ENERGY KINETICS EK-Pak, Owners And Installation Manual

Page 1: ...lasses Hill Rd Lebanon NJ 08833 www energykinetics com First Edition December 2002 X TechDocs Installation_Manuals EK Pak EK Pak Installation Manual 1st doc Note to the installer Attach this manual in...

Page 2: ...fire or explosion may result causing property damage personal injury or loss of life WARNING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other gas...

Page 3: ...room as the burner Do not use or store laundry products paint varnish thinner or other such chemicals near or in the same room as the burner water heater These chemicals cause creation of acids in th...

Page 4: ...ur gas supplier call the fire department OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set the thermostat s to their lowest setting 3 Turn off all electrical power to the burner he...

Page 5: ...es as applicable National Fuel Gas Code ANSI Z223 1 NFPA 54 Installation Codes CAN CGA B149 National Electrical Code ANSI NFPA 70 Canadian Electrical Code Part I CSA 22 1 Electrical Code Chimneys Fire...

Page 6: ...ing 10 Components Diagram 26 EK Pak Hot Water Knockdown 11 Hot Water Piping Schematic 27 Gas Protection Kit 12 Location and Clearances 28 Example Baseboard Sizing 12 General Assembly 29 Example Air Ha...

Page 7: ...utility bills Clean Safe Environmentally Friendly Engineered with total efficiency in mind the EK Pak uses sealed combustion and smart safety monitoring devices to ensure that the system is working fl...

Page 8: ...integrated into the system The extremely versatile design is based upon research development and field testing with homeowners professional installers and service people The EK Pak system has been des...

Page 9: ...ng to the heat load and the supply temperature will always be held constant This example has the option switches set to maintain 180 F supply For example let s say we have a baseboard zone being suppl...

Page 10: ...upon receipt for external damage When unpacking and uncrating inspect each item for internal damage Any damage found should immediately be reported to the freight carrier before installation The recei...

Page 11: ...alve 30 PSI Relief Valve 14 Plate Heat Exchanger Heat Hot Water System Only One Zone Valve Heat Hot Water System Only 4 Zone Control Box with Hot Water Priority Switch Switch must be turned on for Dom...

Page 12: ...Hot Water Piping Schematic Actual piping will vary per application To Tank Connection Feedwater Drain Backflush Smart Pump Check Spring Glass Lined Tank Hot Water Standard Hot Water To House 42 Gal Ta...

Page 13: ...problems if not treated 4 Maintain proper space for servicing Install the unit so it can be connected and serviced easily 5 Avoid installing in areas with high levels of dust sand or debris Particles...

Page 14: ...locks For Erie zone valve set thermostat heat anticipator to 0 35 amperes CAUTION Label all wires prior to disconnection when servicing controls Wiring error can cause improper and dangerous operation...

Page 15: ...ystem by closing its individual manual shutoff valve Gas piping must be properly sized in accordance with the National Fuel Gas Code NFPA 54 or according to state and local codes as applicable Gas pip...

Page 16: ...he sediment trap should be located as close to the inlet of the unit as possible at the time of installation The heating module and its gas connection must be tested for gas leakage before placing the...

Page 17: ...de the building Wait at least three minutes after shutting the main gas valve Record the ending manometer reading and time of day The manometer reading should not have changed o Example start reading...

Page 18: ...hould not increase more than 20 over the 50 draw pressure o Should not increase more than about 2 for Propane or 1 5 for Natural Gas If increase is too much then possibly the regulator is not working...

Page 19: ...Hot water temperature over 125F can cause severe burns instantly or death by scalding Children disabled and elderly are at the highest risk of being scalded Test water temperature before bathing or sh...

Page 20: ...O NOT START BURNER UNTIL THE SYSTEM IS FULL OF WATER Before placing system in operation carefully check for leaks throughout system Tighten pipe joints circulator flanges check gaskets etc as needed H...

