FULTON Endura EDR-750 User manual

INSTALLATION AND
OPERATION MANUAL
Endura (EDR)
Condensing Hydronic Boilers
750,000 - 2,000,000 BTU/HR
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
EDR-IOM-2019-0212

Questions? Please Contact Your Local Manufacturer’s Representative
EDR-IOM-2019-0212 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 .............................................................................. 2-5
Install BoilerTrim ................................................................................................. 2-5
InstallWater Piping.............................................................................................. 2-6
VARIABLE PRIMARY PIPING ARRANGEMENT............................................................................27
PRIMARYSECONDARY PIPING ARRANGEMENT......................................................................210
MeetWater Chemistry Requirements................................................................ 2-10
PREVENT OXYGEN CONTAMINATION........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................212
Fill the BoilerWithWater ................................................................................... 2-12
Gas Supply Piping .............................................................................................. 2-12
INLET GAS PRESSURE................................................................................................................213
GAS PRESSURE REQUIREMENTS...............................................................................................213
LINE GAS PRESSURE REGULATION............................................................................................213
COMPONENTS REQUIRING VENTILATIONTOTHE OUTDOORS ...............................................216
Install Condensate DrainTrap............................................................................. 2-16
SINGLE BOILER DRAINTRAP.....................................................................................................216
MULTIPLE BOILERS SHARING A COMMON DRAINTRAP .........................................................216
Install pH Neutralization Kit............................................................................... 2-19
Venting Requirements....................................................................................... 2-21
Combustion Air Intake ....................................................................................... 2-22
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM..............................................................223
AIR PIPED FROM OUTSIDE BOILER ROOM................................................................................224
Air Filter.............................................................................................................. 2-25
ExhaustVenting ................................................................................................. 2-25
COMMONVENTING LAYOUTS FOR ENDURA.............................................................................228
VENTINGTERMINATIONS ..........................................................................................................232
WALLTHIMBLE INSTALLATION.................................................................................................232
ROOFVENTTERMINATION.........................................................................................................232
SIDEWALL VENT TERMINATION................................................................................................232
Removing an Existing Boiler ............................................................................. 2-33
Assembly of Fulton Multi-Skid Systems............................................................. 2-34
Electrical Connections and Devices.................................................................... 2-35
JUNCTION BOX LOCATIONS FOR FIELD WIRING .......................................................................240
ELECTRICAL AND CONTROLS OPTIONS.....................................................................................240
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: Zero Governing GasValve .............................................. 3-4
TURNDOWN.................................................................................................................................37
SOLA Hydronic Controller - General Operation .................................................... 3-8
STATUS SUMMARY SCREEN.........................................................................................................38
CENTRAL HEAT OPERATION SCREEN...........................................................................................38
CENTRAL HEAT OPERATION  SETPOINT SCREEN.....................................................................310
CENTRAL HEAT CONFIGURATION  SETPOINT SCREEN ...........................................................310
CENTRAL HEAT CONFIGURATION  MODULATION SCREEN ....................................................310
CHANGING HIGH LIMIT SETPOINT ANDVERIFYING CHANGE..................................................311
REVIEWING STATISTICS.............................................................................................................313
ACCESSING LOCKOUT HISTORY .................................................................................................314
SOLA DIAGNOSTICS...................................................................................................................316
SOLA Hydronic Controller - Options Conguration............................................ 3-17
LEAD/LAG INTEGRATED SEQUENCING .....................................................................................317
DOMESTIC HOTWATER DHW TEMPERATURE SENSOR..........................................................321
REMOTE 420 MA SIGNAL FOR SETPOINT ................................................................................322
SUPPLY HEADERTEMPERATURE SENSOR ................................................................................323
OUTDOOR AIRTEMPERATURE SENSOR ....................................................................................324
STACK LIMIT...............................................................................................................................326
DEDICATED BOILER PUMP.........................................................................................................327
MOTORIZED ISOLATION VALVE SET UP .....................................................................................328
ENABLING BURNER FIRE RATE OUTPUT ...................................................................................329
SYSTEM PUMP ENABLE/DISABLE SIGNAL ...............................................................................329
PerformTest of LowWater Cut O ..................................................................... 3-31
PerformTest of Limit Controls ........................................................................... 3-31
PerformTest of Low Gas Pressure Switch .......................................................... 3-31
PerformTest of High Gas Pressure Switch.......................................................... 3-31
General Operation of the Boiler ......................................................................... 3-31
Maintenance 4-1
General................................................................................................................. 4-2
Daily Inspection Schedule ................................................................................... 4-2
Weekly Maintenance Schedule ........................................................................... 4-2
Monthly Maintenance Schedule.......................................................................... 4-2
Procedure for Inspecting the Air Inlet Filter ....................................................... 4-3
Annual Maintenance Schedule............................................................................ 4-3
Replacing GasValve Internal Filter....................................................................... 4-4
Removing and Cleaning Burner Assembly .......................................................... 4-5
Verication of Ignition Gap.................................................................................. 4-6
After All Repairs and Maintenance ...................................................................... 4-7
Troubleshooting................................................................................................. 4-10

