevent scale corrosion in boiler and associated piping, make up water
must be kept to a minimum. This is best achieved by ensuring immediate
repair of all leaks and that system pressure is maintained.
3. If a sealed diaphragm-type expansion tank is used, install an air eliminator
in the hot water piping at the air separator.
4. If an air cushion type expansion tank is used, pipe tank directly into boiler
supply.
5. On multi-zoned systems (or a system with both space and domestic water
heating), air elimination must be provided either in the common piping or
on every loop.
6. When the boiler is installed at a higher level than baseboard radiation (if
used), air elimination must be provided directly above the unit.
Fill the Boiler With Water
To be sure that the boiler is not air-bound, open the pressure-relief valve located
at the rear of the boiler. Leave the relief valve open until a steady ow of water is
observed. Close the valve and nish lling the system.
Install Gas Piping
The Endura boiler is factory test red and combustion is adjusted per the boiler
data plate and test re sheet.
The gas train components are congured to operate at specic gas pressure
requirements. The specic requirements for each boiler are called out on the
boiler nameplate, located on the back of the boiler.
Adhere to the following for gas piping installation:
1. See Table 3 for required natural gas pipe size, based on overall length of
pipe from the meter plus equivalent length of all ttings. Approximate
sizing may be based on 1,020 BTU for 1 cubic foot of natural gas.
2. Piping must be installed such that no piping stresses are transmitted to the
boiler. The boiler cannot be used as a pipe anchor.
3. The boiler and all gas piping connections must be pressure-tested and
checked for leaks before being placed into service. Test with compressed
air or inert gas if possible.
4. The boiler must be disconnected at the boiler manual shuto valve

© The Fulton Companies 2014
2-10
INSTALLATION EDR-IOM-2014-0318 SECTION 2
(located at the end of the supplied gas train) from the gas supply piping
system during any pressure testing of the system at pressures in excess of
2.0 psig (55 inch W.C.).
5. Gas Piping must be installed in accordance with National Fuel Gas Code,
ANSI Z223.1 1991 or latest addenda and any other local codes, which may
apply.
6. The pipe and the ttings used must be new and free of dirt or other
deposits.
7. Piping must be of the proper size to ensure adequate gas supply. A drip leg
and union connection must be installed upstream of the gas safety shut o
valves and must be a 5 inch (127 mm) minimum length.
8. Connect gas supply line to the open end of the tee on which the drip leg is
installed.
9. When making gas-piping joints, use a sealing compound resistant to
liqueed petroleum gases. Do not use Teon tape on gas line threads.
10. After gas piping is completed and before wiring installation is started,
carefully check all piping connections, (factory and eld), for gas leaks. Use a
soap and water solution.
11. The boiler must be disconnected at the boiler shut o valve from the gas
supply piping system during any pressure testing of the system.
NOTE:In cases where a vent line connection must be used on the gas
pressure regulator must be piped to outdoor air by the installer in
accordance with the National Fuel Gas Code, ANSI Z223.1-1991 or latest
addenda. In Canada gas installations must by in accordance with the current
CAN/CSA B149.1 and 2 and/or local codes.
Components RequiringVentilation to the Outdoors
The following do not require ventilation to the outdoors, as there is a vent limiter
in use:
Gas valve on the main fuel train
Lock-up regulator on the main fuel train
Regulator on the ignition enrichment line
An authority having jurisdiction may not permit the use of a vent limiter. In this
case, please use the following general guidelines:
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 lter. Instructions are included in the kit.
Start with the vent and cabinet bulkhead size, and as soon as is practical
increase the pipe size one diameter.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Do not use matches, candles, ame or
other sources of ignition to check for
gas leaks.
4 CAUTION
Some soap used for leak testing is
corrosive to certain types of metals.
Clean all piping thoroughly after
completing the leak check.

