FULTON Endura XE User manual

INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
Endura XE (EXE)
Condensing Hydronic Boilers
399,000 - 750,000 BTU/HR
Featuring PURE Control™
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
EXE-IOM-230112

Questions? Please Contact Your Local Manufacturer’s Representative
EXE-IOM-230112 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................................................................ 2-11
PREVENT OXYGEN CONTAMINATION........................................................................................212
ELIMINATE SYSTEM AIR ............................................................................................................212
Fill the BoilerWithWater ................................................................................... 2-12
Gas Supply Piping .............................................................................................. 2-12
INLET GAS PRESSURE................................................................................................................213
LINE GAS PRESSURE REGULATION............................................................................................213
GAS PIPING INSTALLATION .......................................................................................................214
COMPONENTS REQUIRINGVENTILATIONTOTHE OUTDOORS.................................................214
Install Condensate Drain Trap............................................................................. 2-16
Install pH Neutralization Kit............................................................................... 2-17
Venting Requirements....................................................................................... 2-18
Combustion Air Intake ....................................................................................... 2-19
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM..............................................................220
COMBUSTION AIR DUCTED FROMTHE OUTDOORS..................................................................221
Flue Gas ExhaustVenting................................................................................... 2-22
Common Flue GasVenting Layouts.................................................................... 2-23
COMMONVENTING EXHAUST BACKFLOW PREVENTION.........................................................225
VentingTerminations......................................................................................... 2-26
WALL THIMBLE INSTALLATION.................................................................................................226
ROOFVENTTERMINATION.........................................................................................................227
SIDEWALLVENT TERMINATION................................................................................................227
Removing an Existing Boiler ............................................................................. 2-31
Assembly of Fulton Multi-Skid Systems............................................................. 2-31
Electrical Connections and Devices.................................................................... 2-32
LOCATIONS FOR FIELD WIRING.................................................................................................237
ELECTRICAL AND CONTROLS OPTIONS.....................................................................................237
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
Adjusting andVerifying Combustion................................................................... 3-4
PREPARATIONS BEFORE SETTING COMBUSTION.......................................................................34
LIGHTINGTHE BURNER AND SETTING COMBUSTION................................................................35
VERIFYING SAFETIES AND IGNITION RELIABILITY.....................................................................37
UPON SUCCESSFUL COMPLETION...............................................................................................37
Combustion Parameters...................................................................................... 3-8
Using the PURE Control™ Interface...................................................................... 3-9
NAVIGATION.................................................................................................................................39
PURE Control™ Menu Screens............................................................................ 3-10
BOILER .......................................................................................................................................310
ALARM HISTORY........................................................................................................................310
CIRCULATION .............................................................................................................................310
LEAD/LAG...................................................................................................................................311
PID..............................................................................................................................................312
TEMPERATURE...........................................................................................................................313
CONFIGURATION........................................................................................................................314
Testing Safety Devices........................................................................................ 3-15
PERFORMTEST OF LIMIT CONTROLS........................................................................................315
PERFORMTEST OF LOW GAS PRESSURE SWITCH....................................................................315
PERFORMTEST OF HIGH GAS PRESSURE SWITCH ...................................................................315
PERFORMTEST OF LOW WATER CUT OFF .................................................................................315
Maintenance 4-1
General................................................................................................................. 4-2
Tool List ................................................................................................................ 4-3
Daily Inspection Schedule ................................................................................... 4-4
Weekly Maintenance Schedule ........................................................................... 4-4
Monthly Maintenance Schedule.......................................................................... 4-4
Replacing or Updating the Boiler Control............................................................ 4-4
Annual Maintenance Schedule............................................................................ 4-5
Removing and Cleaning Burner Assembly .......................................................... 4-6
Removing and Cleaning Flame Rod..................................................................... 4-7
Verication of Ignition Electrode Gap.................................................................. 4-8
After All Repairs and Maintenance ...................................................................... 4-9
Parts Diagrams................................................................................................... 4-10
Troubleshooting................................................................................................. 4-16
Service 5-1
Pre-Commissioning Installation Checklist........................................................... 5-3
Installation & Operation“Start-Up”Report ......................................................... 5-5
Annual Maintenance Checklists .......................................................................... 5-7
Notes.................................................................................................................. 5-17

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

© Fulton Group N.A., Inc. 2023
INTRODUCTION EXE-IOM-230112 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 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
SERVICE DOCUMENTS 5

