Oil Heat – Eighteenth Edition – June 2015
13
ZONE CONTROL BY CIRCULATOR:
Zone control by circulators requires a flow valve, circulator and 24-volt relay (Multi
relay kits or Individual relays such as a RIB relay available from Energy Kinetics) for each zone. The main circulator and
boiler bypass line are still used in these cases.
NOTICE:
An additional tee must be installed into the supply
on the inlet
side
of the main circulator. This tee is the supply for circulators with returns for these zones into normal return location.
Call Energy Kinetics and request “Zoning with Circulators” diagram.
ZONE PURGING:
Valves to isolate and purge individual zones should be installed according to good piping practices.
EXPANSION TANK SIZING:
The type and size of expansion tank depends on the total system water volume. The EK1
Frontier contains 2-1/2 gallons of water and the EK2 Frontier contains 4 gallons of water.
NOTICE:
Sizing must consider
cold start
and
hot operation
due to system concepts of energy recovery and rapid heat up.
BOILER BYPASS LINE AND VALVE
NOTICE:
Systems are piped at the factory with the boiler bypass line and bypass ball valve. The bypass
valve must be at least partially open for the boiler to operate properly.
FILLING WITH WATER, VENTING, and PURGING
When piping is completed and all accessories installed the Converter and piping should be filled with water. The
Converter purges itself of air when properly installed.
NOTICE: AIR VENT CAP MUST REMAIN OPEN
.
Vent cap
should be removed and kept in a safe location. Each zone should be purged until a steady stream of water without air
passes out of purge hose. Vent all radiation.
NOTICE:
DO NOT START BURNER UNTIL CONVERTER AND SYSTEM ARE FULL OF WATER
.
Fill to normal
cold system pressure, 10 to 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.
BOILER WATER TREATMENT
Addition of boiler water treatment is recommended to reduce lime buildup inside the boiler. Energy Kinetics
recommends addition of one quart of 8-Way Boiler Treatment per 30 gallons system water. 8-Way Boiler Treatment is
recommended to treat water up to medium hardness. Call Energy Kinetics for more details about boiler water treatment
and about hard water conditions.
ANTI-FREEZE
Only non-toxic antifreeze (such as Propylene Glycol) should be used if adding anti-freeze to a system that produces
domestic hot water. Hard water should not be used in combination with generic antifreeze. Energy Kinetics supplies a
quality inhibited Propylene Glycol anti-freeze with orange dye and an antifoam agent. 8-Way Boiler Treatment can be
added to Energy Kinetics anti-freeze and is recommended in areas of medium water hardness.
NOTICE:
Thoroughly
clean system prior to adding antifreeze.
TSP is recommended for removing flux and other oil based compounds.
Once system has been cleaned and flushed, then add antifreeze to obtain approximately a 30% by volume mixture of
antifreeze in water. Call Energy Kinetics for assistance in calculating how much anti-freeze to add to system.
Bushing
(Installed at Factory)
Full Size Tee (added)
Nipple (added)
Bushing (moved)
1. Remove bushing installed at
factory from boiler supply.
2. Install a nipple (not supplied)
into the existing tee.
3. Install a tee (not supplies) on
to the new nipple.
4. Reinstall the bushing into the
new tee.
SUPPLY
THW
TE
M
P
. S
E
N
S
.
T1
T2
T3
A2
B
A1
S
R
T4
ZHW
Z1
Z2
24VAC
IND
Z3
B1
B2
CIRC
Z4
Ground
Neutral
Line
120 VA
C
Frontier Boiler Supply Piping
Modified piping for Zone
Circulators.
Looking from rear of boiler.
Circulators w/Flow Checks (Supply Side Preferred*)
*Circulator may be Installed Return Side
System Manager
5 Zone Circulator Relay Kit
P/N: 10-0412R-5 Shown
ZONE CIRCULATOR RELAY KITS
TO ACTIVATE EACH CIRCULATOR, USING The
SYSTEM MANAGER'S 24VAC OUTPUTS, USE ONE OF
ENERGY KINETICS MULTIPLE ZONE RELAY KITS.
5 ZONE RELAY KIT P/N: 10-0412R-5
10 ZONE RELAY KIT P/N: 10-0412R-10
15 ZONE RELAY KIT P/N: 10-0412R-15
OR INDIVIDUAL 24V RELAY(S) (EK#10-0412-RIB RIB
RELAY OR EQUIVALENT)
