ENERGY KINETICS EK-Pak Owners And Installation Manual

Natural gas and propane heat and hot water system

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Note to the installer: Attach this manual in its bag on or near the EK-Pak heating system.

The manual must be in plain sight while viewing the system.

First Edition - December, 2002

Owner and Installation

Natural Gas and Propane

Heat and Hot Water System

Energy Kinetics, Inc.

51 Molasses Hill Rd.

Lebanon, NJ 08833

www.energykinetics.com

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Page 1 Natural Gas and Propane Heat and Hot Water System Note to the installer: Attach this manual in its bag on or near the EK-Pak heating system. The manual must be in plain sight while viewing the system. Energy Kinetics, Inc.
Page 2 Retain this manual for use by your qualified service technician only. Should you observe unusual or abnormal operation of the burner or heating module, contact your qualified service technician immediately. Do not attempt to service or repair this product yourself. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 3 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/heating module while waiting for the technician. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 4 2. Turn off all electric power to the burner and heating module if service is to be performed. 3. Actuate the installer supplied Manual Gas Shut Off Valve to the OFF position. Do not force. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 5 Where required by the authority having jurisdiction, the installation must conform to the Standard for: ANSI/ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers These codes are available from: National Fire Protection Association 1 Batterymarch Park Quincy, MA 02269-9101. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 6: Table Of Contents
Mechanical Relay Fan Center Gas Flow Pressure Drop Category III Venting (Z-Vent) Zone Control Replacement Parts Hot Water Storage Tank Inside Limited Lifetime Warranty Back Warranty Transfer Agreement Back Cover Cover EK-Pak Owner & Installation Manual First Edition December 2002...
Page 7: Overview
Overview: Small Package – Large Performance About the size of a large suitcase, the compact EK-Pak is one-fifth the size of systems with comparable capacity. On the wall or in a closet, the EK-Pak fits the smallest home to the largest commercial building.
Page 8: Ek-Pak Technical Specifications
The extremely versatile design is based upon research, development and field testing with homeowners, professional installers and service people. The EK-Pak system has been designed with a high head circulator to obtain maximum water flow rate through the water heater. The advanced design uses a high pressure drop through the heating module heat exchanger to achieve it’s efficiency and extraordinary speed...
Page 9: Typical Control Sequence
♦ Heating module turns off and waits for the next heat call. The EK-Pak heating module is fully modulating and will do everything it can to maintain a constant supply temperature. The return temperature will vary depending on how much heat is taken away at the heat load.
Page 10: Quick Setup Guide
Immediately report any missing items. It is wise to complete the installation before discarding packing material. Store all parts where they will not be damaged or lost during installation. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 11: Components Diagram
Natural Gas #60 Mesh Strainer or Propane Automatic Boiler Feed Feedwater Connection To EK-Pak Purge Ball Valve Domestic Out Install properly sized To Tank diaphragm expansion "C" Port tank. (Not Included) EK-Pak Owner & Installation Manual First Edition December 2002...
Page 12: Hot Water Piping Schematic
Zone Valve shown in phantom are pre-piped on Heat & Hot Water Systems Standard Glass-Lined Hot Water Tank Backflush 42 Gal. Drain Spring Check Smart Pump Feedwater Connection To Tank Tank Drain EK-Pak Owner & Installation Manual First Edition December 2002...
Page 13: Location And Clearances
EK-Pak Mounting: Wall Mounting: The rear panel of the EK-Pak enclosure has keyholes punched across the top on four inch centers. Two screws may be started into the wall and the unit hung on to them.
Page 14: Wiring
Wiring: Electrical connection • The EK-Pak heating module requires 120VAC, 60 Hz, less than 12 amps. • Connect 120VAC from a switched circuit so the heating module is constantly powered. • The EK-Pak heating module has a built-in Ground Fault Interrupter, GFI.
Page 15: Gas Piping Systems
Attention: Check the rating plate on the EK-Pak heating module to verify that it is for the correct type of gas. The heating module cannot be converted from natural gas to propane or from propane to natural gas in the field.
Page 16 To check for gas leaks, use a level to conform to any local codes. gas detector or apply a leak detection solution to the joints. Union 3" Min Sediment Trap/Drip Leg EK-Pak Owner & Installation Manual First Edition December 2002...
Page 17: Gas Pipe Leak Testing
• Apply leak detection solution (as appropriate for your piping) to the piping to find the leak. • Fix the leak and repeat the above leak testing procedure. Start Time Start Manometer End Time End Manometer Reading Reading EK-Pak Owner & Installation Manual First Edition December 2002...
Page 18: Gas Flow Pressure Drop
• Turn off all the appliances by closing their manual shutoff valves. • The EK-Pak gas valve inlet pressure increases to 8” w.c., which is just within the limit. From this test, we can say the piping is properly sized and the main gas regulator is working properly EK-Pak Owner &...
Page 19: Zone Control
