ENERGY KINETICS EK2C Installation & Service Manual
  1. Manuals
  2. Brands
  3. ENERGY KINETICS Manuals
  4. Boiler
  5. EK2C
  6. Installation & service manual

ENERGY KINETICS EK2C Installation & Service Manual

Gas fired hot water boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Gas Fired Hot Water Boiler
MH27877
ANSI Z21.13b-2012
Low-Press Boiler
2MF1
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.
Accel CS
EK1C, EK2C, EK3C
INSTALLATION & SERVICE MANUAL
MANUFACTURED BY:
ENERGY KINETICS, INC.
51 Molasses Hill Road
Lebanon, NJ 08833
(908) 735-2066
www.energykinetics.com
This product meets the
®
Energy Star
guidelines
for efficiency.
Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015
™
Accel CS features
Removable panels
for easy internal
access
National
Board Listed
ASME certified by EKI.
Certificate plate is on the
front center of the vessel.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EK2C and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ENERGY KINETICS EK2C

Summary of Contents for ENERGY KINETICS EK2C

  • Page 1 Accel CS ™ Gas Fired Hot Water Boiler EK1C, EK2C, EK3C Accel CS features Removable panels for easy internal access INSTALLATION & SERVICE MANUAL MANUFACTURED BY: ENERGY KINETICS, INC. 51 Molasses Hill Road Lebanon, NJ 08833 (908) 735-2066 www.energykinetics.com National...

  • Page 2: Please Read This First

    BEST PRACTICE: Notifies you of recommendations made by Energy Kinetics for the installers, which will help ensure optimum operation and longevity of the equipment. If the information in this manual is not followed exactly, a fire or explosion may WARNING: result, causing property damage, personal injury or loss of life.
  • Page 3 WARNING: Have the burner/boiler started up and serviced at least once annually by a qualified service technician. Professional care is necessary to properly service your equipment and verify it is operating reliably. Failure to properly maintain the equipment could result in severe personal injury, death or substantial property damage.

  • Page 4: For Your Safety Read Before Operating

    FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion WARNING: may result causing property damage, personal injury or loss of life. A. This burner does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

  • Page 5: Record Of Installation

    RECORD OF INSTALLATION INSTALLER NAME: INSTALLER ADDRESS: INSTALLER CITY, STATE: DATE INSTALLED: NOTES: All installations must be made in accordance with all State and Local Codes, which may differ from this manual and in accordance with the following Codes, as applicable: National Fuel Gas Code, ANSI Z223.1/NFPA 54: Installation Codes, CAN/CGA B149 National Electrical Code, ANSI/NFPA 70...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Topic Page Topic Please Read This First Boiler Water Treatment Record of Installation Winterizing Accel CS Boiler Wiring and Controls Accel CS Boiler Line Voltage – Electrical Connections Principle of Operation Condensing Energy Manager Surge Suppression Principle of Operation Receiving and Unpacking Hydronic Circulators...

  • Page 7: Accel Cs Boiler

    Manager). For a typical multi-boiler light commercial situation, the installation may include a multi-boiler control along with the appropriate primary/secondary piping. To support both types of installations, Energy Kinetics provides suggested piping and wiring schematic drawings, which will be provided upon request. For any questions about installations not already explained within this manual, consult Energy Kinetics Tech Support at 800-323-2066.

  • Page 8: Condensing Energy Manager Principle Of Operation

    Refuse any individual shipping cartons or packages that are damaged or appear to be damaged. Contact Energy Kinetics and freight carrier. After unpacking, check each item against the packing list. Inspect it thoroughly for loose parts, instruction sheets and packing lists.

  • Page 9: Clearance To Combustibles And Service

    Do not install on carpeting. Place the unit as near to the vent as possible allowing clearance for cleaning and service. If not using an Energy Kinetics supplied stand or wall mounting brackets, provide a solid, level, smooth foundation with clearance for opening covers for service and enough space under the unit for the condensate trap.
  • Page 10 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” "HT" "H" "HB"...

  • Page 11: Venting And Combustion Air

    The Accel CS boiler can be vented using the Energy Kinetics stainless steel sidewall vent system using Z-Vent III stainless steel piping for the vent connections. The Energy Kinetics stainless steel sidewall vent system has been used for many years to vent the System 2000 family of boilers and has a proven track record of operation.
  • Page 12 hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. 5.

