ENERGY KINETICS Resolute Boiler Installation & Service Manual Download | Manualshive

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Resolute Gas Heat – Sixth Edition – September, 2018

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Summary of Contents for Resolute Boiler

Page 1: ...T EDITION MANUFACTURED BY ENERGY KINETICS INC 51 Molasses Hill Road Lebanon NJ 08833 908 735 2066 www energykinetics com or www system2000 com INSTALLER PLEASE HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY NEXT TO THE BOILER USING THE SUPPLIED POUCH CONSUMER PLEASE RETAIN THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS FOR FUTURE REFERENCE This product meets the Energy Star gu...

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Page 3: ...may result causing property damage personal injury or loss of life WARNING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other gas appliance Provide unobstructed combustion air openings sized and located per boiler manual and applicable codes WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not u...

Page 4: ...plosion or equipment damage from corrosive flue products 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 burne...

Page 5: ...to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the thermostat s to their lowest setting 3 Turn off all electrical power to the burner boiler 4 This burner is equipped with an ignition device which automatically lights the burner 5 Do not try to light the burner by hand 6 Turn Gas control...

Page 6: ...s 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 boiler should be installed in such a manner that if the...

Page 7: ... Installation Check Off Procedure 9 Gas Burner Mounting 23 Digital Manager Operation 10 Gas Burner Settings 24 Digital Energy Manager Check 10 Gas Piping Systems 25 2 Minute Digital Energy Manager Diagnostic 11 General Assembly 25 Additional Manager Tests 11 Boiler Mounting 26 Digital Manager Sensor Testing 11 Piping 26 Line Voltage Relays 13 Zone Control 26 Surge Suppression 13 Filling with Water...

Page 8: ...eds 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 90 seconds This rapid response means that your rooms can be heated quickly to temperature The System 2000 EK 1 Resolute can heat water up to 100 000 BTU s per hour A modern power burner fires into the cente...

Page 9: ... 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 ...

Page 10: ...or opening and service NOTICE The stand must be level to allow for proper venting of air from the boiler The Resolute is manufactured with the BACK of the boiler higher than the front to assist in air removal The front door of the Resolute boiler swings down and allows full access to the flue passageways for cleaning Do not run any gas piping or water piping in front of the front door that would p...

Page 11: ... piped from the branch of the dilution air tee to the PVC male adapter on the sealed air box frame Piping of outside air directly to the boiler is required to ensure that adequate fresh air is available for combustion and proper dilution of flue gasses It completely isolates the boiler from the home environment as well as greatly reducing operating noise from the boiler A blocked air intake safety...

Page 12: ...ng combustion test equipment and following the instructions given under Start Up Procedure Gas Burner Settings Model Input Btu Hr Chimney Sidewall Vent Burner Orifice Drill size Approximate air band setting UTL air tube insertion length Diffuser Natural Gas LPG 1 Slot 2 Slot inches EK 1 100 000 N Y 1 0 228 16 0 177 35 N A 2 3 8 B Default Factory Setting GAS PIPING SYSTEMS The boiler and its indivi...

Page 13: ...atio blocks BOILER PITCH The Resolute pressure vessel is manufactured level with the base The top cover of the boiler is pitched with the back higher The base has adjustable feet allowing the base to be leveled PIPING All piping and accessory connections should follow good practice using approved joint sealants Figure 2A indicates a general system piping arrangement and options Piping of individua...

Page 14: ...r Vent Relief Valve T P Gauge Flue Box Test Port Combustion Over Fire Test Port Blocked Boiler Safety Switch Blocked Air Intake Safety Switch Combustion Air Inlet System Circ Return Manifold Return Ball Purge Figure 2B indicates a typical flow schematic for boiler water feeding multiple zones Use Energy Kinetics Smart Thread Sealant P N 10 0620 Figure 2B Supply Return Boiler Water Return Supply Bo...

Page 15: ...piping practices EXPANSION TANK SIZING The type and size of expansion tank depends on the total system water volume The EK 1 Resolute contains 2 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 FILLING WITH WATER VENTING and PURGING When piping is completed and all accessories installed the Converter and pipin...

