ENERGY KINETICS EK2C, EK3C, EK1C Installation & Service Manual

front center of the vesse l.

MH27877

This product meets the

Board Listed

Accel CS features

access

Gas Fired Hot Water Boiler

EK1C, EK2C, EK3C

INSTALLATION & SERVICE MANUAL

INSTALLER: PLEASE HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY

CONSUMER: PLEASE RETAIN THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS FOR

ANSI Z21.13b-2012

Low-Press Boiler

2MF1

NEXT TO THE BOILER USING THE SUPPLIED POUCH.

FUTURE REFERENCE.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015

Accel CS

MANUFACTURED BY:

ENERGY KINETICS, INC.

51 Molasses Hill Road

Lebanon, NJ 08833

(908) 735-2066

www.energykinetics.com

Energy Star® guidelines

for efficiency.

™

Removable panels

for easy internal

National

ASME certified by EKI.

Certificate plate is on the

Please Read This First

Special Attention Flags

Please pay particular attention to the following flags when you see them throughout this manual.

DANGER: Notifies you of hazards that WILL cause severe personal injury, death or substantial property

damage.

WARNING: Notifies you of hazards that CAN cause severe personal injury, death or substantial property

damage.

CAUTION: Notifies you of hazards that WILL or CAN cause minor personal injury or property damage. NOTICE: Notifies you of spec ial instructions on inst allation, operation, or maintenance that are important, but

not normally related to injury or property damage hazards.

BEST PRACTICE: Notifies you of recom mendations made by Energy Kinetics for the installers, which will help ensure

optimum operation and longevity of the equipment.

WARNING: If the information in this manual is not followed exactly, a fire or explosion may

WARNING: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of

Provide unobstructed combustion air openings sized and located per boiler manual

result, causing property damage, personal injury or loss of life.

this or any other gas appliance. and applicable codes.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switc h; do not us e any phone in your building.

• Immediately call your gas s upplier from an outside phone.

• Follow the gas supplier’ s ins tr uc t ions.

• If you cannot reach your gas supplier , c al l t he fir e department.

WARNING: Installation and service must be performed by a qualified installer, service agency or

the gas supplier. Retain this manual for use by your qualified service techni ci an onl y . Should you observe unusual or abnormal operation of the burner or boiler, contact

your qualified service technician immediately. Do not attempt to service or repair this

product yourself.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 1

WARNING:

Have the burner/boiler started up and serviced at least once annually by a qualified service technician. Professional care is necessary to properly service your equipment and verify it is operating reliably. Failure to properly maintain the

equipment could result in severe per

sonal injury, death or substantial property

WARNING:

You must keep the area around the burner/boiler free from the following.

•

Do not store or use gasoline or other flammable vapors or liquids near or in

•

or store laundry products, paint, varnish, thinner or other such chemicals near or in the same room as the burner/boiler. These chemicals cause creation of acids in the burner, heat exchanger and vent system that

•

bustible materials near or in the same room as the

•

Failure to comply could result in severe personal injury, death or substantial property damage due to potential fire, explosion or equipment damage from corrosive flue pr oducts.

Please read through the information provided for you in this manual. Ask your qualified

d free of the

Periodically watch the operation of your burner/boiler through an operating cycle to verify normal operation. If you notice unusual conditions or equipment behavior, contact your

the instructions on the next page to shut down the

burner/boiler while waiting for the technician.

damage.

the same room as the burner.

Do not use

can cause severe damage.

Do not store com

burner/boiler.

General care and maintenance



service technician to explain normal operation of your equipment.

 Daily inspect the space around the burner/boiler to verify the area is clean an

materials listed above.



qualified service technician. Follow

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury (exposure to hazardous materials) or loss of life. Refer to the user’s information manual provided with this boiler. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 2

FOR YOUR SAFETY READ BEFORE OPERATING

A. This burner does not have a pilot. It is equipped with an ignition device which automatically

B. BEFORE OPERATING, smell all around t he boiler area for gas. Be sure to smell next to the

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas “shutoff” valve. Never use tools. If the handle will not turn

may result in a fire or explosion.

D. Do not use this boiler if any part has been under water. Immediately call a qualified service

control, which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

TO TURN OFF GAS TO THE BURNER

1. Set thermostat(s) to their lowest setting.

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

External manual gas shutoff valve, supplied by installer.

A typical ball valve is shown, some models do not have a handle, your installation may

vary.

lights the burner. DO NOT try to light the burner by hand.

floor because some gas is heavier than air and will settle on the floor. See below.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s

instructions.

by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair

technician to inspect the boiler and to replace any part of the control system and any gas

2. Set the thermostat(s) and aquastat(s) to their lowest setting.

3. Turn the service switch located on the front panel “OFF”.

4. This burner is equipped with an ignition device which autom atically lights the burner. Do not try to light the burner by hand.

5. Turn the external manual gas valve ha ndle clockwise to the “CLOSED” position (valve handle will be perpendicular to gas piping).

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow the safety information above. If you don’t smell gas, go to the next step.

7. Turn manual gas valve handle c ounterclockwise to the “OPE N ” posi t ion (valve handle will be parallel to gas piping).

8. Set thermostat(s) to desired sett ing.

9. Turn on all electric power to the burner and boi ler.

10. If the burner/boiler will not operate, follow the inst r uctions “TO TURN OFF GAS TO THE BURNER” below and call your service technician or gas suppl ier.

3. Turn the external manual gas valve handle clockwise to the “CLOSED” position.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 3

2. Turn the service switch on the Accel CS front panel “OFF”.

INSTALLER NAME:

INSTALLER ADDRESS:

INSTALLER CITY, STATE:

DATE INSTALLED:

NOTES:

RECORD OF INSTALLATION

All installations m ust be made in accordance with all State and Loc al Codes, which may differ from this manua l and in accordance with the following Codes, as applicable:

National Fuel Gas Code, ANSI Z223.1/NFPA 54: Installation Codes, CAN/CGA B149 National Electrical Code, ANSI/NFPA 70 Canadian Electrical Code Part I, CSA 22.1, Electrical Code Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211

Where required by the authority having jurisdiction, the installation must conform to the Standard for: ANSI/ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers

These codes are available from: National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269-9101.

