ENERGY KINETICS EK1 Frontier User manual

Fourth Edition August 2022
Manufactured By:
Energy Kinetics, Inc.
51 Molasses Hill Road
Lebanon, NJ 08833
[phone]
www.energykinetics.com
INSTALLER: PLEASE HANG THIS INSTRUCTION MANUAL AND ACCESSORY
INSTRUCTIONS VISIBLY NEXT TO THE BOILER USING THE
SUPPLIED POUCH.
OWNER: PLEASE RETAIN THIS INSTRUCTION MANUAL AND ACCESSORY
INSTRUCTIONS FOR FUTURE REFERENCE.
MH27877
ANSI Z21.13-2014
Low-Press Boiler
ASME certified by
EKI. Certificate plate
is under the jacket on
the steel vessel.
National
Board Listed
EK3 Frontier
Gas Commercial Boiler

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: If the information in this manual is not followed exactly, a 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 appliance.
Provide unobstructed combustion air openings sized and located per boiler
manual and applicable codes.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use
any phone in your building.
Immediately call your gas supplier from an outside phone.
s instructions.
If you cannot reach your gas supplier, call the fire department.
WARNING: Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
Retain this manual for use by your qualified service technician only.
Should you observe unusual or abnormal operation of the burner or
boiler, contact your qualified service technician immediately. Do not attempt to
service or repair this product yourself.

EK3 Frontier Boiler Manual, Gas Edition 2August 2022
WARNING:
Have the burner/boiler started up and serviced at least once annually by a
qualified service technician. Professional care is necessary to properly service
your equipment and verify it is operating reliably. Failure to properly maintain the
equipment could result in severe personal injury, death or substantial property
damage.
WARNING:
You must keep the area around the burner/boiler free from the following. Failure
to comply could result in severe personal injury, death or substantial property
damage due to potential fire, explosion or equipment damage from corrosive flue
products.
Do not store or use gasoline or other flammable vapors or liquids near or in
the same 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/boiler. These chemicals
cause creation of acids in the burner, heat exchanger and vent system that
can cause severe damage.
Do not store combustible materials near or in the same room as the
burner/boiler.
General care and maintenance
Please read through the information provided for you in this manual. Ask your qualified
service technician to explain normal operation of your equipment.
Daily inspect the space around the burner/boiler to verify the area is clean and free of the
materials listed above.
Periodically watch the operation of your burner/boiler through an operating cycle to verify
normal operation. If you notice unusual conditions or equipment behavior, contact your
qualified service technician. Follow the instructions on the next page to shut down the
burner/boiler while waiting for the technician.
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause
property damage, personal injury (exposure to
hazardous materials) or loss of life. Refer to the

Installation and service must be performed by a
qualified installer, service agency or the gas
supplier (who must read and follow the supplied
instructions before installing, servicing, or
removing this boiler. This boiler contains materials
that have been identified as carcinogenic, or
possibly carcinogenic, to humans).

EK3 Frontier Boiler Manual, Gas Edition 3August 2022
FOR YOUR SAFETY READ BEFORE OPERATING
A. This burner does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do not try
to light the burner by hand.
C. Use only your hand to turn the gas supply
ball valve. Never use tools. If the handle
will not move 
call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.
B. Before OPERATING, smell all around the
boiler area for gas. Be sure to smell next to
the floor because some gas is heavier than
air and will settle on the floor. See below.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not
use any phone in your building
Immediately call your gas supplier from a
   Follow the gas

If you cannot reach your gas supplier, call
the fire department.
D. Do not use this boiler if any part has been
under water. Immediately call a qualified
service technician to inspect the boiler and
to replace any part of the control system
and any gas control, which has been under
water.
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/boiler.
4. This burner is equipped with an ignition device which automatically lights the burner.
5. Do not try to light the burner by hand.
6. Turn Gas Supply Ball Valve clockwise to OFF.
7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you
smell gas, STOP! Follow the safety information above. If you do not smell gas, go to the next
step.
8. Turn Gas Supply Ball Valve counterclockwise to ON.
9. Set thermostat(s) to desired setting.
10. Turn on all electric power to the burner and boiler.
11. If the burner/boiler will not operate, follow the instructions 
 below and call your service technician or gas supplier.
TO TURN OFF GAS TO THE BURNER
1. Set thermostat(s) to their lowest setting.
2. Turn off all electric power to the burner and boiler if service is to be performed.
3. Turn Gas Supply Ball Valve clockwise to OFF. Do not force.
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
ON
OFF

