EK3 Frontier Boiler Manual
14
Seventh Edition- October 2015
PREPARE FOR START UP
DANGER:
MAKE CERTAIN THE FOLLOWING REQUIREMENTS HAVE BEEN SATISFIED BEFORE START UP:
1. The boiler and piping are completely filled with water.
2. Re-check wiring to ensure that it is correct and in accordance with appropriate wiring diagrams and codes.
3. Verify that proper nozzle is used and installed correctly.
4. Verify electrode settings.
5. Verify the burner settings for air band position and head position
(see "Oil Burner Settings" Table)
.
6. Oil supply is connected to burner. Oil supply lines and shut-off valves are open.
7.
CAUTION:
DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR ANY OIL CONTAINING GASOLINE.
8. Fuel pump and fuel lines are purged.
9. Verify operating oil pressure at gauge port.
10. Flue pipe properly connected from unit to chimney. All joints are secured and sealed.
11. Combustion air supply is available and sufficient. (
See “Combustion Air”)
12. Adjust valve in domestic hot water circuit under circulator approximately ¾ of the way open.
13. Punch a ¼” sampling hole in flue pipe as near to unit as possible in flue outlet for flue gas temperature and loosen
1/8” NPT hex plug in front jacket (to right of burner) for the over fire sampling location.
14.
CAUTION:
All covers, enclosures, and guards must be maintained in place at all times, except during maintenance
and servicing.
15.
CAUTION:
Do not start burner unless the front door is closed and the nuts have been properly tightened.
16.
DIGITAL MANAGER
Install Digital Manager
The Digital Manager is shipped in its own protective shipping box.
NOTICE:
The option switches can be set very easily before
the Manager is installed. Locate the prewired quick connectors fastened to the front of the junction box by two cable ties. Cut
the two cable ties and discard. Fasten the Digital Manager to the junction box with the four corner screws. Slide the two quick
connectors onto the Digital Manager. Label each zone on the manager, using the adhesive labels supplied.
Low Voltage Wiring
Digital Manager Operates Only On 24 Volts 60 HZ Power
WARNING
: Make All Connections With Power Off at Main Circuit Box
Typical low voltage wiring diagrams for the Digital Manager are shown along with piping schematics near the back of this
manual (refer to table of contents). Thermostats must be located on inside walls away from cold drafts, windows or heat from
fireplaces, appliances or sunlight. Set thermostat heat anticipators to 0.1 amps (or “hot water”). Call Energy Kinetics to request
alternate low voltage wiring diagrams to handle special situations such as air handler wiring, heat pump wiring, isolation relays
for thermostats, and isolation relays for heat motors or circulators, etc.
The single 24-volt/50VA transformer is suitable for the Digital Manager and five zone outputs (zone valves or relays).
NOTICE:
Additional load such as extra valves may require greater transformer capacity. To add transformers, wire in parallel
as follows: wire terminal “A” on one transformer to “A” on the other. Repeat with other low voltage terminal “B”. Be sure to
verify 24VAC output from all transformers.
The Digital Manager is designed to heat domestic water and up to four (4) heating zones. Use Energy Kinetics supplied
zone valves with four wire connections. For more than four heating zones, use Energy Kinetics expanded 10 or 15 zone Digital
Manager, or call Energy Kinetics for alternatives.
START UP PROCEDURE
1. Turn on system supply switch and burner supply switch. The Digital Manager lights should come on briefly, the circulator
relay should close briefly, and then the Digital Manager should only show one red light next to 'power'.
2. The hot water tank aquastat should call for heat, if not, adjust a thermostat to call for heat. Burner and bypass circulator
should come on at the same time. If not, check primary control and reset it if necessary.
3. Check for burner light off. On an oil supply system with one pipe, it will be necessary to bleed air from fuel pump. On a two
pipe system, several starts may be required to clear air from fuel pump, or bleed air from pump.
4. On light off, water temperature and chimney temperature will start to rise. A slight odor is common on initial light off as
combustion flame former and converter surfaces warm for the first time.
5.
NOTICE:
Perform smoke test immediately after light off. Smoke test should show yellow after initial one minute of
operation due to the combustion flame former sizing heating up. If the smoke test shows dark grey or black after one
minute of operation, shut off boiler immediately and repeat "Prepare for Start Up" checklist.
6. As Unit reaches temperature, Digital Manager “Heating” light will signal heat distribution to zone(s) calling for heat. (On first
start up, this will usually be the hot water storage tank zone.) Once boiler water temperature reaches 160
o
– 180
o
F., adjust
hot water temperature flowing to storage tank. With hot water flowing fully from a domestic faucet, adjust valve under
domestic circulator pump so water temperature going into tank is approximately 140
o
F. (Hand can be held on pipe just
briefly.) Water must be flowing fully from a household hot water tap to accurately adjust flow and temperature entering
tank.
7. Allow system to run about 15 minutes before testing and recording burner operation. (
See "Oil Burner Operation")
8.
CAUTION:
Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when the
combustion flame former is very hot.
9.
CAUTION:
NEVER BURN GARBAGE OR PAPER IN THE UNIT, AND NEVER LEAVE COMBUSTIBLE MATERIAL
AROUND IT.