A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cutoff device.

Make sure relief discharge pipes from all reliefs are properly placed to safely contain discharge. Make sure relief discharge pipes, such as from a boiler or a hot water storage tank, will safely contain hot water and/or boiling water. Make sure relief discharge pipes, such as from a boiler or a radiant heating system, will safely contain water treate d with bo iler chemicals and/or antifreeze. Reliefs include the boiler pressure relief valve, the back flow preventer discharge port, and the domestic hot water tank temperature and pressure relief valve. Any other reliefs, such as from radiant heating systems, must also follow these guidelines.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 4

TABLE OF CONTENTS

Page

Topic

Page

Topic

Please Read This First

Boiler Water Treatment

Record of Installation

Winterizing

Accel CS Boiler

Wiring and Controls

Principle of Operation

Receiving and Unpacking

Hydronic Circulators

Clearance to Combustibles and Service

Low Voltage Wiring

Boiler Weight, Water Content

Installation with More than Five Zones

Boiler Dimensions

Condensing Energy Manager Operation

Venting and Combustion Air

Condensing Energy Manager Interface

Removal from Common Vent System

Condensing Energy Manager Option Switches

Length of Run, Intake and Vent

Hydronic Control Settings

Sidewall Vent Limitations

Auto Reset High Limit

Vent Outlet Location

Sola User Interface

Venting Materials And Venting Options

Prepare for Start Up

Venting with EK Sidewall Vent Kit

Start Up Procedure

Venting with PP, low profile

Air Free Method of Measuring CO

Venting with PP, snorkel style

Gas Valve Setup Procedure

Venting with PP, snorkel style below grade

Troubleshooting with the Energy Manager

Venting with PP, concentric hood

Operating Without an Energy Manager

Venting with PP, vertical through chase

Diagnostics with the Accel CS display

Hanging of Vent Piping

Lockouts, holds and alerts

Combustion Air

Flashing light on Manager

Condensate Drain Trap

Monitor light on the Manager

Gas Piping

Pump Exercise

Gas Pipe Sizing

Frost Protection

Gas Supply Pressure

Temperature Sensors

LPG Orifice

Drawings - Piping

Converting from one gas to another

Drawings – Wiring

Gas Valve Description

Annual Tune Up & Inspection

General Assembly

Burner head removal

Boiler Mounting

Top insulation replacement

Boiler Mounting on Boiler Base

Commercial Installation Kit

Wall Mounting The EK1C Boiler

Replacement Parts

Hydronic Piping

Exploded View of Boiler

Cover

Filling with Water, Venting and Purging

Accel CS Boiler

Condensing Energy Manager

34 Line Voltage – Electrical Connections

35 Surge Suppression

Inside

31 Zone Control

32 Domestic Hot Water

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 5

Back

Limited Lifetime Warranty

Warranty Transfer Agreement

Accel CS BOILER

IMPORTANT MESSAGE TO HOMEOWNER: These instructions should be carefully read and kept for future reference to

gain the best performance from your Accel CS boiler.

CONGRATULATIONS ON YOUR PURCHASE OF THE Accel CS BOILER with its highly efficient condensing low mass hydronic heat exchanger, modulating burner and state of the art zone and domestic hot water control. It is the product of years of engineering and advanced design, which brings together in a single system all elements needed to provide efficient home heat. This operation and maintenance information has been prepared so that you may better understand and use your Energy Kinetics Accel CS boiler and Heating System.

The Accel CS Boiler basically consists of a heat source (gas burner with control), an energy converter, piping, sheet metal chassis and outer covers. For a typical residence, the installation may include a circulating water pump and up to five zones controlled by the electronic Condensing Heat and Hot Water Hybrid Energy Recovery Control (Condensing Energy Manager). For a typical multi-boiler light commercial situation, the installation may include a multi-boiler control along with the appropriate primary/secondary piping. To support both types of installations, Energy Kinetics provides suggested piping and wiring schematic drawings, which will be provided upon request. For any questions about installations not already explained within this manual, consult Energy Kinetics Tech Support at 800-323-2066.

Accel CS BOILER - PRINCIPLE of OPERATION

The Boiler remains cold until a thermostat calls for heat. The Condensing Energy Manager receives the call for heat and opens the respective heat or hot water zone, turns on the main circulator and burner. When the thermostats are satisfied, the Condensing Energ y Manager turns off the burner and enters the energy recovery stage. The circulator and zone (zone valve or zone circulator) stay energized to deliver the heat remaining in the boiler to your home.

When energy recovery is complete and the Boiler has cooled off, the Condensin g Energy Manager turns off the system and waits for another thermostat (or tank thermostat) to call for heat. The Accel CS runs the burner onl y when you need heat and delivers that heat only where you need heat.

The Accel CS Energy Converter is the product of advanced thermal engineering. It is designed with thirty seven fire tubes, optimized to produce the maximum condensation with water side baffles to direct hydronic water flow and improve heat transfer. This is a “forced circulation counter-flow” design that provides very efficient transfer of heat from the burning fuel to the circulating water. The superior insulation of the boiler minimizes heat losses to the surroundings, resulting in directing heat to your home in an efficient and quiet manner.

The Accel CS has an extremely high annual efficiency (over 99% of steady state) because it runs only when your home needs heat. Energy recovery is completed at the end of each heat call, virtually eliminating off cycle losses.

Your Accel CS holds a small volume of water and it begins to supply heat very quickly. Maximizing condensing operation by operating with lower boiler temperatures during war mer outdoor weather can cause longer and slower responses to thermostat calls. The innovative SmartBoost™ function accelerates the response to recovery from thermostat night setbacks for enhanced comfort and savings. Depending on the model, the Accel CS can heat water with input rates of up to 399,000 BTU’s per hour.