EK3 Frontier Boiler Manual, Gas Edition 4August 2022
EK3 Owner & Installation Manual
RECORD OF INSTALLATION
This manual covers the Energy Kinetics System 2000 EK3 Frontier Boiler. The boiler is
designed and equipped and has been tested to generate hot water in a low pressure closed
loop system. The boiler is a major component of a closed loop system that can be used as a
heat source for hydronic heating, hydronic air handler, radiant, domestic hot water, spa, and/or
pool heating systems. Call Energy Kinetics to obtain piping and wiring instructions for
applications, such as hydronic heating, radiant heating, domestic hot water, hydronic air
handler, swimming pool heating, multiple boilers, injection loops, etc. The installer of the
system is responsible for the final design of the system and for adding the balance of the
needed parts to complete the system.
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:
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, Fireplaces, Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211
Where required by the authority having jurisdiction, the installation must conform to the Standard for:
ANSI/ASME CSD-1 Controls and Safety Devices for Automatically Fired Boilers
These codes are available from:
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269-9101.
INSTALLER NAME:
INSTALLER ADDRESS:
INSTALLER CITY, STATE:
DATE INSTALLED:
NOTES:

EK3 Frontier Boiler Manual, Gas Edition 5August 2022
TABLE OF CONTENTS
PLEASE READ THIS FIRST...................................................................................................................................................................1
GENERAL CARE AND MAINTENANCE.................................................................................................................................................2
FOR YOUR SAFETY READ BEFORE OPERATING..............................................................................................................................3
WHAT TO DO IF YOU SMELL GAS .......................................................................................................................................................3
OPERATING INSTRUCTIONS ...............................................................................................................................................................3
TO TURN OFF GAS TO THE BURNER..................................................................................................................................................3
RECORD OF INSTALLATION ................................................................................................................................................................4
EK3 FRONTIER GAS HEAT BOILER - COMMERCIAL - RESIDENTIAL...............................................................................................6
PRINCIPLE OF OPERATION - SYSTEM 2000 BOILERS......................................................................................................................7
RECEIVING AND UNPACKING..............................................................................................................................................................8
LOCATION AND CLEARANCE...............................................................................................................................................................8
CHIMNEY VENTING...............................................................................................................................................................................9
GAS BURNER MOUNTING..................................................................................................................................................................11
GAS BURNER SETTINGS....................................................................................................................................................................11
GAS PIPING SYSTEMS........................................................................................................................................................................11
AQUASTAT SETTINGS........................................................................................................................................................................12
BOILER MOUNTING.............................................................................................................................................................................13
ZONE CONTROL..................................................................................................................................................................................13
FILLING WITH WATER VENTING, AND PURGING.............................................................................................................................13
ANTI-FREEZE.......................................................................................................................................................................................13
WINTERIZING.......................................................................................................................................................................................13
PIPING AND WIRING DIAGRAMS .......................................................................................................................................................14
ENERGY MANAGER............................................................................................................................................................................14
WIRING AND CONTROLS....................................................................................................................................................................14
PREPARE FOR START UP..................................................................................................................................................................15
THE AIR-FREE METHOD OF MEASURING CO..................................................................................................................................15
GAS BURNER OPERATION.................................................................................................................................................................16
INSTALL ENERGY MANAGER.............................................................................................................................................................19
DIP SWITCH SETTINGS ......................................................................................................................................................................19
EXPANDED ENERGY MANAGER .......................................................................................................................................................21
ENERGY MANAGER OPERATION......................................................................................................................................................22
2-MINUTE ENERGY MANAGER DIAGNOSTIC...................................................................................................................................23
ADDITIONAL MANAGER TESTS .........................................................................................................................................................25
DISPLAY MANAGER RETURN SENSOR (THERMISTOR) TESTING.................................................................................................26
LINE VOLTAGE RELAYS .....................................................................................................................................................................26
TROUBLESHOOTING WITH THE ENERGY MANAGER.....................................................................................................................27
OPERATION WITHOUT THE ENERGY MANAGER ............................................................................................................................28
ANNUAL MAINTENANCE.....................................................................................................................................................................30
REPLACEMENT PARTS.......................................................................................................................................................................31
SYS-08-024 EK3 GAS WITH DIGITAL MANAGER ..............................................................................................................................32
SYS-08-019 EK2 WITH ZONE CIR AND DHW.....................................................................................................................................33
SYS-08-020 EK3 WITH HEAT,DHW & INJECTION..............................................................................................................................34
SYS-02-023 LARGE DHW STORAGE VOLUME..................................................................................................................................41
SYS-04-019 MULTIPLE EK3 BOILER INTALLATION ..........................................................................................................................48
COMMON FLUE PIPE SIZING .............................................................................................................................................................52
LIMITED WARRANTY...........................................................................................................................................................................55