© Fulton Group N.A., Inc. 2023
2-2
INSTALLATION EXE-IOM-230112 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.
This hydronic heating boiler is not
suitable for use as a domestic water
heater. Do not heat potable water,
such as used for showers, sinks,
dishwashers, or washdown process
directly through the boiler.
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 XE hot water boiler is an automatic, fuel-red, ultra high-
eciency boiler. Combustion air supply may be ducted to the boiler from the
outdoors or utilize conventional methods.
The boiler is capable of sidewall venting when the appropriate venting materials
are used, and when permitted by local code requirements.
This boiler is ETL listed and labeled to ANSI Z21.13-2017/CSA 4.9-2017 standard
for Gas-red low pressure steam and hot water boilers for indoor installation. The
boiler heat exchanger is manufactured and bears the“H”stamp 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. It is hydrostatically tested, test red and
shipped as a complete packaged unit.
Fuel, water and electrical connections are similar to other boilers of this type.
This 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. Improper system conditions can result in incorrect heat
distribution to users of the heating system.
Each 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 and tee
Installation, Operation, and Maintenance 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 EXE-IOM-230112 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. This boiler is designed for room temperatures above 32°F (0°C) and not
exceeding 104°F (40°C).
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 only in the vertical position.
Concrete is strongly recommended. Do not install the boiler on springs.
Use shims if necessary to ensure boiler is level.
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. This boiler supports congurations
for either direct vent installation or for installation using indoor
combustion air.
8. Locate the boiler so that the combustion 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. 2023
INSTALLATION EXE-IOM-230112 SECTION 2
2-4
Specications EXE 399 500 650 750
Rated Input Capacity
1
MBH 399 500 650 750
Minimum Input at Low Fire MBH 33 33 50 50
Output at AHRI-1500 conditions MBH 391 487 626 720
Fuel Consumption at Capacity SCFH 395 495 643 742
Nat. Gas Pressure Required W.C. 3.5 - 14 3.5 - 14 3.5 -14 3.5 - 14
Low FireVariableWater Flow GPM 4 - 105 4 - 105 4 - 125 4 - 125
High FireVariableWater Flow GPM 16 - 105 20 - 105 26 - 125 30 - 125
Minimum Circuit Ampacity (120/1/60) AMP 7.5 10 10 10
Full Load Amps (120/1/60) AMP 6 8 8 8
Water Content GAL 10.4 10.4 17.9 17.9
Dry Weight LBS 450 450 525 525
OperatingWeight LBS 537 537 674 674
Dimensions EXE 399 500 650 750
A. Boiler Width IN 26.3 26.3 26.3 26.3
B. Boiler Height IN 73.7 73.7 73.7 73.7
C. Boiler Skid Depth IN 28.9 28.9 28.9 28.9
Connections EXE 399 500 650 750
D. Flue Gas Vent (dia) IN 4 4 6 6
E. Combustion Air Inlet (dia) IN 4 4 6 6
F.Water Inlet (dia) IN 2 2 2 2
G.Water Outlet (dia) IN 2 2 2 2
H. Gas Inlet (dia) IN 1 1 1 1
I. Condensate Drain (dia) IN 0.75 0.75 0.75 0.75
Minimum Clearance EXE 399 500 650 750
J. Front IN 24 24 24 24
K. Rear  IN 12 12 12 12
L.Top IN 16 16 16 16
M. Sides IN 0 0 0 0
TABLE 1  BOILER DIMENSIONS AND OPERATING REQUIREMENTS
FIGURE 1  DIMENSIONS AND CLEARANCES
NOTES: May be operated up to 10,000 feet elevation, and up to 1,000 feet elevation at 80˚F without de-rate. Consult your Fulton Representative for capacities at higher elevation.
Applies to natural gas with a caloric value of 1,010 BTU per FT3.
Standard natural gas congurations only. Alternate or custom congurations may have dierent requirements; always review the boiler nameplate before installation.
Standard electrical congurations only. Alternate or custom congurations may have dierent requirements; always review the boiler nameplate before installation.
An appliance adapter may be required.
12-inch rear clearance is to combustibles and for maintenance allow for inch rear clearance to accomodate installation of the flue gas exhaust vent
Specications and dimensions are approximate and for reference only. Fulton practices continuous product improvement and reserves the right to change specications and/or dimensions without notice.
MJ
D
E
M
K
C
B
L
A
G
F
H
I
FRONT SIDE REAR TOP