The Accel CS boiler is designed with a removable burner flange and condensate collector that allows access to the inside of the boiler for inspection and cleaning. All access for service is from the front, top, and bottom and the Accel CS boiler may be floor mounted on a stand, or may be optionally mounted on a wall.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 6

CONDENSING ENERGY MANAGER - PRINCIPLE of OPERATION

The left side of the Co nde n s ing Energy Manager is the input side, which provides 24-volt power supply and connections for thermostats. The right side is the output side, which powers the zone valves or zone circulators and signals the burner and main circulator control.

Lights on the Condensing Energy Manager indicate what is calling for heat on left side and right side lights indicate active zone(s), burner operation and Smart Pump and/or Injection zone operation. These function lights are an aid in servicing. The following is a typical cycle.

1. SYSTEM WAITING FOR A CALL: There is not an active thermostat call, and the boiler is off and remains c old, waiti ng

until a call for heat. The red power light on the Condensing Ener g y Manager is glowing.

2. CALL FOR HEAT: A room thermostat call starts the cycle. The thermostat light on the left side will turn on for that zone.

3. HEAT: Output lights for the zone output and heat demand turn on, the main circulator starts, the zone opens and the

burner begins its firing cycle with pre-purge followed b y igniti on. The boiler water circulates through the boiler and the active zone, heating up the water and the connected radiation. The controls include the option for outdoor reset and will set the boiler supply temperature as needed based on the outdoor temperature and the outdoor reset settings.

4. HOT WATER CALL: A hot water call is similar to a heat call, except hot water is most effectively and efficiently

produced and delivered when the boiler supply temperature is between 165ºF and 180ºF. For this reason, upon a call for domestic hot water, the supply set point temperature of the Accel CS boiler is increased to 182ºF. The boiler will heat up the boiler side of the plate heat exchanger. Once the boiler supply temperature has reached 140ºF, the domestic hot water circulator is turned on. With domestic water pumping through the domestic side of the plate heat exchanger and boiler water pumping through the boiler side of the plate heat exchanger, the water in the storage tank will be heated quickly and efficiently. The temperature of the domestic water coming out of the plate heat exchanger is determined by the flow rate of the domestic water. Partially close the ball valve below the smart pump to reduce the flow and increase the temperature, or partially open the ball valve below the smart pump to increase the flow and decrease the temperature. The plate heat exchanger is so effective at heat transfer that this operating temperature still allows a high level of condensation of the flue gas for peak efficiency. Note that this is much more effective than a tank with an internal coil during heating and in the Energy Recovery Cycle. The burner runs as long as there is a thermostat calling and as long as heat is being delivered to the zone. Hot water priority is always active during a hot water call, so the heating zone outputs will be turned off for the duration of the hot water call or up to 25 minutes, which ever comes first.

5. THERMOSTAT SATISFIED: The thermostat light on the left side will go out. The burner will then turn off.

6. ENERGY RECOVERY: The circulator and zone valve remain energized. The circulating water will remove the energy

from the boiler, sending the heat to the last zone that called. The energy recovery stage continues until the boiler temperature has dropped sufficiently or until maximum timing has been reached. The boiler is now sitting cold, waiting for the next call for heat. Maximum timing for heat recovery stage is twenty minutes for space heating zones and is five minutes for the hot water zone. Zone four has the option to shorten maximum heat recovery timing to five minutes.

RECEIVING and UNPACKING

Inspect shipment upon receipt for external damage. Further inspect any items that appear damaged by opening shipping packaging before signing for the freight. Refuse any individual shipping cartons or packages that are damaged or appear to be damaged. Contact Energy Kinetics and freight carrier.

After unpacking, check each item against the packing list. Inspect it thoroughly for loose parts, instruction sheets and packing lists. Immediately report any missing items. It is wise to complete the installation before discarding packing material. Store all parts where they will not be damaged or lost during installation. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 7

CLEARANCE to COMBUSTIBLES and SERVICE

Installation Clearances from Boiler Surfaces, Inches

Clearance to Combustibles

Clearance for Service

Front of boiler

0 inches

20 inches

Left side of boiler body

0 inches

Right side of boiler body

0 inches

Back of boiler body

0 inches

1 inch

Top of boiler body

0 inches

20 inches

Bottom of boiler chassis to floor (Without boiler base)

0 inches

12 inches*

Stainless Steel Class III Vent Pipe (Z-Flex Z-Vent III)

Refer to Manufacturer Specs.

Polypropylene (Centrotherm & DuraVent)

Refer to Manufacturer Specs.

PVC and CPVC Ven t Pip e

Not Recommended

Boiler Weight and Water Content

Model

Weight, dry

Weight, filled with

water and w/stand

Water Content

In Gallons

Supply and

Return Pipe Size

Air Inlet Pipe Size

In Inches

Boiler Flue Outlet

In Inches

EK1C

197 lbs

267 lbs

1” NPT

3”

EK2C

275 lbs

377 lbs

6-1/2

1-1/4” NPT

4”

EK3C

360 lbs

512 lbs

1-1/2” NPT

4”

"W"

SUPPLY

"D"

"A"

"B"

EK1C FLUE CONNECTOR

EK1C AIR INLET EK2C & EK3C FLUE

CONNECTOR

EK2C & EK3C AIR INLET

Due to the low stack temperature of the condensing boiler, the Accel CS boile r may be installed with zero clearance to

combustibles. Specifically, with zero clearance to top, bottom, left, right, front and back.

DANGER: Provide clearance to combustible surfaces in accordance with all local and national codes. Follow National Fire

Protection Association Bulletin NFPA Installation of Gas Burning Equipment and all applicable codes.