Page 21: ...a direct vent Sealed Combustion system All the combustion air supplied to the unit is supplied from outside of the building Suitable piping such as galvanized single wall vent pipe PVC corrugated stai...

Page 22: ...A 54 or Sections 7 2 7 3 or 7 4 of CAN CGA B149 Installation Codes or the applicable provisions of the local building codes The venting system must not exceed a length of 25 ft minus 5 ft for every el...

Page 23: ...9 All joints are secured and sealed 10 Combustion air supply is available and sufficient See Combustion Air and Venting Start Up Procedure FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not f...

Page 24: ...he Burner 1 Set thermostat s to their lowest setting 2 Turn off all electric power to the burner and heating module if service is to be performed 3 Actuate the Manual Gas Shut Off Valve to the OFF pos...

Page 25: ...an The following systems and parts should be checked Refer to the heating module manual for details and specific instructions 1 Venting systems 2 Burners 3 Manual operation of the pressure relief valv...

Page 26: ...not initiate Purge system of trapped air Check system circulator Check the system strainer and flow sensor for debris or damage Heating Module Error Codes All EK Pak units have a self diagnostics syst...

Page 27: ...mesh screen o Hex plug for cleanout Copper by male adapter Copper tubing Copper by female adapter Hot Water outlet side 150 psi 210F T P relief valve 2 Fitting by female adapters Copper tee All fitti...

Page 28: ...valve leads into terminals 1 2 labeled valve on back Use a short phone jack not an RJ 11 plug cable to connect the valve controller to either of the two jacks on the back of the detector Green light i...

Page 29: ...ard is 60 000 B Hr The baseboard has been oversized by 15 from 62 feet to 71 feet per zone The Siegenthaler program has been used to calculate the actual heat output from the baseboard when one and tw...

Page 30: ...Pak s flow is fixed at 4 gpm and will be divided between all open zones The required total heat output from the two air handlers is 120 000 B Hr The air handlers have been derated to 80 from 80 300 B...

Page 31: ...odule This should prevent the EK Pak from running while the H port is closed on the mixing valve ZONE 1 T T T T ZONE 2 T T ZONE 3 T T ZONE 4 1 2 3 4 ZONE 1 1 2 3 4 ZONE 2 ZONE 3 1 2 3 4 ZONE 4 1 2 3 4...

Page 32: ...0F and 0 180F Reset ratio is 4 Set differential to 20F Warm Weather Shutdown 65F Adjust above settings to suit installation requirements 20F differential turns on second EK Pak Injection Loop Return H...

Page 33: ...Transformer Only THERMOSTAT Y Y G ZONE CONTROL ISOLATE RELAY TO T T ADD 24V R W 4 WIRE THERMOSTATS REQUIRE ISOLATION OUTDOOR CONDENSER CONTACTOR C End Switch From Zone Valve G R W EK Pak Zone Control...

Page 34: ...G EK Pak Zone Control See Wiring Diagram 24 Volts Supplied by Zone Control Outdoor Condenser Contactor 4 Wire Zone Valve to Air Handler Hot Water Coil 5 Wire Thermostat with Independent Heat Cool Tran...

Page 35: ...as needed 4 in x 3 ft Pipe 4 in x 90 degree Elbow 4 in x 45 degree Elbow All parts are UPS shippable 10 0191 SGV2 Z Vent III Basic Kit 10 0191 P43 4 inch x 3 foot Pipe 10 0191 E490 4 inch x 90 degree...

Page 36: ...ion Manual EK Pak Owner Installation Manual First Edition December 2002 35 Z Vent III includes a built in silicone gasket that will seal the flue products inside the pipe Just slip the parts together...

Page 37: ...Materials Item Part Number Description 1 10 0433 Automatic Air Vent 2 10 1216 4 Zone Control Box 3 10 0444 System Circulator 4 10 0150 E Zone Valve 5 10 0446 14 Plate Heat Exchanger 6 10 0211S Header...