FULTON EDR-1000 Installation And Operation Manual

Text of FULTON EDR-1000 User Guide:

• © The Fulton Companies 2014 INSTALLATION EDR-IOM-2014-0318 SECTION 2 2-12 FIGURE 4  CONDENSATE DRAIN PIPING FOR ENDURA BOILERS Figure 4 Notes:  Header must be level or slightly pitched toward the drain.  Header material to be galvanized steel or 316L stainless.  Header should be taken to the lowest point possible and maintain a minimum 5.5 inch (14.2 cm)

• © The Fulton Companies 2014 3-6 OPERATION EDR-IOM-2014-0318 SECTION 3 ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer. This boiler is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand. 13.

• FULTON EDR-1000, © The Fulton Companies 2014 3-10 OPERATION EDR-IOM-2014-0318 SECTION 3 ! 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. Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer. the previous Setpoint screen to the Modulation Screen (Figure 17). This screen provides access to the PID (Proportional, Integral and Derivative) of the contr

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative 2-11 SECTION 2 EDR-IOM-2014-0318 INSTALLATION  For every ten feet of pipe run, increase the pipe size one diameter.  Protect the vent termination from water, dust and insects. Install Condensate Drain A condensate drain kit is intended for use with the Fulton Endura boiler.  Single Boiler Drain Trap The condensate drain kit is Fulton Part Number 4-57-005500. The drain kit must be con gured one per boiler, with a maximum of 4.0 mm BTU total. Adhere to the following for installation: 1. The 1 inc

• FULTON EDR-1000, The Fulton Companies 972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390 www.fulton.com EDR-IOM-2014-0318The heat transfer innovators No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, ho

• FULTON EDR-1000, © The Fulton Companies 2014 3-12 OPERATION EDR-IOM-2014-0318 SECTION 3 ! 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. 4 CAUTION A temperature exceeding 120°F** (48 C) in the boiler room may cause premature failure of electrical components. Provisions should be made to maintain an ambient temperature of 120

• FULTON EDR-1000, © The Fulton Companies 2014 MAINTENANCE EDR-IOM-2014-0318 SECTION 4 4-6 PROBLEM CAUSE CHECK Control does not illuminate 24 VAC Power Supply Check fuse or circuit breaker. Reset or replace as necessary. Fan will not start High temperature is tripped 1. Check sensor wiring connector. 2. Check resistance. 3. Replace sensor if faulty. Low gas is tripped 1. Reset switch, making sure to listen for audible click. 2. Replace switch if setting is below actual pressure. High gas is tripped 1. Reset switch, makiing sure to listen for audible click. 2. Replace switch if setting is above actual pres

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative 3-9 SECTION 3 EDR-IOM-2014-0318 OPERATION ! 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. Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.  Central Heat Operation - Setpoint Screen In this screen (Figure 15) the Setpoint can be changed. Press t

• © The Fulton Companies 2014 INSTALLATION EDR-IOM-2014-0318 SECTION 2 2-14 are not supplied with the boiler). 5. All piping (Figure 4) must be galvanized or stainless steel, and be free of leaks. Copper, carbon steel/iron pipe, PVC or CPVC are not acceptable. 6. Connect 1 inch (25.4 mm) condensate drain(s) (at the rear of the boiler), to the 1 inch (25.4 mm) inlet at the base of the d

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative SECTION 2 EDR-IOM-2014-0318 INSTALLATION 2-21 1/4" TAPPING FOR WATER 100 PSI MAXIMUM (U.S. ONLY) ROOF SUPPORT 4FT 3 IN ( 130 CM ) ADJUSTABLE FLASHING PVC PIPE METAL PLATE FIRE STOP MIN 4FT / 122 CM ABOVE AIR INTAKE PIPING ADJUSTABLE FLASHING ADHESIVE SEAL STORM COLLAR SCREENED INLET IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN. ) ABOVE THIS NORMALLY EXPECTED LEVEL. TYPICAL ROOF PENETRATIONS ( SUGGESTED TERMINAT

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative 3-17 SECTION 3 EDR-IOM-2014-0318 OPERATION Perform Test of Limit Controls Fire the boiler and test the high limit control as follows: 1. Alter high temperature limit to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the boiler locks out. This condition has to be manually reset. 2. Alter the high limit cut o temperature to normal level, typically 10-20 de

• Questions? Please Contact Your Local Manufacturer’s Representative 2-23 SECTION 2 EDR-IOM-2014-0318 INSTALLATION  Horizontal Vent Termination Adhere to the following for installation: NOTE:  The vent termination is joined to the vent pipe outside the wall. Use the same joining procedures for vent pipe and  ttings. 1. The termination of the vent s

