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ENERGY KINETICS SYSTEM 2000 Owners And Installation Manual

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INSTALLER: PLEASE HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY
NEXT TO THE HOT WATER SYSTEM USING THE SUPPLIED POUCH.
CONSUMER: PLEASE RETAIN THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS FOR
FUTURE REFERENCE.
Hot Water Manual
OWNER AND INSTALLATION MANUAL
MANUFACTURED BY:
ENERGY KINETICS, INC.
51 Molasses Hill Road
Lebanon, NJ 08833
(908) 735-2066
www.energykinetics.com
Hot Water Manual – January 2022
or
www.system2000.com

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  • Page 1 Hot Water Manual OWNER AND INSTALLATION MANUAL MANUFACTURED BY: ENERGY KINETICS, INC. 51 Molasses Hill Road Lebanon, NJ 08833 (908) 735-2066 www.energykinetics.com www.system2000.com INSTALLER: PLEASE HANG THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS VISIBLY NEXT TO THE HOT WATER SYSTEM USING THE SUPPLIED POUCH.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Topic Page Topic Table of Contents Line Voltage Wiring Diagram Please Read This First Low Voltage Wiring Overview System Managers Smart Pump Hot Water Making Display Manager Description of Operation Digital Manager Plate Heat Exchanger Hydronic Controls Setting Indirect Water Heater Prepare for Start Up Storage and Production...
  • Page 3 INSTALLER NOTE: ALL INSTALLATIONS MUST BE MADE IN ACCORDANCE WITH ALL NATIONAL, STATE AND LOCAL, PLUMBING, HEATING AND ELECTRICAL CODES THAT MAY DIFFER FROM THIS MANUAL AND IN ACCORDANCE WITH THE FOLLOWING CODES, AS APPLICABLE: N.F.P.A. No. 70: National Electrical Code Canadian Electrical Code, Part I These codes are available from: National Fire Protection Association...

  • Page 4: Domestic Hot Water

    When paired with the System 2000 hot water boiler, with its highly efficient low mass hydronic heat exchanger, you will have a state of the art indirect water heating system. System 2000 is the product of years of engineering and advanced design, which brings together in a single system all elements needed to provide efficient residential and light commercial heat and hot water.
  • Page 5 Boiler hot. Hot water circulator HEAT Tank Thermostat Calling Burner was just running so boiler is still hot. Both circulators ENERGY continue to run, purging heat to RECOVERY the domestic hot Tank Thermostat water tank. Satisfied EXCEPTIONS For Hot Water Priority Turn ON Option Switch #10 –...

  • Page 6: Plate Heat Exchanger

    35,000 BTU/Hr is the average recovery rate for a gas water 20,000 heater 30,000 4.5kW is about 15,000 BTU 40,000 Energy Kinetics rates all equipment with a 77º F rise. 50,000  EK1 is 228 gallons* at 1.00 gph oil firing rate 80,000 ...

  • Page 7: Domestic Hot Water Tank Overview

    Kitchen Sink 1.5 to 2.5 tank life Clothes Washer 5 to 8 o Energy Kinetics ships 40 gallon glass lined tanks Automatic Dishwasher with a 10 year warranty standard with heat & hot Whirlpool, Hot Tub 12 to 24+ water systems, larger sizes available (ask for capacity in gallons) Vaughn “High Flow”...

  • Page 8: Commercial Applications

    Commercial Applications Many commercial applications use multiple boilers and are piped with primary/secondary loop heating systems. With these systems the installer has the option of installing the plate heat exchanger(s) in the boiler bypass (one per boiler), use a Hot Water Zone Kit or as a zone off the primary loop. There are benefits to each and the best location should be determined by the requirements for domestic hot water.

  • Page 9: Commercial Requirements For Hot Water

    Commercial Requirements for Hot Water Determine the type of consumption  Residential – Multiple family  Commercial – Split out temperature requirements  120º F for fixtures  140º  180º F for dishwashers  Additional tank or mixing valve may be required ...

  • Page 10: Requirements For Various Kitchen Uses

    Table 1 Hot Water Demand per Fixture for Various Types of Buildings (Gallons of water per hour per fixture, calculated at a final temperature of 140º F) Private Apartment Office Industrial Fixture Hotel School Residence House Building Plant Basin, Private Lavatory Basin, Public Lavatory Bathtub Dishwasher...

