FULTON Endura User manual

INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
Endura (EDR)
Condensing Hydronic Boilers
750,000 - 2,000,000 BTU/HR
with SOLA Control
Serial/ National
Board Number
Model
Fulton Order
Owner
Site Name
Date
EDR-SOLA-IOM-2022-0216

Questions? Please Contact Your Local Manufacturer’s Representative
EDR-SOLA-IOM-2022-0216 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
GAS PIPING INSTALLATION .......................................................................................................214
COMPONENTS REQUIRINGVENTILATIONTOTHE OUTDOORS.................................................216
Install Condensate Drain Trap............................................................................. 2-16
SINGLE BOILER DRAINTRAP.....................................................................................................216
MULTIPLE BOILERS SHARING A COMMON DRAINTRAP .........................................................219
Install pH Neutralization Kit............................................................................... 2-21
Venting Requirements....................................................................................... 2-21
Combustion Air Intake ....................................................................................... 2-23
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM..............................................................224
COMBUSTION AIR DUCTED FROMTHE OUTDOORS..................................................................225
Combustion Air Filter ......................................................................................... 2-25
Flue Gas ExhaustVenting................................................................................... 2-27
Common Flue GasVenting Layouts.................................................................... 2-29
COMMONVENTING EXHUAST BACKFLOW PREVENTION.........................................................229
VENTINGTERMINATIONS..........................................................................................................233
WALL THIMBLE INSTALLATION.................................................................................................233
ROOFVENTTERMINATION.........................................................................................................233
SIDEWALL VENT TERMINATION................................................................................................233
Removing an Existing Boiler ............................................................................. 2-34
Assembly of Fulton Multi-Skid Systems............................................................. 2-35
Electrical Connections and Devices.................................................................... 2-36
JUNCTION BOX LOCATIONS FOR FIELD WIRING .......................................................................241
ELECTRICAL AND CONTROLS OPTIONS.....................................................................................241
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:The Neg-Reg System ..................................................... 3-4
TURNDOWN.................................................................................................................................38
SOLA Hydronic Controller - General Operation .................................................... 3-9
STATUS SUMMARY SCREEN.........................................................................................................39
CENTRAL HEAT OPERATION SCREEN...........................................................................................39
CENTRAL HEAT OPERATION  FIRING RATE SCREEN.................................................................310
CENTRAL HEAT OPERATION  SETPOINT SCREEN....................................................................310
CENTRAL HEAT CONFIGURATION  SETPOINT SCREEN...........................................................311
CENTRAL HEAT CONFIGURATION  MODULATION SCREEN ....................................................312
CHANGING HIGH LIMIT SETPOINT ANDVERIFYING CHANGE..................................................313
REVIEWING STATISTICS.............................................................................................................315
ACCESSING LOCKOUT HISTORY .................................................................................................315
SOLA DIAGNOSTICS...................................................................................................................317
SOLA Hydronic Controller - Options Conguration ............................................ 3-19
LEAD/LAG INTEGRATED SEQUENCING .....................................................................................319
DOMESTIC HOTWATER DHWTEMPERATURE SENSOR..........................................................323
REMOTE420 MA SIGNAL FOR SETPOINT ................................................................................324
SUPPLY HEADERTEMPERATURE SENSOR ................................................................................325
OUTDOOR AIR TEMPERATURE SENSOR ....................................................................................326
STACK LIMIT...............................................................................................................................329
DEDICATED BOILER PUMP.........................................................................................................329
MOTORIZED ISOLATION VALVE SET UP .....................................................................................330
ENABLING BURNER FIRE RATE OUTPUT...................................................................................331
SYSTEM PUMP ENABLE/DISABLE SIGNAL ...............................................................................332
PerformTest of LowWater Cut O ..................................................................... 3-33
PerformTest of Limit Controls ........................................................................... 3-33
PerformTest of Low Gas Pressure Switch .......................................................... 3-33
PerformTest of High Gas Pressure Switch.......................................................... 3-33
General Operation of the Boiler ......................................................................... 3-34
Maintenance 4-1
General................................................................................................................. 4-2
Tool Lists............................................................................................................... 4-3
Daily Inspection Schedule ................................................................................... 4-4
Weekly Maintenance Schedule ........................................................................... 4-4
Monthly Maintenance Schedule.......................................................................... 4-4
Procedure for Inspecting the Air Inlet Filter ....................................................... 4-4
Annual Maintenance Schedule............................................................................ 4-5
Replacing GasValve Internal Filter....................................................................... 4-6
Removing and Cleaning Burner Assembly .......................................................... 4-7
Verication of Ignition Gap.................................................................................. 4-8
After All Repairs and Maintenance ...................................................................... 4-9
Troubleshooting................................................................................................. 4-12

