ENERGY KINETICS EK1 Frontier Service manual

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
[phone]
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
®

Twenty Ninth Edition – July 2005 2
RECORD OF INSTALLATION
INSTALLER NAME:
INSTALLER ADDRESS:
INSTALLER CITY, STATE:
DATE INSTALLED:
NOTES:
INSTALLER NOTE:
ALL INSTALLATIONS MUST BE MADE IN ACCORDANCE WITH ALL STATE AND LOCAL CODES THAT MAY
DIFFER FROM THIS MANUAL.
All installations must be made in accordance with all State and Local Codes, which may differ from this manual and in
accordance with the following Codes, as applicable:
N.F.P.A. No. 70: National Electrical Code
A.N.S.I. / N.F.P.A. No. 31: Installation of Oil Burning Equipment
A.N.S.I. / N.F.P.A. No. 211: Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances.
If this oil fired boiler is converted to gas fired by field mounting a listed gas conversion burner, then install in accordance
with A.N.S.I. Z223.1/N.F.P.A. No. 54: National Fuel Gas Code
These codes are available from:
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269-9101.

Twenty Ninth Edition – July 2005 3
Table of Contents:
Page Topic Page Topic
2 Record of Installation 12 Wiring and Controls
3 Table of Contents 12 Electrical Connection - Line Voltage
3 Please read this first 12 Line Voltage Wiring Diagram
4 SYSTEM 2000 Boiler - Principle of Operation 12 Low Voltage Wiring
5 Digital Energy Manager - Principle of Operation 13 Low Voltage Wiring Diagram
5 Receiving and Unpacking 13 Install Digital Manager
5 Location and Clearance 13 Digital Manager Option Switch Settings
6 Boiler Weight, Water Content, Air Inlet Sizes 14 Hydronic Control Settings
6 Combustion Air 14 Prepare for Start Up
7 Chimney Venting 14 Start Up Procedure
7 L-Vent Chimney 15 Oil Burner Operation
7 Sidewall Venting 16 Expanded Digital Manager Installation
8 Fuel Systems 16 Security System Interface Wiring
8 Oil Burner Settings 17 Digital Manager Operation Summary
8 Oil Burner Mounting 18 Complete Quick Check of the Digital
Manager
9 General Assembly 19 Digital Manager Sensor Testing
9 Boiler Mounting 20 Troubleshooting with Digital Manager
10 Piping 20 Operation without the Digital Manager
10 Zone Control 20 Service Board Mode
10 Hot Water Storage Tank 21 Diagnostics with the Digital Manager
11 Heat Exchanger and Bypass 22 Annual Maintenance
11 Filling with Water, Venting, and Purging 23 Replacement Parts
11 Boiler Water Treatment 23 Amulet Replacement
11 Anti-Freeze 23 Combustion Chamber Replacement
11 Winterizing 24 Assembly Drawing
24 Parts ListInside
Back
Cover
Warranty Transfer Agreement Back
Cover
Limited Lifetime Warranty
Please Read This First…
Special Attention Flags
Please pay particular attention to the following flags when you see them throughout this manual.
DANGER: Notifies you of hazards that WILL cause severe personal injury, death or substantial property damage.
WARNING: Notifies you of hazards that CAN cause severe personal injury, death or substantial property damage.
CAUTION: Notifies you of hazards that WILL or CAN cause minor personal injury or property damage.
NOTICE: Notifies you of special instructions on installation, operation, or maintenance that are important, but not
normally related to injury or property damage hazards.
WARNING: Do not store or use gasoline or other flammable vapors and liquids in the vicinity
of this or any other combustion appliance.
CAUTION: DO NOT TAMPER WITH THE UNIT OR CONTROLS.

Twenty Ninth Edition – July 2005 4
SYSTEM 2000®Standard Boiler
IMPORTANT MESSAGE TO HOMEOWNER: These instructions should be carefully read and kept for future reference to
gain the best performance from your System 2000 boiler.
CONGRATULATIONS ON YOUR PURCHASE OF THE SYSTEM 2000 BOILER with it's highly efficient low mass hydronic
heat exchanger, the Energy Converter. It is the product of years of engineering and advanced design, which brings
together in a single system all elements needed to provide efficient home heat and hot water. This operation and
maintenance information has been prepared so that you may better understand and use your Energy Kinetics System
2000 Boiler and Heating System.
SYSTEM 2000 Boiler - Principle of Operation:
SYSTEM 2000 comprises a heat source, the energy converter, circulating water, a heavily insulated hot water storage tank
and five (or more) zones controlled by an electronic control, the Digital Manager.
The Boiler sits cold until a thermostat calls for heat. The Digital Manager receives the call for heat and turns on the
main circulator and burner. Water circulates within the boiler as it warms up to operating temperature. When ready, the
zone valves open and deliver heat to the zones calling for heat. When the thermostats are satisfied, the Digital Manager
turns off the burner and enters the energy recovery stage. The circulator and zone valve stay energized to deliver the heat
remaining in the boiler to your home or to the domestic hot water storage tank.
When energy recovery is complete and the Boiler has been cooled off, the Digital Manager turns off the system and
waits for another thermostat (or tank thermostat) to call for heat. SYSTEM 2000 runs the burner only when you need heat
and delivers that heat only where you need heat.
The System 2000 Energy Converter is the product of advanced thermal engineering. It is designed with two separate
passageways, nearly 10 feet long, coiled around each other. Water travels along one passageway from your home toward
the center of the unit and heated gases travel from the unit center toward the chimney. This is a “forced circulation counter-
flow” design and it provides very efficient transfer of heat from the burning fuel to the circulating water. The superior
insulation of the boiler minimizes heat losses to the surroundings, resulting in directing heat to your home in an efficient and
quiet manner.
SYSTEM 2000 has an extremely high annual efficiency (over 99% of steady state) because it runs only when your
home or hot water storage tank needs heat. Energy recovery is completed at the end of each heat or hot water call, virtually
eliminating off cycle losses.
Your System 2000 holds a minimal quantity of water so it begins to supply heat in about 90 seconds. This rapid
response means that your rooms can be heated quickly to temperature. Rapid response also means that domestic hot
water is always available in the insulated storage tank and can be replaced almost as quickly as you use it. The System
2000 EK1 Boiler can heat water up to 120,000 BTU’s per hour and the EK2 Boiler up to 240,000 BTU/hr.
A modern retention head oil burner fires into the center of System 2000 where a high temperature, light weight ceramic
chamber provides ideal conditions for “near perfect” efficient, pollution-free combustion. Your System 2000 is tightly sealed
so all products of combustion pass only to the chimney or sidewall vent.