EK3 Frontier Boiler Manual, Gas Edition 6August 2022
EK3 FRONTIER GAS HEAT BOILER - COMMERCIAL - RESIDENTIAL
IMPORTANT MESSAGE: These instructions should be carefully read and kept for future reference to gain the
best performance from your System 2000 Frontier boiler.
CONGRATULATIONS ON THE PURCHASE OF a SYSTEM 2000 BOILER with its 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 the elements needed to provide an efficient source for heat and hot water. This
operation and maintenance information has been prepared so that you may better understand and use your Energy
Kinetics Frontier Boiler and Heating System.
The EK3 Frontier is ASME certified and National Board listed, perfect for commercial installations. The
required manual reset high temperature limit and the manual reset low water cutoff are both included. The boiler is

EK3 Packages Include:

Front Service, thru side swing door, right side hinge.
EK3 Firing Rates: 300,000/ 350,000/399,000 Btu/Hour
Carlin 201GAS Burner
Microprocessor-based interrupted ignition primary control
Flame current test jack
9,000 volt solid state electronic igniter
1/6 HP PSC burner motor
Removable orifice, increase or decrease burner input
Wiring Harness w/ Door Switch and Service Outlet
Manual reset high temperature limit
Manual reset low water cutoff
Complete supply, return, bypass piping
Bypass Circulator, Taco 007
Injection Circulator, Taco 0012IFC
Air Purge with two (2) Air Vents
T&P Gauge
One (1) 3/4Drain Valve
ASME 30 psi Relief Valve
Cold start, cold finish operation with energy recovery
Return temperature sensor for condensing protection
Relay for control of injection circulator included.
EK3 Options Include:
Air Inlet Box kit for field mounting
Fabricated steel base
Domestic hot water making is an option,
consult the factory for hot water zone kits.
Input
(BTU/hr)
Gross Output
(BTU/hr) LP
Gross Output
(BTU/hr) NG
300,000
260,000
255,000
350,000
299,000
292,000
399,000
335,000
327,000
EK3 with Energy manager,
Easy access, front opening door.
Shown with optional base

EK3 Frontier Boiler Manual, Gas Edition 7August 2022
PRINCIPLE OF OPERATION - SYSTEM 2000 BOILERS
SYSTEM 2000 comprises a heat source, the energy converter, circulating water, and five (or more) zones controlled
by an electronic control, the Energy manager.
The Boiler sits cold until a thermostat calls for heat. The Energy manager receives the call for heat and turns on the
bypass circulator and burner. Water circulates within the boiler as it warms up to operating temperature. When ready,
the supply circulator and zone valve(s) open and deliver heat to the zone(s) calling for heat. When the thermostats are
satisfied, the Energy manager turns off the burner and enters the energy recovery stage. The circulators and zone
valve stay energized to deliver the heat remaining in the boiler to the last zone calling or to the domestic hot water
storage tank.
When energy recovery is complete and the Boiler has been cooled off, the Energy manager turns off the system and
waits for another thermostat (or tank aquastat) 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 18 feet long, coiled around each other. Water travels along one passageway from the
heat emitters toward the center of the unit. Heated gases travel from the unit center toward the chimney. This is a
-ning fuel to the
circulating water. The superior insulation of the boiler minimizes heat losses to the surroundings, resulting in heat
directed to the desired zones 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
heat zones or hot water storage tank needs heat. Energy recovery is completed at the end of each heat call, virtually
eliminating off cycle losses.
Your System 2000 holds a minimal quantity of water so it begins to supply heat in about two minutes. This rapid
response means that your rooms can be heated quickly to temperature. The System 2000 EK3 Frontier can provide
heated water up to 327 er hour on Propane.
The burner fires into the center of System 2000 where a high temperature, light weight ceramic flame former
-free combustion. Your System 2000 is tightly sealed so
all products of combustion pass only to the chimney.
PRINCIPLE OF OPERATION Energy manager
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, circulators, zone valves or zone circulators and the domestic
hot water circulator. See photo of the Manager on the cover.
Lights on the Energy manager indicate zone(s) 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 starts the cycle. The thermostat light on the left side will turn on for that
zone.
3. PRE-HEAT: Output lights for the bypass circulator and burner turn on, the bypass circulator starts, and the burner
begins firing. Water circulates within the boiler and through the bypass as it warms up to operating temperature.
4. HEAT: Once the boiler water has heated up (about two minutes) to 150º F for gas burners (option switch 1 ON),
the Manager will turn on the zone output light on the right side. The zone valve will open, the main supply
(injection) circulator will start and hot water will flow to the zone needing heat. 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 170º F/190º F (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 150F, 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 130ºF. With the zone outputs closed, the boiler water will
quickly reheat and once the return temperature reaches 150ºF, then the Manager will reopen the zone valve and
start the supply circulator.
7. THERMOSTAT 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 bypass circulator, main supply (injection) 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