NOTICE: Do not install on c arpeting. Place th e unit as near to the vent as possible allowi ng clearance for c leaning and

service. If not using an Energy Kinetics supplied stand or wall mounting brackets, provide a solid, level, smooth foundation with cleara nce for opening covers for service and enough s pace under the unit f or the condensate trap.

NOTICE:

When determining boiler location, consider hydronic piping, venting, air intake and wiring.

*Minimum recommended clearance to allow a condensate trap/neutralizer/pump.

Figure 1A - Boiler Dimensions - Top View

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 8

DIMENSIONS

Model

“H”

“HT”

“HB”

“W”

“D”

“D2”

“A”

“B”

EK1C

40-5/8”

4-5/8”

12”

25-7/8”

15”

10”

3-7/8”

4-13/16”

EK2C

45-3/8”

6-1/2”

12”

28-1/8”

18-1/2”

10”

5-1/8”

6-1/2”

EK3C

47-1/4”

5-1/2”

12”

32”

22-3/8”

10”

4-5/8”

10”

"W"

"HB"

"H"

"HT"

"D2"

"D"

Figure 1B - Boiler Dimensions - Front and Side Views

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 9

Model Firing Rate Range

Max In

(BTUs)

Min In

(BTUs)

Max Out

(BTUs)

Min Out

(BTUs)

EK1C

Standard 120,000 24,000 114,000 22,800

“Smart” Rate 90,000 18,000 85,500 17,100

Standard 200,000 40,000 190,000 38,000

EK2C

“Smart” Rate 150,000 30,000 142,500 28,500

Standard 399,000 79,800 379,050 75,810

EK3C

“Smart” Rate 300,000 60,000 285,000 57,000

VENTING AND COMBUSTION AIR

Overview

The Accel CS boiler is a direct vented condensing boiler. Venting of the burnt flue gases requires approved flue piping listed herein. Fresh air for combustion must be supplied to the boiler from outdoors using approved intake piping listed below. The boiler cabinet doors must be in place and tightened during normal operation. When venting through the side of a building, fresh air intake and flue gas venting must enter and exit on the same side of the building. When venting through a chimney (where the chimney is used as a chase for a liner rated for positive pressure condensing operation), fresh air can be piped alongside the liner inside the chimney chase or fresh air can also be taken from the basement.

The Accel CS boiler can be vented using the Energy Kinetics stainless steel sidewall vent system using Z-Vent III stainless steel piping for the vent connections. The Energy Kinetics stainless steel sidewall vent system has been used for many years to vent the System 2000 family of boilers and has a proven track record of operation.

The Accel CS boiler can also be vented using approved polypropylene venting systems such as manufactured by Centrotherm and by DuraVent. The Accel CS boiler may not be vented usin g PVC , CPVC, or ABS piping.

BEST PRACTICE: Pipe the combustion Air Inlet directly to the outdoors, even if venting vertically through a liner inside a

chimney chase to avoid any of the contaminations often found in indoor air and to improve overall efficiency of operation.

The installation of the flue vent and combustion air piping must comply with local codes and requirements and with the National Fuel Gas Code NFPA 54, ANSI Z223.1 for installations in the USA or with CSA B149.1 or B149.2 for installations in Canada

NOTICE: The Accel CS boiler requires a special venting system designed for pressurized venting rated ANSI Z21.13

Category 4. As such, the flue gas will condense in the flue and provision must be made to accommodate this.

DANGER: All flue piping must be tightly sealed as per the pipe manuf ac tur er’s recom mendation to insure against leakag e

WARNING: Sidewall venting (direct vent) requires outside air to be piped directly to the boiler. WARNING: No solid fuel appliance or fireplace should be installed in a flue common with this heating appliance.

of noxious fumes, deadly carbon monoxide and/or condensate water.

WARNING: You may use any of the vent and air piping options covered in this manual. Do not use any other method or

WARNING: Do not insulate the plastic flue pipes as excessive sagging of the plastic sections could result.

material when installing this appliance.

REMOVAL FROM COMMON VENT SYSTEM

DANGER: When any existing appliance, such as a boiler, is removed from a common venting system, the common

venting system is likely to be too large for proper venting of the appliances remaining connected to it. Testing of the remaining venting system must be performed according to the following procedure.

At the time of removal of the existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, clos e all building doors and windows , and all doors between the space in w hich the appliances

remaining connected t o the common venting system are loc ated and other spaces of the building . Turn on clothes dryers and any appliance not c onnected to the common venting system. T urn on any exhaust fans, suc h as range

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 10

hoods and bathroom ex hausts, so the y will operate at m aximum speed. Do not operate a s umm er exhaust fan. C lose fireplace dampers.

4. Place in operation th e appliance be ing inspected. F ollow the light ing instructions . Adjust ther mostat so applia nce will operate continuously.

5. Test for spillage after five minutes of main burner operation. Use a draft gauge or pressure gauge to verify that the vent pipe at the breech of the appliance is under draft (negative pressure) relative to the room.

6. Repeat steps 4 and 5 for each appliance connected to the common venting system, one appliance at a time.

7. After it has been determined that e ach appliance remaining connec ted to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

8. Any improper operation of the comm on venting system should be cor rected so the installation conf orm s to the National Fuel Gas Code, ANSI Z2 23.1/NFPA 54 and/or CAN/ CGA B149 Installat ion Codes. When resizing an y portion of the common venting s ystem, the comm on venting s ystem should be r esized to app roach the m inimum size as determined using the appropriate ta bles in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NF PA 54 and/or CAN/CGA B149, Installation Codes.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 11

LENGTH OF RUN, INTAKE AND VENT

Vent

Size

Natural

Gas

EK1C

Low

High

Low

High

EK1C

Low

High

Low

High

15'

1400

6000

1200

4600

15'

1500

6200

1300

4800

25'

1500

6200

1200

4800

25'

1600

6400

1300

5000

50'

1600

6500

1200

5000

50'