  • Page 13: Length Of Run, Intake And Vent

    1400 6100 1300 5900 75' 1400 6400 1300 6100 100' 1500 6200 1400 6000 100' 1400 6400 1300 6100 EK2C Low High High EK2C High High 1200 5100 1000 4100 15' 1300 5600 1100 4300 1200 5300 1000 4200 25'...

  • Page 14: Sidewall Vent Limitations

    Vent Pipe Joint Connections WARNING: Joint connections not meeting full insertion can leak, causing severe personal injury, death or substantial property damage. DANGER: Fasteners (screws, rivets, etc.) must not penetrate the components of the vent system either when joining pipes and fittings or using support straps. Drilling holes in the components is not permitted. Exception: For exterior components only, one stainless steel screw per joint may be used to fix direction of vent.

  • Page 15: Vent Outlet Location

    Regardless of input, the flue gas outlet terminal and air intake shall be located at least 1 ft. above grade or at least 1 ft. above expected snow level, whichever is higher. Although not required, Energy Kinetics recommends at least 2 ft.

  • Page 16: Venting Materials And Venting Options

    Vertically vented systems should have outside air connected to the boiler. The Accel CS boilers have a flue collar made of Z-Vent III AL29-4C stainless steel - 3” on the EK1C / 4” on the EK2C &...
  • Page 17 Energy Kinetics stocks and sells Centrotherm PPs Vent Items DuraVent Part Item Description Energy Kinetics Centrotherm Part No. Part No. 3” Appliance adapter, stainless to PPs 10-1000 ISSA0303 3” Appliance adapter, stainless to PPs 10-0194 2” Intake adapter, PVC to PPs...
  • Page 18 4” PPs pipe, 2 ft long, black 10-1040 ISVL042UV 4” PPs pipe, 3 ft long, gray 10-1038 ISVL043 VENTING WITH ENERGY KINETICS SIDEWALL VENT KIT 3” Stainless Steel Vent Kit and Optional Parts Item Energy Description Kinetics Part Combo Vent Hood (Includes: hood, trim ring, silicone sealant, mtg hardware, elbow & shield) 10-0332-1* Non-Combo Hood (Includes: hood, trim ring, silicone sealant, mtg hardware, elbow &...
  • Page 19 SIDEWALL VENTING WITH POLYPROPYLENE – Low Profile 2” or 3” Low Profile Wall Mount Termination. Part No: Description: 10-0584 Low Profile Vent Kit 2in PPs 10-0585 Low Profile Vent Kit 3in PPs Low Profile Parallel Wall Termination incorporates air intake and exhaust into a single aesthetically pleasing termination.
  • Page 20 SIDEWALL VENTING WITH POLYPROPYLENE – Snorkel style 2” or 3” non-concentric side wall vent termination, snorkel style. Part No: Description: 10-0581 Sidewall Vent Kit 2in PPs 10-0580 Sidewall Vent Kit 3in PPs 10-0587 Sidewall Vent Kit 4in PPs VENTING GUIDELINES WHEN USING TWO PIPES (SNORKEL STYLE) 1.
  • Page 21 BELOW GRADE SIDEWALL VENTING WITH POLYPROPYLENE – Snorkel style 2” or 3” non-concentric side wall vent termination, snorkel style. VENTING GUIDELINES WHEN USING TWO PIPES (SNORKEL STYLE) 1. Use a properly installed window well (no window present) or equivalently constructed well with adequate drainage 2.
  • Page 22 SIDEWALL VENTING WITH POLYPROPYLENE - Concentric Concentric through the wall termination, with 3” piping 30 31 Note: For Centrotherm: Made 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 ICTC Adapter.
  • Page 23 VENTING VERTICALLY WITH POLYPROPYLENE Part No: Description: 10-0582 Chimney Vent Kit 2in PPs 10-0583 Chimney Vent Kit 3in PPs 10-0586 Chimney Vent Kit 4in PPs The Accel CS boiler may be installed with polypropylene vent materials vertically through the roof of a building. Combustion air may be piped alongside the vertical vent using a dedicated polypropylene liner or PVC pipe.