  • Page 11: Commercial Tank Sizing Worksheet

    Commercial Tank Sizing Worksheet Description 140º F Water Fixture Gal/hr per fixture Number of Fixtures Total Gal/hr Basins, Private Lavatory Basins, Public Lavatory Bathtubs Dishwasher Kitchen Sink Laundry, Stationary Tub Pantry Sink Shower Service Sink Semicircular Wash Sink Clothes Washer in Apartment Commercial Kitchen Fixtures: Vegetable Sink Single Pot Sink...

  • Page 12: Hot Water Requirements For Pools

    20,000 30,000 35,000 40,000 Assumes minimal heat loss Request a copy of the Pool Heating Procedure from Energy Kinetics’ Tech Support Team. Domestic Expansion Tank Sizing  Beware of check valves in the cold water supply  Newer water meters and all flow/pressure regulators have internal check valves ...

  • Page 13: Hot Water Recirculation

    Store all parts where they will not be damaged or lost during installation. 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 this manual are recommended.
  • Page 14 PIPING SO THE DOOR CAN OPEN: To avoid conflicts with the door opening, piping should be in accordance with FIG. 2B, 2C and the section on “Clearance for Cleaning and Service” in the Installation or Tech Manual. The door opens and drops into the notches on the boiler legs.

  • Page 15: Hot Water Storage Tank

    One alternative is to install the plate heat exchanger as a zone using one of Energy Kinetics Hot Water Zone kits. Hot Water Zone kits are designed to reduce the fouling caused by hard water plating out on the domestic side of the plate heat exchanger.

  • Page 16: Wiring And Controls

    “B”. Be sure to verify 24VAC output from all transformers. The Digital Energy Manager is designed for hot water and up to four (4) heating zones. Use Energy Kinetics supplied Smart Pump zone valves with two wire connections. For more than four...

  • Page 17: System Managers

    System Managers Figure 4A FIELD WIRING FACTORY WIRING *Field Wiring terminated to input terminal A1 and to output terminal 24VAC are to be w ired into the open lugs provided at those l o cations. ZONE 4 HOT WA TER T ANK or ADDITIONAL ZONE HOT WA TER CIRC RELA Y ZONE 1...

  • Page 18: Digital Manager

    Digital Manager Digital Energy Manager Option Switch Settings Switches are located on bottom of STANDARD MANAGER DIP SWITCHES EXPANDED MANAGER DIP SWITCHES Digital Energy Manager 1 2 3 4 7 8 9 ZONE: 10 11 12 13 4 ALARM LEADS COMMON NORM.

  • Page 19: Normal Operation

    The heated water returns to the top of the tank into the “C” inlet. The System 2000 tank has a dip tube, which disperses the heated water evenly in the top of the tank.
  • Page 20 DEFECTIVE CHECK VALVE- Check valve, integral or above circulator may be defective. ADD SCALE STOPPER- Add an Energy Kinetics Scale Stopper to the cold water supply line feeding the tank. INSTALL A HOT WATER ZONE KIT- Moves the Plate Heat Exchanger from the boiler bypass where hot water is circulated through it whenever boiler is running, to a remote zone where the hot water only flows through the plate heat exchanger when a call for hot water opens the hot water zone valve.
  • Page 21 Hot Water Diagnosis TEST WITH BOILER MAKING HOT WATER ONLY (Not heating any zones) Run hot water faucet for entire test Boiler Side of Heat Exchanger is Blocked (Due to corrosion, system leaks) Domestic Out 100°F – 130°F Boiler In 190°F –...
  • Page 22 These brazed plate heat exchangers can be cleaned by flushing with acid or other chemical processes. For heating swimming pools and hot tubs, contact your field representative or call Energy Kinetics. (Call for pricing) Now, technology brings an exceptional advancement in the fight against corrosion and ®...
  • Page 23 All Models are Brazed Plate units. Union (1) 1” NPT, Brass 10-0437-UNION All Plates are 316 Stainless Steel. Double Wall Plate Heat Exchangers for use where required by code. January 2022...
  • Page 24 Smart Pump for Premier Frontier Systems Piping Installation The Smart Pump is shipped with all Premier Packages. It greatly simplifies domestic hot water piping of the system. The Smart Pump is a compact assembly and can be located right at the hot water storage tank or right off the Plate Heat Exchanger.