Questions? Please Contact Your Local Manufacturer’s Representative 2-11
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
For every ten feet of pipe run, increase the pipe size one diameter.
Protect the vent termination from water, dust and insects.
Install Condensate Drain
A condensate drain kit is intended for use with the Fulton Endura boiler.
Single Boiler Drain Trap
The condensate drain kit is Fulton Part Number 4-57-005500. The drain kit must
be congured one per boiler, with a maximum of 4.0 mm BTU total.
Adhere to the following for installation:
1. The 1 inch (25.4 mm) condensate drain will be reduced and connected to
the 3/4 inch (19.05 mm) inlet on the base of the drain kit.
2. A condensate collecting tank and condensate pump will be required if a
oor drain is not available to collect condensate (collecting tank and pump
are not supplied with the boiler).
3. All piping (Figure 4) must be galvanized or stainless steel, and be free of
leaks. Copper, carbon steel/iron pipe, PVC or CPVC are not acceptable.
4. The 3/4 inch (19.05 mm) drain outlet must remain below the 1 inch (25.4
mm) boiler condensate drain.
5. Connect the 3/4 inch (19.05 mm) drain outlet to an appropriate waste line
following applicable codes. The 3/4 inch (19.05 mm) drain connection on
the drain tank must be the highest point prior to going to the drain. Failure
to keep drain piping lower than this point will result in overow of the
drain tank. Slope the drain pipe away at a minimum pitch of 1 inch (25.4
mm) for every 12 feet (3.65 m).
Multiple Boilers Sharing A Common Drain Trap
The condensate drain kit is Fulton Part Number 4-57-000440. The maximum
number of units to attach per condensate drain kit is 12mm BTU total.
Adhere to the following for installation:
1. The Fulton Endura boiler 1 inch (25.4 mm) condensate drain will be
connected to the 1 inch (25.4 mm) inlet on the drain kit. One or more drain
lines may be connected to this inlet (max of 12 MM BTU per drain).
2. If the water supply must be temporarily disconnected, the boilers must be
turned o to prevent accidental ue gas emission into the boiler room.
3. The condensate drain cover must be kept on at all times, except during
maintenance of the drain. This drain should be checked regularly in your
boiler maintenance schedule.
4. A condensate collecting tank and condensate pump will be required if a 
oor drain is not available to collect condensate (collecting tank and pump
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
If the water supply must be
temporarily disconnected from the
condensate drain trap, the boilers
must be turned o to prevent
accidental ue gas emission into the
boiler room.
4 CAUTION
An uninterruptible water supply is
required and shall be connected to the
¼” (U.S. only) compression tting on
the condensate drain. The water supply
maintains a water level in the drain kit
to prevent accidental ue gas emission
into the boiler room.

© The Fulton Companies 2014
INSTALLATION EDR-IOM-2014-0318 SECTION 2
2-12
FIGURE 4  CONDENSATE DRAIN PIPING FOR ENDURA BOILERS
Figure 4 Notes:
Header must be level or slightly pitched toward the drain.
Header material to be galvanized steel or 316L stainless.
Header should be taken to the lowest point possible and
maintain a minimum 5.5 inch (14.2 cm) drop from 1.5 inch
(38.1 mm) condensate drain kit/trap outlet. See Detail A.
1.5 inch (38.1 mm) condensate drain kit/trap outlet is never
to be above 1 inch boiler condensate outlet.
For multiple boiler installation, maintain and minimum pipe
size of 1 inch (25.4 mm) for the header piping.
The maximum capacity to attach per condensate drain kit is
12 MMBH total. Detail A
0.25” U.S. TAPPING
PROVIDED FOR WATER
CONNECTION TO MAINTAIN
WATER SEAL
5.5 INCH 14.2 CM
MINIMUM
REAR VIEW
Detail A
Condensate
Drain Kit