Twenty Ninth Edition – July 2005 5
Digital Manager - Principle of Operation:
The left side of the Manager is the input side, which provides 24-volt power supply and connections for thermostats.
The right side is the output side, which starts the burner, circulator, zone valves or zone circulators and the domestic hot
water circulator. See photo of the Manager on the cover.
Lights on the Digital Manager indicate what is calling for heat (left side) and (right side) lights indicate active zone(s),
burner operation and circulator operation. These function lights are an aid in servicing. The following is a typical cycle.
1. SYSTEM WAITING FOR A CALL: The boiler is turned off and sits cold, waiting until a call for heat. The red power light
on the Manager is glowing.
2. CALL FOR HEAT: A room thermostat call or hot water call (aquastat) starts the cycle. The thermostat light on the left
side will turn on for that zone.
3. PRE-HEAT: Output lights for the main circulator and burner turn on, the circulator starts, and the burner begins firing.
The boiler water circulates through the energy converter via the bypass line, heating up the water.
4. HEAT: Once the boiler water has heated up to 140F (about 90 seconds), the Manager will turn on the zone output light
on the right side. The zone valve will open and hot water will flow to the zone needing heat (for hot water, the zone
output starts the hot water tank circulator). The burner runs as long as there is a thermostat calling and as long as heat
is being delivered to the zone. The burner may shut off if the return temperature exceeds 170F/190F (RED burner light
turns off) or if the high limit temperature is exceeded (RED burner light stays on, but the high limit aquastat shuts the
burner off).
5. ANOTHER CALL FOR HEAT: If another zone calls for heat while the burner is already running and the return
temperature is above 140F, the zone output will turn on, immediately supplying heat to the zone.
6. MONITOR RETURN TEMPERATURE: The Manager continually senses the return temperature and will turn off the
zone outputs if the return temperature drops below 120oF (130o F if Option Switch #1 is ON). With the zone outputs
closed, the boiler water will quickly reheat and once the return temperature reaches 140oF (150o F if Option Switch #1
is ON), then the Manager will reopen the zone valves.
7. THERMOSTAT (or Aquastat) SATISFIED: The thermostat light on the left side will go out. The burner light and the
burner will then turn off.
8. ENERGY RECOVERY: The circulator and zone valve remain energized. The circulating water will remove the energy
from the converter, sending the heat to the last zone that called. The energy recovery stage continues until the return
temperature has dropped sufficiently or until maximum timing has been reached. The boiler is now sitting cold, waiting
for the next call for heat. Maximum timing for heat recovery stage is usually set at twenty minutes for space heating
zones and is fixed at five minutes for the Hot Water zone. (See Digital Energy Manager Option Switch Settings).
Receiving and Unpacking:
Inspect shipment 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 receiver is
responsible for following the claims procedure of the freight carrier. The freight carrier is responsible for taking prompt
action on all claims. If freight cannot be inspected at the time of delivery, sign the bill of lading “Subject to Inspection” and
inspect the shipment as soon as possible after receipt. Replacements for parts damaged in shipment are available upon
receipt of a signed copy of a claim report (concealed damage claims should be filed immediately against the freight carrier
by the consignee).
After unpacking, check each item against the packing list. Inspect it thoroughly for loose parts, instruction sheets and
packing lists. Immediately report any missing items. It is wise to complete the installation before discarding packing
material. Store all parts where they will not be damaged or lost during installation.
Location and Clearance:
DANGER:Provide clearance to combustible surfaces in accordance with all local and national codes. Follow National
Fire Protection Association Bulletin NFPA Installation of Oil Burning Equipment and all applicable codes.
Installation
Clearances
Clearance to
Combustibles
Clearance for Service
Minimum Recommended
FRONT 12” 12” 18”
EK1 BACK 6” 12” 18” OR MORE
EK2 BACK 6” 18” 24” OR MORE
RIGHT SIDE W/ FLUE 6” 12” 15”
LEFT SIDE/RIGHT W/OUT FLUE 6” 6” 15”
TOP 6” 6” 12”
FLUE CONNECTION 9” 6” 6”

Twenty Ninth Edition – July 2005 6
Installations should utilize the Energy Kinetics prefabricated boiler stand to provide a solid, level, and smooth
foundation for the boiler. Place the unit as near to the chimney or vent as possible allowing clearance for rear cleaning and
service. If not using an Energy Kinetics supplied stand, provide a solid, level, and smooth foundation with clearance for
door opening and service.
NOTICE: The stand must be level to allow for proper venting of air from the boiler. The System 2000 Boiler is
manufactured with the front of the boiler higher than the back to assist in air removal.
Clearances, Water Content, Weight, and Air Inlet Dimensions
Model Water Content Weight Lbs
Air Inlet
Pipe Size A B C D Burner E
E
With Air Box
EK1 2 ½ gal. 250 2" 17 ½” 13” 2 ½” 1” Beckett 11” 13”
EK2 4 gal. 350 3" 24 ¾” 20 ¼” 3 ½” 1 ¼” Carlin 14” 15 ½”
Riello 13” 13”
COMBUSTION AIR
The System 2000 Boiler must be installed in an area where adequate fresh air is available to support combustion. The
Frontier is provided with a sealed Air Box that can be piped to air outside the building. Piping of outside air directly to the
boiler is highly recommended because it completely isolates the boiler from the home environment, as well as greatly
reducing operating noise from the boiler.
Boiler with outside air piping:
In modern houses with tight construction, the connection of the Air Box to an outside air source to provide combustion
air is highly recommended. The outside air source must be located high enough above grade to be at least 12” above
expected snow accumulation.
WARNING: For systems with sidewall venting, combustion air piping from outside the building is required. The
Energy Kinetics sidewall vent kit contains specific instructions for installation that must be followed. Combustion air may be
supplied through PVC pipe. For EK1 use, 2" pipe up to 20 feet in length with up to (5) 90-degree elbows. For EK2 use, 3"
pipe up to 20 feet in length with up to (5) 90-degree elbows. A total equivalent length of 45 feet is allowed. Each 90 degree
elbow is the equivalent of 5 feet of straight pipe. For example, if three 90 degree elbows are used, then the length of pipe
run may increase to 35 feet. For longer runs up to 40 feet with up to five 90 degree elbows, immediately increase pipe size
by 1", to 3" for EK1 and 4" for EK2. An unglued or Tek-screw joint allows the door to swing down when the air inlet pipe is
disconnected.
Boiler without outside air piping:
WARNING: The confined space shall be provided with two permanent openings, one near the top of the enclosure
and one near the bottom. Each opening shall have a free area of not less than one square inch per 1,000 BTU per hour of
the total input rating of all appliances in the enclosure, freely communicating with interior areas having adequate infiltration
from the outside.
WARNING: Modern buildings of tight construction, as well as the operation of attic and exhaust fans, kitchen
ventilation systems, clothes dryers or fireplaces may create conditions of unsatisfactory combustion or venting. Provisions
must be made to use combustion air that communicates with a well-ventilated attic or with the outdoors (such as using a
louver or grate). The opening should have a free area of not less than one (1) square inch per 4,000 BTU per hour of the
total input rating.
Figure 1
Dimension
Drawing
24 1/8"
24 1/8" 1"
5 1/4"
Jacket Extension
Vertical Flue Only
5" Flue (EK-1)
Side Flue Boiler
Vertical Flue Boiler
Sample Port
1/4" Below Supply Pipe
5" Flue (EK-1)
7" Flue (EK-2)
"A"
"B"
"E"
"D" Supply
"D" Return
9 1/4"
Sample Port
"C"
3 3/4" 3/4" 7" Flue (EK-2)