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EXE-IOM-230112 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 of your boiler. 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 equipment
access to facilitate maintenance and a safe work
environment. Side clearance is not necessary unless
required by local code(s).
3. Although 12-inch rear clearance is permitted, some
installations may require or benet from 24-inch rear
clearance.
4. Ensure all labels on the boiler will be fully visible for
maintenance and inspection.
5. Do not mount any boiler room accessories, or other
components, on the cabinet panels.
Install Boiler Trim
Each boiler is supplied with a safety relief valve sized in
accordance with ASME Section IV requirements. Safety relief
valve size is determined by trim pressure and is supplied in
the trim kit. See Table 2 for inlet and outlet sizes.
1. The safety relief valve (Figure 2) must:
» Be mounted to a tee located on the top of the
boiler supply (outlet) piping.
» Be installed in the upright vertical position.
» Not be isolated from the boiler pressure vessel by
any values.
2. Minimum relief valve capacity:
» 500 lbs. per hour for EXE-399
» 500 lbs. per hour for EXE-500
» 750 lbs. per hour for EXE-650
» 750 lbs. per hour for EXE-750
3. 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
Trim Pressure
PSI (kPa)
Inlet Size
inch (mm)
Outlet Size
inch (mm)
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)
FIGURE 2  BOILER TRIM INSTALLATION LOCATION
Notes:
1) Safety Relief Valve (SRV), tee
for SRV, and combination
Pressure & Temperature (P&T)
gauge are shipped loose in
the boiler trim kit.
2) Tee for P&T gauge is not
included with the boiler, it
must be provided by
the installing contractor.
3) Devices shown must be
mounted in accordance with
good practices, these
instructions and local code
by the installing contractor.

© Fulton Group N.A., Inc. 2023
2-6
INSTALLATION EXE-IOM-230112 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, and set to meet or exceed a minimum pressure of 12 psi
at the boiler.
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.
A drain valve is recommended (not provided) on the boiler inlet piping.
Boiler connection dimensions are for reference and not for construction
purposes. Pre-fabricating boiler piping is not recommended.
! 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.
This hydronic heating boiler is not
suitable for use as a domestic water
heater. Do not heat potable water,
such as used for showers, sinks,
dishwashers, or washdown process
directly through the boiler.

Questions? Please Contact Your Local Manufacturer’s Representative 2-7
SECTION 2 EXE-IOM-230112 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.
LNOTE
The upper water connection is the
boiler supply (outlet). The lower water
connection is the boiler return (inlet).
Install ltration in the common loop or per boiler to remove particulates if
appropriate. A #4 or ner mesh size is required.
Install bypass chemical feeder for corrosion inhibitor maintenance if
appropriate.
Install corrosion coupon holder to assess corrosion inhibitor performance if
appropriate.
Before installing the 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
This boiler is 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.
Adhere to the following for variable primary piping arrangements:
Select secondary (system) pump(s) with sucient total dynamic head for
the pressure drop of the loop at design ow. See Figure 3 for the boiler
water pressure drop. This boiler will automatically perform a safe shutdown
in the event of a low ow condition; however, proper design ow is
required to deliver heat to the users and prevent nuisance lockouts.
Install a motorized isolation valve per boiler. This eliminates ow through
idle boilers in accordance with ASHRAE 90.1-2013 (6.5.4.3.2). Blending of
unheated supply water impacts temperature control operation and can
cause manual reset high temperature lockouts.
FIGURE 3  TYPICAL WATER SIDE PRESSURE DROP

© Fulton Group N.A., Inc. 2023
INSTALLATION EXE-IOM-230112 SECTION 2
2-8
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.
FIGURE 4  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; SINGLE BOILER
FIGURE 5  SAMPLE PIPING LAYOUT, PRIMARY ONLY VARIABLE FLOW PIPING; MULTIPLE BOILERS
SYSTEM
(SECONDARY)
PUMP(S)
EXPANSION TANK
NOTE: MUST BE INSTALLED
ON THE SUCTION SIDE OF
THE SECONDARY PUMP(S)
AND PRE-CHARGED PRIOR
TO FILLING SYSTEM
2-POSITION MOTORIZED
ISOLATION VALVE
NOTE: MAY BE INSTALLED
ON EITHER THE BOILER
INLET OR OUTLET, BUT
NEVER ON BOTH
ENDURA XE SERIES
CONDENSING BOILER
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
AIR REMOVAL
SUPPLY WATER
TEMPERATURE SENSOR
NOTE: INSTALL 5 TO 10 PIPE
DIAMETERS DOWNSTREAM
OF THE LAST BOILER
REVERSE
RETURN
CHECK AND
BALANCE VALVE
SYSTEM
(SECONDARY)
PUMP(S)
EXPANSION TANK
NOTE: MUST BE INSTALLED ON
THE SUCTION SIDE OF THE
SECONDARY PUMP(S) AND
PRE-CHARGED PRIOR TO
FILLING SYSTEM
ENDURA XE SERIES
CONDENSING BOILER
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
AIR REMOVAL
NOTE: WITH #4 OR
FINER MESH STRAINER