© Fulton Group N.A., Inc. 2022
TABLE OF CONTENTS EDR-SOLA-IOM-2022-0216
0-2
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. 2022
INTRODUCTION EDR-SOLA-IOM-2022-0216 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
SERVICE DOCUMENTS 5

© Fulton Group N.A., Inc. 2022
2-2
INSTALLATION EDR-SOLA-IOM-2022-0216 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.
This boiler is ETL-certied to Underwriters Laboratories (UL) Edition 7 UL
Standard for Safety Commercial-Industrial Gas Heating Equipment 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.
Please be aware of which burner and control conguration has been designed
specically for your application.
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. Various 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
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 EDR-SOLA-IOM-2022-0216 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. The boiler is designed for room temperatures above 32°F (0°C) and not
exceeding 120°F (48.9°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 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 combustion 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. 2022
INSTALLATION EDR-SOLA-IOM-2022-0216 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-SOLA-IOM-2022-0216 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 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. 2022
2-6
INSTALLATION EDR-SOLA-IOM-2022-0216 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-SOLA-IOM-2022-0216 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 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
The 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 accordance with ASHRAE 90.1-2013 (6.5.4.3.2). Blending of
unheated supply water impacts temperature control and can cause
manual reset high temperature lockouts. Use only one motorized 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 with a cycle time of 45 seconds or less. Do not
install modulating isolation valves on boiler piping.
FIGURE 3  TYPICAL WATER SIDE PRESSURE DROP

© Fulton Group N.A., Inc. 2022
INSTALLATION EDR-SOLA-IOM-2022-0216 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.




R
FULTON ENDURA
CONDENSING HYDRONIC BOILER
AIR REMOVAL
EXPANSION TANK
VARIABLE SPEED
SYSTEM PUMP
HEATING HOT
WATER SUPPLY
HEATING HOT
WATER RETURN
NOTES:
1.
2.
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.




R
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
SE
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
FO
INFORMATION REGARDING CLEARANCES AND INSTALLATI
ON
REQUIREMENTS.
THE PIPING CONFIGURATION SHOULD UTILIZE A REVERSE
RETURN HEADER TO PROPERLY BALANCE FLOW ACROSS THE
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-SOLA-IOM-2022-0216 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.




R
REVISION HISTORY
R
EV REVISION DESCRIPTION CHECKED B.O.M. MECH. ENG ELEC. ENG APPROVED
FULTON ENDURA
CONDENSING HYDRONIC BOILER
NOTES:
1.
2.
3.
THIS IS A TYPICAL ARRANGEMENT FOR REFERENCE PURP
OS
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
F
INFORMATION REGARDING CLEARANCES AND INSTALLAT
IO
REQUIREMENTS.
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




R
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. 2022
2-10
INSTALLATION EDR-SOLA-IOM-2022-0216 SECTION 2
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 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 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.
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-SOLA-IOM-2022-0216 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. 2022
INSTALLATION EDR-SOLA-IOM-2022-0216 SECTION 2
2-12
R
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
This 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. A lock-up style regulator is factory-mounted in
the gas train. Do not modify the gas train.
The gas train (See Figure 8) pressure requirements are
detailed on the boiler data plate, located at the rear of the
boiler.
This boiler is factory test red and combustion is adjusted per
the Factory Test Fire Report.
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-SOLA-IOM-2022-0216 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 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 pipeline.
The inlet pressure used for sizing should be measured
directly at the regulator inlet. Measurements taken at

© Fulton Group N.A., Inc. 2022
INSTALLATION EDR-SOLA-IOM-2022-0216 SECTION 2
2-14
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.
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 Figures
6 and 7 for piping arrangements.
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 pressure-tested and
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 1.0 psig (28 inch W.C.).
FIGURE 10  ENDURA SINGLE BOILER GAS SUPPLY PIPING
GAS SUPPLY
MANUAL
SHUTOFF VALVE
LINE GAS PRESSURE REGULATOR (SEE NOT
E 1
SEE NOTE 2,3
NOTES:
1.
2.
3.
4.
5.
REQUIRED FOR INSTALL
AT
W.C. INLET PRESSURE. F
IE
REQUIRED 10 PIPE DIAM
ET
REGULATOR CONNECTIO
N
STRAIGHT UNINTERRUP
TED
OUTLET AND ANY FITTI
NGS
THE LINE REGULATOR S
HO
MINIMUM OF 10 LINEAR
FE
REGULATOR OUTLET AN
D B
THIS DRAWING IS NOT
FOR
REFER TO THE INSTALLA
TI
INFORMATION REGARDI
NG
AND OTHER INSTALLATI
ON
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.