Aquastat Settings; General Assembly; Boiler Mounting; Zone Control - ENERGY KINETICS EK3 Frontier Owners & Installation Manual

AQUASTAT SETTINGS

With Digital Manager:

11D18 automatic reset high limit, set at 205

L4006E manual reset high limit, set at 210

Or, Carlin EZ-Temp manual reset high limit, set at 210
DANGER:
Double check that the manual reset high limit aquastat is set to 210

GENERAL ASSEMBLY

Assembly of various packaged units is illustrated throughout this manual. The use of non-Energy Kinetics supplied
pump, controls and accessories should follow good practices. The diagrams and locations presented in the manual are
recommended.

BOILER MOUNTING

PIPING SO THE DOOR CAN OPEN: To avoid conflicts with the door opening, piping should be in accordance with
the boiler specifications drawing and the piping schematics in this manual. The door opens to the right hand side of the
boiler. The burner and air box also need clearance when the door opens. Do not locate any piping in front of the boiler
unless clearance from the door is verified. This also applies to the oil line piping and the combustion air piping. NOTICE:
Air inlet pipe must be disconnected to allow door to swing open.
BOILER PITCH: The Frontier pressure vessel is manufactured with the rear higher to allow for proper air removal. This
pitch is carefully set at the factory when the boiler is built. Be sure to level the stand prior to mounting the boiler on a
stand. When the stand is level, the pitch is correct and the back of the boiler will be higher than the front.

ZONE CONTROL

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.
ZONE CONTROL BY CIRCULATOR: Zone control by circulators requires a flow valve, circulator and 24-volt relay (fan
type such as Honeywell R8225B) for each zone. The boiler bypass circulator is still used in these cases.
NOTICE: Refer to piping schematic for location of zone circulators.
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 EK3
Frontier contains 7-1/2 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 CIRCULATOR

NOTICE: Systems are piped at the factory with the boiler bypass circulator. The bypass circulator piping
and wiring must not be changed from the factory configuration. The bypass circulator runs whenever the burner
is powered for heat and ensures the proper flow rate through the boiler.
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 CAPS MUST REMAIN OPEN. Vent caps
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.
EK3 Frontier Boiler Manual
o
F, 10F Differential (195
o
F
o
F
11
Seventh Edition- October 2015
o o
F/205 F)
o
F. Do not exceed a setting of 210
o
F.