  • Page 24: Hanging Of Vent Piping

    HANGING OF VENT PIPING Vent Piping Slope Stainless Steel: The vent pipe manufacturer states the flue piping must slope 1/4” minimum per foot of run so that the condensed water will flow back into the boiler and go through the neutralizer before being discharged. Polypropylene: The vent pipe manufacturer states the flue piping must slope 5/8”* minimum per foot of run so that the condensed water will flow back into the boiler and go through the neutralizer before being discharged.

  • Page 25: Combustion Air

    COMBUSTION AIR The ACCEL CS is provided with a sealed outer jacket that when piped to the air outside the building provides a clean fresh air supply for combustion. Piping of outside air directly to the boiler isolates the boiler from the home environment and any of the contaminants often found in indoor air.

  • Page 26: Gas Piping

    CAUTION: The condensate drain line must remain unobstructed and allow free flow of the condensate. The condensate must not be subjected to conditions where freezing could occur and obstruct flow. Flow obstruction can result in leakage causing possible water damage to the boiler and surrounding area. GAS PIPING The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of the gas supply piping system at test pressures in excess of 1/2 psi (3.5 kPa, 14 in wc).

  • Page 27: Gas Pipe Sizing

    GAS PIPE SIZING Size the gas piping from meter outlet to boiler in accordance with the below table. Use total output of all connected appliances. Divide total input in BTU/hour by 1000 to obtain the approximate number of cubic feet per hour of natural gas. Pipe lengths given in table are equivalent length of straight pipe.

  • Page 28: Gas Supply Pressure

    GAS SUPPLY PRESSURE Pressure required at gas valve inlet pressure port: Natural Gas: • Minimum operating inlet gas pressure 3.5” w.c. • Maximum operating inlet gas pressure 10.5” w.c. LPG: • Minimum operating inlet gas pressure 8.0” w.c. • Maximum operating inlet gas pressure 13.0”...

  • Page 29: Lpg Orifice

    LPG. Failure to comply could result in personal injury, death or substantial property damage. NOTICE: LPG orifice must be Energy Kinetics part number 10-1614 for EK1C, 10-1614-2 for EK2C or 10-1612-3 for EK3C. EK1C and EK2C gas valve assembly shown Accel CS Boiler - Gas Heat - Eighth Edition –...

  • Page 30: Converting From One Gas To Another

    The Accel CS boiler’s gas burner is factory set for using either natural gas or LPG. A conversion kit with detailed instructions can be purchased from Energy Kinetics if necessary to convert from one gas to another. The kit includes the orifice required to convert from natural gas to LPG, plus the proper labels and tags to show that the gas valve has been converted from natural gas to LPG or to show that the gas valve has been converted from LPG to natural gas.

  • Page 31: General Assembly

    The Accel CS boiler can be mounted either free standing on a base or EK1C’s may be mounted on a wall (wall mounting for EK2C and EK3C is not recommended). Mounting the boiler on a base and standing the boiler near a wall will make for a clean looking installation, because wiring and piping running behind the boiler will be hidden from view.

  • Page 32: Hydronic Piping

    ZONE CONTROL BY ZONE CIRCULATOR: Zone control by circulators requires a flow valve, circulator and 24-volt relay (fan type such as Honeywell R8225B or RIB relay or Energy Kinetics relay box kit) for each zone. The main circulator and domestic heat exchanger are still used in these cases. Refer to Zone Piping diagrams in the Drawings section of the manual.

  • Page 33: Domestic Hot Water

    DOMESTIC HOT WATER The Accel CS boiler uses a Plate Heat Exchanger (PHE) to make domestic hot water that is stored in an insulated tank. The PHE separates the boiler water from the domestic water. The boiler circulator pumps hot boiler water through the boiler side of the PHE, while the domestic circulator (the Smart Pump) circulates cold domestic water from the tank through the domestic side of the PHE.

  • Page 34: Filling With Water, Venting And Purging

    Domestic Hot Water Production Rate at 140°F (50°F Source) EK1C with 40 Gallon Buffer Tank EK2C with 40 Gallon Buffer Tank EK3C with 80 Gallon Buffer Tank First Hour...
  • Page 35 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 antifreeze and is recommended in areas of hard water.
  • Page 36 The Condensing Energy Manager is designed to operate up to five zones. A typical installation will have one hot water zone and up to four heating zones. Use Energy Kinetics supplied full port zone valves with two wire connections or other full port two wire zone valves.
  • Page 37 Domestic Hot Water Smart Pump Operation When using an Energy Kinetics DHW storage tank and plate heat exchanger, operation of the DHW Smart Pump relay output is controlled by the Condensing Energy Manager. Upon a thermostat call from the storage tank, the Manager will turn on the zone valve output and after 2 seconds will send a heat demand to the Sola.
  • Page 38 send a demand for heat to the Sola control. The Sola control will start the burner and turn on the main boiler circulator relay. The two second delay will give the zone valve time to open slightly before the main boiler circulator is turned on. Burner Short Cycle Protection: There is a burner short cycle delay of 30 seconds for domestic hot water and 2 minutes for heat zones.
  • Page 39 When lit, this light indicates 24 volts between the terminals 24VAC and IZ. This provides power to a 24-volt injection zone valve if the system is so equipped. When this light is on, the Condensing Energy Manager will tell the Sola control to turn on the Loop Circulator relay output.
  • Page 40 Option Switch Settings, 12 Zone Expanded Manager Option Description Function ( OFF is the factory default for all switches) Switch OFF = Slide to Front ON = Slide to Rear Zone 5 Output. Z5 is the only zone heating Loop circulator, injection zone valve Normal or Injection.
  • Page 41 Auto Reset Stack Limit Built into the Sola control Domestic Hot Water Tank Thermostat Hot (about 120 Energy Kinetics PN: 10-0414 Storage Tank (On Tank) (To suit individual installation) AUTO RESET HIGH LIMIT The Sola is a 24VAC boiler operating control and will modulate the burner fan speed down in 20% increments if the boiler stack temperature exceeds 220°F and will turn off the burner if the stack temperature exceeds 230°F.
  • Page 42 PRESS: (down arrow) until Max outdoor temp Quick Start is highlighted. BACK PRESS: OK CH setpoint 138°F DHW setpoint 180°F PRESS: (up arrow) / (down arrow) to add one or Outdoor reset Enable Low water temp 118°F INFO to subtract one from the setting. When finished Max outdoor temp 68°F Min outdoor temp...

  • Page 43: Inside

    Outdoor Temperature Sensor Selection The Sola boiler control must have an outdoor temperature sensor connected in order for the outdoor temperature reset feature to work. The Accel CS boiler comes standard with a wired outdoor temperature sensor and is configured at the factory to work with the wired outdoor temperature sensor.

  • Page 44: Cover

    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) percentage is taken from the combustion gases along with the as-measured CO reading.

  • Page 45: Gas Valve Setup Procedure

    2. Set appliance ‘max modulation rate’ to maximum desired fan speed: INFO > Advanced Setup > Modulation Config. Use left and right EK1C & EK2C Gas Valve arrows only. To delete prior setting, arrow to DEL and press OK until cleared, then use arrows to enter the max fan speed.
  • Page 46 Make sure to tighten inlet pressure tap, offset cap screw and combustion test port. 11. The target O2 reading is 4.5%. The valve used in the EK1C and EK2C boilers is capable of holding 4.5% O2 plus or minus 0.2% O2.

  • Page 47: Troubleshooting With The Energy Manager

    TROUBLESHOOTING WITH THE ENERGY MANAGER  Does the Sola Control need to be reset? YES: Troubleshoot as standard burner lockout. Did homeowner reset control? YES: Troubleshoot as standard burner lockout. NO: Reset Manager. Run through standard heat cycle.  Does boiler supply and return heat up properly? Check boiler circulator.

  • Page 48: Cover

    DIAGNOSTICS USING THE ACCEL CS DISPLAY The Home screen shows the current state of the boiler control. At any time, you can press the System setpoint 160°F Operating temp 158°F Home button and the display will return to the Home screen. The first five rows show the current Outlet temp 158°F temperatures of the system.

  • Page 49: Lockouts, Holds And Alerts

    Lockout History Lockout History • 109 Ignition Failed Records last 15 Lockouts 0 None • 0 None Using the arrow/cursor buttons – navigate to the Lockout record of choice and push the 0 None OK button to view Lockout details stored at the time the Lockout occurred. 0 None 0 None •...
  • Page 50 FAQ: “I’m getting a code that isn’t listed in this manual. What should I do?” There are several hundred different lockout, hold, and alert codes programmed into the Sola boiler control. If a code comes up that isn’t listed and discussed in this manual, it will be a rare event, so be sure to write down or take a picture of the code.

  • Page 51: Flashing Light On Manager

    fault will go into a hold condition and will shut off the burner until the sensor or wiring is repaired. Hold 95 Standby The stack sensor is used as a stack high limit safety. If the sensor wiring is broken, the Stack sensor fault stack temperature reading on the display will read OPEN, the control will go into a hold condition and will shut off the burner until the sensor or wiring is repaired.

  • Page 52: Temperature Sensors

    TEMPERATURE SENSORS The Sola control uses thermistors to measure temperatures. The Sola will measure and display: • boiler supply temperature (Outlet temp) • boiler return temperature (Inlet temp) • flue gas temperature (Stack temp) • outdoor temperature (Outdoor temp) The user interface display uses the words shown above in parenthesis as the label for each of the four temperatures. Common industry terms are used throughout this manual, such as boiler supply temperature, and the user interface display uses its own set of terms.

  • Page 53: Drawings - Piping

    DRAWINGS - PIPING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 54 DRAWINGS - PIPING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 55 DRAWINGS - PIPING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 56 DRAWINGS - PIPING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 57 DRAWINGS - PIPING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 58 DRAWINGS - PIPING Z5 (ERC Z1) Z6 (ERC Z2) Z7 (ERC Z3) Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...

  • Page 59: Drawings - Wiring

    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 Canadian Electric Code, Part I. Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 60 DRAWINGS - WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 61 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 62 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 63 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 64 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 65 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 66 DRAWINGS – WIRING Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...

  • Page 67: Annual Tune Up & Inspection

    ANNUAL TUNE UP & INSPECTION DANGER: The boiler and burner may be hot. Allow boiler enough time to cool down so that the burner can be handled safely before proceeding. Materials required: • New Scotch Brite pad, • A Citrus type cleaner in a spray bottle, •...

  • Page 68: Top Insulation Replacement

    The insulation board in the top of the combustion chamber is of high quality material and will normally not need to be replaced. A replacement board, if required, is available from Energy Kinetics. DANGER: Before starting make sure gas and electric are turned off external to boiler.

  • Page 69: Replacement Parts

    REPLACEMENT PARTS Obtain replacement parts from your local Energy Kinetics dealer. Contact Energy Kinetics at 800-323-2066 or www.energykinetics.com for help locating your nearest authorized dealer. Accel CS boiler Spare Parts List Burner (See Figure): Description Part No. #15, 1C: 10-0436C PHE NO UNIONS, REPLACEMENT FOR ACCEL CS #19, 2C &...
  • Page 70 ACCEL CS WIRELESS OUTDOOR RESET KIT 10-1636 TACO 007: 10-0432T TACO PUMP IRON TACO 010: 10-0438 TACO 0012: 10-0449F TACO 007: 10-0432C PUMP CARTRIDGE (MAIN CIRC. - C.I.) TACO 010: 10-0438C CONBRACO AUTOFEED/BACKFLOW PREVENTER-COMBO UNIT 10-0518 FLOAT VENT, 3/4~ NPT 10-0434H BOILER PRESSURE RELIEF VALVE, 30 PSI 10-0516...
  • Page 71 Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...
  • Page 72 THIS IS A BLANK PAGE Accel CS Boiler - Gas Heat - Eighth Edition – January, 2015...

  • Page 73: Commonwealth Of Massachusetts

    Commonwealth of Massachusetts ♦ Approval No. C1-0713-539 (EK1C), C1-0415-454 (EK2C, EK3C) ♦ This Energy Kinetics gas fired hot water boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters. ♦ When an Energy Kinetics gas fired hot water boiler is installed in the Commonwealth of Massachusetts, the following requirements must be met.

  • Page 74: Limited Lifetime Warranty

    In the event that such pressure vessel is found to be defective in material or workmanship during the first seven years, Energy Kinetics 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.

  • Page 75: Warranty Transfer Agreement

    The End User is required to make available for inspection by Energy Kinetics or its representative, the parts claimed to be defective and, if requested by Energy Kinetics, to ship said parts prepaid to Energy Kinetics at the above address 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.

This manual is also suitable for:

Ek3cEk1c

Table of Contents

Save PDF