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

Accel CS

™

Gas Fired Hot Water Boiler

EK1C, EK2C, EK3C

INSTALLATION & SERVICE MANUAL

MANUFACTURED BY:

ENERGY KINETICS, INC.

51 Molasses Hill Road

Lebanon, NJ 08833

(908) 735-2066

www.energykinetics.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.

ASME certified by EKI.

Certificate plate is on the

front center of the vessel.

MH27877

ANSI Z21.13b-2012

Low-Press Boiler

2MF1

This product meets the

Energy Star

guidelines

for efficiency.

National

Board Listed

Accel CS features

Removable panels

for easy internal

access

Содержание EK1C

Страница 1: ...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 AS...

Страница 2: ...RNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life WARNING Do not store or use gasoline or other fla...

Страница 3: ...explosion 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 ex...

Страница 4: ...ve 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 automatically lights t...

Страница 5: ...atically 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...

Страница 6: ...42 Start Up Procedure 18 Venting with PP low profile 43 Air Free Method of Measuring CO 19 Venting with PP snorkel style 44 Gas Valve Setup Procedure 20 Venting with PP snorkel style below grade 46 T...

Страница 7: ...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 ene...

Страница 8: ...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...

Страница 9: ...onic piping venting air intake and wiring Installation Clearances from Boiler Surfaces Inches Clearance to Combustibles Clearance for Service Front of boiler 0 inches 20 inches Left side of boiler bod...

Страница 10: ...2015 9 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 F...

Страница 11: ...n must be made to accommodate this DANGER All flue piping must be tightly sealed as per the pipe manufacturer s recommendation to insure against leakage of noxious fumes deadly carbon monoxide and or...

Страница 12: ...ed to the common venting system one appliance at a time 7 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above...

Страница 13: ...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...

Страница 14: ...S 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 man...

Страница 15: ...m 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...

Страница 16: ...ial Item Material Standards Appliance Adapter 1 Stainless Steel AL29 4C UL 1738 Polypropylene UL 1738 ULC S636 Vent Pipe Fittings 1 Stainless Steel AL29 4C UL 1738 Polypropylene PPs UL 1738 ULC S636 A...

Страница 17: ...LPT0202 N A 14 3 Locking ring typical 10 1010 IANS03 3PPS LB 15 3 Wall mount brackets 10 1009 IASC03 3PPS WSM 16 3 Bird Screen 10 1007 IASPP03 3PPS BG 17 3 PPs elbow 45 black 10 1006 ISELL0345UV 3PPS...

Страница 18: ...te 4 SS Mounting Screws Inserts 1 Tube Silicone Sealant Replaces Combination Vent Hood with Non Combo Vent Only Hood Item Description Energy Kinetics Part No 41 Combo Vent Hood Includes hood trim ring...

Страница 19: ...ermination 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 e...

Страница 20: ...ation 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...

Страница 21: ...ructed 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 ru...

Страница 22: ...de 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 IC...

Страница 23: ...ney 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 Description Centrotherm Part No DuraVent Part...

Страница 24: ...stalled with a pitch of 1 4 minimum per foot of run If a mix of pipe with long sockets and standard sockets is used then all piping in that run must slope 5 8 minimum per foot BEST PRACTICE Slope all...

Страница 25: ...o photo for assembly of trap 3 Remove threaded drain nut and rubber seal from trap 4 Put flexible PVC drain tube through the threaded nut and install rubber seal flange down as shown in Figure 5 Push...

Страница 26: ...SI Z223 1 NFPA 54 or according to state and local codes as applicable Gas piping must be sized to provide the maximum firing rate gas flow for all appliances in the building For natural gas installati...

Страница 27: ...a natural gas installation If in the future the boiler is ever converted from LPG to natural gas then the gas piping will already be properly sized For LPG drawing up to 150 000 Btu Hr 60 Cubic Feet...

Страница 28: ...h it can be larger The gas valve must be disconnected at the flexible pipe flare fitting and plugged at the outgoing side of the flex pipe when checking for leaks in the gas supply piping at pressures...

Страница 29: ...boiler on LPG Verify LPG orifice is installed before operating boiler on LPG Failure to comply could result in personal injury death or substantial property damage NOTICE LPG orifice must be Energy K...

