ENERGY KINETICS System 2000 Frontier Instructions Manual

SYSTEM 2000 BOILER - PRINCIPLE OF OPERATION
SYSTEM 2000 comprises a heat source, the energy converter, circulating water, and five (or more) zones controlled
by an electronic control, the Digital Manager.
The Boiler sits cold until a thermostat calls for heat. The Digital Manager receives the call for heat and turns on the
main circulator and burner. Water circulates within the boiler as it warms up to operating temperature. When ready, the
zone valves open and deliver heat to the zones calling for heat. When the thermostats are satisfied, the Digital Manager
turns off the burner and enters the energy recovery stage. The circulator and zone valve stay energized to deliver the
heat remaining in the boiler to your home or to the domestic hot water storage tank.
When energy recovery is complete and the Boiler has been cooled off, the Digital Manager turns off the system and
waits for another thermostat (or tank aquastat) to call for heat. SYSTEM 2000 runs the burner only when you need heat
and delivers that heat only where you need heat.
The System 2000 Energy Converter is the product of advanced thermal engineering. It is designed with two separate
passageways, nearly 10 feet long, coiled around each other. Water travels along one passageway from your home
toward the center of the unit and heated gases travel from the unit center toward the chimney. This is a "forced circulation
counter-flow" design and it provides very efficient transfer of heat from the burning fuel to the circulating water. The
superior insulation of the boiler minimizes heat losses to the surroundings, resulting in directing heat to your home in an
efficient and quiet manner.
SYSTEM 2000 has an extremely high annual efficiency (over 99% of steady state) because it runs only when your
home or hot water storage tank needs heat. Energy recovery is completed at the end of each heat call, virtually eliminating
off cycle losses.
Your System 2000 holds a minimal quantity of water so it begins to supply heat in about 90 seconds. This rapid
response means that your rooms can be heated quickly to temperature. The System 2000 EK1 Frontier can heat water up
to 100,000 BTU's per hour and the EK2 Frontier up to 200,000 BTU/hr.
A modern retention head oil burner fires into the center of System 2000 where a high temperature, light weight
ceramic chamber provides ideal conditions for "near perfect" efficient, pollution-free combustion. Your System 2000 is
tightly sealed so all products of combustion pass only to the chimney or sidewall vent.
The FRONTIER Boiler is designed with a hinged front cover that allows access to the inside of the boiler for inspection
and cleaning. All access for service is from the front, so the FRONTIER Boiler can be placed directly against a wall or into
a closet.
DIGITAL MANAGER - PRINCIPLE OF OPERATION
(See Section E, Digital Manager for detailed trouble shooting and diagnostics)
The left side of the Manager is the input side, which provides 24-volt power supply and connections for thermostats.
The right side is the output side, which starts the burner, circulator, zone valves or zone circulators and the domestic hot
water circulator. See photo of the Manager on the cover.
Lights on the Digital Manager indicate what is calling for heat (left side) and (right side) lights indicate active zone(s),
burner operation and circulator operation. These function lights are an aid in servicing. The following is a typical cycle.
1. SYSTEM WAITING FOR A CALL: The boiler is turned off and sits cold, waiting until a call for heat. The red power
light on the Manager is glowing.
2. CALL FOR HEAT: A room thermostat call starts the cycle. The thermostat light on the left side will turn on for that
zone.
3. PRE-HEAT: Output lights for the main circulator and burner turn on, the circulator starts, and the burner begins firing.
The boiler water circulates through the energy converter via the bypass line, heating up the water.
4. HEAT: Once the boiler water has heated up to 140F (about 90 seconds), the Manager will turn on the zone output
light on the right side. The zone valve will open and hot water will flow to the zone needing heat. The burner runs as
long as there is a thermostat calling and as long as heat is being delivered to the zone. The burner may shut off if the
return temperature exceeds 170F/190F (RED burner light turns off) or if the high limit temperature is exceeded (RED
burner light stays on, but the high limit aquastat shuts the burner off).
5. ANOTHER CALL FOR HEAT: If another zone calls for heat while the burner is already running and the return
temperature is above 140F, the zone output will turn on, immediately supplying heat to the zone.
6. MONITOR RETURN TEMPERATURE: The Manager continually senses the return temperature and will turn off the
zone outputs if the return temperature drops below 120
closed, the boiler water will quickly reheat and once the return temperature reaches 140
is ON), then the Manager will reopen the zone valves.
7. THERMOSTAT SATISFIED: The thermostat light on the left side will go out. The burner light and the burner will then
turn off.
B1-1
FRONTIER BOILER
Instructions, Service Version, Oilheat Edition
o o
F (130 F if Option Switch #1 is ON). With the zone outputs
o o
F (150 F if Option Switch #1