© Fulton Group N.A., Inc. 2019
TABLE OF CONTENTS EDR-IOM-2019-0212
0-2

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

© Fulton Group N.A., Inc. 2019
INTRODUCTION EDR-IOM-2019-0212 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

© Fulton Group N.A., Inc. 2019
2-2
INSTALLATION EDR-IOM-2019-0212 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
The standard conguration for
this boiler is certied for indoor
installation only.
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
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-2019-0212 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. Do not install the boiler on springs.
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.

© Fulton Group N.A., Inc. 2019
INSTALLATION EDR-IOM-2019-0212 SECTION 2
2-4
TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS
FIGURE 1  VIEWS OF ENDURA HYDRONIC BOILER
Alternate gas pressure arrangements may apply based on conguration and/
or local code requirements. Please verify gas pressure ratings for your boiler by
viewing the boiler name plate and consulting with the authority having jurisdiction.
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 may be available as an option; please consult factory.
Note: All dimensions are approximate and are subject to change without notice.
MODEL EDR 750 1000 1500 2000
Input
MM BTU/Hr
kW
.75
219
1.0
293
1.5
411
2.0
549
Fuel Cons. @ rated cap.
(Nat. Gas)
FT3/Hr
M3/Hr
750
21.2
1000
28.32
1500
42.5
2000
56.7
Output at AHRI Test
Condition
BHP
KCal/h
21.7
183,638
28.4
239,396
41.9
353,424
56
472,240
Natural Gas Pressure
W.C. 4-28 4-28 4-28 4-28
Electrical*
120 V, 60 Hz, 1 Phase
20 Amp
(10FLA)
20 Amp
(10FLA)
25 Amp
(20FLA)
25 Amp
(20FLA)
Water Content
Gal
Liters
50
189
50
189
104
394
102
386
Dry Weight
LBS
KG
1430
649
1430
649
2260
1025
2260
1071
Operating Weight
LBS
KG
1848
838
1848
838
3128
1419
3210
1456
MODEL EDR 750 1000 1500 2000
A. Boiler Width IN
CM
28
72
28
72
33.9
86
33.9
86
B. Overall Boiler Height IN
CM
67.8
172.2
67.8
172.2
80
203.2
80
203.2
C. Overall Boiler Depth IN
CM
50.2
127.5
50.2
127.5
60.6
153.8
60.6
153.8
D. Exhaust Outlet Diameter (ID) IN
CM
6
15.2
6
15.2
6
15.2
8
15.2
E. Water Inlet/Outlet Diameter IN
CM
2
5.08
2
5.08
4
10.2
4
10.2
F. Min. Clearance (top) IN
CM
18
46
18
46
18
46
18
46
G. Air Inlet Diameter (top access) IN
CM
6
15.25
6
15.25
8
20.3
8
20.3
H. Min. Clearance (sides) IN
CM
1
2.5
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-2019-0212 INSTALLATION
2-5
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 (Figure 1). This will allow access around
the equipment to facilitate maintenance and a safe
work environment. A 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 upright 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-750
EDR-1000
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