Страница 30: ...alve adjustment procedure given under the section Gas Valve Setup Procedure shown deeper in this manual The burner is set at the factory for an oxygen O2 flue gas reading of 4 0 to 5 0 with a target o...

Страница 31: ...second person lay the boiler down on back of the unit Using hardware provided thread a bolt with a flat washer through one of the four mounting holes in the top of the base and thread it into the cor...

Страница 32: ...he gas line piping All piping and accessory connections should follow good practice using approved joint sealants The following pages include several general system piping arrangements and options Pip...

Страница 33: ...oved and replaced or deep cleaned of scale by flushing with acid or other chemical cleaning Principle of Operation The boiler will remain cold in standby until there is a call for domestic hot water f...

Страница 34: ...er 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 copper and the boiler pump will easily drive the flo...

Страница 35: ...protected 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 protec...

Страница 36: ...t pump wiring isolation relays for thermostats and isolation relays for heat motor zone valves or circulators etc The Condensing Energy Manager is designed to be compatible with power stealing thermos...

Страница 37: ...degrees on the boiler side if the DWH temperature needs adjustment The DHW Setpoint can be changed from the factory default of 182 F by using the Sola display Press the info button and select Quick St...

Страница 38: ...turn on for a few seconds to verify operation of the relays A Thermostat Lights When any thermostat light is on it indicates that a thermostat is calling for heat If all lights are OFF the burner will...

Страница 39: ...ng output for zone 3 Loop circulator injection zone valve and Z3 are all enabled 4 Supply temperature settings controlled by Manager or Sola Manager controls boiler supply temperature using Auto Expre...

Страница 40: ...ly zone heating output for zone 8 Loop circulator injection zone valve and Z8 are all enabled 15 Zone 9 Output Normal or Injection Z9 is the only zone heating output for zone 9 Loop circulator injecti...

Страница 41: ...l may be reset from safety lockout by pushing the reset button on the boiler control or by using the display If normal operation cannot be established after ONE reset then do not make further attempts...

Страница 42: ...res NOTE Customized settings will only store and function if the Condensing Energy Manager is powered up and option switch 4 is turned ON To program maximum boiler water supply temperature PRESS INFO...

Страница 43: ...p nipple After attaching the gauge open the gas service valve and take your reading Refer to the Gas Supply Pressure section for allowable readings If the inlet gas pressure passes this test the unit...

Страница 44: ...Max 4 0 min 4 5 Target Natural Gas 5 0 Max 4 0 min 4 5 Target 5 CO Carbon Monoxide Must be less than 400 ppm air free 6 Stack Temperature 230 o F Max depends on return temp DANGER Verify flame failur...

Страница 45: ...counter clockwise to decrease O2 for EK1Cs and EK2Cs For EK3Cs the throttle valve can be turned continuously 4 full turns of the throttle adjustment screw will leave the throttle back at the starting...

Страница 46: ...K button 5 Keep appliance running until stabilized about 15 to 20 minutes make adjustment when necessary 6 Set appliance to minimum fire by selecting Set Low Rate 7 Remove cap screw with a Torx T 40 s...

Страница 47: ...ecting the two thermostat wires to the B1 and B2 terminals on the right hand quick connect Manually open all zone valves for zones requiring heat Leave the quick connectors disconnected until a new Ma...

Страница 48: ...t connected Minimum flame signal is 1 uA Review sensor temperature readings Press the right arrow again to move to the Digital input output screen Digital IO screen Review digital inputs and outputs B...

Страница 49: ...ally require service attention The history of lockout events is stored in non volatile memory which means that up to fifteen lockout events can be stored and displayed even if the power to the boiler...

Страница 50: ...r level is restored Hold 67 ILK OFF Standby Condensate pump high water switch contacts if connected are open before startup or open mid cycle resulting in immediate burner shutdown High water conditio...

Страница 51: ...one valves will be opened by the Manager zone outputs and heating operation will continue The Sola will not turn on the bronze Smart Pump for domestic hot water production unless the tank thermostat i...

Страница 52: ...3 4 5 6 7 8 9 40 26109 25400 24712 24045 23399 22771 22163 21573 21000 20445 60 15314 14925 14548 14180 13823 13477 13140 12812 12494 12185 70 11884 11592 11308 11032 10763 10502 10248 10000 9760 9526...