Twenty Ninth Edition – July 2005 7
CHIMNEY VENTING:
WARNING: Masonry chimneys must have a tile or metal liner. The liner must:
1) Extend above the masonry.
2) Have an insulating air gap, isolating the liner from the chimney, allowing for rapid heat-up and draft establishment.
3) Be sealed at each joint to prevent air infiltration and damage from condensation.
NOTICE: Inspect Chimney and Chimney base after initial three months of heating season.
The installation of a chimney cap is recommended. The base of the chimney must always have a drop leg below the
flue connector to allow scale and condensation to accumulate without blocking the flue pipe.
CAUTION: If drop leg is in excess of 12 inches deep, backfill with loose gravel or sand to obtain a maximum of 12-inch
depth. All clean out doors must be sealed to prevent cold air entry into chimney.
In retrofit installations, have chimney thoroughly cleaned. Carefully inspect chimney, base of chimney, and liner prior to
installation of System 2000 Boiler.
CAUTION: If liner is not sound, or if existing tile liner fails to contain intermittent condensation, or if excessive debris is
found at the base of the chimney, then it is recommended to install a properly sized metal liner approved for use with oil
heat appliances.
The metal liner diameter and length should be as recommended by the metal liner manufacturer. Corrugated metal
liners should be at least 5" diameter for EK1 and 6" diameter for EK2. Connection of a flexible metal liner directly to the flue
collar of the boiler is an acceptable connection method and is recommended. Energy Kinetics does not recommend use of
a base tee when a corrugated metal liner is installed. Alternatively, a flexible metal vent connector may be used between
the flue collar of the boiler and a flexible metal liner. Call Energy Kinetics for details on metal liners.
Chimney connectors should be positioned to create the shortest possible run of flue pipe to the chimney. The overall
horizontal length of flue piping should not exceed 15 feet. Long runs or low firing rates may require insulated flue pipe such
as L-Vent or All-Fuels to keep the temperature at base of chimney adequate for draft and to prevent corrosion of piping and
connectors.
Because the System 2000 boiler uses a power burner, the flue pipe may experience some positive pressure on start
up. Energy Kinetics recommends that all pipe joints be sealed with high temperature silicone sealant to ensure passage of
all combustion products to the chimney.
Normally, pitch horizontal flue pipe up toward chimney approximately ¼” per foot. For existing installations, it is
permissible for the flue connection of the boiler to be higher than the chimney thimble, provided adequate draft is
established.
If a minimum of -0.02” w.c. draft overfire is not present after sufficient burner run time to heat up the chimney, there is a
problem that will need to be corrected. Call Energy Kinetics for help resolving draft problems. Under normal
circumstances, there is NO need for a DRAFT REGULATOR and one should not be installed. Call Energy Kinetics with
questions about flue pipe sizing.
WARNING: No solid fuel appliance or fireplace should be installed in a flue common with this heating appliance. The
flue gas exit of the venting system must be at least three (3) feet above the point at which it passes through the roof and at
least two (2) feet higher than any portion of a building within 10 feet horizontally of its location.
L-Vent Chimney:
SYSTEM 2000 Boilers typically have flue gas temperatures between 350F and 450F during normal operation. Due to
the low flue gas temperatures, L-Vent chimney pipe is suitable for use with SYSTEM 2000 Boilers. L-Vent chimney pipe
may require smaller chase dimensions than other chimney pipe materials and should be considered for new installations
with SYSTEM 2000 Boilers. Call Energy Kinetics for help locating sources of L-Vent.
1. L-Vent must be U.L. Listed to U.L. 641.
2. L-Vent to be installed in accordance with the vent manufacturer’s instructions.
3. System 2000 and L-Vent must be installed in strict compliance with all State and Local Codes and with the regulations of
the authorities having jurisdiction, which may differ from and which take precedence over these instructions or the vent
manufacturer’s instructions.
Sidewall Venting:
1. System 2000 Boilers may be installed with Energy Kinetics' sidewall vent kit in accordance with kit instructions.
2. WARNING: Sidewall vent systems must have outside air connected to the air box and both air box air intake and vent
hood must be located on the same side of the structure.
3. NOTICE: The sidewall vent inducer should be located above the boiler flue outlet, preferably a minimum of four feet
vertical distance, which will provide some natural draft to the boiler (and cooling of the burner) in case of a power failure.
4. When installing a sidewall venting system from another manufacturer, ensure that the manufacturer’s instructions are
followed. Vent manufacturer should confirm that the equipment is suitable for use with System 2000.
5. Set the draft over fire through the puff switch opening between -.10" to -.12" w.c. with the burner running, after allowing
time for sufficient warm-up. Check/adjust CO2. Re-check the draft over fire and adjust draft if necessary.
6. To provide power to the sidewall vent, install the plug-in relay supplied with the sidewall vent kit into the junction box
relay board and set the Digital Manager Option Switch #2 to the “ON” (down) position. This enables the “Inducer” light
and allows the Digital Manager to control the inducer. Refer to Digital Manager section for option switch settings and
inducer timing details.

Twenty Ninth Edition – July 2005 8
Fuel System:
NOTICE: Inspect and if needed, replace oil lines according to local codes. Oil lines must be absolutely airtight. Use
only flared joints on all copper tubing and use thread sealant suitable for oil on all iron pipe threaded joints. Do not use
teflon tape on fuel system joints. Check all joints and connections for leaks after installation. A high quality fuel filter should
be installed in the fuel line. Energy Kinetics’ “Smart Filter” or equivalent 10-micron filter is recommended. When changing
the Smart Filter, be sure to lubricate cartridge gasket with motor oil, not heating oil.
All piping systems should conform with pump manufacturer’s specifications that are attached to each new pump. The
burner is capable of burning No. 1 or No. 2 heating oil. A fusible link shutoff valve should be installed on the supply line.
NOTICE: A two-stage pump is required if lift from oil tank exceeds approximately ten (10) feet. Follow instructions
provided by pump manufacturer on single and two pipe connections for bypass plug usage and other specific installation
requirements.
Oil Burner Settings:
EK1 Boilers are shipped from the factory preset for 0.85 GPH firing rate and EK2 Boilers are shipped from the factory
preset for 1.40 GPH firing rate. The SYSTEM 2000 Boiler can be fired over a range of firing rates to suit the needs of the
application. The following table lists approximate settings for oil burners based on testing performed at Energy Kinetics.
CAUTION: Final settings for each burner and firing rate for a particular installation must be determined by using
combustion test equipment and following the instructions given under "Start Up Procedure".
CAUTION: Because the energy converter removes heat from the combustion flue gas so efficiently, low firing rates may
not provide high enough flue gas temperature for proper draft in a chimney. The Columns labeled 'Chimney' and 'Sidewall'
show the suitability of the firing rate for a particular combination.
Model Input
GPH
Chimney
Sidewall
Vent
Nozzle@
Pump
Pressure
Beckett AFG1
Delavan 70°A
Carlin 99FRD
Single Slot Air
band
Delavan 60°A
Riello 40F5
Delavan 60°B
.68 N Y .60@130 psi Air band: 0 Shutter: 4 Head: 1.0 Air: 25 Not Recommended
.74 N Y .65@130 psi Air band: 0 Shutter: 5.5 Head: 1.0 Air: 35 Head: 1.0 Air: 2.25
.85 *Y Y .75@130 psi Air band: 0 Shutter: 7 Head: 1.5 Air: 45 Head: 1.5 Air: 2.5
EK1
1.0 Y Y .85@136 psi Air band: 1 Shutter: 8 Head: 2.5 Air: 60 Head: 2.0 Air: 2.75
1the Beckett AFG at 0.68 gph firing rate can be retrofitted with the Beckett Low Firing Rate Baffle. If used, set air band: 0, shutter: 8.5.
Model Input
GPH
Chimney
Sidewall
Vent
Nozzle@
Pump
Pressure
Beckett AFG
Carlin 99FRD
Dual Slot Air band
Delavan 60°B
Riello 40F5
Delavan 60°A
1.20 N Y 1.00@145 psi Not Recommended Head: 2.5 Air: 55 Head: 3.0 Air: 3.5
1.40 *Y Y 1.25@125 psi Not Recommended Head: 3.0 Air: 55 Head: 3.5 Air: 5.5
1.60 Y Y 1.35@140 psi Not Recommended Head: 4.0 Air: 60 Not Recommended
EK2
1.75 Y N 1.50@135 psi Not Recommended Head: 4.5 Air: 80 Not Recommended
*Factory Setting
Oil Burner Mounting:
SYSTEM 2000 Boilers are shipped from the factory with the oil burner pre-mounted. The burner flanges are designed
to insert the burner head 2-3/8” into the boiler. Energy Kinetics installs a ceramic sleeve, (the amulet), to protect the burner
head from the heat of combustion, and then seals the air tube flange joint with a high-grade retort cement. NOTICE: Oil
burners for field installation or for field replacement should be installed according to burner manufacturer instructions,
according to installation instructions below, and with consultation with Energy Kinetics for any special considerations or
adjustments.
Follow these instructions for field installation of Energy Kinetics supplied burners. Start by checking nozzle and
electrode position per manufacturer’s specifications prior to assembly to unit. Test fit the amulet by inserting the amulet into
the boiler opening. If the amulet doesn't easily slide into the boiler, then gently sand the outside diameter of the amulet until
it will fit into the boiler opening. Test fit the amulet onto the burner head. Note that the amulet designed for the Beckett
AFG burner has interior slots to accept the screws on the sides of the head. The amulet for the Beckett AFG has a small
drain hole in the front face, that must be mounted at the bottom (at 6 o'clock position). The amulet for the Carlin and Riello

Twenty Ninth Edition – July 2005 9
burners have smooth interiors. If the amulet is a tight fit on the burner head, then slightly moisten inside the amulet with
water.
Place a 3/8" bead of retort cement onto the burner head at the flange to air tube joint, and slide the (moistened) amulet
over the burner head and against the flange. Ensure proper seating of the amulet by pressing the amulet onto the burner
with a flat object. Leave the excess retort cement at the amulet to flange joint and the cement will provide an airtight seal of
the air tube flange to the boiler face.
The Beckett amulet has an inside edge that will cover the edge of the Beckett burner head. The Beckett retention head
air slots must not be blocked or obstructed by the amulet. If needed, trim a 45 degree chamfer on the inside of the amulet
using a sharp utility knife and maintain a 1/8" clearance to retention head air slots. The Carlin and Riello amulets do not
have an edge and when fully seated the amulets will be flush with the front of the Carlin or Riello burner heads. If needed,
trim the front edge of the amulet to be flush with the front of the burner head.
Once the amulet has been seated and trimmed, then install the burner into the boiler by carefully inserting the air tube
with amulet into the boiler opening while aligning the burner flange holes with the boiler studs. Install flat washers and nuts
onto the boiler studs and tighten all nuts evenly.
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 the manual are
recommended.
Boiler Mounting:
BOILER MOUNTING on STANDARD
BASE, FIGURE 2A: Follow base
assembly instructions packed in the
base carton, or mount on solid, level
blocks.
BOILER PITCH: The System 2000
Boiler pressure vessel is manufactured
with the front ½ to 1 bubble higher to
allow for proper air removal. This pitch
is carefully set at the factory when the
boiler is built. Be sure to level the
stand prior to mounting the boiler on
the stand. When the stand is level, the
pitch is correct and the front of the
boiler will be higher than the back. The
EK1 System 2000 Boiler is pitched 1/4"
and the EK2 System 2000 Boiler is
pitched 7/16".
1. Digital Temperature Sensor 14. Return 1” EK-1 / 1-1/4” EK2
2. Combustion Test Port 15. Boiler Feeder (Premier Pkg Only)
3. Burner 16. Tridicator Gauge
4. Puff Switch 17. Bypass Valve
5. High Limit Aquastat 18. Boiler Side Backflush (Optional)
6. Digital Manager 19. Plate Heat Exchanger
7. Main Circulator 20. Domestic Side Backflush Valve
8. Expansion Tank (Not Supplied) 21. Smart Pump w/Internal Flow Check
9. Zone Valves 22. Tank thermostat (Under Cover)
10. Supply 1” EK-1 / 1-1/4” EK2 23. Cold Water Supply
11. Air Vent (on boiler supply) 24. Aquastat Leads
12. Purge Valve (Premier Pkg Only) 25. Hot Water T&P Relief Valve
13. Ball Valve (Premier Pkg Only)\ 26. Boiler Relief Valve
Figure 2A
LEBANON,NJ 08833
WR
WHITE-RODGERS
3
14
11
5
6
11
26
8
9
19
16
15
20
21
23
17
Hot Water
Tank
Hot Water
Outlet
Return
Dip
Tube
18
8
10
Side View
(Top of Boiler)
7
13
12
Supply
H
C
4
22
24 25
2
1
Boiler Stand or
Block Base

Twenty Ninth Edition – July 2005 10
Piping:
All piping and accessory
connections should follow good
practice using approved joint
sealants. Figure 2B indicates
general system piping arrangement
and options.
Figure 2B indicates a typical flow
schematic for boiler water and
domestic water. Each system will
vary according to job location.
Call Energy Kinetics to obtain piping
and wiring instructions for alternate
applications, such as radiant
heating, swimming pool heating,
multiple boilers, injection loops, etc.
Zone Control:
Zone Control By Valve: The SYSTEM 2000 Boiler is designed to provide multi-zone control of the heating system and
domestic hot water. Energy Kinetics recommends and supplies two wire, full port, 24 volt zone valves for control of each
heating zone. A system with a single heating zone still requires a zone valve to provide control for preheat of unit and to
maintain minimum temperature during operation.
Zone Control By Circulator: Zone control by circulators requires a flow valve, circulator and 24-volt relay (fan type such
as Honeywell R8225B) for each zone. The main circulator, domestic heat exchanger and bypass line are still used in these
cases. NOTICE: An additional tee must be installed into the supply on the inlet side of the main circulator. This tee is the
supply for circulators with returns for these zones into normal return location. Call Energy Kinetics and request “Zoning with
Circulators” diagram.
Zone Purging: Valves to isolate and purge individual zones should be installed according to good piping practices.
Expansion Tank Sizing: The type and size of expansion tank depends on the total system water volume. The EK1
System 2000 Boiler contains 2-1/2 gallons of water and the EK2 System 2000 Boiler contains 4 gallons of water.
NOTICE: Sizing must consider cold start and hot operation due to system concepts of energy recovery and rapid heat
up.
Hot Water Storage Tank:
Figure 2A indicates a typical arrangement of the domestic hot water system. The tank may be located adjacent to or in any
other convenient location. If greater than 10 feet away, use ¾” lines and an air vent on a high return. Insulation of water
lines between the storage tank and Energy Converter and on the hot water supply to the house is recommended for best
fuel efficiency. Energy Kinetics supplied storage tanks come complete with high-density foam insulation, a properly located
aquastat, a temperature/pressure relief valve, and a specially designed dip tube.
DANGER:
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 showering. Temperature limiting, anti-scald mixing
valves are available and recommended.
Hot water storage tank thermostat does not limit the maximum delivered water
temperature. The plate heat exchanger will always provide water that is hotter than
125F into the hot water storage tank where it will mix with the water in the storage tank.
The hot water storage tank can deliver water hotter than 125F depending on the degree
of tank temperature stratification. If codes place limits on maximum delivered water
temperature, an anti-scald mixing valve MUST be installed on hot water tank outlet.
Figure 2B
Typical Flow
Schematic
HC
Domestic
Hot Water
Boiler
Water
Return
To House
Makeup
Boiler Feed
Energy Converter
Cold Water
Back Flow
Preventor
Return
Supply
Supply
Tank
Thermostat
Hot Water
Storage Tank
High Limit
Digital Sensor
Return Temperature

Twenty Ninth Edition – July 2005 11
Heat Exchanger and Bypass:
NOTICE: The heat exchanger is piped at the factory and its location and orientation should not be altered
without consulting with Energy Kinetics. The heat exchanger is mounted in the bypass line at the boiler with a ball
valve. Systems without a heat exchanger are piped at the factory with the bypass line and ball valve. The bypass
valve must be at least partially open for the boiler to operate properly.
Pipe domestic water to the connections as marked on the plate heat exchanger. When ordering a replacement, order
the part number shown in the Assembly Drawing.
WARNING:
The single wall plate heat exchanger complies with 1990 N.S.P.C. provided that both of the following are true:
A) The boiler water (including additives) is practically non-toxic, having a toxicity rating or class of 1 as listed
in Clinical Toxicology of Commercial Products, 5th Edition.
B) The pressure of the boiler water is limited to a max of 30 psig by an approved safety or relief valve.
Filling With Water, Venting, and Purging:
When piping is completed and all accessories installed the Converter and piping should be filled with water. The
Converter purges itself of air when properly installed. NOTICE: AIR VENT CAP MUST REMAIN OPEN.Vent cap should
be removed and kept in a safe location. Each zone should be purged until a steady stream of water without air passes out
of purge hose. Vent all radiation.
NOTICE: DO NOT START BURNER UNTIL CONVERTER AND SYSTEM ARE FULL OF WATER.Fill to normal cold
system pressure, 10 to 12 psi on pressure gauge. Before placing system in operation, carefully check for leaks throughout
system. Tighten pipe joints, circulator flanges, check gaskets, etc., as needed.
Boiler Water Treatment:
Addition of boiler water treatment is recommended to reduce lime buildup inside the boiler. Energy Kinetics
recommends addition of one quart of 8-Way Boiler Treatment per 30 gallons system water. 8-Way Boiler Treatment is
recommended to treat water up to medium hardness. Call Energy Kinetics for more details about boiler water treatment
and about hard water conditions.
Anti-Freeze:
Only non-toxic antifreeze (such as Propylene Glycol) should be used if adding anti-freeze to a system that produces
domestic hot water. Hard water should not be used in combination with generic antifreeze. Energy Kinetics supplies a
quality inhibited Propylene Glycol anti-freeze with orange dye and an antifoam agent. 8-Way Boiler Treatment can be
added to Energy Kinetics anti-freeze and is recommended in areas of medium water hardness. NOTICE: Thoroughly
clean system prior to adding antifreeze. TSP is recommended for removing flux and other oil based compounds. Once
system has been cleaned and flushed, then add antifreeze to obtain approximately a 30% by volume mixture of antifreeze
in water. Call Energy Kinetics for assistance in calculating how much anti-freeze to add to system.
Winterizing:
NOTICE: If the SYSTEM 2000 Boiler may be exposed to freezing temperatures, such as a vacation home shut down
for the winter, then anti-freeze should be added. When a home is winterized by draining all domestic water piping, then the
SYSTEM 2000 Boiler must be protected. It is not recommended to drain the SYSTEM 2000 Boiler, because introducing air
into the boiler can cause rusting inside the boiler shell and also because the Energy Converter has a spiral water passage
that cannot be completely drained of water. When draining the domestic water piping system, be sure to drain the domestic
side of the plate heat exchanger. If the hydronic system will not be drained, then add enough anti-freeze to protect the
entire hydronic system including the boiler, piping, radiation, circulators, etc. If the hydronic system will be drained, then
add shut off valves to isolate the boiler and add anti-freeze to the boiler only, as follows. Drain water from the boiler and
then add anti-freeze to the boiler. Refill boiler with water and run boiler circulator through the bypass to distribute antifreeze
within boiler. Propylene Glycol in water will provide the following freeze protection: 30% down to +8F, 40% to -8F, and 50%
to -27F. Energy Kinetics recommends using 30% anti-freeze to obtain the best boiler performance. Use over 30% anti-
freeze only if lower temperature freeze protection is mandatory.
CAUTION: Always keep the fuel supply valve shut off if the burner is shut down for an extended period of time.

Twenty Ninth Edition – July 2005 12
Wiring and Controls:
The System 2000 Boiler Heating System is furnished with controls and basic accessories as illustrated and described in
this manual. Control, burner and accessory instruction sheets and system wiring diagrams should be attached to this
manual for future reference. DANGER: All wiring must comply with the NEC and any local codes.
Electrical Connection - Line Voltage:
POWER SUPPLY: 120 VOLT 60 HZ, 7.5 Amperes
DANGER: Make All Connections with Power Off at Main Circuit Box
Figures 3A and 3B: Connect power from a separate 15 AMP fused circuit. Install 3rd wire grounding for proper bond
between all electrical accessories. The system switch is included so power can be shut off at the unit for servicing.
Pigtails are provided for the line voltage power connection. Connect black pigtail to hot, white pigtail to neutral, and the
green pigtail to ground. WARNING: The junction box is wired at the factory with the service outlet always powered, even
with the System Emergency Switch turned off. To have the service outlet controlled by the System Emergency Switch,
move the service outlet black lead to top lug of system switch. A low water cut-off may be field installed if required by local
codes and is available from Energy Kinetics.
Line Voltage Wiring Diagram:
Low Voltage Wiring:
DIGITAL MANAGER OPERATES ONLY ON 24 VOLT 60 HZ POWER
WARNING: Make All Connections with Power Off at Main Circuit Box
A typical low voltage wiring diagram for the Digital Energy Manager is shown in Figure 4A. Thermostats must be
located on inside walls away from cold drafts, windows or heat from fireplaces, appliances or sunlight. Set thermostat heat
anticipators to 0.1 amps (or "gas" if gas/electric option). Call Energy Kinetics to request alternate low voltage wiring
diagrams to handle special situations such as air handler wiring, heat pump wiring, isolation relays for thermostats, and
isolation relays for heat motors or circulators, etc.
The single 24-volt/50VA transformer is suitable for the Digital Manager and five zone outputs (zone valves or relays).
NOTICE: Additional load such as extra valves may require greater transformer capacity. To add transformers, wire in
parallel as follows: wire terminal “A” on one transformer to “A” on the other. Repeat with other low voltage terminal “B”. Be
sure to verify 24VAC output from all transformers.
Ground N
High Limit
Aquastat
Outlet YELLOW- 2 Cond.
WHITE BLACK BLACK
WHITE (NEUTRAL)
Switch
N/C
Puff Cell
Cad
Inducer HW Main
CircFan Circ TT
F
F
To Burner
RED (HOT)
GND
WHITE
WHITE
Screw
L
GREEN
WHITE
BLACK
U
T
A
R
E
120V
BLACK
INDXFMR
PWR HW
CIRC CIRC
MAIN
BURN
BLACK
BLACK
RED
BURNER
MAIN CIRC
HW
CIRC
IND
BLACK RED
Neutral 120 VAC Power In
Power Leads
Transformer
Switch
System
BLACK
GREEN WHITE BLACK
1
2
V
0
Hot
Ground
ORANGE
(White)
(Black)
WHITE
IND 24 CIRC
VAC
HW
RED
GREEN
BLUE
Switch
24V
BLACK
BLK
BLACK
Burner
(Blue)
(Orange)
(Red)
(Green)
-B1
-B2
-Circ
-24V
-Ind
-ZHW
Output Cable
from Right Side
of Digital Manager
BLACK
WHITE
WHITE
GREEN
BLACK
FIELD WIRING
USE COPPER CONDUCTORS ONLY
Limit Aquastat
Main Circ
Relay
Burner
Switch
Puff
Direct
Switch
Burner Service
(Neutral)
White
Low Water Cut-Off
(Optional Location)
Voltage
Inducer
Transformer
50 VA
A1 24 V
Black
(Hot) Line
GND
A2
Green
FF
Cad Cell
Eye
System
Emergency
Switch
NO. Relay
Burner &
Main Circ
NO. Relay
HW Circ
Domestic
HW Circ
NO. Relay
Ind/Aux
Figures 3A & 3B

Twenty Ninth Edition – July 2005 13
The Digital Energy Manager is designed for hot water and up to four (4) heating zones. Use Energy Kinetics supplied
zone valves with two wire connections. For more than four heating zones, use Energy Kinetics expanded 10 or 15 zone
Digital Energy Manager, or call Energy Kinetics for alternatives.
Low Voltage Wiring Diagram:
Install Digital Manager:
The Digital Energy Manager is shipped in its own protective shipping box. NOTICE: The option switches can be set
very easily before the Manager is installed. Locate the pre-wired quick connectors fastened to the front of the junction box
by two cable ties. Cut the two cable ties and discard. Fasten the Digital Manager to the junction box with the four corner
screws. Slide the two quick connectors onto the Digital Manager. Label each zone on the manager, using the adhesive on
labels supplied.
Digital Manager Option Switch Settings
Switches are located on bottom of
Digital Energy Manager
Option
Switch
Description
Function
ON = DOWN OFF = UP
1 Low Return Temp. ON = 130o/ 150 o F. (Gas) OFF = 120 o /140 o F. (Oil)
2 Inducer/Chimney ON = Inducer Venting OFF = Chimney Venting
3 Inducer Purge Temp. ON = stop purge when Boiler Return Temp
cools down to 120 o F
OFF = stop purge when Boiler Return Temp
cools down to140 o F (See Switch # 4)
4 Inducer Purge Time ON = 3 minutes minimum OFF = 5 minutes minimum
After purge time, purge controlled by return temperature. (See Switch # 3)
5 Zone 1 Purge Time ON = max 5 minutes energy recovery OFF = max 20 minutes energy recovery
6 Zone 2 Purge Time ON = max 5 minutes energy recovery OFF = max 20 minutes energy recovery
7 Zone 3 Purge Time ON = max 5 minutes energy recovery OFF = max 20 minutes energy recovery
8 Zone 4 Purge Time ON = max 5 minutes energy recovery OFF = max 20 minutes energy recovery
9 High Return Temp. ON = 190 o /175 o F. OFF = 170 o /155 o F. (Normal)
10 Hot Water Priority ON = Priority OFF = No Priority
Figure 4B
EXPANDED MANAGER DIP SWITCHES
NOTE: "ON" is DOWN position
NORM. CLOSED
STANDARD MANAGER DIP SWITCHES
ALARM LEADS
NORM. OPEN
COMMON
21
ON
1234
ON
019876543
ZONE: 8765
6501789
10 11 12 13 419
Figure 4A
ZONE VALVE 3
Z3A1
Lebanon, New Jersey
TRANSFORMER
24V POWER
RED
FROM ZONE 4
SYSTEM 2000
TEMP
LEADS
SENSOR
BLACK
SILVER
TEMP. SENS.
T4
R
CAUTION
MAKING ANY CONNECTIONS
READ INSTRUCTIONS BEFORE
24 VAC CONNECTION ONLY.
B
S
A2
4
TO BURNER RELAY
MAIN CIRC RELAY
MONITOR
CIRCULATOR
160
130
120
100
140
150
190
POWER
170
ONLY
CHIMNEYLESS
BURNER
INDUCER
4
CIRC
B2 T
IND
B1
24VAC
T
FIELD WIRING
FACTORY WIRING
ZONE 3
ZONE 1
ZONE 2
SYSTEM 2000
80
70
60
90
THW
T2
T3
T1
2
3
1
THERMOSTAT
HOT WATER TANK
HW CIRC RELAY
ZONE VALVE 2
ZONE VALVE 4
2
3
1
HOT WATER
HEATING
Z4
Z1
Z2
ZHW
ZONE VALVE 1
SYSTEM 2000
SYSTEM 2000
*Field Wiring terminated to input terminal A1 and to output terminal 24VAC are to
be wired into the open lugs provided at those locations.