© Fulton Group N.A., Inc. 2019
2-6
INSTALLATION EDR-IOM-2019-0212 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, you must analyze and treat each installation uniquely.
Adhere to the following for water piping installation (see Figures 4  7):
Manual isolation valves are recommended on both water connections for
ease of service.
Install piping so that the boiler is not supporting any piping load.
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.
To prevent scale and 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 maintaining system pressure.
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.
Provide at least 6 inches (152 mm) clearance from hot water pipes to
combustibles.
When used 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.
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 should be designed to
add water to the system at the outlet of the boiler but 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.
Install ltration in the common loop or per boiler to remove particulates if
appropriate. A #4 or ner mesh size is required.
! 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-2019-0212 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.
Install bypass chemical feeder for corrosion inhibitor maintenance if
appropriate.
Install corrosion coupon holder to assess corrosion inhibitor performance if
appropriate.
Before installing an 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.
Variable Primary Piping Arrangement
Endura boilers are designed for installation in variable primary ow piping
arrangements (see Figures 4 and 5), sometimes referred to as full ow systems.
This arrangement eliminates temperature mixing associated with primary-
secondary piping, thereby delivering the lowest temperature water directly
to the boiler return connections and increasing thermal eciency of the
condensing boiler plant.
NOTE:Although it is acceptable to install Endura boilers in a primary-secondary
conguration, it is not required.
Adhere to the following for variable primary piping arrangements:
Select pump(s) with sucient total dynamic head for the pressure drop of the
loop at design ow. See Figure 3 for the water side pressure drop through
the boiler. The Endura boiler does not have a minimum ow requirement.
It will automatically perform a safe shutdown in the event of a low ow or
zero ow condition; however, proper design ow will be required to deliver
heat to users and prevent nuisance high temperature limit trips.
Use motorized isolation valves: Ensure system eectiveness by eliminating
ow through idle boilers accordance with ASHRAE 90.1-2013 (6.5.4.3.2).
Blending of unheated supply water may impact temperature control
operation or cause manual reset high temperature lockouts. One
FIGURE 3  TYPICAL WATER SIDE PRESSURE DROP

