Frontier Gas Heat – PN 10-2027 – June 2018 5
TABLE OF CONTENTS
EK1 Frontier and EK2 Frontier ................................................................................................................................................ 1
INSTALLATION & SERVICE MANUAL .................................................................................................................................... 1
GAS HEAT EDITION ................................................................................................................................................................. 1
PLEASE READ THIS FIRST ..................................................................................................................................................... 2
TABLE OF CONTENTS ............................................................................................................................................................ 5
SCOPE ....................................................................................................................................................................................... 6
SYSTEM 2000
®
FRONTIER BOILER ........................................................................................................................................ 7
SYSTEM 2000 BOILER - PRINCIPLE of OPERATION ........................................................................................................... 7
DIGITAL MANAGER - PRINCIPLE of OPERATION ................................................................................................................ 7
RECEIVING and UNPACKING ................................................................................................................................................. 8
LOCATION and CLEARANCE ................................................................................................................................................. 8
CLEARANCE for CLEANING and SERVICE ........................................................................................................................... 9
COMBUSTION AIR .................................................................................................................................................................. 9
VENTING ................................................................................................................................................................................... 9
CHIMNEY CONNECTOR ........................................................................................................................................................ 10
CHIMNEY VENTING ................................................................................................................................................................ 10
L-VENT CHIMNEY ................................................................................................................................................................... 10
B-VENT CHIMNEY .................................................................................................................................................................. 11
SIDEWALL VENTING ............................................................................................................................................................. 11
VENTING MATERIALS ........................................................................................................................................................... 11
REMOVAL FROM COMMON VENT SYSTEM ....................................................................................................................... 11
GAS BURNER MOUNTING .................................................................................................................................................... 12
GAS BURNER SETTINGS ...................................................................................................................................................... 12
GAS PIPING SYSTEMS .......................................................................................................................................................... 12
GENERAL ASSEMBLY ........................................................................................................................................................... 13
BOILER MOUNTING ............................................................................................................................................................... 13
PIPING ..................................................................................................................................................................................... 15
ZONE CONTROL .................................................................................................................................................................... 15
FILLING WITH WATER, VENTING, and PURGING .............................................................................................................. 16
BOILER WATER TREATMENT .............................................................................................................................................. 16
ANTI-FREEZE.......................................................................................................................................................................... 16
WINTERIZING.......................................................................................................................................................................... 16
LINE VOLTAGE WIRING DIAGRAMS ................................................................................................................................... 17
WIRING and CONTROLS ....................................................................................................................................................... 17
ELECTRICAL CONNECTION - LINE VOLTAGE ................................................................................................................... 18
LOW VOLTAGE WIRING ........................................................................................................................................................ 18
START UP PROCEDURE ....................................................................................................................................................... 24
The AIR-FREE METHOD of MEASURING CO ...................................................................................................................... 25
GAS BURNER OPERATION ................................................................................................................................................... 25
OUTPUT SIDE ................................................................................................................................................................ 27
2-Minute Energy Manager Diagnostic .................................................................................................................................. 28
Step 1: ..................................................................................................................................................................................... 28
Make sure you have no thermostat calls (turn thermostats down or disconnect after labeling zones). ...................... 28
Additional Manager Tests ..................................................................................................................................................... 29
Line Voltage Relays ............................................................................................................................................................... 30
Surge Suppression ................................................................................................................................................................ 30
NOTE for sidewall vent systems: Add a 120VAC jumper from BURN to IND. This will run the inducer continuously,
so caution should be used in systems without antifreeze.ANNUAL TUNE UP & INSPECTION .................................... 32
Step 3 Inspect Flue Passage ................................................................................................................................................ 33
Annual Tune Up & Inspection ............................................................................................................................................... 34
Step 3 Open Front ................................................................................................................................................................ 34
REPLACEMENT PARTS ......................................................................................................................................................... 35
AMULET REPLACEMENT ...................................................................................................................................................... 35
COMBUSTION CHAMBER REPLACEMENT ......................................................................................................................... 35
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