ENERGY KINETICS System 2000 Owners And Installation Manual
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ENERGY KINETICS System 2000 Owners And Installation Manual

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MH28303
.
UL 726;
Low-Press Boiler
INSTALLER:
HOMEOWNER/USER: READ AND SAVE THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS FOR
Frontier Oil Heat – PN 10-2021 – October 2021
This product meets the Energy Star
guidelines for efficiency
Frontier Boilers
EK1 & EK2 Frontier
OWNER AND INSTALLATION MANUAL
OILHEAT EDITION
Manufactured By:
Energy Kinetics, Inc.
51 Molasses Hill Road
Lebanon, NJ 08833
www.energykinetics.com
HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY NEXT
TO THE BOILER USING THE SUPPLIED POUCH.
FUTURE REFERENCE.
(908) 735-2066
®
®
®
National Board
Listed
ASME certified by EKI.
Certificate plate is under
the jacket on the steel
vessel.

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Summary of Contents for ENERGY KINETICS System 2000

  • Page 1 EK1 & EK2 Frontier OWNER AND INSTALLATION MANUAL OILHEAT EDITION Manufactured By: UL 726; ASME certified by EKI. Energy Kinetics, Inc. Low-Press Boiler Certificate plate is under the jacket on the steel 51 Molasses Hill Road vessel. Lebanon, NJ 08833 (908) 735-2066 www.energykinetics.com...

  • Page 2: Please Read This First

    Please Read This First Special Attention Flags Please pay particular attention to the following flags when you see them throughout this manual. DANGER: Notifies you of hazards that WILL cause severe personal injury, death or substantial property damage. WARNING: Notifies you of hazards that CAN cause severe personal injury, death or substantial property damage. CAUTION: Notifies you of hazards that WILL or CAN cause minor personal injury or property damage.

  • Page 3: Table Of Contents

    Five Zone Display Manager Record of Installation Dip Switch Settings Message to Homeowner Display Manager Option Menu Descriptions Principle of Operation – System 2000 Expanded Energy Manager Boilers Principle of Operation - Energy Manager 15 Zone Manager Installation Instructions Receiving and Unpacking...

  • Page 4: Homeowner/User Note

    If the burner goes into lock out again, contact a qualified service agency for help. ANNUAL MAINTENANCE The SYSTEM 2000 boiler requires an annual tune-up by a qualified service agency to maintain top efficiency and peak performance and to verify proper performance of all safety devices.

  • Page 5: Record Of Installation

    SCOPE This manual covers the Energy Kinetics System 2000 Frontier Boiler. The boiler is designed and equipped and has been tested to generate hot water in a low pressure closed loop system. The boiler is a major component of a closed loop system that can be used as a heat source for hydronic, radiant, domestic hot water, spa, and/or pool heating systems.
  • Page 6 When energy recovery is complete and the Boiler has been cooled off, the Energy 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.

  • Page 7: Receiving And Unpacking

    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 F (130 F if Option Switch #1 is ON). With the zone outputs closed, the boiler water will quickly reheat and once the return temperature reaches 140 F (150 F if Option Switch #1 is ON), then the Manager will reopen the zone valves.

  • Page 8: Combustion Air

    Place the unit as near to the chimney or vent as possible allowing clearance for front cleaning and service as shown in Figure 1B. If not using an Energy Kinetics supplied stand, provide a solid, level, and smooth foundation with clearance for door opening and service.

  • Page 9: Chimney Venting

    The metal liner diameter and length should be as recommended by the metal liner manufacturer. Corrugated metal liners should be at least 5" diameter for EK1 and 6" diameter for EK2. Energy Kinetics has 5” for EK1 and 6” for EK2 flexible metal chimney connectors available to be used between the boiler flue collar and the chimney.

  • Page 10: Vent Chimney

    2. L-Vent to be installed in accordance with the vent manufacturer’s instructions. System 2000 and L-Vent must be installed in strict compliance with all State and Local Codes and with the regulations of the authorities having jurisdiction, which may differ from and which take precedence over these instructions or the vent manufacturer’s instructions.