© Fulton Group N.A., Inc. 2019
INSTALLATION EDR-IOM-2019-0212 SECTION 2
2-8
FIGURE 5  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; MULTIPLE BOILERS
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.
DRAWING NUMBER REV
G-35-100014 -
ENDURA BOILER PRIMARY ONLY
VARIABLE FLOW SINGLE BOILER PIPING
DIAGRAM
DESCRIPTION:
DRAWN BY:
M.BERWALD
CHECKED BY:
N/A
B.O.M. REVIEW
MECH. ENG:
SMT
ELEC. ENG:
APPROVED BY:
N/A
K.BOTTORFF
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and
drawings are
proprietary and are the
exclusive property of
The Fulton Companies.
The corporation does
not permit their use
except with prior
written consent.
The items shown in
this drawing may be
covered by one or
more patents of The
Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
1/20/2015 2/2/2015
1/30/2015
UNLESS OTHERWISE NOTED:
DIMENSIONS ARE IN INCHES
TOLERANCES ON
FRACTIONS 1/4
(2) PLACE DEC. .01
(3) PLACE DEC. .005
ANGLES 2 DEG.
SURFACE FINISH
250 MICRO-INCHES
R
SHEET 1 OF 1
-INITIAL RELEASE --- --- --- --- ---
REVISION HISTORY
REV REVISION DESCRIPTION CHECKED B.O.M. MECH. ENG ELEC. ENG APPROVED
FULTON ENDURA
CONDENSING HYDRONIC BOILER
AIR REMOVAL
EXPANSION TANK
VARIABLE SPEED
SYSTEM PUMP
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
NOTES:
1.
2.
3.
THIS IS A TYPICAL ARRANGEMENT FOR REFERENCE PURPOSE
S
ONLY. ACTUAL INSTALLATIONS MAY REQUIRE ADDITIONAL
COMPONENTS WHICH ARE NOT SHOWN FOR CLARITY.
THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.
REFER TO THE INSTALLATION AND OPERATION MANUALS FOR
INFORMATION REGARDING CLEARANCES AND INSTALLATION
REQUIREMENTS.
DRAWING NUMBER REV
G-35-100005 A
ENDURA BOILER PRIMARY ONLY
VARIABLE FLOW MODULAR PLANT PIPING
DIAGRAM WITH 1" SIDE CLEARANCE
DESCRIPTION:
DRAWN BY:
M. BERWALD
CHECKED BY:
N/A
B.O.M. REVIEW
MECH. ENG:
N/A
ELEC. ENG:
APPROVED BY:
N/A
K.BOTTORFF
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and
drawings are
proprietary and are the
exclusive property of
The Fulton Companies.
The corporation does
not permit their use
except with prior
written consent.
The items shown in
this drawing may be
covered by one or
more patents of The
Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
7/7/2014
7/7/2014
UNLESS OTHERWISE NOTED:
DIMENSIONS ARE IN INCHES
TOLERANCES ON
FRACTIONS 1/4
(2) PLACE DEC. .01
(3) PLACE DEC. .005
ANGLES 2 DEG.
SURFACE FINISH
250 MICRO-INCHES
R
SHEET 1 OF 1
AREMOVED CONDENSATE PIPING, UPDATED
CALLOUTS & DESCRIPTION. M.E.B 1/20/15 N/A N/A SMT 2/2/15 N/A KDB
1/30/15
REVISION HISTORY
REV REVISION DESCRIPTION B.O.M. ELEC. ENG MECH. ENG CHECKED APPROVED
FULTON ENDURA
C
ONDENSING HYDRONIC BOILERS
RETURN
WATER TEMPERATURE
SENSOR
HEATING HOT
WATER RETURN
TWO POSITION
MOTORIZED
ISOLATION VALVE
SUPPLY WATER
TEMPERATURE
SENSOR
AIR REMOVAL
EXPANSION TANK
VARIABLE SPEED
SYSTEM PUMP
HEATING HOT
WATER SUPPLY
NOTES:
1.
2.
3.
4.
THIS IS A TYPICAL ARRANGEMENT FOR REFERENCE PURPO
SES
ONLY. ACTUAL INSTALLATIONS MAY REQUIRE ADDITIONAL
COMPONENTS WHICH ARE NOT SHOWN FOR CLARITY.
THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.
REFER TO THE INSTALLATION AND OPERATION MANUALS
FOR
INFORMATION REGARDING CLEARANCES AND INSTALLATI
ON
REQUIREMENTS.
THE PIPING CONFIGURATION SHOULD UTILIZE A REVERSE
RETURN HEADER TO PROPERLY BALANCE FLOW ACROSS THE
BOILERS. WHERE REVERSE RETURN CANNOT BE USED, IT IS
RECOMMENDED TO INSTALL A BALANCING VALVE PER BOILER.
REVERSE
RETURN
(SEE NOTE 4)
FIGURE 4  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; SINGLE BOILER