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 2 EXE-IOM-230112 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.
FIGURE 6  SAMPLE PIPING LAYOUT, PRIMARY  SECONDARY PIPING; SINGLE BOILER
SYSTEM
(SECONDARY)
PUMP(S)
EXPANSION TANK
NOTE: MUST BE INSTALLED ONTHE
SUCTION SIDE OF THE SECONDARY
PUMP(S) AND PRE-CHARGED PRIOR
TO FILLING SYSTEM
DEDICATED BOILER
(PRIMARY) PUMP
NOTE: PUMP INTO THE
BOILER RETURN (INLET)
ENDURA XE SERIES
CONDENSING BOILER
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
AIR REMOVAL
SUPPLY WATER
TEMPERATURE SENSOR
NOTE: INSTALL 5TO 10 PIPE
DIAMETERS DOWNSTREAM
OF CLOSELY SPACED TEES
CLOSELY SPACED TEES
NOTE: ≤ 4 DIAMETERS
#4 OR FINER
MESH STRAINER
REVERSE RETURN
PRIMARY HEADER
CHECK
VALVE
BALANCE
VALVE
CHECK AND
BALANCE VALVE
SECONDARY
HEADER
SYSTEM
(SECONDARY)
PUMP(S)
EXPANSION TANK
NOTE: MUST BE INSTALLED ON THE
SUCTION SIDE OF THE SECONDARY PUMP(S)
AND PRE-CHARGED PRIOR TO FILLING SYSTEM
DEDICATED BOILER
(PRIMARY) PUMP
NOTE: PUMP INTO THE
BOILER RETURN (INLET)
ENDURA XE SERIES
CONDENSING BOILER
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
AIR REMOVAL
SUPPLY WATER
TEMPERATURE SENSOR
NOTE: INSTALL 5 TO 10 PIPE
DIAMETERS DOWNSTREAM
OF CLOSELY SPACED TEES
CLOSELY SPACED TEES
NOTE: ≤ 4 DIAMETERS
#4 OR FINER
MESH STRAINER

© Fulton Group N.A., Inc. 2023
2-10
INSTALLATION EXE-IOM-230112 SECTION 2
Only use one isolation valve 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, but never both. Select a valve actuator with a cycle
time of 45 seconds or less. Do not install modulating isolation valves on
boiler piping.
Ensure ow paths in the hydronic loop and residual heat in the pressure
vessel is adequately dispersed for sucient time after 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 balance ow across the boilers. Where
reverse return cannot be used, it is recommended to install a balancing
valve per boiler.
Do not install three-way mixing valves or minimum temperature
protection. This boiler does not have a minimum return water temperature
requirement.
Install system bypass valve(s) at or after the last coil(s), do not install bypass
valves directly after the secondary (system) pump(s).
Primary-Secondary Piping Arrangement
It is acceptable to install this 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. Blending occurs in the shared piping region.
Adhere to the following for primary-secondary piping arrangements:
Typical decoupling methods include closely spaced tees, a buer tank, or a
hydraulic separator. Where using closely spaced tees, separate by four pipe
diameters or less.
Install the dedicated boiler circulator on the inlet side of the 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 boiler water pressure drop.
For multiple boiler systems:
» A check valve is required per boiler. Motorized isolation valves are
not an acceptable substitute for check valves. 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 balance ow across the
boilers. Where reverse return cannot be used, it is recommended to
install a balancing valve per boiler.
! 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 EXE-IOM-230112 INSTALLATION
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
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.
! 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.
This hydronic heating boiler is not
suitable for use as a domestic water
heater. Do not heat potable water,
such as used for showers, sinks,
dishwashers, or washdown process
directly through the boiler.
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. 2023
INSTALLATION EXE-IOM-230112 SECTION 2
2-12
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.
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
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.
FIGURE 8  MEASURING INLET GAS PRESSURE
Gas Supply Piping
The boiler features a gas red fully modulating burner
requiring gas delivery at a relatively constant pressure
and caloric content. This ensures ecient and reliable
combustion.
The gas train (See Figure 8) pressure requirements are
detailed in Table 1 and on the boiler data plate located at the
rear of the boiler. Do not modify the factory gas train.
This boiler is factory test red and combustion is adjusted per
the Factory Test Fire Report.
Inlet Gas Pressure
NOTE:
USE A MANOMETER
TO CONFIRM INLET
GAS PRESSURE IS
WITHIN APPROPRIATE
RANGE AT BOTH IDLE
(OFF) AND HIGH FIRE
CONDITIONS
MEASURE INLET (SUPPLY)
GAS PRESSURE HERE
MEASURE MAIN VALVE
(MV) DOWNSTREAM GAS
PRESSURE HERE