Страница 53: ...STEM 2000 H C ZHW Z1 Z2 Z3 Z2 Z3 DOMESTIC HOT WATER FIN TUBE BASEBOARD AIR HANDLER WITH HYDRO AIR EXAMPLES OF ZONES PIPED DIRECTLY FROM THE BOILER 03 sys 05 300 rev03 dwg SYS 05 300 08 21 12 JS Zones...

Страница 54: ...EL CS PIPING EXAMPLES IZ IZ ZHW NOTES 1 UP TO THREE ZONES MAY BE PIPED OFF OF A LOOP PRIMARY SECONDARY 2 THE ZONES ON THE LOOP ARE WIRED AS THE FIRST THREE ZONES 3 OPTION SWITCHES 1 2 3 MUST BE SET TO...

Страница 55: ...sys 05 302 rev03 dwg SYS 05 302 08 21 12 JS Combination of Zones EK1C PIPING EXAMPLES NOTES 1 TWO HEAT ZONES Z1 Z2 PIPED OFF A LOOP PRIMARY SECONDARY 2 TWO HEAT ZONES AND A THIRD DOMESTIC HOT WATER DH...

Страница 56: ...ER BECOMES FIRST ZONE CIRC ADDITIONAL ZONE CIRCS FIELD PIPED IN PARALLEL WITH SYSTEM CIRC NOTES 1 WHEN USING THE SYSTEM CIRCULATOR AS A ZONE CIRCULATOR L1 LINE VOLTAGE TO THE CIRC MUST BE DISCONNECTED...

Страница 57: ...DDITIONAL ZONES ON LOOP 1 Thermostat s calls the ERC 2 ERC opens zone valve s powers the loop circ through a 24VAC relay located in the relay box and supplies a call through the B1 B2 contacts to the...

Страница 58: ...HAT LOOP NOTE FOR NEW INSTALLATIONS REQUIRING MORE THEN FIVE ZONES AN ACCEL CS WITH OPTIONAL 12 ZONE CONDENSING MAMAGER SHOULD BE USED DESCRIPTION OF OPERATION FOR ADDITIONAL ZONES ON EXTENSION HEADER...

Страница 59: ...h Edition January 2015 58 DRAWINGS WIRING LINE VOLTAGE WIRING DIAGRAMS All wiring installations in The United States must comply with the NEC and any local codes Canada must be in accordance with the...

Страница 60: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 59 DRAWINGS WIRING...

Страница 61: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 60 DRAWINGS WIRING...

Страница 62: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 61 DRAWINGS WIRING...

Страница 63: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 62 DRAWINGS WIRING...

Страница 64: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 63 DRAWINGS WIRING...

Страница 65: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 64 DRAWINGS WIRING...

Страница 66: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 65 DRAWINGS WIRING...

Страница 67: ...rner flange to the top of the heat exchanger 23 Lift the burner and flange straight up about 2 inches and rotate the fan toward you Tilt the fan down while picking up on the burner Lift it high enough...

Страница 68: ...Wash work clothes separately from other clothing Rinse washer thoroughly afterwards Avoid smoking eating or drinking while dust is present in the work area To install the replacement 1 Remove the burn...

Страница 69: ...RACKETS 10 1616 ACCEL CS HOT SURFACE IGNITER 10 1617 ACCEL CS FLAME ROD 10 1618 ACCEL CS TOP ROUND REFRACTORY INSULATION 10 1619 ACCEL CS BURNER NOZZLE EK1C 10 1620 EK2C 10 1620 2 EK3C 10 1620 3 ACCEL...

Страница 70: ...O 007 10 0432T TACO 010 10 0438 TACO 0012 10 0449F PUMP CARTRIDGE MAIN CIRC C I TACO 007 10 0432C TACO 010 10 0438C CONBRACO AUTOFEED BACKFLOW PREVENTER COMBO UNIT 10 0518 FLOAT VENT 3 4 NPT 10 0434H...

Страница 71: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 70...

Страница 72: ...Accel CS Boiler Gas Heat Eighth Edition January 2015 71 THIS IS A BLANK PAGE...

Страница 73: ...tor with an alarm and battery back 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 o...

Страница 74: ...tics will repair or replace the pressure vessel at its option After 7 years there will be a proportionate charge based upon the time the defective assembly was in service The proportionate charge will...

Страница 75: ...s for inspection or repair In addition the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with this claim before resorting to legal remedies in courts...

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