The Fulton Hydronic PURE Control™ is a sophisticated control system designed for Endura and Endura+ condensing hydronic boilers, offering comprehensive management of boiler operation, sequencing, and integration with building management systems (BMS). This user manual provides detailed instructions for installation, operation, maintenance, and troubleshooting of the control system.
Function Description:
The Hydronic PURE Control™ acts as the central intelligence for Fulton boilers, enabling precise temperature control, multi-boiler sequencing (Lead/Lag operation), and advanced diagnostics. It features an integrated color touchscreen display for intuitive navigation and configuration. The system manages various operational parameters, including modulation rate, setpoint, and safety interlocks, to ensure efficient and safe boiler performance. It supports both standalone and networked boiler configurations, allowing for flexible system design.
Important Technical Specifications:
The control system is compatible with Endura boilers (750,000 - 2,000,000 BTU/HR) and Endura+ boilers (2,500,000 - 6,000,000 BTU/HR). The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV, with a maximum allowable working pressure of 160 psig and an operating temperature of 210°F (99°C).
The control display hardware dimensions are 211.1mm (8.31") wide by 150.1mm (5.91") high. The CPU module measures 114.1mm (4.49") wide by 49.1mm (1.93") deep. Key connections on the CPU include 24VDC power, Ethernet port(s) for Lead/Lag communication, USB ports for data transfer and program updates, a Micro SD slot for operating information, and an audio jack for external speakers.
Modbus registers provide access to a wide range of boiler parameters. For instance, Boiler Status (40000 INT16) indicates the current operational phase (e.g., Standby, Running, Safety Lock Out). Control Status (40001 INT16) shows Lead/Lag position (Lead, Lag 1-10, Local, Manual). Modulation Target (40003 INT16) and Modulation Rate (40004 INT16) are expressed as percentages (0.0 – 100.0%). Boiler Outlet (40017 INT16) and Inlet Water (40018 INT16) temperatures are measured in Fahrenheit (-50.0 – 250.0 F). Setpoint (40024 INT16) is also in Fahrenheit (-50.0 – 250.0 F). VFD Status (40008 INT16) and O2 Sensor Status (40009 INT16) provide detailed operational feedback. BMS Heartbeat (40104 INT16) requires a continuous integer 1 to be written for proper BMS communication.
Usage Features:
The Hydronic PURE Control™ offers a user-friendly touchscreen interface with various menus for comprehensive system management.
- Boiler Control Menu: Provides access to boiler status, safety device status, operator control, boiler history, alarm history, maintenance log, isolation valves, and primary/secondary pump control.
- Lead/Lag Menu: Configures and monitors multi-boiler sequencing. Boilers communicate over a private Ethernet/IP network, with one boiler designated as the Network Originator that manages staging and firing rates. Settings include Lead/Lag Priority, Number of Boilers, Lag Boiler Delay, and # of Valves Open.
- PID Control Menu and Boiler Modifiers: Allows for fine-tuning boiler operation with features like Delta T Protection (EDR+ only), Venting Limitation, Local PID adjustment, Low Fire Hold, Cold Start, Freeze Protection, and Outlet Monitoring. These modifiers can take precedence over calculated firing rates to ensure safe and efficient operation.
- Setpoint Menu: Configures the setpoint source (e.g., Outdoor Reset, BMS Analog, Local Manual) and scaling for various inputs.
- Scheduling Menu: Enables time-based control of normal (occupied) and setback (unoccupied) setpoints.
- Trending Screen: Displays real-time and historical data for various parameters (e.g., Inlet/Outlet Temperature, Setpoint, Firing Rate, O2) which can be exported to a USB drive.
- Admin Menu: Provides advanced setup options, user configuration (passwords, screen access), system configuration (date/time, IP address, factory defaults), auxiliary configuration (system piping, venting material, alarm horn), domestic hot water configuration, and universal data configuration for network data sharing.
- System Diagnostics Menu: Offers advanced troubleshooting tools, including System Snapshots (recording system settings and operating values) and Controls/Sensor/Lead/Lag Diagnostics.
Maintenance Features:
The control system facilitates maintenance through several integrated features:
- Maintenance Log: Allows site personnel to log maintenance activities, providing a historical record of service performed on the boiler.
- Program Updates: The system supports software updates via a USB flash drive, ensuring the control system remains current with the latest features and improvements. The process involves verifying hardware, preparing software on a FAT32 formatted flash drive, and performing the update through the UniApps interface.
- Data Export: The File Manager allows users to save screenshots, snapshots, and trending data to a USB drive for analysis and troubleshooting. This data can be crucial for diagnosing intermittent issues or optimizing boiler performance.
- Alarm History: Stores a chronological list of up to 100 alarms, providing detailed information including LMV3 Error Code and Error Diagnostic, which aids in rapid troubleshooting.
- Safety Device Status Screen: Displays real-time status of boiler safeties and interlocks, including a low water test feature, to assist in diagnosing safety-related issues.
- Factory Defaults: The ability to load factory defaults from the Admin menu provides a quick way to reset the controller to its original settings if configuration issues arise.
- User Defaults: User-defined settings can be saved to the Micro SD card and restored, simplifying configuration after updates or resets.
The Hydronic PURE Control™ is designed to provide robust and flexible control for Fulton boilers, enhancing operational efficiency, safety, and ease of maintenance.
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