Twenty Ninth Edition – July 2005 14
For a typical oil fired boiler with a sound chimney, supplying domestic hot water and properly sized heat zones, all option
switch settings will be "OFF". Turn switch 1 on to provide increased condensing protection (recommended for gas fired
boilers). For sidewall vent applications, turn switch 2 on and then usually leave switches 3 and 4 off.
Switches 5 through 8 are usually off, but can be turned on if the heat zone tends to overheat during energy recovery.
Switch 9 is usually off, but can be turned on to supply higher temperature water to under-radiated heating zones or during
very cold weather. Switch 10 is usually off, but when turned on the Manager will close heat zones 1 through 4 during a hot
water call for up to 25 minutes.
Hydronic Control Settings
Control Model No. Normal Setting
HIGH LIMIT AQUASTAT
(Located front and center of boiler)
White Rodgers Model 1145-42
Energy Kinetics PN: 10-0415
215oMaximum
10 o Differential: 215 o– 205 o F.
HOT WATER TANK
THERMOSTAT
(Located on domestic storage tank)
Energy Kinetics PN: 10-0414 120 o Normal
(To suit individual installation)
Prepare For Start Up:
DANGER: MAKE CERTAIN THE FOLLOWING REQUIREMENTS HAVE BEEN SATISFIED BEFORE START UP:
1. The boiler and piping are completely filled with water.
2. Re-check wiring to ensure that it is correct and in accordance with appropriate wiring diagrams and codes.
3. Verify that proper nozzle is used and installed correctly.
4. Verify electrode settings.
5. Verify the burner settings for air band position and head position (See "Oil Burner Settings" Table).
6. Oil supply is connected to burner. Oil supply lines and shut-off valves are open.
7. Fuel pump and fuel lines are purged.
8. Verify operating oil pressure at gauge port.
9. Adjust bypass valve on boiler side to heat exchanger ½ way open. (See #4 under “Oil Burner Operation”)
10. Flue pipe properly connected from unit to chimney. All joints are secured and sealed.
11. Combustion air supply is available and sufficient. (See “Combustion Air”)
12. Adjust valve in domestic hot water circuit under circulator approximately ¾ of the way open.
13. Punch a ¼” sampling hole in flue pipe as near to unit as possible in flue outlet and loosen 1/8” brass plug in front jacket
(under the burner) for use as the overfire sampling location.
14. Caution: All covers, enclosures, and guards must be maintained in place at all times, except during maintenance and
servicing.
15. Caution: Do not start burner unless the rear cover is closed and the nuts have been properly tightened
Start Up Procedure:
1. Turn on system supply switch and burner supply switch. The Digital Manager lights should come on briefly, the
circulator relay should close briefly, and then the Digital Manager should only show one red light next to 'power'.
2. The hot water tank thermostat should call for heat, if not, adjust a thermostat to call for heat. Burner and main circulator
should come on at the same time. If not, check primary control and reset it if necessary.
3. Check for burner light off. On an oil supply system with one pipe, it will be necessary to bleed air from fuel pump. On a
two pipe system, several starts may be required to clear air from fuel pump, or bleed air from pump.
4. On light off, water temperature and chimney temperature will start to rise. A slight odor is common on initial light off as
combustion chamber and converter surfaces warm for the first time.
5. NOTICE: Perform smoke test immediately after light off. Smoke test should show yellow after initial one minute of
operation due to the combustion chamber sizing heating up. If the smoke test shows dark gray or black after one
minute of operation, shut off boiler immediately and repeat "Prepare for Start Up" checklist.
6. As Unit reaches temperature, Digital Manager “Heating” light will signal heat distribution to zone(s) calling for heat. (On
first start up, this will usually be the hot water storage tank zone.) Once boiler water temperature reaches 160o– 180 o
F., adjust hot water temperature flowing to storage tank. With hot water flowing fully from a domestic faucet, adjust
valve under domestic circulator pump so water temperature going into tank is approximately 140 o F. (Hand can be
held on pipe just briefly.) Water must be flowing fully from a household hot water tap to accurately adjust flow and
temperature entering tank.
7. Allow system to run about 15 minutes before testing and recording burner operation. (See "Oil Burner Operation")
8. Caution: Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when
the combustion chamber is very hot.

Twenty Ninth Edition – July 2005 15
Oil Burner Operation:
NOTICE: For reliable operation, set Air-Fuel mixture conservatively based on installation conditions. CO2/O2
reading should be taken through 1/4" test port in the puff switch opening just underneath burner. Use ¼” steel or copper
sample tube and extend at least eight (8) inches into front cover to obtain accurate readings. Smoke test and stack
temperature should be taken at flue outlet.
NOTICE: For accurate efficiency calculations, measure flue gas temperature in flue pipe. Flue box and over fire
temperatures may be higher than flue gas temperature measured in the flue pipe.
Installation Conditions CO2 Setting O2Setting
Normal Conditions 11% 6.5%
Active Area (Washer, Dryer, Shop) 10 ½% 6.8%
Outside Oil Tank 10% 7.1%
Note 1: For combinations of above, use lowest CO2level or highest O2level.
Note 2: When Air Box is used, CO2must be checked with air box cover in place.
AFTER 15 MINUTES RUNNING, CHECK AND RECORD:
1. DRAFT OVER FIRE/CHIMNEY ………………………………… -0.02” to -0.12” w.c.
2. DRAFT OVER FIRE/POWER VENT …………………………… -0.10" to -0.12” w.c.
3. CO2/O2 …………………………………………………………… See table above
4. STACK TEMPERATURE …………………………………………350 o to 450 o F
5. SMOKE TEST …………………………………………………… Verify 0 smoke at breech
Draft over fire with a chimney should be a minimum of -.02” w.c.
If not, recheck chimney, chimney base and flue pipe for blockage or clean out door openings.
Draft over fire with a power vent (sidewall vent) should be -0.10" to -0.12" w.c.
If not, adjust power vent damper, check power vent fan is turning, or vent blockage.
1. DANGER: Verify proper operation of high limit aquastat by closing the bypass valve temporarily and allowing system
temperature to rise. At approximately 205 o F to 215oF, the high limit aquastat should shut off burner.
2. DANGER: Verify proper operation of boiler pressure relief valve by following instructions on pressure relief valve,
which calls for a 'try lever test'. Make sure discharge pipe is properly placed to safely contain discharge and open relief
valve using the try lever.
3. NOTICE: Check that each thermostat operates proper zone.
4. NOTICE: Bypass valve must be adjusted to raise return water temperature to approximately 120o F. on start up after
any zone valve opens. This prevents condensation from occurring in boiler passages. The digital manager provides
condensing protection by closing the zone valves when the return drops below 120o F (130o F when Option switch #1 is
on).
The following adjustments will help minimize zone cycling.
a. On copper baseboard systems, valve normally should be ½ open.
b. On large water volume systems or high heat load systems, where the return temperature from the system is below
120oF, open bypass completely and throttle zone returns to increase bypass flow. If returns are still below 120oF,
set option switch 1 to on.

