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EK3 Frontier

Oilheat Commercial Boiler

Owner & Installation Manual

Manufactured By:

Energy Kinetics, Inc.

51 Molasses Hill Road

Lebanon, NJ 08833

(908) 735-2066

www.energykinetics.com

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.

Seventh Edition October 2015

ASME Certified

National Board Listed

MH28303

UL 726;

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

Low-Press Boiler

Содержание EK3 Frontier

Страница 1: ...ics com 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...

Страница 2: ...rosive 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 c...

Страница 3: ...Voltage Relays 9 L Vent Chimney 20 Line Voltage 9 Side Wall Power Venting 20 Surge Suppression 9 Fuel Systems 21 Trouble Shooting with the Digital Manager 9 Oil Burner Settings 21 Operation without th...

Страница 4: ...o 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 boi...

Страница 5: ...ckflow 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 MANU...

Страница 6: ...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...

Страница 7: ...r 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 Ma...

Страница 8: ...ron 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...

Страница 9: ...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 Car...

Страница 10: ...lexible 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 th...

Страница 11: ...ld be taken through 1 4 test port in front jacket opening just to right of burner Sample tube must extend at least eight 8 inches into front cover to obtain accurate readings Smoke test and stack temp...

Страница 12: ...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...

Страница 13: ...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 temperatur...

Страница 14: ...y 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...

Страница 15: ...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 t...

Страница 16: ...to under radiated heating zones or during very cold weather Switch 10 is usually off but when turned on the Manager will close heat zones 1 through 4 during a hot water call for up to 25 minutes SECUR...

Страница 17: ...ded 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 FROM TRANSFORMER 24V POWER T3 TEMP SENS RED SENSOR LEADS TEMP SILVER R T4 S BL...

Страница 18: ...Indicates boiler RETURN temperature not supply temperature The Manager is the operating aquastat and will turn off the burner if return temperature reaches 170 F operating limit The zone outputs will...

Страница 19: ...e output lights If the light is ON the zone valve will be open For hot water the bronze circulator will be running If the zone valve is not open with the light on check the zone valve and it s wiring...

Страница 20: ...anty tag and return manager to Energy Kinetics If problem goes away there is a problem with the output wiring check all wiring re connect quick connector and repeat steps 1 2 and 3 until problem is re...

Страница 21: ...ead with the sensor connected to the Manager you will burn out the sensor the Manager or both in less than a second To test the function of each zone output never apply a jumper to the Digital Manager...

Страница 22: ...manager If system is active zone will receive heat when 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 sp...

Страница 23: ...geable with the Classic and Digital Managers Rebuilt Managers are available and require the return of a rebuildable Manager Check Main Power Check Transformer for 24 volts Check A1 A2 terminals on Man...

Страница 24: ...into back of bottom passage and then brush outer passages from top of unit to bottom on left and right in each circuit Vacuum loose scale and soot at the bottom of the outer pass and in the flue box...

Страница 25: ...d loose fitting clothing gloves and eye protection Use a properly fitted NIOSH certified respirator for dusty activities and where exposure levels are unknown Use hand tools whenever possible if cutti...

Страница 26: ...TOR WHITE 120 MONITOR 100 HOT WATER SENSOR LEADS TEMP TRANSFORMER FROM 24V POWER RD SLVR BLK 24 VAC CONNECTION ONLY READ INSTRUCTIONS BEFORE MAKING ANY CONNECTIONS CAUTION 4 3 2 1 MAIN CIRC RELAY TO B...

Страница 27: ...Feed Return Primary Loop 2 Min Supply High Limit Aquastat Open on Rise Auto Reset Notes 1 Set aquastats on boiler per boiler manual 2 Keep injection piping as short as practical under 10 feet if possi...

Страница 28: ...ELL A A F F VIOLET ORANGE BLUE BLACK WHITE IGNITER VIOLET WHITE BLACK WHITE WHITE BLACK PSC BURNER MOTOR WHITE TACO 007 HIGH LIMIT AQUASTAT WR 11D18 Direct Break on rise Automatic Reset Set 205 195 F...

Страница 29: ...06E 1117 Direct Break on rise Manual Reset Set 210 F RED TACO 0012 Injection Circulator TACO 006 RED Smart Pump OUTLET SCREW GROUND SYSTEM SWITCH LOW WATER CUT OFF MANUAL RESET JUMPER REMOVED Alarm TA...

Страница 30: ...ECTION ONLY CAUTION BLK 4 1 2 3 150 130 140 100 MONITOR 120 CIRCULATOR 190 POWER 160 170 2 3 4 5 4 ONLY BURNER CHIMNEYLESS INDUCER 1 2 3 DIGITAL MANAGER HOT WATER 1 1 4 ZONE VALVE FOR INJECTION W R 13...

