FULTON Endura - Page 3

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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 Boiler Trim ................................................................................................. 2-5
Install Water Piping .............................................................................................. 2-6
VARIABLE PRIMARY PIPING ARRANGEMENT ............................................................................27
PRIMARYSECONDARY PIPING ARRANGEMENT ......................................................................210
Meet Water Chemistry Requirements ................................................................ 2-10
PREVENT OXYGEN CONTAMINATION ........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................212
Fill the Boiler With Water ................................................................................... 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 REQUIRING VENTILATION TO THE OUTDOORS .................................................216
Install Condensate Drain Trap ............................................................................. 2-16
SINGLE BOILER DRAIN TRAP .....................................................................................................216
MULTIPLE BOILERS SHARING A COMMON DRAIN TRAP .........................................................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 FROM THE OUTDOORS..................................................................225
Combustion Air Filter ......................................................................................... 2-25
Flue Gas Exhaust Venting ................................................................................... 2-27
Common Flue Gas Venting Layouts .................................................................... 2-29
COMMON VENTING EXHUAST BACKFLOW PREVENTION ......................................................... 229
VENTING TERMINATIONS ..........................................................................................................233
WALL THIMBLE INSTALLATION .................................................................................................233
ROOF VENT TERMINATION .........................................................................................................233
SIDE WALL 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
Commission The Boiler ......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION .................................................................................33
Commission The 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 AND VERIFYING 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 HOT WATER DHW TEMPERATURE SENSOR..........................................................323
REMOTE 420 MA SIGNAL FOR SETPOINT ................................................................................324
SUPPLY HEADER TEMPERATURE 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
Perform Test of Low Water Cut O ..................................................................... 3-33
Perform Test of Limit Controls ........................................................................... 3-33
Perform Test of Low Gas Pressure Switch .......................................................... 3-33
Perform Test 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 Gas Valve 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