ENERGY KINETICS EK1C, Installation & Service Manual

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Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015 33
Once the boiler supply temperature has reached 140ºF, the Condensing Energy Manager will turn on the SP (Smart
Pump) output light and will send a command to the Sola to turn on the Smart Pump relay output. The Smart Pump will then
start to circulate the cold domestic water from the bottom of the storage tank, through the plate heat exchanger which will
heat up the domestic water. The heated domestic water then enters the storage tank through the dip tube which will help
stratify the storage tank. The burner will continue to fire, heating the flow of domestic water into the storage tank, until the
storage tank thermostat is satisfied.
The flow rate of the domestic water through the plate heat exchanger determines the temperature of the domestic water
going into the top of the tank. While running a constant flow from a hot water tap of about 2 gpm, let the boiler stabilize,
and then adjust the ball valve just below the smart pump until the domestic water temperature coming out of the plate heat
exchanger is about 140ºF. Higher flow rates will lower the water temperature, and lower flow rates will increase the water
temperature.
Once the storage tank thermostat is satisfied, the Condensing Energy Manager turns off the heat demand to the Sola
boiler control which will turn off the burner. The Condensing Energy Manager will keep the hot water zone valve, the boiler
pump and the Smart Pump all running until the boiler supply temperature has cooled off to near room temperature or until
five minutes have elapsed. The key to recovering the energy in the boiler is the stratification of the water in the storage
tank. The cold water in the bottom of the tank will remove the heat from the boiler and put the heat into the storage tank
where the heat will be useful. Once the boiler has cooled off, the Condensing Energy Manager will turn everything off, will
restore the boiler supply setpoint to the heating setpoint and wait for another call for hot water.
Domestic Hot Water Production Rate at 140°F (50°F Source)
EK1C with 40 Gallon Buffer Tank EK2C with 40 Gallon Buffer Tank EK3C with 80 Gallon Buffer Tank
First Hour
Draw 190 gallons per hour 290 gallons per hour 580 gallons per hour
Continuous
Draw 150 gallons per hour 250 gallons per hour 500 gallons per hour
Domestic Hot Water Piping
The plate heat exchanger and the Smart Pump will be piped as a zone off the boiler header as shown in the above
diagram. The plate heat exchanger and the Smart Pump should be mounted at the storage tank. The boiler side piping
should be ¾” copper and the boiler pump will easily drive the flow out to the heat exchanger.
FILLING WITH WATER, VENTING and PURGING
Check Boiler System Water Chemistry
Water pH Level should be no lower than 7.0. Check pH using litmus paper or have it chemically tested by a water
treatment company. If pH does not meet this requirement, contact a local water treatment company and correct this issue
before filling system.
Water Hardness should be less than 20 grains. If the local water hardness is 20 grains or higher, consult a local water
treatment company for help reducing the water hardness. Chloride concentration must be less than 200ppm. Chlorinated
fresh water is normally safe to use as the chlorine levels for drinking water are usually less then 5ppm.
NOTICE: AIR VENT CAP MUST REMAIN OPEN. Vent cap should be removed and kept in a safe location.
Note that existing piping and radiation systems may contain significant levels of contaminants such as minerals, deposits,
sludge, dirt or other debris. Existing contaminants may adversely affect system operation and reliability, and may cause
damage to the Accel CS boiler, piping or any hydronic components. Tri-Sodium Phosphate (TSP) is recommended for
removing flux and other oil based compounds. Once the existing system has been cleaned and flushed, proceed with filling
the system with water.
When piping is completed, all accessories installed and the boiler, piping and attached radiation have been flushed of all
sediment, the system should be purged of all air.
For zoned systems, each zone should be isolated and purged separately until a steady stream of clean water without air
passes out of purge hose. Vent all radiation.
NOTICE: DO NOT START BURNER UNTIL BOILER AND SYSTEM ARE FULL OF WATER.
Fill to a normal cold system pressure, typically 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.
WARNING: Failure to repair all system leaks will cause make-up water to be added to the system continuously. This will
reduce the life of the boiler as a result of mineral buildup in the heat exchanger thereby reducing heat transfer
and overheating the heat exchanger. Furthermore, if the make-up water contains a significant amount of
dissolved oxygen, it may promote oxygen corrosion of iron containing hydronic components. Scale buildup or
corrosion of the pressure vessel is not a manufacturing defect, and is not covered under the warrantee.