Страница 31: ...rgy Kinetics Part Numbers 1 10 0412 24V Control Relay HW R8225B 2 10 0151 E 3 4 Zone Valve w End Switches 3 10 0152 Transformer 24V 50VA WIRING CONFIGURATIONS ZONING with ZONE VALVES Preferred Method...

Страница 32: ...G with CIRCULATORS Alternate Method 24V POWER FROM TRANSFORMER SENSOR SLVR TEMP BLK RD LEADS To System Junction Box See Line Voltage Wiring BURNER CIRCULATOR 150 READ INSTRUCTIONS BEFORE MAKING ANY CO...

Страница 33: ...24V RELAY One per HW Zone WIRING CONFIGURATIONS A NON PRIORITY ZONE S for DOMESTIC HOT WATER Note set purge time to 5 minutes for zone s Z1 Z4 Not ZHW used TO SYSTEM JUNCTION BOX See Line Voltage Wiri...

Страница 34: ...10 0205 Smart Pump Assy 006B IFC with Harness WIRING CONFIGURATION PRIORITY ZONE for DOMESTIC HOT WATER Smart Pump powered by HW Circ Relay in System Junction Box ZONE VALVE w End Switches 2 2 24V RE...

Страница 35: ...ator Injection Header Circulator Taco 0012 See Note 6 Flow Check Bypass Circulator Taco 007 LWCO Boiler Feed Sensor Well for Digital Manager ZXX Notes 1 Use EK 2 size supply and return headers 1 1 4 d...

Страница 36: ...itches 3 10 0152 Transformer 24V 50VA 4 10 0156 1 1 4 Zone Valve w End Switch D C To System Junction Box See Line Voltage Wiring 170 160 POWER 190 120 MONITOR 100 140 130 150 24V RELAY SUPPLY 1 CIRC 2...

Страница 37: ...O 006 RED RED TACO 007 TACO 0012 OUTLET SCREW GROUND SYSTEM SWITCH HW CIRC IND BURNER MAIN CIRC 120V 24 VAC PRIMARY CONTROL FOR BURNER TT Alarm CAD CELL F F A A T T WHITE WHITE WHITE A 1 P1 P2 2 BLACK...

Страница 38: ...t Break on rise Manual Reset Set 210 F RED TACO 0012 Injection Circulator TACO 006 RED Smart Pump OUTLET SCREW GROUND SYSTEM SWITCH LOW WATER CUT OFF MANUAL RESET JUMPER REMOVED Alarm TACO 007 ByPass...

Страница 39: ...e piped for make up water 6 A multi boiler control Tekmar is suggested 7 A short length of pipe between the supply return tees reduces head loss and pressure difference between them The center to cent...

Страница 40: ...for your application S1 S2 4 Relay N Power L 5A Alarm C A 5A Relay 1 1 5A Relay 2 2 5A Relay 3 3 5A 4 5A ENERGY MANAGER SYSTEM 2000 Plate Heat Exchanger Location Pro s Con s Primary Loop It allows the...

Страница 41: ...emp Sensor Tekmar 070 T2 4 Thermostats U1 Optional Timer Tekmar 031 ZC1 ZC3 Zone Circs Switching Relays Erie SR 100 or Equivalent Available Drawings for Domestic Hot Water Storage Tank Piping Descript...

Страница 42: ...Plate Heat Exchangers PHE taking advantage of the combined boiler output Allows the use of FMC controlled boilers and still have the capability of Domestic Hot Water Priority Takes advantage of the s...

Страница 43: ...K 3 EK 3 EK 3 EK 3 EK 3 See Note 1 12 Dia or 12 x16 12 12 16 Dia or 16 x16 See Note 1 18 Dia or 16 x18 See Note 1 12 12 16 14 Dia or 12 x16 Three Boiler Flue Pipe Sizing EK 3 EK 3 EK 3 See Note 1 EK 3...

Страница 44: ...51 8 45 7 Flue 331 8 12 25 13 291 4 161 2 4X 1 2 X 7 8 Slot Door Open Air Box On 41 4 161 2 41 4 193 4 50 See Note 1 Notes 1 With Burner Air Frame and High Limit Aquastat removed boiler depth is 32 4...

Страница 45: ...S 04 020 09 27 05 JS 4 EK3 Boilers Foot Print Drawing Phantom Lines indicate 2 6 30 Clearance from Boiler 2 6 11 1 8 7 1 2 11 11 2 6 1 2 6 6 2 2 6 7 2 2 6 Notes Foot print shown provides clearance req...

Страница 46: ...over any labor for removal or reinstallation of the alleged defective part transportation to Energy Kinetics if necessary and other materials necessary to perform the exchange This warranty does not c...

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