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EDR-IOM-2019-0212 INSTALLATION
2-9
FIGURE 7  SAMPLE PIPING LAYOUT, PRIMARY  SECONDARY PIPING; MULTIPLE BOILERS
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.
DRAWING NUMBER REV
G-35-100015 -
ENDURA BOILER PRIMARY - SECONDARY
SINGLE BOILER PIPING DIAGRAM
DESCRIPTION:
DRAWN BY:
M.BERWALD
CHECKED BY:
N/A
B.O.M. REVIEW
MECH. ENG:
SMT
ELEC. ENG:
APPROVED BY:
N/A
K.BOTTORFF
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and
drawings are
proprietary and are the
exclusive property of
The Fulton Companies.
The corporation does
not permit their use
except with prior
written consent.
The items shown in
this drawing may be
covered by one or
more patents of The
Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
1/20/2015 2/2/2015
1/30/2015
UNLESS OTHERWISE NOTED:
DIMENSIONS ARE IN INCHES
TOLERANCES ON
FRACTIONS 1/4
(2) PLACE DEC. .01
(3) PLACE DEC. .005
ANGLES 2 DEG.
SURFACE FINISH
250 MICRO-INCHES
R
SHEET 1 OF 1
-INITIAL RELEASE --- --- --- --- ---
REVISION HISTORY
R
EV REVISION DESCRIPTION CHECKED B.O.M. MECH. ENG ELEC. ENG APPROVED
FULTON ENDURA
CONDENSING HYDRONIC BOILER
NOTES:
1.
2.
3.
4.
THIS IS A TYPICAL ARRANGEMENT FOR REFERENCE PURP
OSES
ONLY. ACTUAL INSTALLATIONS MAY REQUIRE ADDITION
AL
COMPONENTS WHICH ARE NOT SHOWN FOR CLARITY.
THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.
REFER TO THE INSTALLATION AND OPERATION MANUALS
FOR
INFORMATION REGARDING CLEARANCES AND INSTALLAT
ION
REQUIREMENTS.
CENTER TO CENTER DISTANCE BETWEEN BOILER (PRIMARY)
SUPPLY AND RETURN MANIFOLDS SHOULD BE 4 PIPE
DIAMETERS OR LESS.
BOILER
(PRIMARY)
PUMP
HEATING HOT
W
ATER RETURN
SUPPLY WATER
TEMPERATURE
SENSOR
SEE NOTE 4
AIR REMOVAL
EXPANSION TANK
SYSTEM
(SECONDARY)
PUMP
HEATING HOT
WATER SUPPLY
DRAWING NUMBER REV
G-35-100006 A
ENDURA BOILER PRIMARY-SECONDARY
MODULAR PLANT PIPING DIAGRAM WITH
1" SIDE CLEARANCE
DESCRIPTION:
DRAWN BY:
M. BERWALD
CHECKED BY:
N/A
B.O.M. REVIEW
MECH. ENG:
N/A
ELEC. ENG:
APPROVED BY:
N/A
K.BOTTORFF
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and
drawings are
proprietary and are the
exclusive property of
The Fulton Companies.
The corporation does
not permit their use
except with prior
written consent.
The items shown in
this drawing may be
covered by one or
more patents of The
Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
7/7/2014
7/6/2014
UNLESS OTHERWISE NOTED:
DIMENSIONS ARE IN INCHES
TOLERANCES ON
FRACTIONS 1/4
(2) PLACE DEC. .01
(3) PLACE DEC. .005
ANGLES 2 DEG.
SURFACE FINISH
250 MICRO-INCHES
R
SHEET 1 OF 1
AREMOVED CONDENSATE PIPING, UPDATED
CALLOUTS & DESCRIPTION. M.E.B. 1/20/15 N/A N/A SMT 2/2/15 N/A KDB
1/30/15
REVISION HISTORY
REV REVISION DESCRIPTION B.O.M. ELEC. ENG MECH. ENG CHECKED APPROVED
NOTES:
1.
2.
3.
4.
5.
THIS IS A TYPICAL ARRANGEMENT FOR REFERENCE PURPOS
ES
ONLY. ACTUAL INSTALLATIONS MAY REQUIRE ADDITIONAL
COMPONENTS WHICH ARE NOT SHOWN FOR CLARITY.
THIS DRAWING IS NOT FOR CONSTRUCTION PURPOSES.
REFER TO THE INSTALLATION AND OPERATION MANUALS F
OR
INFORMATION REGARDING CLEARANCES AND INSTALLATIO
N
REQUIREMENTS.
THE PIPING CONFIGURATION SHOULD UTILIZE A REVERSE
RETURN HEADER TO PROPERLY BALANCE FLOW ACROSS TH
E
BOILERS. WHERE REVERSE RETURN CANNOT BE USED, IT IS
RECOMMENDED TO INSTALL A BALANCING VALVE PER BOILE
R.
CENTER TO CENTER DISTANCE BETWEEN BOILER (PRIMARY)
SUPPLY AND RETURN MANIFOLDS SHOULD BE 4 PIPE
DIAMETERS OR LESS.
FULTON ENDURA
CONDENSING HYDRONIC BOILERS
HEATING HOT
WATER SUPPLY
SYSTEM (SECONDARY)
PUMP
AIR REMOVAL
EXPANSION TANK
SUPPLY WATER
TEMPERATURE SENSOR
SEE NOTE 5
RETURN WATER
TEMPERATURE SENSOR
HEATING HOT
WATER RETURN
BOILER (PRIMARY)
PUMP
REVERSE RETURN
(SEE NOTE 4)
FIGURE 6  SAMPLE PIPING LAYOUT, PRIMARY  SECONDARY PIPING; SINGLE BOILER
CLOSELY SPACED TEES
(<4 DIAMETERS)
CLOSELY SPACED TEES
(<4 DIAMETERS)