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EDR-IOM-2014-0318 INSTALLATION
2-13
TABLE 3  NOMINAL PIPE SIZE
Nominal
Pipe Size
ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. Pressure drop of
0.5”wc/Equivalent length of pipe (feet)
Inch (mm) Inch (mm) 90 Elb
Feet
(meter)
Tee
Feet
(meter)
20 40 60 80 100 150 200
1-1/4 (31.75) 1.380 (35.05) 3.45 (1.05) 6.9 (2.10) 950 ----- ----- ----- ----- ----- -----
1-1/2 (38.1) 1.610 (40.89) 4.02 (1.22) 8.04 (2.45) 1460 990 810 ----- ----- ----- -----
2 (50.8) 2.067 (52.50) 5.17 (1.57) 10.3 (3.13) 2750 1900 1520 1300 1150 950 800
2-1/2 (63.5) 2.469 (62.71) 6.16 (1.87) 12.3 (3.74) 4350 3000 2400 2050 1850 1500 1280
3 (76.2) 3.068 (77.92) 7.67 (2.33) 15.3 (4.66) 7700 5300 4300 3700 3250 2650 2280
4 (101.6) 4.026 (102.26) 10.10 (3.07) 20.2 (6.15) 15800 10900 8800 7500 6700 5500 4600
6 (152.4) 6.07 (154.17) 10.10 (3.07) 23.60 (7.19) ----- ----- ----- ----- 20200 16503 12766
8 (203.2) 7.98 (202.69) 13.30 (4.05) 29.10 (8.86) ----- ----- ----- ----- 41200 33660 29128
FIGURE 5  FULTON PH NEUTRALIZING KIT WITHOUT PUMP

© The Fulton Companies 2014
INSTALLATION EDR-IOM-2014-0318 SECTION 2
2-14
are not supplied with the boiler).
5. All piping (Figure 4) must be galvanized or stainless
steel, and be free of leaks. Copper, carbon steel/iron
pipe, PVC or CPVC are not acceptable.
6. Connect 1 inch (25.4 mm) condensate drain(s) (at the
rear of the boiler), to the 1 inch (25.4 mm) inlet at the
base of the drain tank. The header must be at least 5.5
inches (14.2 cm) below the condensate outlet of the
individual boiler, and must remain  ooded - achieved
by ensuring it is at least 5.5 inches (14.2 cm) below the
outlet of the condensate drain trap.
7. Connect the 1.5 inch (38.1 mm) drain outlet to an
appropriate waste line following applicable codes. The
1.5 inch (38.1 mm) drain connection on the drain tank
must be the highest point prior to going to the drain.
Failure to keep drain piping lower than this point will
result in over ow of the drain tank. Slope the drain
pipe away at a minimum pitch of 1 inch (25.4 mm) for
every 12 feet (3.65 m).
8. (U.S. Only) Attach a ¼”water supply to the
compression  tting on the oat. The water line must
be connected to an uninterruptible supply. Fulton
recommends connecting it before the“fast ll” valve
to the boiler supply but after the back  ow preventer
to avoid contamination of a potable water supply.
Maximum allowable water pressure to the compression
tting is 100 PSI (689.5 kPa).
Install pH Neutralization Kit
The pH Neutralization Kit is a Fulton-provided kit designed to
bring the pH level of the boiler’s condensate to a neutral level.
It is not a replacement or alternative for the Condensate Drain
Trap. See Figure 5.
Adhere to the following for pH Kit installation:
1. Use stainless or galvanized pipe and ttings to connect
condensate drain to kit.
2. Connect kit downstream of Condensate Drain Trap. See
Figure 6.
3. Pipe outlet to appropriate drain.
4. Check condensate pH periodically.
TOP VIEW
30 3/8
[771]
12 1/2
[318]
3 13/16
[97]
(TYP.)
FRONT VIEW
1 1/2" PLASTIC FITTING
CONNECTION TO DRAIN
1" NPT
CONNECTION
TO BOILER
10 3/4
[273]
11 1/4
[286]
ISOMETRIC VIEW
2
3
1
43
1. Neutralizer Kit with Magnesium Oxide
2. Condensate Drain Kit Assembly
3. 1 1/2” by 3” NPT Stainless or Galvanized Nipple
4. 1 1/2” Stainless or Galvanized Union
FIGURE 6  FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK