ENERGY KINETICS EK3 Frontier Owners & Installation Manual

EK3 Frontier

Oilheat Commercial Boiler

Owner & Installation Manual

Manufactured By:

Energy Kinetics, Inc.

51 Molasses Hill Road

MH28303

UL 726; CAN/CSA-B140.7-05 CAN/CSA-B140.0-03 CAN/CSA-B139-M91

Low-Press Boiler

INSTALLER: HANG THIS INSTRUCTION MANUAL AND ACCESSORY

INSTRUCTIONS VISIBLY NEXT TO THE BOILER USING THE SUPPLIED POUCH.

OWNER: READ AND SAVE THIS INSTRUCTION MANUAL AND ACCESSORY

INSTRUCTIONS FOR FUTURE REFERENCE.

Lebanon, NJ 08833

(908) 735-2066

www.energykinetics.com

Seventh Edition October 2015

National Board Listed

ASME Certified

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 special instructions on installation, operation, or maintenance that are important, but not

normally related to injury or property damage hazards.

WARNING: Retain this manual for use by your qualified service technician only. 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.

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 personal injury, death or substantial property damage.

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

 Do not store or use gasoline or other flammable vapors or liquids near or in the same room

as the burner.

 Do not use 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 can cause severe damage.

 Do not store combustible materials near or in the same room as this boiler

combustion appliance.

CAUTION:

WARNING:

DO NOT TAMPER WITH THE UNIT OR CONTROLS – CALL YOUR SERVICE PERSONNEL.

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).

General care and maintenance

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



explain normal operation of your equipment.

Daily inspect the space around the burner/boiler to verify the area is clean and free of the materials listed



above.

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 qualified service technician. Follow the instructions on the next page to shut down the burner/boiler while waiting for the technician.

or any other

EK3 Frontier Boiler Manual 1 Seventh Edition- October 2015

TABLE OF CONTENTS

Page Topic Page Topic

1 2 3 3 4 5 6 6 7 7 7 8 8 9 9 9

9 10 10 11 11 11 11 11 11 12 12 12 12 13 13

Please read this first Table of Contents Owner/User Note Emergency Shut Down Instructions Record of Installation System 2000 EK3 Frontier Boiler Principle of Operation – System 2000 Principle of Operation - Digital Manager Receiving and Unpacking Moving the Boiler Location and Clearance Combustion Air Chimney Venting L-Vent Chimney Side Wall/Power Venting Fuel Systems Oil Burner Settings Oil Burner Mounting Beckett CF 500 Oil Burner Operation Aquastat Settings General Assembly Boiler Mounting Zone Control Boiler Bypass Circulator Filling with Water, Venting and Purging Boiler Water Treatment Anti-Freeze Winterizing Piping & Wiring Diagrams

Wiring and Controls Electrical Connection – Line Voltage

14 14 14 14 15 15 16 17 18 19 19 20 20 20 20 21 21 22 23 24 24 24 25 27 35 38 42 43 44

Back

Cover

Prepare for Start Up Digital Manager, Install Digital Manager, Low Voltage Wiring Start Up Procedure Digital Manager Option Switch Settings Security System Interface Wiring 10 & 15 Zone Manager Install Instructions Digital Manager Operation Digital Energy Manager Check 2 Minute Digital Manager Diagnostics Additional Manager Tests Digital Manager Sensor Testing Line Voltage Relays Line Voltage Surge Suppression Trouble Shooting with the Digital Manager Operation without the Digital Manager Diagnostics with the Digital Manager Annual Maintenance Amulet Replacement Flame Former Replacement Replace Parts SYS-08-019 EK3 w/Dig Mgr, w/Single Zone Inj SYS-08-020 EK3 w/Dig Mgr, w/Heat & DHW & Inj SYS-08-021 EK3 w/Dig Mgr, w/Heat & DHW SYS-04-019 Mult EK3 Boiler Installation Common Flue Pipe Sizing EK3 Frontier Boiler Spec Drawing Footprint Drawing, Four EK3 Boilers

Limited Five Year Warranty for Commercial/Industrial Boilers

EK3 Frontier Boiler Manual 2 Seventh Edition- October 2015

OWNER/USER NOTE:

EMERGENCY SHUT DOWN INSTRUCTIONS:

Turn power off to boiler by switching the “Oil Burner Emergency Switch” (typically located at the top of basement stairway or at boiler room entrance) to the OFF position. If unable to locate the “Oil Burner Emergency Switch” then switch the “System Emergency Switch” located at the boiler, on the left hand side of the system junction box located on the top right hand side of the boiler. Shut off oil supply valve.

NOTICE

Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under wate r.

IN CASE OF NO HEAT

In case of no heat coming from the boiler, perform the following actions or call a qualified service

agency for help.

 Look at the Digital Manager and write down all lights showing on the Digital Manager.

o Refer to the Digital Manager Operation Summary for the meaning of the lights. o Reset the Digital Manager by turning off and back on the System Switch on the left side

of the Manager.

 Remove the burner cover and look at the two LEDs on the burner control. If the red LED is on

constantly, then press and hold in the reset button for one second. The burner will then try to relight. If the burner relights successfully, then no further action is needed.

 If the burner goes into lock out again, contact a qualified service agency for help.

ANNUAL MAINTENANCE

The SYSTEM 2000 boiler requires an annual tune-up by a qualified service agency to maintain top efficiency and peak performance and to verify proper performance of all safety devices.

PERIODIC MAINTENANCE

The SYSTEM 2000 boiler requires minimal attention from the user.

- Daily inspect the space around the burner/boiler to verify the area is clean and free of any flammable or combustible materials.

- Once a month it is recommended that the owner/user inspect the boiler and to watch the operation of the boiler. The owner/user should:

 Inspect flue connections.

o Look for evidence of deterioration from corrosion or other sources. Watch the flue pipes during a start up of

the boiler and look and smell for evidence of escaping flue products.

o For a chimney installation particularly examine the joint between the boiler outlet and the flue pipe. Also

examine the joint between the flue pipe and the base of the chimney.

 Inspect for evidence of water, such as leakage from the safety pressure relief valve.

 Watch the Digital Manager during one heating cycle of the boiler.

 Verify the pressure gauge on the boiler is reading between 5 psi and 30 psi.

 Verify the temperature gauge on the boiler reads no more than 220F at the end of a heating call.

If any of the above items seem unusual or out of the ordinary, then immediately call your qualified service agency.

EK3 Frontier Boiler Manual 3 Seventh Edition- October 2015

EK3 Owner & Installation Manual

RECORD OF INSTALLATION

INSTALLER NAME:

INSTALLER ADDRESS:

INSTALLER CITY, STATE:

DATE INSTALLED:

NOTES:

SCOPE

This manual covers the Energy Kinetics System 2000 EK3 Frontier Boiler. The boiler is designed and equipped and has been tested to generate hot water in a low pressure closed loop system. The boiler is a major component of a closed loop system that can be used as a heat source for hydronic heating, hydronic air handler, radiant, domestic hot water, spa, and/or pool heating systems. Call Energy Kinetics to obtain piping and wiring instructions for applications, such as hydronic heating, radiant heating, domestic hot water, hydronic air handler, swimming pool heating, multiple boilers, injection loops, etc. The installer of the system is responsible for the final design of the system and for adding the balance of the needed parts to complete the system.

COMMONWEALTH OF MASSACHUSETTS When the boiler is installed within the Commonwealth of Massachusetts:

 This product must be installed by a licensed plumber

 If antifreeze is used, a reduced pressure backflow preventer device shall be used.

INSTALLER NOTE: ALL INSTALLATIONS MUST BE MADE IN ACCORDANCE WITH ALL NATIONAL, STATE AND LOCAL, PLUMBING, HEATING AND ELECTRICAL CODES THAT MAY DIFFER FROM THIS MANUAL AND IN ACCORDANCE WITH THE FOLLOWING CODES, AS APPLICABLE:

N.F.P.A. No. 70: National Electrical Code A.N.S.I. / N.F.P.A. No. 31: Installation of Oil Burning Equipment A.N.S.I. / N.F.P.A. No. 211: Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances Canadian Electrical Code, Part I

If this oil fired boiler is converted to gas fired by field mounting a listed gas conversion burner, then install in accordance with A.N.S.I. Z223.1/N.F.P.A. No. 54: National Fuel Gas Code

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

Canadian Standards Association 5060 Spectrum Way Mississauga, Ontario L4W 5N6 CANADA

A boiler should be installed in such a manner that, if the pressure vessel or any connection thereto should leak, the resulting flow of water will not cause damage to the area in which it is installed. A boiler’s pressure relief valve, backflow preventer, and all other devices must be piped to the nearest drain to avoid damage in the event the valve is actuated.

EK3 Frontier Boiler Manual 4 Seventh Edition- October 2015

Sixth Edition October 2010

SYSTEM 2000® EK3 FRONTIER OILHEAT BOILER - COMMERCIAL - RESIDENTIAL

IMPORTANT MESSAGE: These instructions should be carefully read and kept for future reference to gain the best

performance from your System 2000 Frontier boiler.

CONGRATULATIONS ON THE PURCHASE OF A SYSTEM 2000 BOILER with its highly efficient low mass hydronic heat exchanger, the Energy Converter. It is the product of years of engineering and advanced design, whi ch brings together in a single system all the elements needed to provide an efficient source for heat and hot water. This operation and maintenance information has been prepared so that you may better understand and use your Energy Kinetics Frontier Boiler and Heating System.

The EK3 Frontier is ASME certified and National Board listed, perfect for commercial installations. The required manual reset high temperature limit and the manual reset low water cutoff are both included. The boiler is packaged with circulators, piping, controls, wiring, and burner mounted. The boiler will fit through a 34” doorway.

The EK3 Frontier comes with the System 2000 Digital Manager control system with built in energy recovery cycle.

Oil Heat EK3 Packages Include:

 Energy Converter (boiler) Flue 7” at 45 degrees,  Front Service, thru side swing door, right side hinge.  EK3 Firing Rates: 2.25 gph to 3.00 gph,  Beckett CF500 Burner

o Primary control with oil delay o Oil valve o 20,000 peak volt Igniter o 1/3 HP burner motor o Two stage ‘B’ fuel pump

 One Flexible Oil Line  Wiring Harness w/ Door Switch and Service Outlet

o Manual reset high temperature limit o Manual reset low water cutoff

 Complete supply, return, bypass piping

o Bypass Circulator, Taco 007 o Injection Circulator, Taco 0012IFC o Air Purge with two (2) Air Vents o T&P Gauge o One (1) 3/4” Drain Valve o ASME 30 psi Relief Valve

 Cold start, cold finish operation with energy recovery  Return temperature sensor for condensing protection  Relay for control of injection circulator included.

EK3 Options Include:

 Air Inlet Box kit for field mounting  Smart oil filter kit  Fabricated steel base  Additional flex oil line (required for 2 pipe installs)  Domestic hot water making is an option, consult

the factory for hot water zone kits.

Input (GPH)

Gross Output

(BTU/hr)

2.25 272,000

2.60 313,000

3.00 357,000

EK3 with Digital Manager,

Easy access, front opening door.

SYSTEM 2000

HEAT EXCHANGER

Shown with optional base

MODEL 18U

LEBANON, NJ 08833

SYSTEM 2000

ENERGY MANAGER

THERMOSTAT

HEATING

HOT WATER

THW

ZHW

Z344A1

24VAC

CHIMNEYLESS ONLY

INDUCER

TEMP. SENS.

IND

BURNER

ERGY

KIN

ETICS

CIRCULATOR

Lebanon, New Jersey

POWER 190

CIRC

170

CAUTION

160 150

24 VAC CONNECTION ONLY.

140

READ INSTRUCTIONS BEFORE

130

MAKING ANY CONNECTIONS

120 100 ALARM

T R A

R E

EK3 Frontier Boiler Manual 5 Seventh Edition- October 2015

A M

E L

I F

T R A

R E

I F

SYSTEM 2000 - PRINCIPLE OF OPERATION

SYSTEM 2000 comprises a heat source, the energy converter, circulating water, and five (or more) zones controlled

by an electronic control, the Digital Manager.

The Boiler sits cold until a thermostat calls for heat. The Digital Manager receives the call for heat and turns on the bypass circulator and burner. Water circulates within the boiler as it warms up to operating temperature. When ready, the supply circulator and zone valve(s) open and deliver heat to the zone(s) calling for heat. When the thermostats are satisfied, the Digital Manager turns off the burner and enters the energy recovery stage. The circulators and zone valve stay energized to deliver the heat remaining in the boiler to the last zone calling or to the domestic hot water storage tank.

When energy recovery is complete and the Boiler has been cooled off, the Digital Manager turns off the system and waits for another thermostat (or tank aquastat) to call for heat. SYSTEM 2000 runs the burner only when you need heat and delivers that heat only where you need heat.

The System 2000 Energy Converter is the product of advanced thermal engineering. It is designed with two separate passageways, nearly 18 feet long, coiled around each other. Water travels along one passageway from the heat emitters toward the center of the unit. Heated gases travel from the unit center toward the chimney. This is a “forced circulation counter-flow” design and it 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 heat directed to the desired zones in an efficient and quiet manner.

SYSTEM 2000 has an extremely high annual efficiency (over 99% of steady state) because it runs only when your heat zones or hot water storage tank needs heat. Energy recovery is completed at the end of each heat call, virtually eliminating off cycle losses.

Your System 2000 holds a minimal quantity of water so it begins to supply heat in about two minutes. This rapid response means that your rooms can be heated quickly to temperature. The System 2000 EK3 Frontier can provide heated water up to 357,000 BTU’s per hour.

A modern retention head oil burner fires into the center of System 2000 where a high temperature, light weight ceramic flame former provides ideal conditions for “near perfect” efficient, pollution-free combustion. Your S ystem 2000 is tightly sealed so all products of combustion pass only to the chimney.

DIGITAL MANAGER - PRINCIPLE OF OPERATION

The left side of the Manager is the input side, which provides 24-volt power supply and connections for thermostats. The right side is the output side, which starts the burner, circulators, zone valves or zone circulators and the domestic hot water circulator. See photo of the Manager on the cover.

Lights on the Digital Manager indicate zone(s) calling for heat (left side) and (right side) lights in dicate active zone(s), burner operation and circulator operation. These function lights are an aid in servicing. The following is a typical cycle.

1. SYSTEM WAITING FOR A CALL: The boiler is turned off and sits cold, waiting until a call for heat. The red power

light on the 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. PRE-HEAT: Output lights for the bypass circulator and burner turn on, the bypass circulator starts, and the burner

begins firing. Water circulates within the boiler and through the bypass as it warms up to operating temperature.

4. HEAT: Once the boiler water has heated up to 140º F (about two minutes), the Manager will turn on the zone output

light on the right side. The zone valve will open, the main supply (injection) circulator will start and hot water will flow to the zone needing heat. The burner runs as long as there is a thermostat calling and as long as heat is being delivered to the zone. The burner may shut off if the return temperature exceeds 170º F/190º F (RED burner light turns off) or if the high limit temperature is exceeded (RED burner light stays on, but the high limit aquastat shuts the burner off).

5. ANOTHER CALL FOR HEAT: If another zone calls for heat while the burner is already running and the return

temperature is above 140F, the zone output will turn on, immediately supplying heat to the zone.

6. MONITOR RETURN TEMPERATURE: The Manager continually senses the return temperature and will turn off the

zone outputs if the return temperature drops below 120º F (130º closed, the boiler water will quickly reheat and once the return temperature reaches 140º F (150º is ON), then the Manager will reopen the zone valve and start the supply circulator.

7. THERMOSTAT SATISFIED: The thermostat light on the left side will go out. The burner light and the burner will then

turn off.

8. ENERGY RECOVERY: The bypass circulator, main supply (injection) circulator, and zone valve remain energized.

The circulating water will remove the energy from the converter, sending the heat to the last zone that called. The energy recovery stage continues until the return 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 usually set at twenty minutes for space heating zones and is fixed at five minutes for the Hot Water zone. (See Digital Manager Option Switch Settings).

F if Option Switch #1 is ON). With the zone outputs

F if Option Switch #1

EK3 Frontier Boiler Manual 6 Seventh Edition- October 2015

RECEIVING and UNPACKING

Inspect shipment upon receipt for external damage. When unpacking and uncrating, inspect each item for internal damage. Any damage found should immediately be reported to the freight carrier before installation. The receiver is responsible for following the claims procedure of the freight carrier. The freight carrier is responsible for taking prompt action on all claims. If freight cannot be inspected at the time of delivery, sign the bill of lading “Subject to Inspection” and inspect the shipment as soon as possible after receipt. Replacements for parts damaged in shipment are available upon receipt of a signed copy of a claim report (concealed damage claims should be filed immediately against the freight carrier by the consignee).

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.

MOVING THE BOILER

The boiler is shipped bolted to a pallet. Use a pallet jack or fork lift to move the boiler while mounted on the pallet. The boiler has two features designed to help with moving the boiler. There are four welded in nuts at the top of the front and rear covers that can be used to screw in eyebolts or lifting bolts. Use a chain hoist or cherry picker to lift the boiler. The boiler legs have four holes to accept 3/4” iron pipe. Remove the boiler drain from underneath the front of the boiler and slide (2) 6 foot pieces of 3/4” iron pipe into the holes from side to side of the boiler. Use the two pipes to lift, steer, and stabilize the boiler. Use of a wheeled dolly or cart is recommended once the boiler has been removed from the pallet.

If the front door and burner are removed, then the boiler can be hand trucked from the front and will fit through a 34” door. Use pieces of wood (4x4’s) to space the boiler shell from the hand truck uprights, so the mounting studs and the junction box will be protected.

The boiler is 33” wide and will fit through a 34” door when moving from front to back. If the front door and burner are removed and the manual reset aquastat on the rear is removed, the boiler will be 32” front to back and will fit through a 33” door when moving sideways. If the aquastat well on the rear is also removed, then the boiler will be 31” front to back and will fit through a 32” door when moving sideways. When the front door has been removed, the door mounting studs will be exposed and can be easily damaged unless proper care is taken. It is recommended that pieces of wood be attached to help protect the studs from impact.

LOCATION and CLEARANCE

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

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

Installation Clearances from

Boiler Surfaces, Inches

Front of boiler 13 36*

Left side of boiler body 0 2

Right side of boiler body 0 16*

Back of boiler body 7 36

Top of boiler body 13 16

Bottom of boiler legs to floor 0 0

L-Vent: from flue pipe 3 3

Standard Flue: from flue pipe 9 9

* Minimum recommended clearance to allow door to fully open.

Clearance to

Combustibles

Clearance for

Service

Boiler Weight and Water Content

Weight 675 lbs Water Content 7-1/2 gallons Air Inlet Pipe Size 4 " Boiler Flue Outlet 7 “ Supply & Return

Piping

1-1/2”

EK3 Frontier Boiler Manual 7 Seventh Edition- October 2015

COMBUSTION AIR

The System 2000 Boiler must be installed in an area where adequate fresh air is available to support co mbustion.

The EK3 Frontier can be provided with a sealed Air Box that can be piped to air outside the building. Boiler with outside air piping: Piping of outside air directly to the boiler is highly recommended becau se it completely

isolates the boiler from the interior environment, as well as greatly reducing operating noise from the boiler. In multiple boiler installations, each boiler air intake should be piped separately. The outside air source must be located high enough above grade to be at least 12” above expected snow accumulation. Use 4” PVC to pipe in the fresh air, 20 feet max and five 90 degree elbows or less. Up to 40 feet max using 5” PVC and five 90 degree elbows or less.

Boiler without outside air piping:

WARNING: The confined space shall be provided with two permanent openings, one near the top of the enclosure and

one near the bottom. Each opening shall have a free area of not less than one square inch per 1,000 BTU per hour of the total input rating of all appliances in the enclosure, freely communicating with interior areas

having adequate infiltration from the outside.

WARNING: Modern buildings of tight construction, as well as the operation of attic and exhaust fans, kitchen ventilation

systems, clothes dryers or fireplaces may create conditions of unsatisfactory combustion or venting. Provisions must be made to use combustion air that communicates with a well-ventilated attic or with the outdoors (such as using a louver or grate). The opening should have a free are a of not less than one (1)

CHIMNEY VENTING

square inch per 4,000 BTU per hour of the total input rating.