1600

6700

1300

5200

EK1C

Low

High

Low

High

EK1C

Low

High

Low

High

15'

1300

5900

1200

5600

15'

1300

6200

1200

5900

25'

1300

6000

1200

5700

25'

1300

6200

1200

5900

50'

1400

6100

1300

5800

50'

1300

6300

1300

6000

75'

1400

6100

1300

5900

75'

1400

6400

1300

6100

100'

1500

6200

1400

6000

100'

1400

6400

1300

6100

EK2C

Low

High

Low

High

EK2C

Low

High

Low

High

15'

1200

5100

1000

4100

15'

1300

5600

1100

4300

25'

1200

5300

1000

4200

25'

1300

5700

1100

4400

50'

1300

5500

1100

4300

50'

1300

5800

1100

4500

75'

1400

5700

1100

4400

75'

1400

5900

1200

4600

100'

1400

5800

1100

4500

100'

1400

6000

1200

4700

EK3C

Low

High

Low

High

EK3C

Low

High

Low

High

15'

1400

6700

1200

5400

15'

1600

7200

1300

5600

25'

1500

7000

1200

5800

25'

1600

7500

1300

5900

50'

1600

7800

1200

6200

50'

1700

7800

1300

6400

EK3C

Low

High

Low

High

EK3C

Low

High

Low

High

15'

1500

7100

1200

5400

15'

1500

7300

1200

5600

25'

1500

7100

1200

5400

25'

1500

7400

1200

5700

50'

1500

7200

1200

5500

50'

1600

7600

1200

5800

75'

1600

7200

1200

5500

75'

1600

7800

1300

5900

100'

1600

7300

1300

5600

100'

1600

7800

1300

6000

Inlet & Outlet

Pipe Size

2”

50 Feet

3”

100 Feet

3”

50 Feet

4”

100 Feet

3”

50 Feet

4”

100 Feet

Model

EK1C

EK2C

EK3C

Fan Speed Set Guide:

Use the following chart to select the optimal fan speed range based on your venting parameters.

Maximum Length*

*Air Inlet and Vent Pipe:

Subtract 5 feet from the maximum length for each elbow added. A total equivalent length of 50 feet is allowed. For example, if (5) ninety degree elbows are used, subtract 5 x 5 ft = 25 feet from the maximum of 50 equivalent feet, for a maximum of 50 ft – 25 ft =25 feet of straight pipe allowed.

LPG Standard RPMs Alternate RPMs

Standard RPMs Alternate RPMs

2”

Venting

3” Venting

Fan Speed Set Guide (Continued)

4” Venting

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 12

Vent Pipe Joint Connections

WARNING: Joint connections not meeting full insertion can leak, causing severe personal injury, death or substantial

property damage.

DANGER: Fasteners (screws, rivets, etc.) must not penetrate the components of the vent system either when joining

pipes and fittings or using support straps. Drilling holes in the components is not permitted. Exception: For exterior components onl y, one stainless steel screw per joint may be used to fix direction of vent.

CAUTION: Damaged gaskets can cause leakage of dangerous levels of carbon monoxide or property damage due to

condensate leaks.

Each female end of each component uses a gasket installed by the vent manufacturer. Check each

component to ensure the gasket is present and not damaged from shipping.

Stainless Steel: Pipe insertion at joint must be at least 1.75” minimum Gear clamps must be tightened to a minimum of 40 in/lbs with a maximum of 50 in/lbs.

WARNING: Over tightening the gear clamp can cause the seal to fail. DO NOT use power tools when tightening gear

clamps.

Polypropylene: Locking rings must be used at each interior connection to meet the requirements of ULC-S636 & UL-1738.

SIDEWALL VENT LIMITATIONS

The Accel CS boiler and the vent system must be carefully installed, adjusted and maintained. It should be annually

checked and adjusted if necessary.

The conventional chimney can absorb, unseen, the many things that can go wrong with a combustion system such as poor ignition, improper air adjustment, accumulation of pet hair or lint on the inlet shutter, component malfunctions, improper setup or installation, etc.

With sidewall venting, the eff ect of these conditi ons ca n result in an ex haust that may contain odors or incompletely burned fuel. These flue products, while still effectively discharged outside the home, may cause discoloration to siding or areas immediately surrounding the vent. The flue by-products may be corrosive and can cause damage to nearby objects such as condensers, playground equipment, landscaping, shrubs, etc. The exhaust may emit odors similar to a poorly tuned car exhaust. This would normall y not be appare nt when dis char ge d fr om a chimney well above the roofline.

No one can guarantee that at all times the exhaust will be without a trace of odor or corrosive by-products for all the reasons described above which may be beyond the control of the homeowner, manufacturer, installer or service company. Periodic cleaning of the area around the vent may be required if the appearance is objectionable in the vie w of the homeowner. This cannot be the responsibility of the manufacturer, installer or service company.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 13

VENT OUTLET LOCATION

Vent must be at least 1 ft. from any doors or windows. (Energy Kinetics recommends 4 ft minimum whenever possible)

Vent must be at least 3 ft. from inside corners. Recommend 10 ft.

Air in-let must be at least 1 ft. above anticipated snow

level. (Energy Kinetics recommends 2ft minimum

whenever possible).

Vent must be at least 4 ft.

below windows (though not

recommended)

Vent must be at least 7 ft. above

public walkways

SIDEWALL VENT/INLET TERMINATION

LOCATION REQUIREMENTS

Vent termination must be at least 3ft above any

forced air intakes within 10 feet.

Vent must be at

least 1 ft. below

the soffit of roof of the structure.

Multiple boiler Vent/Inlet

terminations must have

1ft min clearance

between edge of inlet

opening and adjacent

termination

12"-15"

Above Air Inlet

Vent Must Be PPS

Air Inlet May Be Piped with PPS or PVC

4" Min Horizontal Separation

The hood or exhaust pipe should be located so that proper clearances are maintained, according to local code. Per the National Fuel Gas Code NFPA 54 ANSI Z223.1, the flue gas outlet termination of a direct vent application with an input over 50,000 Btu/hr shall be located at least 1 ft from any door, window, or air inlet to the structure.

Note that the Accel CS boiler meets the definition of a direct vent appliance as used in NFPA 31 & NFPA 54. Regardless of input, the flue gas outlet terminal and air intake shall be located at least 1 ft. above grade or at least 1 ft. above expected snow level, whichever is higher. Although not requ ir ed, En erg y Ki netics recom mends at least 2 ft. above grade whenever possible. Both the vent hood and air intake must be at least 5 ft. from any supply tank vents.

The vent terminal shall not be installed closer than 3 ft. from an inside corner of an L-shaped structure and must be at least 1 ft. from the soffit of the roof of the structure.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 14

VENTING MATERIALS AND OPTIONS

Where to obtain venting materials

Manufacturer

Material

Product

Telephone

Web Address

Energy Kinetics EK1 or EK 2

sidewall vent kit

Z-Flex

Stainless steel

Z-Vent III, 2”, 3” or 4”

800-654-5600

www.novaflex.com

Centrotherm

Polypropylene

Innoflue, 2”, 3” or 4”

877-434-3432

www.centrotherm.us.com

DuraVent

Polypropylene

PolyPro, 2”, 3”, or 4”

800-835-4429

www.duravent.com

Venting material must be Listed by a nationally recognized testing agency.

Manufacturer

Material

Agency

Minimum Thickness

Energy Kinetics

Stainless steel

0.020”

Z-Flex

Stainless steel

0.020”

Centrotherm

Polypropylene

ETL

0.020”

DuraVent

Polypropylene

ETL

0.020”

Approved Vent and Air Inlet Pipe Mater ial

Item

Material

Standards

Stainless Steel (AL29-4C)

UL-1738

ULC-S636

Stainless Steel (AL29-4C)

UL-1738

ULC-S636

PVC Schedule 402

ANSI/ASTM D1785

UL-1738

ULC-S636

CPVC Schedule 402

ASTM F441

ABS Schedule 402

ASTM F628

Notes:

2. Use of PVC, CPVC, or ABS is only allowed for Air Inlet piping

The Accel CS Boiler can generate exiting flue gas temperatures between room temperature and 230oF, depending on the modulated firing rate and the boiler water temperature. The Accel CS boiler can be safely vented using a variety of venting materials. Approved materials include stainless steel, such as 316, 316L, 316Ti or AL 29-4C. Plastic venting products made from polypropylene are approved. Plastic venting products made from other plastics, such as PVC, CPVC, or ABS are not approved. Any of the plastic pipe materials may be safely used for air intake piping, but not for venting.

The venting materials for the Accel CS boiler may be obtained from Energy Kinetics, from Z-Flex, from Centrotherm or from DuraVent. The Z-Flex, Centrotherm and DuraVent products may also be obtained from any stocking distributor that carries these products.

Energy Kinetics Stainless steel

Appliance Adapter1

Vent Pipe & Fittings1

Air Inlet Pipe & Fittings

Polypropylene

Polypropylene (PPs)

800-323-2066 www.EnergyKinetics.com

1. Only Stainless Steel and Polypropylene material permitted for Venting

The Accel CS boiler may be vented using several different options, materials, and methods.

1) Energy Kinetics EK1 or EK2 sidewall vent kit using 3” Z-Vent III piping.

2) Sidewall venting using Polypropylene in 2”, 3” or 4” diameters.

a) Two pipe with low profile termination (2” & 3” only). b) Two pipe with snorkel termination. c) Concentric through the wall (2/4”, 3/5” or 4/6”).

3) Vertically with Polypropylene in 2”, 3” or 4” diameters.

a) Using a chimney as a chase.

WARNING: Sidewall vent systems must have outside air connected to the boiler and both intake and vent hood must be located on the same side of the structure. Vertically vented systems should have outside air connected to the boiler.

The Accel CS boilers have a flue collar made of Z-Vent III AL29-4C stainless steel - 3” on the EK1C / 4” on the EK2C & EK3C. If the boiler is vented using Z-Vent III stainless steel vent materials, then the venting may be directly connected to the flue outlet. If the boiler is vented using either of the two polypropylene materials, then a stainless steel to polypropylene appliance adapter is required. The fresh air inlet pip e si ze at the boiler is 3” on th e EK1C / 4” on the EK2C & EK3C. PVC pipe may be used for air inlet only. When using one of the approved polypropylene terminations, it may be necessary to adapt from PVC to polypropylene using the appropriately sized PVC to polypropylene adapter.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 15

Item Description

Energy Kinetics stocks and sells

Centrotherm PPs Vent Items

Energy Kinetics

Part No.

Centrotherm

Part No.

3” Appliance adapter, stainless to PPs

10-1000

ISSA0303

N/A 1 3” Appliance adapter, stainless to PPs

10-0194

N/A

N/A 2 2” Intake adapter, PVC to PPs

10-1023

ISAGL0202

2PPS-AD

3” Intake adapter, PVC to PPs

10-1013

ISAGL0303

3PPS-AD

4” Intake adapter, PVC to PPs

10-1024

ISAGL0404

4PPS-AD

5” Intake adapter, PVC to PPs

10-1025

ISAGL0505

5PPS-AD

Energy Kinetics stocks and sells

Centrotherm PPS Vent Items

Energy Kinetics

Part No.

Centrotherm

Part No.

