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Owner & Installation Manual
MH28303
UL 726;
CAN/CSA-B140.7-05
CAN/CSA-B140.0-03
CAN/CSA-B139-M91
Low-Press Boiler
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.
EK3 Frontier
Oilheat Commercial Boiler
Manufactured By:
Energy Kinetics, Inc.
51 Molasses Hill Road
Lebanon, NJ 08833
(908) 735-2066
www.energykinetics.com
Seventh Edition October 2015
National Board Listed
ASME Certified
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Summary of Contents for ENERGY KINETICS EK3 Frontier
- Page 1 EK3 Frontier Oilheat Commercial Boiler Owner & Installation Manual Manufactured By: Energy Kinetics, Inc. 51 Molasses Hill Road Lebanon, NJ 08833 National Board Listed (908) 735-2066 MH28303 www.energykinetics.com UL 726; CAN/CSA-B140.7-05 CAN/CSA-B140.0-03 CAN/CSA-B139-M91 Low-Press Boiler ASME Certified INSTALLER: HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY NEXT TO THE BOILER USING THE SUPPLIED POUCH.
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Page 2: Please Read This First
Periodically watch the operation of your burner/boiler through an operating cycle to verify normal operation. If you notice unusual conditions or equipment behavior, contact your qualified service technician. Follow the instructions on the next page to shut down the burner/boiler while waiting for the technician. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 3: Table Of Contents
Emergency Shut Down Instructions Start Up Procedure Record of Installation Digital Manager Option Switch Settings System 2000 EK3 Frontier Boiler Security System Interface Wiring Principle of Operation – System 2000 10 & 15 Zone Manager Install Instructions Principle of Operation - Digital Manager... -
Page 4: Owner/User Note
Verify the temperature gauge on the boiler reads no more than 220F at the end of a heating call. If any of the above items seem unusual or out of the ordinary, then immediately call your qualified service agency. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 5: Record Of Installation
NOTES: SCOPE This manual covers the Energy Kinetics System 2000 EK3 Frontier Boiler. The boiler is designed and equipped and has been tested to generate hot water in a low pressure closed loop system. The boiler is a major component of a closed loop system that can be used as a heat source for hydronic heating, hydronic air handler, radiant, domestic hot water, spa, and/or pool heating systems. - Page 6 The boiler is packaged with circulators, piping, controls, wiring, and burner mounted. The boiler will fit through a 34” doorway. The EK3 Frontier comes with the System 2000 Digital Manager control system with built in energy recovery cycle.
- Page 7 Your System 2000 holds a minimal quantity of water so it begins to supply heat in about two minutes. This rapid response means that your rooms can be heated quickly to temperature. The System 2000 EK3 Frontier can provide heated water up to 357,000 BTU’s per hour.
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Page 8: Receiving And Unpacking
Top of boiler body Supply & Return Bottom of boiler legs to floor 1-1/2” Piping L-Vent: from flue pipe Standard Flue: from flue pipe * Minimum recommended clearance to allow door to fully open. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 9: Combustion Air
The System 2000 Boiler must be installed in an area where adequate fresh air is available to support combustion. The EK3 Frontier can be provided with a sealed Air Box that can be piped to air outside the building. Boiler with outside air piping: Piping of outside air directly to the boiler is highly recommended because it completely isolates the boiler from the interior environment, as well as greatly reducing operating noise from the boiler. -
Page 10: Vent Chimney
It is recommended that Frontier systems be equipped with a (optional) fuel filter and a (optional) flexible fuel line. Call Energy Kinetics to obtain optional UL Listed fuel filter and optional UL Listed flexible fuel line. The flexible fuel line allows the door to open without disconnecting the fuel supply. -
Page 11: Oil Burner Mounting
Start by checking nozzle and electrode position per manufacturer’s specifications prior to assembly to unit. The EK3 Frontier boiler uses the Beckett CF500 burner. The CF500 burner will accept the Frontier amulet, EK part number 10-0718. The amulet must be modified by trimming back the inside front edge. The inside front edge has a lip designed to protect the head. -
Page 12: Aquastat Settings
ZONE CONTROL BY VALVE: The SYSTEM 2000 Boiler is designed to provide multi-zone control of the heating system and optionally can supply domestic hot water. 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 maintain minimum temperature during operation. -
Page 13: Boiler Water Treatment
Refill boiler with water and run boiler circulator through the bypass to distribute antifreeze within boiler. Propylene Glycol in water will provide the 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 temperature freeze protection is mandatory. -
Page 14: Wiring And Controls
Emergency Switch turned off. To have the service outlet controlled by the System Emergency Switch, move the service outlet black lead to top lug of system switch. A manual reset low water cut-off is factory installed by Energy Kinetics. EK3 Frontier Boiler Manual... -
Page 15: Prepare For Start Up
The Digital Manager is designed to heat domestic water and up to four (4) heating zones. Use Energy Kinetics supplied zone valves with four wire connections. For more than four heating zones, use Energy Kinetics expanded 10 or 15 zone Digital Manager, or call Energy Kinetics for alternatives. -
Page 16: Digital Manager Option Switch Settings
NOTICE: Some security systems may require an “abort delay” of one second to avoid a transient signal on Manager power-up. If an abort delay is not available, use Energy Kinetics System Monitor (provided separately part # 10-0168). Alarm contacts are “dry” (no voltage is provided). - Page 17 5. Option switches control energy recovery for extra zone outputs (see Digital Manager Option Switch Settings). NOTICE: When operating without an expanded manager, use a service card for the bottom half and jumper upper zones from T to Z (x). EK3 Frontier Boiler Manual Seventh Edition- October 2015...
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Page 18: Digital Manager Operation
On indicates 24 volts from manager CIRC to manager 24VAC. This pulls in the 24-volt coil on the Burner/Main circulator relay, providing 120-volt power to both the bypass circulator and the burner. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 19: Digital Energy Manager Check
INPUT SIDE OUTPUT SIDE relay, the circulator and associated wiring. (THERMOSTATS) Remember: Most no heat problems are not caused by the Manager. The Manager cannot cause a burner lockout. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 20: Additional Manager Tests
1, 2, and 3. If problem persists, call technical support or replace manager. Note malfunction on warranty 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 resolved. -
Page 21: Digital Manager Sensor Testing
Manager. An easy way to check the supply voltage is to plug a voltmeter in at the service outlet located on the system junction box. SURGE SUPPRESSION The Relay Board located in the system junction box is equipped with built-in surge suppression on the 120VAC circuit. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 22: Troubleshooting With The Digital Manager
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 N/O contacts. Contact Energy Kinetics for connection details. EK3 Frontier Boiler Manual... -
Page 23: Diagnostics With The Digital Manager
Service Board Mode- With power off, remove the RED lead of the temperature sensor to run in this mode. A Service Board for temporary operation without Manager is available. This is interchangeable with the Classic and Digital Managers. Rebuilt Managers are available and require the return of a rebuildable Manager. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 24: Annual Maintenance
22. CAUTION: Always keep the fuel supply valve shut off if the burner is shut down for an extended period of time. 23. CAUTION: Do not start the burner unless the front door is closed and the nuts have been properly tightened. EK3 Frontier Boiler Manual Seventh Edition- October 2015... -
Page 25: Amulet Replacement
The flame former is of high quality refractory ceramic fiber material and will normally not need to be replaced. A replacement, if required, is available from Energy Kinetics. Ensure that the burner head is protected by the amulet, wet pack or a similar material. - Page 26 Direct, Break on rise Automatic Reset PRIMARY CONTROL Set @ 215/205°F TACO TACO FOR BURNER 0012 IFC HIGH LIMIT AQUASTAT (HW L4006E 1117) Direct, Break on rise CAD CELL Manual Reset Set @ 220°F EK3 Frontier Boiler Manual Seventh Edition- October 2015...
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- Page 39 7 T EMP. S ENS. EK3 Frontier Boiler Manual Seventh Edition- October 2015...
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Page 43: Common Flue Pipe Sizing
EK-3 12" EK-3 Notes: EK-3 1. Boiler Flue Size: Ø7” 2. Pipe each boiler’s air intake separately. 12" EK-3 3. Use schedule 40 PVC for intake piping. Six Boiler Flue Pipe Sizing EK3 Frontier Boiler Manual Seventh Edition- October 2015... - Page 44 ENERGY KINETICS SYSTEM 2000 SPECIFICATIONS EK-3 FRONTIER BOILER 40" 15" " 4X 1/2"X 7/8" Slot 12" Notes: 1. With Burner, Air 50" Frame and High Limit See Note 1 " Aquastat removed, boiler 25" depth is 32". " 13" "...
- Page 45 2'-6" 6'-2" 2'-6" 2'-6" 2'-8" 11'-2" 6'-1" 5'-9" 1'-10 " 1'-4 " EK3 Frontier Boiler Manual Seventh Edition- October 2015...
- Page 46 Energy Kinetics, the purchaser shall pay a proportionate charge for the time the defective pressure vessel has been in service based upon a percentage of the list price of such vessel at the time Energy Kinetics is notified of the defect as follows: 2nd year - 30%, 3rd year - 40%, 4th year - 50%, and 5th year - 60%.
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