  • Page 25: Smart Pump For Standard Boiler Premier Systems

    Smart Pump for Standard Boiler Premier Systems Piping Installation The Smart Pump is shipped on all Premier Packages. It greatly simplifies domestic hot water piping of the system. It pre-pipes and pre-wires the domestic circulator and associated piping. The Smart Pump is a compact assembly and is located right under the plate heat exchanger and close to the boiler.
  • Page 26 Hot Water Zone Kits APPLICATION Energy Kinetics Hot Water Zone Kits are designed to reduce the fouling caused by hard water plating out on the domestic side of the plate heat exchanger. Heated water only flows through the boiler side of the heat exchanger during a call for hot water, reducing the exposure of domestic water to a heated surface and reducing the effects of scaling.

  • Page 27: Hot Water Zone Kit (Smart Tank Piping)

    Typically Pre-installed On System 2000 Boilers in Bypass Optional Boiler Return Zone Valve Scale Stopper (Optional Hot Water P/N:10-0650 Zone Kit) E N E RGY Cold Water K I N E T I CS M ODE L X X U...

  • Page 28: Hot Water Zone Kit (Vaughn Featherweight Hot Water Storage)

    Optional Boiler Return Scale Stopper P/N:10-0650 Zone Valve Cold Water Supply Boiler Supply **Zone Circulator Dr awings Available from Energy Kinetics** T op View Hot Water Hot Water HX in Supply Supply Longer Nipple No Diptube HX out Cold Water Supply...

  • Page 29: Hot Water Systems A, B, C

    Hot Water Systems A, B, C SOLVING HOT WATER NEEDS IS AS EASY AS A, B, C The solution is easy for homeowners who never have enough hot water. High demand, fouled coils, or electric hot water heaters, which do not have adequate recovery, can be easily improved. Three simple solutions provide gallons of hot water storage capacity to eliminate the problem during peak periods.
  • Page 30 All Tanks are heavily insulated with 2” foam, the equivalent of R-15 for minimal heat loss. Typically, less than eight cents a day is lost, and the water will actually stay hot for several days. Three tank sizes are available: 40 gallon (standard), 80 gallon and 120 gallon.
  • Page 31 SYSTEM C: (CONVERSION OF ELECTRIC HOT WATER TANK TO INDIRECT HEAT WITH A PLATE HEAT EXCHANGER) HOT WATER TANK CONVERSION INSTALLATION INSTRUCTIONS 1. Turn off electric supply to hot water tank and disconnect power supply back to circuit breaker. 2. Drain water from tank. Remove drain valve. 3.

  • Page 32: Indirect Water Heater Installation

    (right) side. The System Manager has a hot water Tank Drain Note: priority option, refer to the System 2000 Indirect Coil Drain All piping must allow clearance Installation & Service Manual for information. for Frontier Boiler door opening.
  • Page 33 January 2022...
  • Page 34 WHI TE-RODGERS January 2022...

  • Page 35: Drawing, Sys-02-021 2 Temp Service W/Mixing Valve

    Cold Water Supply Standard Glass-Lined Hot Tank Drain Water Storage Tank 2 Temperature Service w/Mixing Valve Hot Water Tank Piping for the Energy Kinetics Smart Pump DRAWN BY: REV: DATE: DWG. NO. J.Szwed 07/31/03 SYS-02-021 CAD FILENAME: sys-02-021-rev1.dwg...
  • Page 36 Tables: Plate Heat Exchanger: Boiler Side Temperature vs. Domestic Side Temperature E ample: #14 PHE with a 007 boiler circulator, maximum domestic flow shown Side 1 = Boiler Side Side 2 = Domestic Side Pressure drop, feet H Load Temp Flow Temp Flow...
  • Page 37 152.4 5.64 0.93 210,728 146.6 155.5 5.64 0.93 196,512 149.5 158.4 5.61 0.93 The chart above shows domestic side values using a 006 domestic circulator, it is the same size circulator used for the Energy Kinetics Smart Pump. January 2022...
  • Page 38 January 2022...
  • Page 39 Hot Water Manual January 2018 Technical Support Hot Line Customer Service Hot Line Order Status Hot Line One Call Does It All! 1-800-323-2066 www.energykinetics.com 51 Molasses Hill Road Lebanon, NJ 08833-3254...

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