EK3 Frontier Boiler Manual, Gas Edition 8August 2022
stage is usually set at twenty minutes for space heating zones and is fixed at five minutes for the Hot Water zone.
(See 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 lad
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.
MOVING THE BOILER
The boiler is shipped bolted to a pallet. Use a pallet jack or fork lift to move the boiler while mounted on the pallet. The
boiler has two features designed to help with moving the boiler. There are four welded in nuts at the top of the front and rear
covers that can be used to screw in eyebolts or lifting bolts. Use a chain hoist or cherry picker to lift the boiler. The boiler
 6
ze the
boiler. Use of a wheeled dolly or cart is recommended once the boiler has been removed from the pallet.

door. Use pieces of woo
junction box will be protected.

removed 
ill
fit thro
exposed and can be easily damaged unless proper care is taken. It is recommended that pieces of wood be attached to help
protect the studs from impact.
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 Gas Burning Equipment and all applicable codes.
* Minimum recommended clearance to allow door to fully open.
NOTICE: The boiler base or stand must be level to allow for proper venting of air from the boiler. The Frontier is
manufactured with the BACK of the boiler higher than the front to assist in air removal.
Boiler Weight and Water Content
Weight
675 lbs
Water Content
7-1/2 gallons
Air Inlet Pipe Size

Boiler Flue Outlet

Supply & Return
Piping
1-
Installation Clearances from
Boiler Surfaces, Inches
Clearance to
Combustibles
Clearance for
Service
Front of boiler
13
36*
Left side of boiler body
0
2
Right side of boiler body
0
16*
Back of boiler body
7
36
Top of boiler body
13
16
Bottom of boiler legs to floor
0
0
B-Vent (Gas Only):from flue pipe
3
3
L-Vent: from flue pipe
3
3
Standard Flue: from flue pipe
9
9

EK3 Frontier Boiler Manual, Gas Edition 9August 2022
COMBUSTION AIR
The System 2000 Boiler must be installed in an area where adequate fresh air is available to support combustion.
The EK3 Frontier can be 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 interior environment,
as well as greatly reducing operating noise from the boiler. In multiple boiler installations, each boiler air intake should

. and five 90 degree elbows or less. Up
to 40 feet max. 
WARNING: Do not connect any combustion air piping to the burner when input is set for 399,000 Btu/Hr.
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.
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 operation.
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-
inches 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
gas heat appliances.
The metal liner diameter and length should be as recommended by the metal liner manufacturer. Corrugated
metal liners should be at least 8" diameter. Connection of a flexible metal liner directly to the flue collar of the boiler is
an acceptable connection method and is recommended. 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.

permissible for the flue connection of the boiler to be higher than the chimney thimble, provided adequate draft is
established.

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.

EK3 Frontier Boiler Manual, Gas Edition 10 August 2022
L-VENT CHIMNEY
SYSTEM 2000 Boilers typically have flue gas temperatures between 350º F and 450º F 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 
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

B-VENT CHIMNEY
Gas Heat SYSTEM 2000 Boilers at factory default firing rates have flue gas temperatures between 350oF and
450oF during normal operation. Refer to the burner settings table for the default firing rates. Due to the low flue gas
temperatures, Type B gas vent chimney pipe is suitable for use with Gas Heat SYSTEM 2000 Boilers. Type B gas
vent chimney pipe is double walled and may require smaller chase dimensions than other chimney pipe materials and
should be considered for new installations with Gas Heat SYSTEM 2000 Boilers.
A Type B gas vent system shall extend at least five (5) feet of height above the breech of the boiler.
Refer to the section on Gas Vent Termination in the National Fuel Gas Code to determine Minimum Height from
Roof to Lowest Discharge Opening required.
Type B gas vent must be U.L. Listed to U.L. 441. Type B gas vent to be installed and supported in accordance