© Fulton Group N.A., Inc. 2019
2-10
INSTALLATION EDR-IOM-2019-0212 SECTION 2
motorized isolation valve should be installed per boiler; two-position type
actuator, open or closed. It is acceptable to install the valve on either the
inlet or the outlet piping of each boiler.
Motorized isolation valve control: Ensure ow paths in the hydronic loop
and residual heat in the pressure vessel is adequately dispersed when the
burner is disabled. The valve control system must be capable of leaving the
lead boiler valve open at all times.
Use a reverse return header to properly balance ow across the boilers
for multiple boiler systems: Where reverse return cannot be used, it is
recommended to install a balancing valve per boiler.
Do not install three-way mixing valves or minimim temperature protection:
The Endura boiler does not have a minimum return water temperature
requirement.
Primary-Secondary Piping Arrangement
It is acceptable to install the Endura boiler in a primary-secondary arrangement,
although this arrangement is not required. See Figures 6 and 7. Primary-
secondary arrangements are used to decouple the water ow of the primary
(boiler) loop from the secondary (system) loop. Temperature mixing occurs in the
shared piping region.
Adhere to the following for primary-secondary piping arrangements:
Typical shared piping methods include closely spaced tees, a buer tank, or
a hydraulic separator.
When using closely spaced tees as a decoupling method, the tees should be
separated by four pipe diameters or less.
Install the dedicated boiler circulator on the inlet side of the Endura boiler,
pumping into the return connection. Select pump(s) with sucient total
dynamic head for the pressure drop of the loop at design ow. See Figure 3
for the water side pressure drop through the boiler.
For multiple boiler systems:
»Use a single common supply and a single common return connection
into the secondary (system) piping. Do not use separate connections
for each boiler into the secondary piping.
»Use a reverse return primary header to properly balance ow across the
boilers. Where reverse return cannot be used, it is recommended to
install a balancing valve per boiler.
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
! 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.

Questions? Please Contact Your Local Manufacturer’s Representative 2-11
SECTION 2 EDR-IOM-2019-0212 INSTALLATION
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
Hardness: Less than 3.5 grains per gallon (60 ppm) in make-up/ll water.
Calcium buildup on heating surfaces is not covered under warranty.
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.
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.
The maximum concentration is 50% glycol by volume. Only use mixtures
formulated for hydronic systems. DOWFROSTTM HD is recommended. Do
not use automotive glycol.
6. At a minimum, the hydronic uid should be checked for glycol
concentration and pH once a year, or per glycol manufacturer schedule. A
refractometer is recommended.
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.
! 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
Some soap used for leak testing is
corrosive to certain types of metals.
Clean all piping thoroughly after
completing the leak check.
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. If
cleaning is desired, ush the boiler with
clean domestic water only.