Twenty Ninth Edition – July 2005 16
Expanded Digital Manager:
10 & 15 Zone Manager Installation Instructions:
1. Remove cover from junction box. Use a free knockout on the top of the junction box to mount a second or third
transformer, wire black lead to “XFMR” and white lead to “NEUTRAL” on relay board in box. (Use sections marked
“120 VOLTS” only.) A second junction box is not needed for the expanded Digital Energy Manager. Wire additional
transformer(s) in parallel with first transformer. To wire in parallel, wire terminal “A” on one transformer to “A” on the
other. Repeat with other low voltage terminal “B”. Verify 24VAC output from all transformers BEFORE reconnecting
the Manager.
2. Mount long panel on top of box cover with long screws provided in lower 4 holes with spacers down.
3. Mount expanded Digital Energy Manager to cover plate over four long screws and two wide bolts (top 2 holes).
4. Wire the bottom half of expanded manager as five zone Digital Energy Manager. For top half, attach one thermostat
lead to a zone and the other to A1 on lower half of manager. Attach one lead from zone valve or relay to corresponding
zone output and the other lead to 24VAC on lower half.
5. Option switches control energy recovery for extra zone outputs (see Location of Switches: Figure 4B)
NOTICE: When operating without an expanded manager, use a service card for the bottom half and jumper upper zones
from T(x) to Z(x).
Security System Interface Wiring:
The Digital Energy Manager features a monitor interface system, which allows the Manager to alert a home security system
or other signal light or device when a problem is detected. A three-terminal connector is supplied with each Manager. The
wiring detail is shown in Figure 4B. NOTICE: Home security systems may require an “abort delay” of one second to avoid
a transient signal on Manager power-up. If an abort delay is not available, use Energy Kinetics System Monitor (provided
separately part # 10-0168). Alarm contacts are “dry” (no voltage is provided).
Figure 4C
10 Zone Manager
15 Zone Manager
FACTORY WIRING
FIELD WIRING*
* Field Wiring terminated to input terminal A1 and to output terminal 24VAC
are to be wired into the open lugs provided on those terminal locations.
Lebanon, New Jersey
HW CIRC RELAY
HOT WATER TANK
Lebanon, New Jersey
FROM
TRANSFORMER
24V POWER
T3
TEMP. SENS.
RED
SENSOR
LEADS
TEMP SILVER
R
T4
S
BLACK B
A2
A1
T1
T2
THW
TO A1
Z2
B2
CIRC
B1
T
MAIN CIRC RELAY
T
TO BURNER RELAY
24VAC
IND
Z3
ZONE VALVE 2
ZONE VALVE 3
ZHW
Z1
Z4
ZONE VALVE 1
ZONE VALVE 4
TO 24VAC
9
8
7
6
5
ZONE 5
ZONE 6
T5
T6
ZONE 8
ZONE 7
ZONE 9
T8
T7
T9
THERMOST AT HEATING
Z5
Z6
ZONE VALVE 5
ZONE VALVE 6
Z8
Z7
Z9
ZONE VALVE 8
ZONE VALVE 7
5
6
7
8
9
THERMOSTAT
ZONE 3
ZONE 1
ZONE 2
ZONE VALVE 9
T2
T4
A1
T3
B
A2
S
R
TEMP. SENS.
1010
T10
THW
T1
T7
T8
T6
T9
T5
7
5
6
8
9
7
5
6
8
9
THERMOSTAT
T13
T11
T14
T12
11
12
14
13
11
12
14
13
HEATING
Z1
CIRC
IND
B2
B1
Z2
Z3
24VAC
Z10
Z4
ZHW
Z5
Z6
Z8
Z7
Z9
Z13
Z12
Z11
Z14
ZONE 4
60
70
80
50
SYSTEM 2000
50
80
60
70
HEATING
INDUCER
BURNER
CIRCULATOR
140
MAKING ANY CONNECTIONS
READ IN STRUCT IONS BEFOR E
MONITOR
120
100
130
CHIMNEYLESS
CAUTION
24VAC CONNECTIONONLY.
190
160
150
170
POWER
ONLY
4
3
2
1
HOT WATER
THERMOSTAT
4
3
2
1
24 VAC CONNECTION ONLY.
CAUTION
READ INSTRUCTIONS BEFORE
MAKING ANY CONNECTIONS
4
POWER
MONITOR
170
150
160
190
130
100
120
140
CIRCULATOR
BURNER
INDUCER
ONLY
CHIMNEYLESS
4
3
2
THERMOSTAT
1
HOT WATER
3
2
1
HEATING
SYSTEM2000
SYSTEM2000
SYSTEM2000
SYSTEM2000

Twenty Ninth Edition – July 2005 17
Digital Manager Operation:
WARNING: Do Not Jump!
If you apply 24VAC to any digital sensor
lead with the sensor connected to the
Manager, you will burn out both the
sensor and the Manager in less than a
second.
NOTE: The Manager cannot lockout the
primary control on the burner. The 140°F
light flashing will usually indicate that a
burner lockout has occurred.
Testing Manager Lights: To confirm operation of the Manager lights, turn power off briefly and power up the Manager.
On startup, all outputs and temperature lights will turn on for a brief moment.
A) Thermostat Lights:
Indicate a thermostat calling for heat. If all lights are OFF, the burner will not run because there is no call for heat. T4
is located on the bottom. SET HEAT ANTICIPATORS FOR 0.1 AMPS.
B) Digital Temperature Sensor:
Senses return temperature and is required for manager to work properly. 100°F light flashes if sensor is not working
properly. Disconnect RED lead to run in the “Service Board Mode”.
C) Monitor Contacts:
For connection to System Monitor or security systems are located here.
D) Option Switches:
Used to customize system settings. Set option switch 2 to ON for sidewall vent systems.
E) Temperature Display:
Indicates boiler RETURN temperature, not supply temperature.
• The Manager is the operating aquastat and will turn off the burner if return temperature reaches 170°F
(operating limit).
• The zone outputs will open when the return temperature is above 140°F and close zone outputs when the return
temperature drops below 120°F. If a new zone calls when the returns are below 140°F, the new zone will not
open until the temperature exceeds 140° F (even if other zones are open).
• The boiler will typically take about 2 minutes to reach 140°Ffrom a cold start.
When the Manager is working properly and has found a condition that needs service, the 100º, 120º,
130º, or 140º light will flash.
F) Heating or Zone Lights:
Indicate 24-volt power from 24VAC to ZX (ZHW, Z1, Z2, Z3, and Z4). This provides power to 24-volt zone valves or zone
circulator relays. NEVER JUMPER THIS CONNECTION!
G) Inducer Light On:
Indicates 24 volts from IND to 24VAC. This pulls in the 24-volt coil on the inducer relay, providing 120-volts to the
power vent. This will only operate with option switch 2 ON.
H) Burner Light On:
Indicates a closed contact between B1to B2. This is wired to T-T on the burner primary control.
If the burner light goes off, it will delay restart for two minutes to prevent short-cycling the burner
(45 seconds for a hot water call).
I) Circulator Light:
On indicates 24 volts from manager CIRC to manager 24VAC. This pulls in the 24-volt coil on the Burner/Main
circulator relay, providing 120-volt power to both the main circulator and the burner.
Digital Energy Manager Check
Troubleshooting
The burner will not run unless there is a call for heat (thermostat call) or a call for domestic hot water (tank
aquastat).
Note: Do NOT Jumper Connections or Apply Voltage to Test the Manager.
Follow these simple steps: (Continued on next page)
A
B
C D E
I
H
G
F