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative SECTION 4 EDR-IOM-2014-0318 MAINTENANCE 4-7 PROBLEM CAUSE CHECK Main  ame fails Ignition issue 1. Visually verify spark. 2. Replace igniter or transformer, as needed. Gas valve not set properly Verify the last elbow gas pressure matches the start up report. Enrichment issue Verify the pressure of the regulator matches the report. Flame detector failure 1. Visually verify the  ame through the sight glass. 2. Remove  ame detector and visually verify the  ame through the scanner tube. 3. Verify the  ame detector eye is not d

• FULTON EDR-1000, © The Fulton Companies 2014 2-20 INSTALLATION EDR-IOM-2014-0318 SECTION 2  Wall Thimble Installation Adhere to the following for installation (see Figure 7): 1. The thimble is inserted through the wall from the outside. 2. Secure the outside  ange to the wall with nails or screws, and seal with adhesive material. 3. Install the inside  ange to the inside wall, secure with nails or screws, and seal with adhesive material. 4. Pass the vent pipe through the thimble from the outside and join to the rest of the vent system. Seal the pipe t

• FULTON EDR-1000, © The Fulton Companies 2014 3-14 OPERATION EDR-IOM-2014-0318 SECTION 3 4 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. FIGURE 25  VIEWING LOCKOUT FIGURE 26 

• FULTON EDR-1000, © The Fulton Companies 2014 INSTALLATION EDR-IOM-2014-0318 SECTION 2 2-8 FIGURE 3  SAMPLE PIPING LAYOUT MOTORIZED ISOLATION VALVE (OPTIONAL) SYSTEM RETURN WATER AIR SEPARATOR MAKE UP WATER AIR SEPARATOR AND EXPANSION TANK AS DETERMINED APPROPRIATE BY OTHERS SYSTEM PUMPS AND VALVES AS DETERMINED APPROPRIATE BY OTHERS EXPANSION TANK SYSTEM SUPPLY WATER  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 wate

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative 3-3 SECTION 3 EDR-IOM-2014-0318 OPERATION ! WARNING Do not attempt to start the boiler for any testing before  lling and purging the boiler. A dry  re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty. Before commissioning the boiler, verify with authorized personnel that the gas lines have been purged. Never attempt to operate a boiler that has failed to pass all the safety checks. Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, wa

• © The Fulton Companies 2014 2-24 INSTALLATION EDR-IOM-2014-0318 SECTION 2 At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation: 1. Seal any unused o

• © The Fulton Companies 2014 INSTALLATION EDR-IOM-2014-0318 SECTION 2 2-16 13. In Canada, for recommended practice, refer to CSAB1.  Combustion Air Supply From the Boiler Room Adhere to the following for installation: 1. Adequate combustion air and ventilation must be supplied to the boiler room in accordance with local codes and NFPA54/ANSI Z233.1, Section 5.3, Air for combustion

• FULTON EDR-1000, Questions? Please Contact Your Local Manufacturer’s Representative SECTION 2 EDR-IOM-2014-0318 INSTALLATION 2-27 EXAMPLE ELECTRICAL SCHEMATIC DIAGRAM CONTINUED NOTES: 1. ( ) DENOTES FIELD WIRING BY OTHERS.. 2. TERMINAL BLOCK(S) LOCATED IN CUSTOMER CONNECTION JUNCTION BOX. 3. PB1 AND PB2 ARE COMBINATION PILOT LIGHT - PUSH BUTTON ASSEMBLIES. 4. LOW WATER TEST; PRESS AND HOLD PB2 FOR 3 SECONDS. MOMENTARILY PRESS PB2 TO RESET, OR WAIT 30 SECONDS FOR AUTO RESET. 5. ( ) INDICATES COMPONENTS INSTALLED IN PANEL BOX. 6. REMOVE FACTORY INSTALLED JUMPER FOR E-STOP CONNECTION.

• FULTON EDR-1000, © The Fulton Companies 2014 2-10 INSTALLATION EDR-IOM-2014-0318 SECTION 2 (located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of 2.0 psig (55 inch W.C.). 5. Gas Piping must be installed in accordance with National Fuel Gas Code, ANSI Z223.1 1991 or latest addenda and any other local codes, which may apply. 6. The pipe and the  ttings used must be new and free of dirt or other deposits. 7. Piping must be of the proper size to ensure adequate gas supply. A drip leg and union connection must be installed upstream of the gas safety shut o valves and must be a 5 inch (1

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