10 feet away, use ¾” lines and a manual air vent on a high return. Insulation of water lines between the storage tank and EK-Pak and on the hot water supply to the house is recommended for best fuel efficiency. Energy Kinetics supplied storage tanks come complete with high-density foam insulation, a properly located aquastat, a temperature/pressure relief valve, and a specially designed dip tube.
Page 20: Flush, Purge, And Fill System With Water
Energy Kinetics recommends addition of one quart of 8-Way Boiler Treatment per 30 gallons system water. 8-Way Boiler Treatment is recommended to treat water up to medium hardness. Call Energy Kinetics for more details about heating module water treatment and about hard water conditions.
Page 21: Combustion Air And Venting
5 elbows for runs up to 40 feet. Exhaust Venting: WARNING: The EK-Pak must be connected to a 4” Category III gas vent pipe in order to direct any dangerous exhaust byproducts to the outdoors. WARNING: Do not common vent this appliance with any other vented appliance.
Page 22 The system must be supported along it’s horizontal length at all elbow locations and joints (every 48” or less) using straps around pipes maintaining the clearance to combustibles listed in Z-Flex Installation and Maintenance Instructions. The pipe length may be cut using snips or EK-Pak Owner & Installation Manual First Edition December 2002...
Page 23: Prepare For Start Up
• Do not touch any electric switch; do not use any phone in your building • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 24: Start Up
CO ppm and one measuring O2 or CO2 percentage. If air-free CO is determined with a single meter, an integral electronic chip calculates the air-free level from as-measured CO ppm and O2 percentage. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 25: Annual Maintenance
The unit only takes six seconds to ignite and six more to reach operating temperature. If the unit is taking longer then twelve seconds to initiate, check the system strainer and the flow sensor for debris or damage. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 26 Check the system strainer and flow sensor for debris or damage. Heating Module Error Codes: All EK-Pak units have a self-diagnostics system for errors. If there are any problems with the installation or the unit itself, it will signal an error code by flashing a pair of lights on the computer board.
Page 27 EK-Pak Owner and Installation Manual EK-Pak Domestic Hot Water Knockdown The EK-Pak hot water knockdown kit is a package of carefully selected components. The hot water knockdown kit is designed to heat cold potable water by flowing directly through the heating module.
Page 28: Gas Protection Kit
For your safety and protection, Energy Kinetics includes with each LP/Propane EK-Pak, a Gas Protection Kit for gas leak & carbon monoxide detection. • Each and every EK-Pak unit that is Propane/LP fired is shipped with a combustible gas/carbon monoxide detector. The detector is available separately for Natural Gas fired EK-Pak heaters.
Page 29: Example Baseboard Sizing
One EK-Pak and four zones of baseboard. The EK-Pak flow is fixed at 4 gpm and will be divided between all open zones. The required total heat output from the baseboard is 60,000 B/Hr. The baseboard has been oversized by 25%, from 30 feet to 37 feet per zone.
Page 30: Example Air Handler Sizing
Each running at 790 CFM air flow, blower on high speed and against 0.30 inches static air pressure. The EK-Pak's flow is fixed at 4 gpm and will be divided between all open zones. The required total heat output from the three air handlers is 120,000 B/Hr. The air handlers have been derated to 78%, from 53,900 B/Hr at 3 gpm to 42,200 B/Hr at 1.33 gpm per zone.
Page 31: Example Piping Diagram For Baseboard, Domestic And Radiant
100° then set the aquastat setpoint at 90° with the differential at 10°.) When the radiant loop is above 90F, the aquastat will open, taking away the heat call to the heating module. This should prevent the EK-Pak from running while the "H" port is closed on the mixing valve.
Page 32 For loops greater than 100', increase to next pipe size. Notes: Pipe sizing is based on using EK-Pak's with a maximum 140F return temperature. Each EK-Pak has an expansion tank and relief valve. Additional expansion tank capacity may be needed for large systems.
Page 33: Example Wiring Diagram For Air Handler With Electronic Fan Center
ADD 24V RELAY TO 4 Fan speed may be changed by using a different motor ISOLATE ZONE CONTROL lead. 5 For motor speed selection, see the diagram on the fan housing. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 34: Example Wiring Diagram For Air Handler With Mechanical Relay Fan Center
Cooling Mode: The thermostat will run the Air Handler fan. Fan “ON” Mode will turn the fan on at the cooling fan speed (M1). Fan speed may be changed by using a different motor lead. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 35: Category Iii Venting (Z-Vent)
4 inch x 45 degree Elbow 10-0191-RC 4 inch Rain Cap 10-0191-RF 4 inch Adjustable Roof Flashing, 0/12 to 6/12 pitch 10-0191-TS 4 inch Top Support/Storm Collar 10-0497 Stainless Steel Air Inlet Vent Screen EK-Pak Owner & Installation Manual First Edition December 2002...
Page 36 EK-Pak Owner and Installation Manual Z-Vent III includes a built-in silicone gasket that will seal the flue products inside the pipe. Just slip the parts together and clamp for a tight seal. EK-Pak Owner & Installation Manual First Edition December 2002...
Page 37: Replacement Parts
10-0734 Spark Electrode & Flame Sensor 10-0735 Igniter 10-0736 Gas Valve 10-0737 10-0423-12 Hot Water Storage Tank 10-0421 ½” Spring Check Valve 10-0432 Smart Pump 10-1206 Plug In Service Aid/Remote Control EK-Pak Owner & Installation Manual First Edition December 2002...