Gas Heat System 2000 boilers and Type B gas 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 ve
REMOVAL FROM COMMON VENT SYSTEM
When any existing appliance, such as a boiler, is removed from a common venting system, the common venting
system is likely to be too large for proper venting of the appliances remaining connected to it. Testing of the remaining
venting system must be performed according to the following procedure.
At the time of removal of the existing appliance, the following steps shall be followed with each appliance
remaining connected to the common venting system placed in operation, while the other appliances remaining
connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which the
appliances remaining connected to the common venting system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage after five minutes of main burner operation. Use a draft gauge or pressure gauge to verify that
the vent pipe at the breech of the appliance is under draft (negative pressure) relative to the room.
6. Repeat 4) and 5) for each appliance connected to the common venting system, one appliance at a time.
7. After it has been determined that each appliance remaining connected to the common venting system properly
vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-
burning appliance to their previous condition of use.
8. Any improper operation of the common venting system should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation Codes. When resizing any
portion of the common venting system, the common venting system should be resized to approach the minimum
size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CAN/CGA B149, Installation Codes.

EK3 Frontier Boiler Manual, Gas Edition 11 August 2022
GAS BURNER MOUNTING
EK3 Frontier Gas Heat Boilers are shipped from the factory with the burner mounted. If the burner ever needs to be
remounted, follow these directions. The burner flanges are designed to insert the burner head 2-Energy
Kinetics supplies 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. The ceramic sleeve must be installed or burner damage will occur.
NOTICE: Gas burners should be installed according to burner manufacturer instructions, according to installation
instructions below, and with consultation from Energy Kinetics for any special considerations or adjustments.
To install burner, s             
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. The amulet for the Carlin burners has a smooth interior. 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 Carlin amulet does not have an edge and when fully seated the amulet will be flush with the front of the Carlin
burner head. 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.
GAS BURNER SETTINGS
201GAS Burners are shipped from the factory standard with the 350,000 Btu/Hr firing rate orifice. 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 Carlin 201GAS burners based on extensive testing.
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".
EK3 with
201Gas
Burner
Input
Btu/Hr
Oil Pump
Opening.
Plug Installed
Orifice Size
Installed In
ipple
Approximate
Air Band
Setting
Air Tube
Insertion
Length
Diffuser
Style
Natural Gas
300,000
YES

10
2-
A
350,000*
YES
(0.500)
35
2-
A
399,000
NO**

65
2-3/8"
A
Propane
300,000
YES

16
2-
A
350,000*
YES
0.406)
50
2-3/8"
A
399,000
NO**
 (0.453)
85
2-3/8"
A
*Default Factory Setting
** Do not connect any air intake piping when upfiring burner to the 399,000 Btu/hr rate.
GAS PIPING SYSTEMS
The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure
testing of the gas supply piping system at test pressures in excess of 1/2 psi (3.5 kPa, 14 in wc).
The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any
pressure testing of the gas piping system at test pressures equal to or less than 1/2 psi (3.5 kPa, 14 in wc).
A manual shut off valve and a sediment trap must be provided in the gas piping upstream of the regulator and electric gas
valve at the boiler. The boiler and its gas connection must be tested for gas leakage before placing the boiler in operation.
Gas piping must be properly sized in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or according
to state and local codes as applicable. Gas piping must be sized to provide the maximum firing rate gas flow for all
appliances in the building. For Natural Gas installations, be sure to verify that the gas meter is properly sized for all
appliances. Do not use any service 90oelbows. Use only full port shutoff valves. If in doubt, oversize the piping.
The following table provides suggested sizing for Black Iron Pipe. Be sure to add the appropriate equivalent length for
every fitting and elbow used. For other types of pipe or tubing, consult NFPA 54 or the manufacturer of the pipe or tubing or
your gas supplier for pipe sizing information.
For Propane Gas, drawing up to 399,000 Btu/Hr (156 Cubic Feet per Hour).
For Natural Gas, drawing up to 399,000 Btu/Hr (399 Cubic Feet per Hour).

