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ENERGY KINETICS EK1 User Manual

ENERGY KINETICS EK1
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TWENTY NINTH EDITION – JULY 2005
Standard Boiler
Owner and Installation Manual
Oil Heat Edition
Manufactured By:
Energy Kinetics, Inc.
51 Molasses Hill Road
Lebanon, NJ 08833
(908) 735-2066
www.energykinetics.com
INSTALLER: PLEASE HANG THIS INSTRUCTION MANUAL AND ASSESSORY INSTRUCTIONS VISIBLY
NEXT TO THE BOILER USING THE SUPPLIED POUCH.
CONSUMER: PLEASE RETAIN THIS INSTRUCTION MANUAL AND ACCESSORY INSTRUCTIONS FOR
FUTURE REFERENCE.
ASME certified by EKI.
Certificate plate is under the
jacket on the steel vessel.
This product meets the Energy
Star
®
guidelines for efficiency
®
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ENERGY KINETICS EK1 Specifications

General IconGeneral
BrandENERGY KINETICS
ModelEK1
CategoryBoiler
LanguageEnglish

Summary

RECORD OF INSTALLATION

SYSTEM 2000 Boiler - Principle of Operation

IMPORTANT MESSAGE TO HOMEOWNER

Instructions should be carefully read and kept for future reference to gain the best performance.

Digital Energy Manager - Principle of Operation

Receiving and Unpacking

Inspect shipment for external damage. Store all parts safely and report any missing items.

Location and Clearance

Provide clearance to combustible surfaces and follow national codes for installation.

COMBUSTION AIR

Boiler with outside air piping

Connect Air Box to an outside air source for combustion air, recommended for tight construction.

Boiler without outside air piping

Confined spaces need permanent openings for combustion air, ensuring adequate infiltration.

CHIMNEY VENTING

L-Vent Chimney

L-Vent chimney pipe is suitable for SYSTEM 2000 boilers due to lower flue gas temperatures.

Sidewall Venting

Instructions for installing sidewall venting kits and ensuring proper air supply.

Fuel System

Oil Burner Settings

Lists approximate settings for oil burners based on testing, final settings require combustion test equipment.

Oil Burner Mounting

Instructions for installing the oil burner, including the ceramic amulet and retort cement.

General Assembly

Boiler Mounting

Follow base assembly instructions or mount on solid, level blocks. Boiler has a specific pitch for air removal.

Piping

Zone Control

Controls heating zones and domestic hot water using 24-volt zone valves for each zone.

Hot Water Storage Tank

Arrangement of the domestic hot water system. Insulation is recommended for fuel efficiency.

Heat Exchanger and Bypass

Filling With Water, Venting, and Purging

Fill system with water, keep vent cap open, and purge zones until a steady stream of water.

Water System Maintenance

Covers boiler water treatment, anti-freeze, and winterizing procedures for system protection.

Wiring and Controls

Electrical Connection - Line Voltage

Connect 120V power from a dedicated circuit. Ensure proper grounding for all electrical accessories.

Low Voltage Wiring

Digital Manager operates on 24-volt power. Thermostats require careful placement away from drafts.

Digital Manager

Low Voltage Wiring Diagram

Diagram illustrating low voltage wiring for the Digital Energy Manager and its components.

Install Digital Manager

Instructions for mounting the Digital Manager to the junction box and connecting the quick connectors.

Digital Manager Option Switch Settings

Details the function of each option switch on the Digital Manager for system customization.

Prepare For Start Up

Hydronic Control Settings

Lists normal settings for the High Limit Aquastat and Hot Water Tank Thermostat.

Start Up Procedure

Step-by-step guide for initial boiler start-up, including checks and adjustments.

Oil Burner Operation

Installation Conditions

Advises on setting Air-Fuel mixture conservatively based on installation conditions for efficient operation.

Operational Checks

Instructions for checking draft, CO2/O2, stack temperature, and smoke test after 15 minutes of running.

Expanded Digital Manager

10 & 15 Zone Manager Installation Instructions

Instructions for installing the expanded Digital Energy Manager with additional zone capabilities.

Security System Interface Wiring

How to connect the Digital Energy Manager to a home security system for monitoring.

Digital Manager Operation

Digital Energy Manager Check

Guide to troubleshooting by observing Manager lights and temperature indicators for problem diagnosis.

Troubleshooting

Basic troubleshooting steps for common issues like the burner not running.

2-Minute Digital Energy Manager Diagnostic

Additional Manager Tests

Case 1: Zones heating intermittently

Test procedure for diagnosing intermittent zone heating issues.

Case 2: 140 F light Flashing without burner lockout

Test procedure for addressing the 140F flashing light without a burner lockout.

Digital Manager Sensor Testing

How to test the digital temperature sensor, with warnings about applying voltage.

Troubleshooting With the Digital Manager

Line Voltage Relays

Explains the role of line voltage relays in controlling the burner, circulator, and inducer.

Surge Suppression

Details the surge suppression features on the system's relay board.

Flashing Light Indicators

Explains what different flashing lights on the Manager indicate and potential causes.

Operation without the Digital Manager

Service Board Mode

How to place the Manager in "SERVICE BOARD MODE" for conventional boiler operation.

Diagnostics with the Digital Manager

Explains Manager lights, their conditions, and corresponding diagnoses for troubleshooting.

Annual Maintenance

CLEANING PROCEDURE

Step-by-step instructions for cleaning the boiler's internal surfaces and flue passages.

Replacement Parts

Amulet Replacement

Recommends replacing the ceramic sleeve "amulet" each time the air tube is removed for protection.

Combustion Chamber Replacement

Provides instructions for replacing the combustion chamber if it becomes necessary.

LIMITED LIFETIME WARRANTY

THREE YEAR –LIMITED WARRANTY FOR RESIDENTIAL WATER BOILERS

Warranty covering defects in material and workmanship for three years from installation.

ADDITIONAL COMPONENT LIMITED WARRANTIES

Covers Digital Energy Manager (5 years) and other supplied components per manufacturer.

LIMITED LIFETIME WARRANTY FOR THE PRESSURE VESSEL

Covers the pressure vessel for the lifetime of the original owner, with prorated charges after 10 years.

WARRANTY TRANSFER

WARRANTY SERVICE

Instructions on how to obtain prompt warranty service and contact Energy Kinetics.

Warranty Transfer Agreement

Form for the original owner to transfer the warranty to a new owner.

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