Twenty Ninth Edition – July 2005 18
1) Look at the Manager
2) See what it is telling you is supposed to be happening.
3) See if it is happening, and if it is not, find out why (see below).
4) If you do not find the problem, perform the 2 Minute Digital Manager Diagnostic to check all Manager functions.
2-Minute Digital Energy Manager Diagnostic
Most no-heat problems are not caused by the manager. Perform this test to prove proper manager function. Do
NOT replace the manager if it functions properly in these tests.
Step 1: Make sure you have no thermostat calls (turn thermostats down or disconnect after labeling zones).
Step 2: Turn System Switch OFF for 5 seconds.
Turn System Switch ON while carefully observing the temperature LED bars.
Temperature bars should briefly light at random, and then all the temperature
lights will turn ON and then OFF. The power light will stay ON.*
If each temperature light comes on and goes off, this proves:
• All the temperature lights work
• The processor is functioning properly
(Continued on next page)
Example of brief random
temperature lights on startup
Remember:
Most no heat problems are not caused by the Manager.
and
The Mana
g
er cannot cause a burner lockout.
These are input lights. These lights indicate when a
thermostat or tank aquastat is calling and only come on
when there is an external connection.
• If the light is not ON, check the thermostat(s) and
thermostat wiring.
• If the light is ON, the thermostat or tank aquastat is calling
These are zone output lights.
If the light is ON, the zone valve will be open. For hot
water, the bronze circulator will be running.
If the zone valve is not open with the light on, check the
zone valve and it’s wiring. For hot water, check the hot
water relay, wiring and the bronze circulator.
This is the sidewall vent inducer output.
This light will only operate if option switch 2 is on.
• If the light is ON, the inducer will be running.
• If the light is ON and the inducer is not running, check
the inducer, wiring inducer relay and it’s wiring.
This is the burner output. This light indicates T-T is
made on the burner.
• If the light is ON, the burner will be running.
• If the light is ON and the burner is not running, check
the burner, limit tank thermostat, wiring, burner/main
circulator rela
y
and burner service switch.
This is the burner/main circulator output. This
indicates 24 volts is applied to the burner/main
circulator relay coil.
• If the light is ON, the main circulator will be running
and the primary control will have line voltage.
• If the light is on and the circulator is not running,
check the burner/main circulator relay, the circulator
and associated wiring.
INPUT SIDE
(THERMOSTATS)
OUTPUT SIDE

Twenty Ninth Edition – July 2005 19
Step 3: Turn System Switch OFF for 5 seconds.
Turn System Switch ON while carefully observing the output lights.
Output lights should briefly light at random, and then all output lights will turn
ON and then OFF.*
This proves the following:
• All the output lights and outputs work
• The lights (except Burner) are in the output circuit, so 24 VAC should be
present
• The processor works (second verification)
*If you observe problems in step 2 or step 3, turn Burner Service Switch OFF, disconnect the right hand (output)
quick connector and repeat steps 1, 2, and 3. If problem persists, call technical support or replace manager. Note
malfunction on warranty tag and return manager to Energy Kinetics. If problem goes away, there is a problem with the
output wiring – check all wiring, re-connect quick connector and repeat steps 1, 2 and 3 until problem is resolved.
You’re done. The manager is functioning properly. Remember to reset thermostats to original set point, to re-
connect wiring connections, connect the quick connector and to turn the Service Switch ON.
Additional Manager Tests
Note: If you have a burner lockout, trouble shoot as any conventional burner lockout.
Perform the following tests ONLY if you have either of the following:
Case 1: Zones heating intermittently
Step 1: Have all connected thermostats including hot water aquastat call continuously for at least 10 minutes. Service
Switch must be ON. Turn burner switch off to prevent zone overheating and to maintain thermostat calls
continuously.
Step 2: Observe thermostat Lights.
• If any thermostat input lights (left side) are not ON, check wiring and thermostats.
• If thermostat input light (left side) is OFF within 10 minutes, and with thermostat call present, thermostat input LED
is bad. Solution: Move thermostat wire lead and zone valve wire lead to an open zone if available or replace
manager.
Case 2: 140 F light Flashing without burner lockout (monitor light is ON)
Step 1: Turn service switch OFF and disconnect right hand (output) quick connector.
Step 2: Using a multi-meter, check the resistance from B1 to B2 on the manager solder strips. This will be an open circuit
(infinite resistance).
Step 3: Turn service switch ON and start a thermostat call while observing the resistance from B1 to B2. Burner light
should come on.
• If resistance is less than 3 ohms, manager is functioning properly. Look elsewhere for a problem.
• If resistance is greater than 3 ohms after 3 seconds of operation, B1-B2 contact is bad. Solution: Replace
manager. Note: For 140F light flashing with a good B1-B2 manager relay (step 3 above), see next page.
Digital Manager Sensor Testing
The temperature sensor in the return line allows better boiler control, and virtually eliminates condensation
caused by cold returns.
The temperature sensor is a mini computer chip sealed with epoxy inside a copper well. The chip
communicates continuously with the Manager thousands of times a minute.
The Digital Manager is the tester of the digital temperature sensor. It verifies that it is connected and working
properly.
The sensor cannot be tested with an ohm meter/volt meter or other device. Doing so could cause it to fail!
The sensor operates on 5 volts DC. Never connect 24 volts to the black, silver or red sensor terminals
(labeled B, S, or R.)
A caution: T4 thermostat input is adjacent to R, the red sensor terminal. When making thermostat
connections, never do so with power on.
Once firm proper connections have been made, power up.
We believe many sensors and Managers have been damaged by 24V being jumped or connected to B, S, or R.
Look carefully while making any connections to the Manager.
WARNING: Do Not Jump!
If you apply 24V to any digital sensor lead with the sensor connected to the Manager, you will burn out the sensor, the
Manager or both in less than a second.
System Switch

Twenty Ninth Edition – July 2005 20
To test the functioning of each output zone, never apply a jumper to the Digital Manager output terminals. The
easiest way to test each zone output is to remove the red sensor lead. The Manager should go into Service Board
mode. Adjust each thermostat to call for heat and the corresponding zone should come on if working properly.
Rule #1: Never use a jumper to test the function of the Digital Manager.
Rule #2: Never use a jumper to test the function of the Digital Sensor.
Rule #3: Never use a jumper to test the zones outputs.
Rule #4: Only use a jumper from A1 to the thermostat inputs, if you can’t reach the thermostats.
Rule #5: Always carry a Service Board with you.
Line Voltage Relays
Remember that behind the Manager is the junction box with the line voltage relays. The line voltage relays are
controlled by the Manager.
The burner and circulator power is controlled by one line voltage relay. If both burner and circulator are without power,
check the relay.
If the domestic hot water circulator does not have power, check the hot water relay.
If equipped with an inducer and the inducer does not have power, check the inducer relay. Also, check to be sure
dipswitch #2 is turned “on”.
Line Voltage
System 2000 requires 120 VAC. The supply voltage must be within 108 VAC min / 132 VAC max for reliable operation
of the boiler and the Manager. An easy way to check the supply voltage is to plug a volt meter in at the service outlet
located on the system junction box.
Surge Suppression
The Relay Board located in the system junction box is equipped with built-in surge suppression on the 120VAC circuit.
Older systems can be retrofitted using plug-in surge suppressors which we have in stock.
Troubleshooting With the Digital Manager:
Flashing Light indicates that Digital Manager has detected a problem.
Monitor light comes on after a twenty-minute period during which the system attempts to recover.
• 100OLight Flashing
• Monitor Light ON
• 120Olight flashing, or
• 130Olight flashing
• Monitor light ON
• 140Olight flashing
• Monitor light ON
 Digital temperature sensor wiring loose or not functional.
 Check Sensor wiring. Check lead for damage.
 Digital Energy Manager will function in service board mode.
Circulator and inducer run constantly, burner runs on high
limit aquastat. All inputs turn on respective outputs.
 If Manager is left in this mode, reset limit aquastat to 165o/180oF.
 Digital Energy Manager detected a problem.
 120Olight flashing: Freeze condition was detected.
 130Olight flashing: Excessive temperature condition. Zones
could not extract heat from boiler. Check zone valves, heat
exchanger and boiler circulation. High limit aquastat may not be
functioning.
TO RESET MANAGER
The Manager can be reset to normal
operation by turning the system switch off and
back on again.
If condition is not corrected, the appropriate
temperature light will flash and again set the
monitor light.
 Digital Energy Manager detected a problem.
 140Olight flashing: Burner failure or boiler circulation failure.
Boiler return temperature has not increased enough to open
zones in 20 minutes for fuel oil (80 minutes if option switch #1 is
ON)
 Does Primary Control need to be reset?
YES: Troubleshoot as standard burner lockout.
NO: Did homeowner reset control?
YES: Troubleshoot as standard burner lockout.
NO: Reset Manager. Run through standard heat cycle.
 Does boiler return heat up properly?
NO: Check circulator. Possible closed or blocked bypass.
YES: Intermittent problem. Check low voltage wiring for
tightness from Manager through relay board and cad cell
relay to TT. Check line voltage at burner, in and out of cad
cell relay. Check limit aquastat for proper operation. See if
burner/main circulator relay is properly plugged in and
working properly.