© Fulton Group N.A., Inc. 2019
INSTALLATION EDR-IOM-2019-0212 SECTION 2
2-12
ISOMETRIC VIEW
(PARTIALLY EXP LODED FOR CLARITY)
DRAWING NUMBER REV
G-35-100009 A
TYPICAL ENDURA FUEL TRAIN
DESCRIPTION:
DRAWN BY:
M.BERWALD
CHECKED BY:
MEH
B.O.M. REVIEW
MECH. ENG:
SMT
ELEC. ENG:
APPROVED BY:
N/A
D.MCNITT
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and drawings
are proprietary and are the
exclusive property of The
Fulton Companies. The
corporation does not
permit their use except
with prior written consent.
The items shown in t his
drawing may be covere d
by one or more patents of
The Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
9/14/2014
9/24/2014
9/24/2014
9/29/2014
UNLESS OTHERWISE NOTED
DIMENSIONS ARE IN INCHES
R
SHEET 1 OF 1
(1) PLACE DEC. `0.03
(2) PLACE DEC. `0.015
(3) PLACE DEC. `0.005
ANGLE `0.5 DEG
SURFACE FINISH
250 MICRO-INCHES
TOLERANCES
FRACTION &
WHOLE VALUE
`1/8
NOTES:
1.
REFERENCE DRAWING ONL Y INTENDED FOR G ENERAL LAYOU T
PURPOSES ON LY.
AUPDATED TO C OMPLY WITH NEW G AS TRAIN
LAYOUT. B.M.P. 12 /16/2015 --- --- --- --- K.D.B.
12/16/15
-INITIAL RELEAS E --- --- --- --- ---
REVISION H ISTORY
REV REVISION DESCRIP TION B.O.M. ELEC. ENG MECH. EN G CHECKED AP PROVED
Fuel Train Inlet
Note: Measure Inlet
gas pressure here
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 on the suction side of the system circulator(s).
4. If an air cushion type expansion tank is used, pipe tank
directly into boiler supply on the suction side of the
system circulator(s).
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
Gas Supply Piping
The Endura is a gas red fully modulating boiler that requires
gas delivery at a relatively constant pressure and caloric
content. This ensures ecient and reliable combustion. A
lock-up style regulator is factory-mounted in the gas train. Do
not modify the gas train.
The packaged gas train (See Figure 8) is congured to operate
at specic gas pressure requirements. The requirements are
detailed on the boiler name plate, located on the back of the
boiler.
The Endura boiler is factory test red and combustion is
adjusted per the boiler data plate and test re sheet.
FIGURE 8  TYPICAL GAS TRAIN VARIES BY SIZE/MODEL
FIGURE 9  MEASURING INLET GAS PRESSURE
Measure
inlet supply
gas pressure
here
Lockup Regulator
with Integral Vent Limiter
Main Gas Valve
(see Figure 26)
Ignition Enrichment Regulator
with Integral Vent Limiter
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.

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EDR-IOM-2019-0212 INSTALLATION
2-13
TABLE 3  SCH 40 PIPE NATURAL GAS CAPACITY
Nominal
Pipe Size
ID Equivalent Pipe Length Max Capacity in ft3 of natural gas per hour. 14”wc pressure.
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
Inlet Gas Pressure
Adhere to the following:
Static inlet gas pressure: Measure while boiler is idle.
Verify pressure is within allowable range.
Dynamic inlet gas pressure: Measure while boiler is in
operation at maximum ring rate. Verify pressure is
within allowable range.
The gas delivery system must provide a stable and
consistent pressure across the entire turndown range,
including light o and idle conditions.
Maximum inlet gas pressure drop from static to
dynamic must not exceed 15%, or the maximum
allowable by local code (CSA B149 clause 6.3.2 for
Canada). The stricter of the two shall apply.
Gas Pressure Requirements
The minimum gas pressure required is 4”W.C. For gas pressures
exceeding 28”W.C. (14”W.C. Canada), a step down regulator
(not supplied) must be installed in the gas supply piping.
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 down below maximum pressure.
Proper selection and installation of a gas pressure regulator
is essential in providing ideal conditions for ecient and
reliable combustion. Adhere to the following guidelines
when selecting and installing a gas pressure regulator:
A sediment trap is recommended prior to the inlet of
the regulator.
If the level of pipe system cleanliness is unacceptable
or unknown, it is recommended that a gas lter be
installed prior to the regulator.
On the outlet of the regulator: Install a straight and
uninterrupted section of pipe matching regulator
connection size with a minimum length of 10 pipe
diameters prior to any valves or ttings.
When installed in close proximity to an appliance, some
regulators may experience oscillation (hunting) or an
outlet pressure spike when demand ends. Provide
adequate volume by locating the regulator a minimum
of 10 total linear feet of pipe from boiler fuel train inlet.
Consult the regulator manufacturer for installation
requirements.
The body size should never be larger than the pipe size.
However, a properly sized regulator may be smaller
than the pipeline.
The inlet pressure used for sizing should be measured
directly at the regulator inlet. Measurements taken at
any other point may be subject to losses associated
with upstream piping.
Consult the regulator manufacturer for orice selection.
If two or more springs are available for a particular
outlet pressure in the desired range use the spring with
the lower range for better accuracy.
NOTE:Regulators are not intended for use as “shut o”
devices. As per ANSI Z21.80/CSA 6.22 lock-up is dened as an
outlet pressure not more than 150% or 5” W.C., whichever is
greater, above the setpoint after a downstream safety shuto
valve closes within 2 seconds.