Questions? Please Contact Your Local Manufacturer’s Representative 2-13
SECTION 2 EXE-IOM-230112 INSTALLATION
Measure at the location shown in Figure 8 and 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.
Line Gas Pressure Regulation
When inlet gas pressure exceeds 14”W.C. a line gas regulator (not provided)
listed and labeled to ANSI Z21.80/CSA 6.22 will be used to step the gas pressure
down below the boiler’s maximum gas pressure.
Proper selection and installation of a gas pressure regulator is essential in
providing conditions for ecient and reliable combustion. Adhere to the
following guidelines when selecting and installing a gas pressure regulator:
A line pressure regulator listed and labeled to ANSI Z21.80/CSA 6.22
is recommended. 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. Appliance
regulators are not a substitution for line gas pressure regulators and must
not be used.
A gas pressure relief valve may be required for overpressure protection,
refer to the local code(s) adopted by the AHJ.
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 recommended
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 pipe size.
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.

© Fulton Group N.A., Inc. 2023
INSTALLATION EXE-IOM-230112 SECTION 2
2-14
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.
For multiple boiler installations it is recommended
that an individual line gas pressure regulator be
used to step-down the gas pressure at each boiler.
Where a single regulator is used for multiple boilers
the regulator must be appropriate for the entire gas
delivery turndown range. This includes all boilers on at
full re to one boiler on at low re.
Gas Piping Installation
Field gas piping must be installed in accordance with NFPA
54 National Fuel Gas Code, ANSI Z223.1, and any other local
codes which may apply. 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 Figure
9for the typical eld piping arrangement.
2. Piping must be of the proper size to ensure adequate
gas supply. It is typical for gas delivery piping to be up-
sized one or several diameters larger than boiler gas
inlet size.
3. The pipe and the ttings used must be new and free of
dirt or other deposits.
4. When making gas-piping joints, use a sealing
compound resistant to the fuel gas serving the boiler.
5. Install a manual gas shuto valve and union (not
supplied) prior to the boiler.
6. Piping must be installed such that no piping stresses
are transmitted to the boiler. The boiler cannot be used
as a pipe anchor.
7. All gas piping connections must be checked for leaks
before being placed into service. Test with compressed
air or inert gas if possible.
8. The boiler gas train must be disconnected at the boiler
manual shuto valve from the gas supply piping system
during any pressure testing of the system at pressures
in excess of 0.5 psig (14 inch W.C.).
9. After completing pressure testing and obtaining any
necessary approvals from the AHJ, introduce gas service
and purge gas piping in accordance with local codes.
Do not purge their contents into a conned space or
where fuel gas can accumulate.
10. The boiler gas train has been factory leak tested,
however, ttings may loosen during shipping or
installation. After gas piping is completed and before
wiring installation is started, all piping connections
(factory and eld) must be carefully checked for gas
leaks. Use a soap and water solution or combustible
gas detector. A GAS-Mate®0119 or equivalent is
recommended.
Components RequiringVentilation to the
Outdoors
An authority having jurisdiction (AHJ) may not permit the
use of a vent limiter on some or all components. If venting is
required, use the following general guidelines:
Drill an appropriately sized penetration for each vent
line through the topmost panel on the rear of the boiler
cabinet. Do not install any vent lines through removable
panels. Properly seal around the pipe with silicone to
maintain a sealed cabinet and ensure combustion air
will not bypass the lter.
Each component must have a separate vent line to
the outdoors. Vent lines must not be manifolded or
combined with any other vent or exhaust systems.
Start with the vent connection size and as soon as it is
practical, increase the pipe size one diameter. For every
ten feet of vent, increase the pipe size one diameter.
Never reduce the vent size.
Protect the vent termination from debris, dust and
insects. Install the vent termination above the snow
line and point down to prevent ingress of water. The
termination must be a minium of 3 ft (0.9 m) from a
source of ignition.