The document describes the SYSTEM 2000 Frontier Boiler by Energy Kinetics, an oil-fired hydronic heating system designed for efficient home heating and domestic hot water.
Function Description:
The SYSTEM 2000 boiler is a low-pressure, closed-loop system that serves as a heat source for hydronic heating, radiant heating, domestic hot water, spa, and/or pool heating systems. It operates on a "forced circulation counter-flow" design, where water circulates through one passageway and heated gases through another, ensuring highly efficient heat transfer from burning fuel to circulating water. The boiler remains cold until a thermostat or tank aquastat calls for heat. The Digital Manager, an electronic control, receives the call, activates the main circulator and burner, and opens zone valves to deliver heat. After satisfying the heat call, the Digital Manager enters an "energy recovery" stage, utilizing residual heat in the boiler to further heat the home or domestic hot water tank, virtually eliminating off-cycle losses. This rapid response system can heat rooms quickly, typically supplying heat in about 90 seconds. The boiler is tightly sealed to ensure all combustion products are directed to the chimney or sidewall vent.
Important Technical Specifications:
- Power Supply: 120 VAC, 60 Hz, 7.5 Amperes. Supply voltage must be within 108 VAC min / 132 VAC max for reliable operation.
- Water Content: EK1 Frontier holds 2-1/2 gallons, EK2 Frontier holds 4 gallons.
- Boiler Flue Outlet: EK1 Frontier is 2", EK2 Frontier is 3".
- Air Inlet Pipe Size: EK1 Frontier is 4", EK2 Frontier is 6".
- Weight: EK1 Frontier is 270 lbs, EK2 Frontier is 350 lbs.
- Heating Capacity: EK1 Frontier can heat water up to 100,000 BTU's per hour, and EK2 Frontier up to 200,000 BTU/hr.
- Annual Efficiency: Extremely high (over 99% of steady state).
- Boiler Pitch: Manufactured with a slight rear pitch (1/2 to 1 bubble higher) for proper air removal. EK1 Frontier is pitched 1/4", EK2 Frontier is pitched 7/16".
- Input GPH (Oil Burner Settings):
- EK1 Frontier: Factory preset for 0.85 GPH, adjustable from 0.68 to 1.0 GPH.
- EK2 Frontier: Factory preset for 1.40 GPH, adjustable from 1.20 to 1.75 GPH.
- Combustion Air: Requires adequate fresh air. Outside air piping is highly recommended, using PVC pipe (2" for EK1, 3" for EK2, up to 20 feet with up to 5 90-degree elbows). Total equivalent length of 45 feet allowed.
- Chimney Venting: Flue gas temperatures typically between 350F and 450F. L-Vent chimney pipe (U.L. Listed to U.L. 641) is suitable. Metal liners should be at least 5" diameter for EK1 and 6" for EK2.
- Sidewall Venting: Requires outside air connected to the air box. Sidewall vent inducer should be above the boiler flue outlet. Draft over fire between -0.10" to -0.12" w.c.
- Safety High Limit Aquastat: Normal setting 220° F Maximum, 10° Differential: 215/205° F.
- Domestic Hot Water Tank Aquastat: Normal setting 120° F (adjustable).
- Pressure Relief Valve: 30 psi.
- Expansion Tank Sizing: Depends on total system water volume.
Usage Features:
- Digital Manager: The electronic control unit features input lights (left side) indicating thermostat calls and output lights (right side) indicating active zones, burner, circulator, and inducer operation. It displays boiler RETURN temperature and acts as the operating aquastat, turning off the burner if return temperature reaches 170°F. Flashing lights indicate detected problems.
- Zone Control: Supports multi-zone heating control using 2-wire, full-port, 24-volt zone valves. Can also be configured for zone control by circulators with flow valves and 24-volt relays.
- Hot Water Priority: The Digital Manager can prioritize hot water calls for up to 25 minutes (if Option Switch #10 is ON), closing heat zones 1-4 during this time.
- Energy Recovery: After a heat call, the circulator and zone valve remain energized to extract remaining heat from the converter, reducing off-cycle losses.
- Service Board Mode: The Digital Manager can be placed into a "Service Board Mode" by removing the RED temperature sensor lead, allowing the boiler to run like a conventional boiler with continuous circulator operation and burner controlled by the high limit aquastat.
- Antifreeze: Only non-toxic Propylene Glycol antifreeze should be used, especially if the system produces domestic hot water. A 30% by volume mixture is recommended for optimal performance.
- Security System Interface: The System Manager includes a monitor interface system to alert a home security system or other device when a problem is detected.
Maintenance Features:
- Annual Tune-Up: Required by a qualified service agency to maintain top efficiency and performance and verify safety devices. Includes initial draft loss and CO2 test, opening/closing front cover, inspecting flue passage, cleaning boiler, removing drawer assembly, checking electrode settings, porcelain condition, nozzle, and verifying safety functions.
- Periodic Maintenance:
- Daily inspection of the area around the burner/boiler for flammable or combustible materials.
- Monthly observation of burner/boiler operation through an operating cycle.
- Inspection of flue connections for deterioration or escaping flue products.
- Inspection for water leakage from the safety pressure relief valve.
- Verification of pressure gauge (5-30 psi) and temperature gauge (no more than 220F at end of heating call).
- Boiler Cleaning: The Frontier Boiler has a hinged front cover for easy access for inspection and cleaning. All service access is from the front.
- Boiler Water Treatment: Addition of 8-Way Boiler Treatment (1 quart per 30 gallons) is recommended to reduce lime buildup, especially in areas with medium water hardness.
- Amulet Replacement: A new ceramic sleeve "amulet" is recommended each time the air tube is removed.
- Combustion Chamber Replacement: The high-quality refractory ceramic fiber combustion chamber normally does not need replacement, but replacements are available from Energy Kinetics.
- Backflush Plate Heat Exchanger: Instructions provided for backflushing the heat exchanger to address "hard" (lime) domestic water supply.
- Fuel Filter: A high-quality UL Listed 10-micron fuel filter is recommended in the fuel line.
- Troubleshooting: The Digital Manager provides diagnostic lights and a 2-minute diagnostic procedure to help identify problems. A troubleshooting guide is included for common issues.
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