WARNING: Masonry chimneys must have a tile or metal liner. The liner must:

1) Extend above the masonry.

2) Have an insulating air gap, isolating the liner from the chimney, allowing for rapid heat-up and draft establishment.

3) Be sealed at each joint to prevent air infiltration and damage from condensation.

NOTICE: Inspect Chimney and Chimney base after initial three months of operation.

The installation of a chimney cap is recommended. The base of the chimney must always have a drop leg below the

flue connector to allow scale and condensation to accumulate without blocking the flue pipe.

CAUTION: If drop leg is in excess of 12 inches deep, backfill with loose gravel or sand to obtain a maximum of 12-

inches depth. All clean out doors must be sealed to prevent cold air entry into chimney.

In retrofit installations, have chimney thoroughly cleaned. Carefully inspect chimney, base of chimney, and liner prior

to installation of System 2000 Boiler.

CAUTION: If liner is not sound, or if existing tile liner fails to contain intermittent condensation, or if excessive debris is

found at the base of the chimney, then it is recommended to install a properly sized metal liner approved for use with oil heat appliances.

The metal liner diameter and length should be as recommended by the metal liner manufacturer. Corrugated metal liners should be at least 8" diameter. Connection of a flexible metal liner directly to the flue collar of the boiler is an acceptable connection method and is recommended. Alternatively, a flexible metal vent connector may be used between the flue collar of the boiler and a flexible metal liner. Call Energy Kinetics for details on metal liners.

Chimney connectors should be positioned to create the shortest possible run of flue pipe to the chimney. The overall horizontal length of flue piping should not exceed 15 feet. Long runs or low firing rates may require insulated flue pipe such as L-Vent or All-Fuels to keep the temperature at base of chimney adequate for draft and to prevent corrosion of piping and connectors.

Because the System 2000 boiler uses a power burner, the flue pipe may experience some positive pressure on start up. Energy Kinetics recommends that all pipe joints be sealed with high temperature silicone sealant to ensure passage of all combustion products to the chimney.

Normally, pitch horizontal flue pipe up toward chimney approximately ¼” per foot. For existing installations, it is permissible for the flue connection of the boiler to be higher than the chimney thimble, provided adequate d raft is established.

If a minimum of +0.08” w.c. draft overfire is not present after sufficient burner run time to heat up the chimney, there is a problem that will need to be corrected. Call Energy Kinetics for help resolving draft problems. Under normal circumstances, there is NO need for a DRAFT REGULATOR and one should not be installed. Call Energy Kinetics with questions about flue pipe sizing.

WARNING: No solid fuel appliance or fireplace should be installed in a flue common with this heating appliance. The

flue gas exit of the venting system must be at least three (3) feet above the point at which it passes through the roof and at least two (2) feet higher than any portion of a building within 10 feet horizontally of its location.

EK3 Frontier Boiler Manual 8 Seventh Edition- October 2015

L-VENT CHIMNEY

SYSTEM 2000 Boilers typically have flue gas temperatures between 350º F and 450º F during normal operation. Due to the low flue gas temperatures, L-Vent chimney pipe is suitable for use with SYSTEM 2000 Boilers. L-Vent chimney pipe may require smaller chase dimensions than other chimney pipe materials and should be considered for new installations with SYSTEM 2000 Boilers. Call Energy Kinetics for help locating sources of L-Vent.

1. L-Vent must be U.L. Listed to U.L. 641.

2. L-Vent to be installed in accordance with the vent manufacturer’s instructions.

3. System 2000 and L-Vent must be installed in strict compliance with all State and Local Codes and with the

regulations of the authorities having jurisdiction, which may differ from and which take precedence over these

instructions or the vent manufacturer’s instructions.

SIDE WALL/POWER VENTING

Energy Kinetics currently does not offer a kit for sidewall venting or power venting of the EK3 Frontier.

FUEL SYSTEMS

NOTICE: Inspect and if needed, replace oil lines according to local codes. Oil lines must be absolutely airtight. Use

only flared joints on all copper tubing and use thread sealant suitable for oil on all iron pipe threaded joints. Do not use Teflon tape on fuel system joints. Check all joints and connections for leaks after installation. A high quality fuel filter should be installed in the fuel line. A high quality UL Listed 10-micron fuel filter is recommended. When changing the fuel filter, be sure to lubricate cartridge gasket with motor oil, not heating oil.

It is recommended that Frontier systems be equipped with a (optional) fuel filter and a (optional ) flexible fuel line. Call Energy Kinetics to obtain optional UL Listed fuel filter and optional UL Listed flexible fuel line. The flexible fuel line allows the door to open without disconnecting the fuel supply. The flexible line connects the fuel pump to the Smart Filter. The fuel filter can be mounted on the right hand side of the standard base. A fusible link shutoff valve should be installed at the inlet of the fuel filter or as required by the authority having jurisdiction. If the oil supply is higher than the burner, then an anti-siphon valve (OSV) should be installed. All piping systems should conform with pump manufacturer’s specifications that are attached to each new pump. The burner is capable of burning No. 1 or No. 2 heating oil.

CAUTION: DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR ANY OIL CONTAINING GASOLINE. NOTICE: Order an additional flexible fuel line for two-pipe systems. A two-stage pump is required if lift from oil tank

exceeds approximately ten (10) feet. Follow instructions provided by pump manufacturer on single and two pipe connections for bypass plug usage and other specific installation requirements.

CAUTION: ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.

OIL BURNER SETTINGS

EK3 Frontier Boilers are shipped from the factory preset for 2.25 GPH firing rate. The SYSTEM 2000 Boiler can be fired over a range of firing rates to suit the needs of the application. The following table lists approximate settings for oil burners based on testing performed at Energy Kinetics. CAUTION: Final settings for each burner and firing rate for a particular installation must be determined by using combustion test equipment and following the instructions given under "Start Up Procedure". CAUTION: The EK3 Frontier has been tested for use with chimney venting. Consult factory for sidewall vent applications.

Model

Input

GPH

Nozzle @ Pump Pressure

Output

Btu/Hr

Beckett CF 500

2.25* 2.00 Hago 45º P@ 130 psi 272,000 Head: 0.5 Shutter: 4.0 Band: 0.0

EK3

2.60 2.25 Hago 45º P@ 135 psi 313,000 Head: 1.5 Shutter: 5.5 Band: 0.0

3.00 2.50 Hago 45º P@ 145 psi 357,000 Head: 2.5 Shutter: 7.0 Band: 0.0

* Factory Setting

EK3 Frontier Boiler Manual 9 Seventh Edition- October 2015

OIL BURNER MOUNTING

The burner is premounted at the factory. If field installation or replacement of Energy Kinetics supplied burner is required, follow these instructions. Start by checking nozzle and electrode position per manufacturer’s specifications prior to assembly to unit. The EK3 Frontier boiler uses the Beckett CF500 burner. The CF500 burner will accept the Frontier amulet, EK part number 10-0718. The amulet must be modified by trimming back the inside front edge. The inside front edge has a lip designed to protect the head. The CF500 head requires that the inside lip be trimmed flush with the insid e diameter of the amulet. Test fit the amulet by inserting the amulet into the boiler opening. If the amulet doesn't easily slide into the boiler, then gently sand the outside diameter of the amulet until it will fit into the boiler opening. Test fit the amulet onto the burner head. The amulet for the Beckett CF500 burner has smooth interiors. If the amulet is a tight fit on the burner head, then slightly moisten inside the amulet with water.

Place a 1/2" bead of retort cement onto the burner tube at the flange to air tube joint, and slide the (moistened) amulet over the burner head and against the flange. Ensure proper seating of the amulet by pressing the amulet onto the burner with a flat object. If needed, trim the front edge of the amulet to be recessed behind the front shroud of the burner head. Leave the excess retort cement at the amulet to flange joint and the cement will provide an airtight seal of the air tube flange to the boiler face. If needed, add extra retort cement to seal the air tube flange to the boiler face and to the insulation inside the boiler door. The EK3 does run with some positive pressure in the combustion a rea and enough retort cement must be used to provide a proper seal against that positive pressure.

Once the amulet has been seated and trimmed, and retort cement added, then install the burner into the boiler by carefully inserting the air tube with amulet into the boiler opening while aligning the burner flange holes with the boiler studs. Install flat washers and nuts onto the boiler studs and tighten all nuts evenly.

BECKETT CF500 OIL BURNER OPERATION

NOTICE: For reliable operation, set Air-Fuel mixture conservativ ely based on installation conditions. CO2/O2

and draft readings should be taken through 1/4" test port in front jacket opening just to right of burner. Sample tube mu st extend at least eight (8) inches into front cover to obtain accurate readings. Smoke test and stack temperature should be taken at flue outlet. NOTICE: For accurate efficiency calculations, measure flue gas temperature in flue pipe. Overfire temperatures will be higher than flue gas temperature measured in the flue pipe. Be sure to measure CO stack temperature at the flue outlet. If using a digital flue gas analyzer, use a separate thermocouple inserted into the flue outlet to measure flue temperature while drawing the gas sample from the over fire port.

Installation Conditions CO

Normal Conditions Active Area (Washer, Dryer, Shop) Outside Oil Tank

12.5% 4.2%

12.2% 4.6%

12.0% 4.9%

Setting O2 Setting

Note 1: For combinations of above, use lowest CO2 level or highest O2 level.

Note 2: When Air Box is used, CO

must be checked with air box cover in place.

AFTER 15 MINUTES RUNNING, CHECK AND RECORD:

1. DRAFT AT FLUE OUTLET …………………………………. -0.02” to -0.12” w.c.

2. DRAFT AT OVER FIRE ……………………………… +0.08" to -0.02” w.c.

3. DRAFT LOSS ……………………………… 0.06" to 0.10” w.c.

4. CO

………………………………………………………………. See table above

2/O2

5. STACK TEMPERATURE …………………………………………. 350

6. SMOKE TEST …………………………………………………….. Verify 0 smoke at breech Draft over fire with a chimney should be -0.02” to +0.08” w.c. If not, recheck chimney, chimney base and flue pipe for blockage or clean out door openings.

Draft Loss Definition: The draft loss through boiler is found by subtracting the overfire draft reading from the breech draft reading. For example, if the breech draft is -0.04" w.c., and overfire draft is +0.02" w.c., then subtracting the two readings gives a draft loss of 0.06" w.c., which is acceptable. If the draft loss exceeds 0.10" w.c., then the boiler may need to be cleaned or there may be some other blockage that will need to be addressed.

1. DANGER: Verify proper operation of high limit aquastat:

a. With a Digital Manager:

i. Remove all heat and hot water calls (No input lights on left side of manager).

ii. Turn System switch off, then remove red sensor lead from the left side quick connect.

iii. Restore power. The 100

shortly, in less than a minute.

iv. At approximately 205

light will flash on the manager’s temperature display, and the burner should start

F to 215o F, the high limit aquastat should shut off burner.

v. Turn off power and reconnect the red sensor lead.

DANGER: Verify proper operation of boiler pressure relief valve by following instructions on pressure relief valve,

which calls for a 'try lever test'. Make sure discharge pipe is properly placed to safely contain discharge and open relief valve using the try lever.

in the over fire port and the

2/O2

to 450o F

EK3 Frontier Boiler Manual 10 Seventh Edition- October 2015

AQUASTAT SETTINGS

With Digital Manager:

 11D18 automatic reset high limit, set at 205 o F, 10F Differential (195 o F/205 o F)  L4006E manual reset high limit, set at 210  Or, Carlin EZ-Temp manual reset high limit, set at 210

DANGER: Double check that the manual reset high limit aquastat is set to 210

GENERAL ASSEMBLY Assembly of various packaged units is illustrated throughout this manual. The use of non-Energy Kinetics supplied

pump, controls and accessories should follow good practices. The diagrams and locations presented in the manual are recommended.

BOILER MOUNTING

PIPING SO THE DOOR CAN OPEN: To avoid conflicts with the door opening, piping should be in accordance with

the boiler specifications drawing and the piping schematics in this manual. The door opens to the right hand side of the boiler. The burner and air box also need clearance when the door opens. Do not locate any piping in front of the boiler unless clearance from the door is verified. This also applies to the oil line piping and the combustion air piping. NOTICE: Air inlet pipe must be disconnected to allow door to swing open. BOILER PITCH: The Frontier pressure vessel is manufactured with the rear higher to allow for proper air removal. This pitch is carefully set at the factory when the boiler is built. Be sure to level the stand prior to mounting the boiler on a stand. When the stand is level, the pitch is correct and the back of the boiler will be higher than the front.

ZONE CONTROL

ZONE CONTROL BY VALVE: The SYSTEM 2000 Boiler is designed to provide multi-zone control of the heating system

and optionally can supply domestic hot water. Energy Kinetics recommends full port, 24-volt zone valves for control of each heating zone. A system with a single heating zone still requires a zone valve to provide control for preheat of unit and to maintain minimum temperature during operation.

ZONE CONTROL BY CIRCULATOR: Zone control by circulators requires a flow valve, circul ator and 24-volt relay (fan type such as Honeywell R8225B) for each zone. The boiler bypass circulator is still used in these cases.

NOTICE: Refer to piping schematic for location of zone circulators. ZONE PURGING: Valves to isolate and purge individual zones should be installed according to good piping practices. EXPANSION TANK SIZING: The type and size of expansion tank depends on the total system water volume. The EK3

Frontier contains 7-1/2 gallons of water. NOTICE: Sizing must consider cold start and hot operation due to system concepts of energy recovery and rapid heat up.

BOILER BYPASS CIRCULATOR

NOTICE: Systems are piped at the factory with the boiler bypass circulator. The bypass circulator piping and wiring must not be changed from the factory configuration. The bypass circulator runs whenever the burner is powered for heat and ensures the proper flow rate through the boiler.

FILLING WITH WATER, VENTING, and PURGING

When piping is completed and all accessories installed, the Converter and piping should be filled with water. The

Converter purges itself of air when properly installed. NOTICE: AIR VENT CAPS MUST REMAIN OPEN. Vent caps should be removed and kept in a safe location. Each zone should be purged until a steady stream of water without air passes out of purge hose. Vent all radiation. NOTICE: DO NOT START BURNER UNTIL CONVERTER AND SYSTEM ARE FULL OF WATER. Fill to normal cold system pressure, 10 to 12 psi on pressure gauge. Before placing system in operation, carefully check for leaks throughout system. Tighten pipe joints, circulator flanges; check gaskets, etc., as needed.

F. Do not exceed a setting of 210 o F.

EK3 Frontier Boiler Manual 11 Seventh Edition- October 2015

BOILER WATER TREATMENT

Addition of boiler water treatment is recommended to reduce lime buildup inside the boile r. Energy Kinetics recommends addition of one quart of 8-Way Boiler Treatment per 30 gallons system water. 8-Way Boiler Treatment is recommended to treat water up to medium hardness. Call Energy Kinetics for more details about boiler water treatment and about hard water conditions.

ANTI-FREEZE

Only non-toxic antifreeze (such as Propylene Glycol) should be used if adding anti-freeze to a system that produces domestic hot water. Hard water should not be used in combination with generic antifreeze. Energy Kineti cs supplies a quality inhibited Propylene Glycol anti-freeze with orange dye and an antifoam agent. 8-Way Boiler Treatment can be added to Energy Kinetics anti-freeze and is recommended in areas of medium water hardness. NOTICE: Thoroughly clean system prior to adding antifreeze. TSP is recommended for removing flux and other oil based compounds. Once system has been cleaned and flushed, then add antifreeze to obtain approximately a 30% by volume mixture of antifreeze in water. Call Energy Kinetics for assistance in calculating how much anti-freeze to add to system.

WINTERIZING

NOTICE: If the SYSTEM 2000 Boiler may be exposed to freezing temperatures, then anti-freeze should be added. When a property is winterized by draining all domestic water piping, then the SYSTEM 2000 Boiler must be protected. It is not recommended to drain the SYSTEM 2000 Boiler, because introducing air into the boiler can cause rusting inside the boiler shell and also because the Energy Converter has a spiral water passage that can not be completely drained of water. When draining the domestic water piping system, be sure to drain the domestic side of the plate heat exchanger. If the hydronic system will not be drained, then add enough anti-freeze to protect the entire hydronic system including the boiler, piping, radiation, circulators, etc. If the hydronic system will be drained, then add shut off valves to isolate the boiler and add anti-freeze to the boiler only, as follows. Drain water from the boiler and then add anti-freeze to the boiler. Refill boiler with water and run boiler circulator through the bypass to distribute antifreeze within boiler. Propylene Glycol in water will provide the following freeze protection: 30% down to +8F, 40% to -8F, and 50% to -27F. Energy Kinetics recommends using 30% anti-freeze to obtain the best boiler performance. Use over 30% anti-freeze only if lower temperature freeze protection is mandatory. Caution: Always keep the fuel supply valve shutoff if the burner is shut down for an extended period of time.

PIPING and WIRING DIAGRAMS

All piping and threaded accessory connections should follow good practice using approved joint sealants.

Use Energy Kinetics Smart Thread Sealant P/N 10-0620

Digital Manager Use the Digital Manager control with one or more zones directly off the boiler is needed and benefit from the Digital Manager energy recovery cycle, such as for large load with multiple zones (5 10 & 15 zone versions of the Digital Manager are available), primary/secondary injection (5 10 & 15 zone ERC Controls are avail able) with multiple boilers, or as a dedicated hot water maker. The Digital Manager has built in condensing p rote ctio n. Tekmar multiple boiler controls are recommended, for 2, 4, 9, or more boilers.

For piping and wiring boilers with a Digital Manager and single zone injection, refer to drawing SYS-08-019. This drawing shows the factory wiring of the Digital Manager boiler.

For piping and wiring boilers with a Digital Manager with heat, domestic hot water and injection, refer to drawing SYS-08-020. The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to the system junction box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the zone valve end switches which are fed from the 24VAC lug.

For piping and wiring boilers with a Digital Manager with heat and domestic hot water, refer to drawing SYS-08-021. The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to the system junction box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the zone valve end switches which are fed from the 24VAC lug.

For piping and pipe sizing of Primary/Secondary Loops, refer to drawing SYS-04-019. NOTE: When zoning with zone valves, make sure the piping/wiring configuration prevents “dead-heading ” of the 0012

system circlator. Four wire zone valves as shown in drawings SYS-08-020 and 08-021 use end switches to pull in a relay that starts the system circulator after the valve has opened. A bypass installed on the end of the supply and return headers that is adjusted by a ball valve allows 2 wire zone valves to be used as shown in drawing SYS-08-023.

EK3 Frontier Boiler Manual 12 Seventh Edition- October 2015

WIRING and CONTROLS

The Frontier Heating System is furnished with controls and basic accessories as illustrated and described in this manual. Control, burner and accessory instruction sheets and system wiring diagrams should be attached to this manual for future reference.

DANGER: All wiring must comply with the NEC and any local codes. All wiring for installations in Canada must be

done in accordance with the Canadian Electrical Code, Part I.

ELECTRICAL CONNECTION - LINE VOLTAGE

POWER SUPPLY: 120 VOLT 60 HZ, 15 Amperes

System 2000 requires 120 VAC. The supply voltage must be within 108 VAC min / 132 VAC max for reliable operation of the boiler and the Manager. An easy way to check the supply voltage is to plug a voltmeter in at the service outlet located on the side of the system junction box.

DANGER: Make All Connections with Power Off at Main Circuit Box

Connect power from a separate 15 AMP fused circuit. Install 3rd wire grounding for proper bond between all electrical accessories. The system switch is included so power can be shut off at the unit for servicing.

the green pigtail to ground.

WARNING: The junction box is wired at the factory with the service outlet always powered, even with the System

Emergency Switch turned off. To have the service outlet controlled by the System Emergency Switch, move the service outlet black lead to top lug of system switch. A manual reset low water cut-off is factory installed by Energy Kinetics.

Pigtails are provided for the line voltage power connection. Connect black pigtail to hot, white pigtail to neutral, and

EK3 Frontier Boiler Manual 13 Seventh Edition- October 2015

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ENERGY KINETICS EK3 Frontier Owners & Installation Manual

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