  • Page 11: Oil Burner Settings

    EK1 Boilers are shipped from the factory preset for 0.85 GPH firing rate and EK2 Boilers are shipped from the factory preset for 1.40 GPH firing rate. The SYSTEM 2000 Boiler can be fired over a range of firing rates to suit the needs of the application.
  • Page 12 The amulet has an inside edge that will cover the edge of the burner head. The air slots in the retention head must not be blocked or obstructed by the amulet. If needed, trim a 45 degree chamfer on the inside of the amulet using a sharp utility knife and maintain a 1/8"...

  • Page 13: General Assembly

    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”...

  • Page 14: Piping

    This tee is the supply for circulators with returns for these zones into normal return location. Call Energy Kinetics and request “Zoning with Circulators” diagram. 5 Zone Circulator Relay Kit...

  • Page 15: Boiler Bypass Line And Valve

    WINTERIZING NOTICE: If the SYSTEM 2000 Boiler may be exposed to freezing temperatures, such as a vacation home shut down for the winter, then anti-freeze should be added. When a home is winterized by draining all domestic water piping, then the SYSTEM 2000 Boiler must be protected.

  • Page 16: Line Voltage Wiring Diagrams

    POWER SUPPLY: 120 VOLT 60 HZ, 7.5 Amperes 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 voltmeter in at the service outlet located on the side of the system junction box.

  • Page 17: Low Voltage Wiring And Diagram

    Set thermostat heat anticipators to 0.1 amps (or "gas" if gas/electric option). Call Energy Kinetics to request alternate low voltage wiring diagrams to handle special situations such as air handler wiring, heat pump wiring, isolation relays for thermostats, and isolation relays for heat motors or circulators, etc.

  • Page 18: Five Zone Display Manager

    Five Zone Display Manager The Display Manager is an Energy Manager that is equipped with an LCD display, and four pushbutton keys. With the exception of the Fuel Type (oil/gas) and Venting (chimney/inducer) options, all setup options are selected through option screens via the display and keys. The Fuel Type and Venting options can be viewed, but not set, in the option screens.

  • Page 19: Dip Switch Settings

    Dip Switch Settings Set dip switches for Fuel type: Oil or Gas and Vent type: Chimney or Inducer INSTALLATION TIPS  Dip Switches “OFF” Display Managers are shipped with both dip switches “OFF” (set for an oil NOTE: “ON” is DOWN position Bottom edge of Energy Manager system with a chimney).

  • Page 20: Expanded Energy Manager

    EXPANDED ENERGY MANAGER ZONE OUTPUTS ZONE INPUTS 15 Zone Manager 24VAC (THERMOSTATS) (ZONE VALVES OR Figure 4C ZONE CIRC RELAYS) ZONE 14 ZONE 14 ZONE 13 ZONE 13 ZONE 12 ZONE 12 ZONE 11 ZONE 11 ZONE 10 ZONE 10 ZONE 9 ZONE 9 ZONE 8...

  • Page 21: Hydronic Control Settings

    Tank Aquastat Energy Kinetics PN: 10-0414 Water Tank (On Tank) (To suit individual installation) For legacy controls, contact Energy Kinetics Factory Setting PREPARE FOR START UP DANGER: MAKE CERTAIN THE FOLLOWING REQUIREMENTS HAVE BEEN SATISFIED BEFORE START UP: 1. The boiler and piping are completely filled with water.

  • Page 22: Boiler Operation And Safety Checks

    BOILER OPERATION AND SAFETY CHECKS Check for proper boiler operation and proper safety operation. Correct any deficiency. DANGER: Verify proper operation of high limit aquastat. a. Remove all heat and hot water calls (No input lights on left side of manager). b.

  • Page 23: Oil Burner Operation

    OIL BURNER OPERATION NOTICE: For reliable operation, set Air-Fuel mixture conservatively based on installation conditions. CO and draft readings should be taken through 1/4" test port in front jacket opening just to right of burner (see FIG. 6). Sample tube must extend at least eight (8) inches into front cover to obtain accurate readings. Smoke test and stack temperature should be taken at flue outlet.

  • Page 24: Energy Manager Operation

    Energy Manager Operation WARNING: Do Not Jump! If you apply 24VAC to any Energy sensor lead with the sensor connected to the Manager, you will burn out both the sensor and the Manager in less than a second. NOTE: The Manager cannot lockout the primary control on the burner.

  • Page 25: Energy Manager Check

    Energy Manager Check Troubleshooting The burner will not run unless there is a call for heat (thermostat call) or a call for domestic hot water (tank aquastat). Note: Do NOT Jumper Connections or Apply Voltage to Test the Manager. Follow these simple steps: Look at the Manager See what it is telling you is supposed to be happening.
  • Page 26 1, 2, and 3. If problem persists, call technical support or replace manager. Note malfunction on warranty tag and return manager to Energy Kinetics. If problem goes away, there is a problem with the output wiring –...

  • Page 27: Additional Manager Tests

    Additional Manager Tests Perform the following tests ONLY if you have any of the following: Case 1) Zones heating intermittently Case 2) E140 or E150 displayed WITHOUT a burner lockout Case 3) E100 or E190 displayed If you have a burner lockout, troubleshoot as any conventional burner lockout. Case 1: Zones heating intermittently Step 1: Have all connected thermostats including hot water aquastat call continuously for at least 10 minutes.

  • Page 28: Line Voltage Relays

    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.

  • Page 29: Troubleshooting With Energy Manager

    TROUBLESHOOTING with the ENERGY MANAGER Display Manager Error Codes and Faults An error code on the display indicates that Display Manager has detected a problem. E100: Temperature sensor is not working properly. This indicates that the Manager is in service board mode. Circulator and inducer run constantly, burner runs off the high limit aquastat.

  • Page 30: Operation Without The Energy Manager

    F and zone will get heat on call. 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. EMERGENCY HEAT WITHOUT ENERGY MANAGER or RELAY BOARD (Temporary Operation Only –...

  • Page 31: Annual Tune Up & Inspection

    ANNUAL TUNE UP & INSPECTION Step 1 Initial Test (Draft Loss & CO Make sure air box cover is in place before testing 1. Remove 1/8” brass plug from the “over fire” test port (2) next to the burner and the flue box (1) next to the puff switch.
  • Page 32 Annual Tune Up & Inspection - Continued Step 7 Check Burner 1. Check end cone through air tube opening with drawer assembly removed. 2. Check Fan/Air Inlet for dirt or lint. 3. Install drawer assembly and check ignitor. 4. Check Filter condition. Replace annually or if vacuum exceeds 7” for single pipe systems.

  • Page 33: Replacement Parts

    The combustion chamber is of high quality refractory ceramic fiber material and will normally not need to be replaced. A replacement chamber, if required, is available from Energy Kinetics. The proper part number for the Frontier chamber must be specified when ordering. For interim operation, the unit may be run without a combustion chamber if necessary.
  • Page 34 Replacement Parts Obtain replacement parts from your local Energy Kinetics dealer. Contact Energy Kinetics at 800-323-2066 or www.energykinetics.com for help locating your nearest authorized dealer. ITEM Frontier Frontier DESCRIPTION PART NO. PART NO. 10-0710 10-0810 Combustion Chamber 10-0394 10-0395 Energy Converter (Frontier)
  • Page 35 NOTES: Frontier Oil Heat – PN 10-2021 – October 2021 - 34 -...
  • Page 36 II. ADDITIONAL COMPONENT LIMITED WARRANTIES 1. Energy Kinetics warrants that its Energy Manager is free from defects in material and workmanship for a period of five years from the date of installation. The warranty is extended to the End User for the lifetime of the unit by a manufacturer sponsored rebuild program offered at nominal cost.
  • Page 37 The End User is required to make available for inspection by Energy Kinetics or its representative, the parts claimed to be defective and, if requested by Energy Kinetics, to ship said parts prepaid to Energy Kinetics at the above address for inspection or repair. In addition, the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with this claim before resorting to legal remedies in courts.

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