Page 16: ...iler performance Use over 30 anti freeze only if lower temperature freeze protection is mandatory WIRING and CONTROLS The Resolute Heating System is furnished with controls and basic accessories as illustrated and described in this manual Figure 3A shows the Digital Manager Control configuration DANGER All wiring must comply with the NEC and any local codes ELECTRICAL CONNECTION LINE VOLTAGE POWER...

Page 17: ...r 2015 15 LINE VOLTAGE WIRING DIAGRAMS All wiring installations in The United States must comply with the NEC and any local codes Canada must be done in accordance with the Canadian Electric Code Part I Figure 3A Resolute Figure 3B Resolute ...

Page 18: ... more than five heating zones use Energy Kinetics expanded 10 or 15 zone Digital Manager or call Energy Kinetics for alternatives LOW VOLTAGE WIRING DIAGRAM INSTALL DIGITAL MANAGER The Digital Manager is shipped in its own protective shipping box NOTICE Make sure option switches ONE and TWO are set to ON The option switches can be set very easily before the Manager is installed Locate the pre wire...

Page 19: ...as boiler installation supplying properly sized heat zones switch 1 will be ON and switch 2 will be ON all other option switch settings will be OFF Switch 1 is turned on to provide increased condensing protection for gas fired boilers Switch 2 is turned on for inducer operation NOTICE The inducer output will not operate unless Option Switch 2 in the Digital Energy Manager is set to ON When the bur...

Page 20: ...out an expanded manager use a service card for the bottom half and jumper upper zones from T x to Z x 10 ZONE MANAGER 15 ZONE MANAGER Figure 4C FROM TRANSFORMER 24V POWER T3 TEMP SENS RED SENSOR LEADS TEMP SILVER R T4 S BLACK B A2 A1 T1 T2 THW TO A1 Z2 B2 CIRC B1 T MAIN CIRC RELAY T TO BURNER RELAY 24VAC IND Z3 ZONE VALVE 2 ZONE VALVE 3 ZHW Z1 Z4 ZONE VALVE 1 ZONE VALVE 4 TO 24VAC 9 8 7 6 5 ZONE 5...

Page 21: ...lation Factory Setting 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 gas orifice size is used 4 Verify electrode and flame sense rod settings 5 Verify the b...

Page 22: ... system to run about 15 minutes before testing and recording burner operation See Gas Burner Operation The AIR FREE METHOD of MEASURING CO Air free measurement of CO takes account of the amount of excess air by incorporating an adjustment to the as measured ppm value thus simulating air free oxygen free conditions in the combustion gases To do this a reading of oxygen O2 or carbon dioxide CO2 perc...

Page 23: ...aise return water temperature to approximately 130o F on start up after any zone valve opens This prevents condensation from occurring in boiler passages The digital manager provides condensing protection by closing the zone valves when the return drops below 130o F Check option switches on the Digital Manager and verify that switch one 1 is set to ON The following adjustments will help minimize z...

Page 24: ...ch opening E Allow Burner to run 15 minutes before adjusting burner air settings F Verify final draft over fire reading is between 0 05 to 0 25 inches H20 steady state NOTE Air Box Cover And Air Intake Piping MUST BE IN PLACE WHEN TAKING READINGS Min Max Min Max Record LP CO2 9 7 to 10 7 O2 4 5 to 6 0 OR NAT CO2 8 6 to 9 2 O2 4 5 to 5 5 4 RECORD TEMPERATURE and CO from BREECH Min Max Record Draft ...

Page 25: ...r is the operating aquastat and will turn off the burner if return temperature reaches 170 F operating limit With option switch 1 turned on for systems with gas burners the zone outputs will open when the return temperature is above 150 F and close zone outputs when the return temperature drops below 130 F If a new zone calls when the returns are below 150 F the new zone will not open until the te...

