Replacement Parts; Amulet Replacement - ENERGY KINETICS System 2000 Frontier Instructions Manual

Line Voltage Relays
Remember that behind the Manager is the junction box with the line voltage relays. The line voltage relays are
controlled by the Manager.
The burner and circulator power is controlled by one line voltage relay. If both burner and circulator are without
power, check the relay.
If the domestic hot water circulator does not have power, check the hot water relay.
If equipped with an inducer and the inducer does not have power, check the inducer relay. Also check to be sure
dip switch #2 is turned "on".
Line Voltage
System 2000 requires 120 VAC. The supply voltage must be within 108 VAC min / 132 VAC max for reliable
operation of the boiler and the Manager. An easy way to check the supply voltage is to plug a volt meter 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. Older systems can be retrofitted using plug-in surge suppressors, which we have in stock.
OPERATION WITHOUT the DIGITAL MANAGER
SERVICE BOARD MODE:
The Digital Manager can be placed into "SERVICE BOARD MODE" by turning off the system switch and
removing the RED temperature sensor lead from the left side input connector, and turning power back on.
Removing the RED lead does exactly the same thing as inserting the traditional green "Service Board". The
traditional service board may still be used if desired. SERVICE BOARD MODE allows the boiler to run like a
conventional boiler. The burner is controlled by the high limit aquastat and the circulator runs continuously. If this
mode is used, temporarily reset high limit aquastat to 165
TEMPORARY OPERATION WITH JUMPERS
(With partially functional Manager still in place and without service board)
If a particular function of the Manager fails, use appropriate jumper action below with Manager in place.
BURNER: Jumper BB or TT on burner control. Burner will run on limit whenever Manager calls circulator. The
boiler may overheat slightly during energy recovery. Temporarily reset limit aquastat to 165
MAIN CIRCULATOR: Remove blue CIRC lead from right side and connect to A2 on the left side, using an
extension lead. The circulator will run constantly and the burner runs on Manager call.
ZONE/HOT WATER CONTROL: Remove zone valve and thermostat leads for zone. Connect a thermostat lead to
A1. Connect a zone valve lead to A2. Wire the remaining thermostat and zone valve leads together. Zone valves
will open whenever the Thermostat calls but it will not activate manager. If system is active, zone will receive heat
when another calls or run system with high limit aquastat set to 165
IF A PLUG-IN RELAY FAILS: Replace with spare relay. If spare is not available, temporarily install a relay with
24VAC coil and 120VAC contacts. Contact Energy Kinetics for connection details.

REPLACEMENT PARTS

To order replacement parts, specify serial number
stamped onto nameplate, part description and part number
from parts list and assembly drawing at the end of this
section.

AMULET REPLACEMENT

It is recommended that a new ceramic sleeve "amulet"
be installed each time the air tube is removed from unit. See
instructions that come with each amulet. The Frontier
amulet is larger than the standard amulet, so be sure to
order the proper part number shown in the Assembly
Drawing. Using a standard amulet will allow excessive heat
back to the front jacket and may damage burner tube.
o o
/180 F.
o o
/180 F and zone will get heat on call.
REMOVE 3 NUTS
TO OPEN BOILER
LOOSEN, BUT
DO NOT REMOVE
NUTS, THE DOOR
HINGES ON BOLTS
o o
/180 F.
FLUEBOX
TEST PORT
(Smoke & Draft
Loss Calc)
OVER FIRE
TEST PORT
(CO / O & Draft)
2 2
B1-12