© Fulton Group N.A., Inc. 2019
INSTALLATION EDR-IOM-2019-0212 SECTION 2
2-14
Appliance regulators must not be used as line gas pressure
regulators to step down the gas pressure. For additional
information regarding gas regulator selection and installation
consult your regulator manufacturer, any applicable local
codes or ordinances, the standard for line pressure regulators
ANSI Z21.80/CSA 6.22, and The National Fuel Gas Code NFPA
54/ANSI Z223.1.
Gas Piping Installation
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. See Figures
6 and 7 for piping arrangements.
2. Install a manual gas shuto valve and union prior to the
boiler.
3. Piping must be installed such that no piping stresses
are transmitted to the boiler. The boiler cannot be used
as a pipe anchor.
4. 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.
5. The boiler must be disconnected at the boiler manual
shuto valve (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.).
6. 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.
7. The pipe and the ttings used must be new and free of
dirt or other deposits.
8. 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.
9. Connect gas supply line to the open end of the tee on
which the drip leg is installed.
DRAWING NUMBER REV
G-35-100007 -
ENDURA SINGLE BOILER GAS SUPPLY
PIPING
DESCRIPTION:
DRAWN BY:
M.BERWALD
CHECKED BY:
D.MCNITT
B.O.M. REVIEW
MECH. ENG:
SMT
ELEC. ENG:
APPROVED BY:
N/A
MEH
N/A
JOB NUMBER:
PROJECT NAME:
PROJECT MANAGER:
This design and
drawings are
proprietary and are the
exclusive property of
The Fulton Companies.
The corporation does
not permit their use
except with prior
written consent.
The items shown in
this drawing may be
covered by one or
more patents of The
Fulton Companies.
1 OF 1
THIRD ANGLE PROJECTION
The Fulton Companies
972 Centerville Road
Pulaski, New York USA 13142
7/25/2014
9/30/2014
9/25/2014
9/25/2014
UNLESS OTHERWISE NOTED:
DIMENSIONS ARE IN INCHES
TOLERANCES ON
FRACTIONS 1/4
(2) PLACE DEC. .01
(3) PLACE DEC. .005
ANGLES 2 DEG.
SURFACE FINISH
250 MICRO-INCHES
R
SHEET 1 OF 1
GAS SUPPLY
MANUAL
SHUTOFF VALVE
LINE GAS PRESSURE REGULATOR (SEE NOTE 1)
SEE NOTE 2,3
-INITIAL RELEASE --- --- --- --- ---
REVISION HISTORY
REV REVISION DESCRIPTION B.O.M. ELEC. ENG MECH. ENG CHECKED APPROVED
NOTES:
1.
2.
3.
4.
5.
REQUIRED FOR INSTALLATION
S WITH GREATER THAN 28"
W.C. INLET PRESSURE. FIELD S
UPPLIED.
REQUIRED 10 PIPE DIAMETERS
EQUIVELENT TO THE
REGULATOR CONNECTION SIZE
. THIS PIPE MUST BE
STRAIGHT UNINTERRUPTED PI
PE BETWEEN REGULATOR
OUTLET AND ANY FITTINGS, V
ALVES, OR ELBOWS.
THE LINE REGULATOR SHOULD
BE INSTALLED WITH A
MINIMUM OF 10 LINEAR FEET
OF PIPE BETWEEN THE
REGULATOR OUTLET AND BOIL
ER FUEL TRAIN INLET.
THIS DRAWING IS NOT FOR CO
NSTRUCTION PURPOSES.
REFER TO THE INSTALLATION
AND OPERATION MANUAL FOR
INFORMATION REGARDING GA
S HEADER SIZING, CLEARANCES
AND OTHER INSTALLATION RE
QUIREMENTS.
FIGURE 10  ENDURA SINGLE BOILER GAS SUPPLY PIPING
Notes:
1. Required for installation with greater than
28”W.C. (14”W.C. Canada) inlet pressure, eld
supplied.
2. Required 10 pipe diameters equivalent to the
regulator connection size. This pipe must be
straight, uninterrupted pipe between regulator
outlet and and any ttings, valves, or elbows.
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.