Page 26: ...t open with the light on check the zone valve and zone valve wiring For hot water check the hot water relay wiring and the bronze circulator This is the sidewall vent inducer output This light will only operate if option switch 2 is on If the light is ON the inducer should be running If the light is ON and the inducer is not running check the inducer wiring inducer relay and it s wiring This is th...

Page 27: ...ll wiring re connect quick connector and repeat steps 1 2 and 3 until problem is resolved You re done The manager is functioning properly Remember to reset thermostats to original set point to re connect wiring connections connect the quick connector and to turn the Service Switch ON Additional Manager Tests Note If you have a burner lockout troubleshoot as any conventional burner lockout Perform ...

Page 28: ...ver apply a jumper to the Digital Manager output terminals The easiest way to test each zone output is to remove the red sensor lead The Manager should go into Service Board mode Adjust each thermostat to call for heat and the corresponding zone should come on if working properly Rule 1 Never use a jumper to test the function of the Digital Manager Rule 2 Never use a jumper to test the function of...

Page 29: ...en another calls or run system with high limit aquastat set to 165o 180o F and zone will get heat on call IF A PLUG IN RELAY FAILS Replace with spare relay If spare is not available temporarily install a relay with 24VAC coil and 120VAC contacts Contact Energy Kinetics for connection details Digital temperature sensor wiring loose or not functional Check Sensor wiring Check lead for damage Digital...

Page 30: ...e available for nominal rebuild charge and require the return of a Manager Manager must be re buildable Preheat cycle zones will open when boiler return is above 150o F 140o F if option switch 1 is off Return temperature dropped during call Zones close until boiler is up to temperature Check Main Power Check Transformer for 24 volts Check A1 A2 terminals on Manager for 24 volts Check boiler temper...

Page 31: ...sists increase firing rate Step 5 Remove Drawer Assembly Refer to burner manual for detailed instructions on removal and for burners other than EZ Gas 1 Close the front cover and finger tighten a nut on the top center stud to hold the cover closed while working on the burner Do not tighten the rest of the nuts at this time because you will need to open the cover up again to check the drawer assemb...

Page 32: ...essure tap b Close the main manual gas valve and turn ON the combination gas valve c Turn on power to System 2000 boiler and adjust a thermostat to call for heat d Burner motor will start The burner control will run for 30 seconds pre purge and then start the ignitor Approximately one second later the combination gas valve will open The manometer should show almost no pressure because the main man...

Page 33: ...mber outlet is snug against the right side of the boiler The 4 x2 support on the back of the chamber should fit securely into the dimple on the rear insulation board 8 Verify that the chamber is centered and ensure that the burner is centered with the chamber when closing the front door Secure and tighten the four nuts Also check the two 3 8 nuts on the lower hinge bolts and ensure that they are t...

Page 34: ...lve w End Switch 10 0412B Relay Board inside Junction Box 10 0415 High Limit Aquastat 10 0717 Amulet ceramic sleeve 10 0416F Plate Heat Exchanger A C F G S H J R D L M K B P ITEM PART NO DESCRIPTION A 10 0710 Combustion Chamber B 10 1077 Energy Converter Resolute C 10 0712 Front Chamber Liner D 10 0713 Rear Chamber Liner PacMan F 10 0715 Front Insulation Board 2 G 10 0720 Front Cover w Studs H 10 ...

Page 35: ...k up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the prop...

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Page 41: ...0 years there will be a proportionate charge based upon the time the defective assembly was in service The proportionate charge will be equal to the appropriate percentage of the trade list price of such pressure vessel at the time the warranty claim is made as determined in the following YEAR 1 st 11 th 12 th 13 th 14 th 15 th 16 th 17 th Percent of Trade list Price 0 5 10 15 20 25 30 35 YEAR 18 ...

Page 42: ...o make all reasonable efforts to settle any disagreement arising in connection with this claim before resorting to legal remedies in courts If you have any questions about the coverage of this warranty contact Energy Kinetics at the above address Lifetime Warranty Transfer Agreement I We the undersigned as the original purchaser of the 90 Resolute home heating system submitted the Warranty Registr...

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