2” Locking ring, typical

10-1017

IANS02

2PPS-LB

2” Wall mount brackets

10-1020

IASC02

2PPS-WSM

2” Bird screen

10-1022

IASPP02

2PPS-BG

2” PPs elbow, 45º

10-1021

ISELL0245

2PPS-E45

2” PPs elbow, 87/90º, long radius, bl ac k

10-1016-B

ISELL0287UV

2PPS-E90B

2” PPs elbow, 87/90º, long, gray

10-1016

ISELL0287

2PPS-E90

2” PPs pipe, 2 ft long, black

10-1015-24B

ISVL022UV

N/A

2” PPs pipe, 3 ft long, black

N/A

2PPS-36B

2” PPs pipe, 3 ft long, gray

10-1015-36

ISVL023

2PPS-36

2” Low profile wall mount termination

10-1029

ISLPT0202

N/A

3” Locking ring, typical

10-1010

IANS03

3PPS-LB

3” Wall mount brackets

10-1009

IASC03

3PPS-WSM

3” Bird Screen

10-1007

IASPP03

3PPS-BG

3” PPs elbow, 45º, black

10-1006

ISELL0345UV

3PPS-E45B

3” PPs elbow, 45º, gray

10-1001

ISELL0345

3PPS-E45

3” PPs elbow, 87/90º, lo ng r adius, bl ac k

10-1008

ISELL0387UV

3PPS-E90B

3” PPs elbow, 87/90º, long, gray

10-1003

ISELL0387

3PPS-E90

3” PPs pipe, 2 ft long, black

10-1004

ISVL032UV

N/A

3” PPs pipe, 3 ft long, black

N/A

3PPS-36B

3” PPs pipe, 3 ft long, gray

10-1002-36

ISVL033

3PPS-36

3” to 2” PPs Reducer

10-1019

ISRD0302

3PPS-R2

3” Low Profile Wall Mount Termination

10-1012

ISLPT0303

3PPS-HTP

3” Side Wall Vent Termination, EK Style Nozzle

ISEK03

N/A

3” ICTC adapter for Centrotherm

N/A

ICTC335

N/A

3”/5” Elbow, 45º

N/A

ICEL3545

N/A

3”/5” Elbow, 87º

N/A

ICEL3587

N/A

3”/5” Concentric pipe, 1 ft long

N/A

ICVLAL351

N/A

3”/5” Concentric pipe, 2 ft long

N/A

ICVLAL352

N/A

3”/5” Concentric pipe, 3 ft long

N/A

ICVLAL353

N/A

3”/5” Concentric wall termination, 5” OD

N/A

ICWT352

3PPS-HK

Joint lube, Centrocerin for Centrotherm

10-1011

IACE50

N/A

2” Wall plate, round rubber, black

10-1032

IAWP02B

N/A

2” Wall plate, square metal, black

N/A

2PPS-WPB

3” Wall plate, round rubber, black

10-1008

IAWP03B

N/A

3” Wall plate, square metal, black

N/A

3PPS-WPB

2” Horizontal Drain Tee

10-1026

ISHDT02

3” Horizontal Drain Tee

10-1027

ISHDT03

3” Test Port

10-1028

ISTP03

3PPS-TP

2” X 35 ft Flex Vent Length

10-1030

IFCK0235

3PPS-FLEX35

2” Coupler, Solid wall to Flex

10-1033

IFS02

2PPS-FAM

2” X 35 ft Flex Chimney Kit

10-1030

IFCK0235

N/A

3” X 35 ft Flex Chimney Kit

10-1014

IFCK0335

N/A

4” X 35 ft Flex Chimney Kit

10-1048

IFCK0435

N/A

DuraVent Part

No.

There are several parts that are used for all arrangements such as the locking rings needed for each joint, elbows,

straight runs of pipe, etc. These common parts are listed here and will not be listed on any of the following arrangements.

Typical venting parts. Order additional venting parts as needed for the job.

Item Description

DuraVent

Part No.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 16

4” Locking ring, typical

10-1041

IANS04

4” Wall mount brackets

10-1045

IASC04

4” Bird screen

10-1044

IASSS04

4” PPs elbow, 45º, black

10-1042

ISEL0445UV

4” PPs elbow, 45º, grey

10-1043

ISEL445

4” PPs elbow, 87/90º, long radius, black

10-1049

ISEL0487UV

4” PPs elbow, 87/90º, long, gray

10-1039

ISEL0487

4” PPs pipe, 2 ft long, black

10-1040

ISVL042UV

4” PPs pipe, 3 ft long, gray

10-1038

ISVL043

Item

Energy No.

Combo Vent Hood (Includes: hood, trim ring, silicone sealant, mtg hardware, elbow & shield)

10-0332-1*

Non-Combo Hood (Includes: hood, trim ring, silicone sealant, mtg hardware, elbow & shield)

10-0333-1**

Extra Pipe 3ft Length

10-0191-P33

Extra Pipe 1ft Length

10-0191-P31

Extra 90 degree Elbow

10-0191-E390

Use Swing Joint(s) to Attain Pitch on Horizontal Run(s)

Inlet Piping Supplied by Installer

When using PVC Air Inlet Piping,

Fix Each Joint with a Stainless Steel

Screw or Glue with PVC Cement

41 Stainless Steel, Gasketed,

Positive Pressure Vent Piping. Kit Includes: (1) Sealed 3" Elbow (3) Lengths of 3" x 3' Pipe Order extra Pipe and Elbows as needed

VENTING WITH ENERGY KINETICS SIDEWALL VENT KIT 3” Stainless Steel Vent Kit and Optional Parts

Description

Kinetics Part

*Kit includes: Sidewall Vent Hood, (1) 90 deg. Elbow & Shield, (1) Trim Plate, (4) SS Mounting Screws & Inserts, (1) Tube Silicone Sealant. **Replaces Combination Vent Hood with Non-Combo, Vent Only Hood

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 17

SIDEWALL VENTING WITH POLYPROPYLENE – Low Profile

14*

* Locking rings must be used on each joint located indoors

2” or 3” Low Profile Wall Mount Termination. Part No: Description:

10-0584 Low Profile Vent Kit 2in PPs 10-0585 Low Profile Vent Kit 3in PPs

Low Profile Parallel Wall Termination incorporates air intake and exhaust into a single aesthetically pleasing termination. Part is paintable to match exterior of structure. Interior wall plate and bird screen included. Exterior exhaust can be extended or re-directed with PPS-UV black elbows or vent lengths. External joints may be fastened with stainless steel screws. Vent lengths and elbows sold separately.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 18

SIDEWALL VENT I NG WITH POLYPROPYLENE – Snorkel style

12"Min/15"Max Vert Separation

Elbows Should be Flush

with Wall/Outer Plate

Bird Screens must

be Installed in both

openings

Exterior Vent Components

May be Fixed Using One

Stainless Steel Screw

Air Inlet Terminations

Must Point Down

Vent Terminations

Must Point Outwards

12" Min / 15" Max Vertical Separation

12"Min Above

Expected Snow Level

Air Inlet Terminations

Must Point Down

A Short Piece of Vent Pipe

Should be Installed into Bell

of the Elbow First, Then the

Bird Screen Installed into it.

201110

14*

* Locking rings must be used on

each joint located indoors

UV Resistant parts should be used on all exterior venting.

2” or 3” non-concentric side wall vent termination, snorkel style. Part No: Description:

10-0581 Sidewall Vent Kit 2in PPs 10-0580 Sidewall Vent Kit 3in PPs 10-0587 Sidewall Vent Kit 4in PPs

VENTING GUIDELINES WHEN USING TWO PIPES (SNORKEL STYLE)

1. Vertical Separation: The exhaust vent must be above the air inlet between 12” and 15”. The air inlet must be a minimum of 12” (24” preferred) above maximum anticipated snow level.

2. Horizontal Separation: The horizontal distance between the air inlet and the exhaust vent must be a minimum of 4” center to center.

3. The outdoor portion of a snorkel style vent should be limited to 4 feet between elbows. Longer runs may require insulation and/or a chimney chase to prevent condensation and freezing in the vent; the chase must provide access for vent pipe inspection

2” Non-concentric side wall vent termination kit, snorkel style 3” Non-concentric side wall vent termination kit, snorkel style 4” Non-concentric side wall vent termination kit, snorkel style

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 19

BELOW GRADE SIDEWALL VENTING WITH POLYPROPYLENE – Snorkel style 2” or 3” non-concentric side wall vent termination, snorkel style.

VENTING GUIDELINES WHEN USING TWO PIPES (SNORKEL STYLE)

1. Use a properly insta lled w in do w well (no windo w pres e nt) or equivalently constructed well with adequate drainage

2. Wall penetration must be at least 5” above the bottom of the window well.

3. Vertical rise must be limited to 4 feet maximum between elbows (see figure below); longer runs may require a chimney chase and/or insulation on the vent to prevent condensation and freezing.

4. Vertical Separation: The exhaust vent must be above the air inlet between 12” and 15”.

5. Horizontal Separation: The horizontal distance between the air inlet and the exhaust vent must be a minimum of 4” center to center.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 20

SIDEWALL VENT I NG WITH POLYPROPYLENE - Concentric

30 31

Concentric through the wall termination, with 3” piping

Note: For Centrotherm: Made from black PPS-UV outer and PPS-UV inner, the concentric wall termination incorporates flue

gas termination and combustion air intake. Use with InnoFlue® Concentric or with InnoFlue® SW by adding an ICTC Adapter.

For DuraVent: Includes 2 appliance adapters, white wall plate, white fire stop, co-linear adapter, White Termination with Bird Guard Screen, UV resistant.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 21

VENTING VERTICALLY WITH POLYPROPYLENE

Description

Centrotherm Part No.

DuraVent Part No.

2” Chimney Liner Kit, with 35 ft of flex

IFCK0235

N/A

3” Chimney Liner Kit, with 35 ft of flex

IFCK0335

N/A

3” Chimney Liner Kit, with 35 ft of flex

IFCK0435

N/A

2” Chimney Liner Kit, order flex separately

N/A

2PPS-FKL

3” Chimney Liner Kit, order flex separately

N/A

3PPS-FKL

4” Chimney Liner Kit, order flex separately

N/A

4PPS-FKL

2” Flex lining, 35 feet

IFVL02035

2PPS-FLEX35

3” Flex lining, 35 feet

IFVL03035

3PPS-FLEX35

4” Flex lining, 35 feet

IFVL04035

4PPS-FLEX35

Part No: Description: 10-0582 Chimney Vent Kit 2in PPs 10-0583 Chimney Vent Kit 3in PPs 10-0586 Chimney Vent Kit 4in PPs

The Accel CS boiler may be installed with polypropylene vent materials

vertically through the roof of a building.

Combustion air may be piped alongside the vertical vent using a dedicated polypropylene lin er or PVC p ip e. Combustion air may also be taken directly from the boiler room, although piping combustion air directly from the outdoors is the best practice.

Chimney Liner

A masonry chimney will not stand up to the corrosive nature of the flue gas from a condensing boiler. The chimney therefore must have a liner installed that complies with UL 1738. An existing chimney may be used as a chase for an approved liner.

Any chimney liner must be made from AL29-4C stainless steel alloy or approved polypropylene product that is designed for positive pressure venting. The chimney liner length must be added to the rest of the flue piping to determine the allowable maximum length.

Optional Venting parts, order as needed for the job.

Notes: For Centrotherm: Includes all components necessary to line a chimney from chimney termination to base support. Rigid vent lengths, elbows and adapters required to connect chimney kit base support to appliance are sold separately. Kit includes 35 feet of flex. For DuraVent: Use for a vertical flex lining system. Includes black UV resistant chimney cap, rigid flue vent, flex support bracket, 4 spacers in 3” kits, male and female flex adapters with gaskets, extended support elbow, wall plate and Appliance adapter. Flex sold separately.

Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 22

+ 52 hidden pages

ENERGY KINETICS EK2C, EK3C, EK1C Installation & Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual