General Assembly; Boiler Mounting - ENERGY KINETICS System 2000 Frontier Instructions Manual

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

BOILER MOUNTING on TANK STAND, FIG. 2A: Ensure that the boiler is properly mounted to the stand using
the 5/16" hardware provided. Bolts should face up so they cannot interfere with removal of the tank at a later time.
Holes in boiler legs must line up with holes in the tank stand.
LO-BOY TANK ORIENTATION: The 40 gallon Lo-Boy tank should be positioned with the tank drain pointing
towards the front left corner of the drain pan. Push the tank all the way to the back of the stand. Center the tank left to
right in the stand.
Premier Option: Return
Zone Valves
Supply Ball & Ball Purge Valves
T&P Gauge
Main/System Circ
High Limit
SYSTEM 2000
ENERGY MANAGER
TH ERM O STA T HOT W AT ER H EAT I N G
THW T1 1 1 ZHW Z4
T2 2 2 Z1
T3 3 3 Z2
A1 4 4 Z3
A2 INDU CER 24VA C
B EN ERGY C H I M N E YLE SS O N LY IND
S KIN ETICS B URNER B1
R L eban on , New Jer sey CIR CULATOR B2
T4 170 190 PO WER CIRC Flue Box Test Port
24 VA C CO N NEC TI O N O NLY . RE AD I NSTR UCT I O NS BE FO RE C AUTION 160 150 140
M AKI NG A NY CO NNECTI O NS 130 120 100 A L A R M
Puff Switch
Combustion/Over fire
Test Port
Combustion
Air Inlet
NOTE:
Tank Stand
Allows The
NOTE:
Boiler To Be
All piping must allow
Mounted Over
clearance for door opening.
Top Of a 40 Gal
Lo-Boy Tank.
Figure 2A
PIPING SO THE DOOR CAN OPEN: To avoid conflicts with the door opening, piping should be in accordance
with FIG. 2A, 2B or dimension D in Fig. 1B. The door opens and drops into the notches on the boiler legs. The burner
and air box also need clearance when the door opens. Do not locate any piping in front of the tank 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 down.
BOILER MOUNTING on STANDARD BASE, FIG. 2B: The back support bar should be mounted to the holes just in
front of the 2" slot. Line up the rear holes in the legs with the holes in the back support bar. Two sets of 5/16" x 1-1/2"
bolting hardware are provided and are used to secure the boiler to the back support bar.
BOILER PITCH: The Frontier pressure vessel is manufactured with the rear ½ to 1 bubble 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 the stand. When the stand is level, the pitch is correct and the back of the boiler will be higher than the front.
The EK1 Frontier is pitched 1/4" and the EK2 Frontier is pitched 7/16".
PIPING
All piping and accessory connections should follow good practice using approved joint sealants.
Figure 2C
Frontier
Use Energy
Kinetics Smart
Thread Sealant
P/N 10-0620
B1-5
Return Manifold
3/4" Air Vent
Relief Valve
Supply
System Circ
Feedwater
Bypass
Connection
Premier Option: Combo
Auto Feed/Backflow
Preventer
Expansion Tank to
be located in return
piping or at the inlet
side of the pump.
Supply
Boiler
Boiler Feed
Water
WR
WHITE-RO DGERS
Typical Flow
Schematic
Supply
Energy Converter
Premier Option: Return
Zone Valves
Supply Ball Valve & Purge
T&P Gauge
Main/System Circ
High Limit
SYSTEM 2000
TH ER M O S TA T ENERGY MANA GER H EA TI N G
H OT WATER
THW 1 1 Z4
T1 ZHW
T2 2 2 Z1
T3 3 3 Z2
A1 4 4 Z3
A2 C H I MN E Y LE S S INDUCER 24VAC
B EN ERGY ON LY BURNER I ND
S KIN ETICS B 1
R Le ba non, Ne w J ers ey CIRCULATOR B 2
T4 P OWE R 1 90 CIRC Flue Box Test Port Flue Box Test Port
CA UT IO N 1 70 1 50 1 60
R E A D I N ST R U C TI O N S B EFO R E 24 VA C C O N N EC TI O N O N LY. M A K I N G A N Y C O N N EC T I O N S 1 40 1 20 1 30
A L A R M 1 00
Puff Switch
Combustion/Over fire
Test Port
Combustion
Air Inlet
Figure 2B
Return
Return
Feedwater
Return Manifold
Connection
3/4" Air Vent
Relief Valve
Supply
System Circ
Bypass
Premier Option: Combo
Auto Feed/Backflow
Preventer
Expansion Tank to
be located in return
piping or at the inlet
side of the pump.