EK3 Frontier Boiler Manual, Gas Edition 12 August 2022
Capacities in Cubic Feet per Hour for Black Iron Pipe Carrying Natural Gas or Propane
NATURAL GAS
PROPANE
Pipe Size
(inches)
Total Length of Gas Piping from Meter to
Burner Connection (Feet)
Pipe Size
(inches)
Total Length of Gas Piping from Meter to Burner
Connection (Feet)
20
40
60
80
100
20
40
60
80
100
Natural Gas @ .60 Specific Gravity, Pressure
Drop 0.3 in. w.c. *
Propane Gas @ 1.55 Specific Gravity, Pressure Drop
0.3 in. w.c.
3/4
118
81
65
56
49
1
350
245
195
170
150
1
217
152
121
105
93
1-1/4
730
500
400
350
305
1-1/4
453
310
248
217
189
1-1/2
1100
760
610
530
460
Pipe Size
(inches)
Natural Gas @ .60 Specific Gravity, Pressure
Drop 0.5 in. w.c. *
Pipe Size
(inches)
Propane Gas @ 1.55 Specific Gravity, Pressure Drop
0.5 in. w.c.
3/4
155
105
86
73
64
1
288
198
161
136
121
1
465
320
260
220
195
1-1/4
589
409
329
285
248
1-1/4
950
660
530
460
400
1-1/4
589
409
329
285
248
*For Natural Gas with a Specific Gravity other than 0.60, Consult National Fuel Gas Code for Correction Factor
Draft Loss Definition: The draft loss through boiler is found by subtracting the overfire draft reading from the breech
draft reading. For example, if the breech draft is -0.04" w.c., and overfire draft is +0.02" w.c., then subtracting the two
readings gives a draft loss of 0.06" w.c., which is acceptable. If the draft loss exceeds 0.10" w.c., then the boiler may need to
be cleaned or there may be some other blockage that will need to be addressed.
1. DANGER: Verify proper operation of high limit aquastat:
Auto Reset High Limit
i. Remove all heat and hot water calls (No input lights on left side of manager).
ii. Turn System switch off, then remove red sensor lead from the left side quick connect.
iii. Verify the auto reset high limit aquastat is set at 215oF.
iv. Restore power. The 100o
in less than a minute.
v. At approximately 205oF to 215oF, the high limit aquastat should shut off burner.
vi. Turn off power and reconnect the red sensor lead.
Manual Reset High Limit
i. Remove all heat and hot water calls (No input lights on left side of manager).
ii. Turn System switch off, then remove red sensor lead from the left side quick connect.
iii. Change the manual reset high limit aquastat from 220oF down to 190oF
iv. Restore power. The 100o
momentarily.
v. At approximately 180oF to 190oF, the manual reset high limit aquastat should shut off burner.
vi. Turn off power, reset the aquastat to 220oF and reconnect the red sensor lead.
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.
AQUASTAT SETTINGS
With Energy manager:
11D18 automatic reset high limit, set at 215oF, 10F Differential (205oF/215oF)
L4006E manual reset high limit, set at 220oF
Or, Carlin EZ-Temp manual reset high limit, set at 220oF
Or DualGard 2450-3 automatically configured to 200°F automatic and 205ºF manual reset
L4006B reverse control on return, set at 150oF, 20oF Differential (130oF/150oF)

DANGER: Double check that the manual reset high limit aquastat is set to 220oF. Do not exceed a setting of 220oF.

EK3 Frontier Boiler Manual, Gas Edition 13 August 2022
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
PIPING SO THE DOOR CAN OPEN: To avoid conflicts with the door opening, piping should be in accordance with the
boiler specifications drawing and the piping schematics in this manual. The door opens to the right hand side of the boiler.
The burner and air box also need clearance when the door opens. Do not locate any piping in front of the boiler unless
clearance from the door is verified. This also applies to the gas line piping and the combustion air piping. NOTICE: Air inlet
pipe must be disconnected to allow door to swing open.
BOILER PITCH: The Frontier pressure vessel is manufactured with the rear 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 a stand.
When the stand is level, the pitch is correct and the back of the boiler will be higher than the front.
ZONE CONTROL
ZONE CONTROL BY VALVE: The SYSTEM 2000 Boiler is designed to provide multi-zone control of the heating system
and optionally can supply domestic hot water. Energy Kinetics recommends full port, 24-volt zone valves for control of each
heating zone. Note: A system using single zone injection, (injecting into a primary loop) does not require the use of a zone
valve to provide control for preheat or to maintain temperature during operation. The Taco 0012 system injection circulator is
all that is needed.
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 boiler bypass circulator is still used in these cases. The Taco 0012 system
injection circulator may be used as one of the zone circulators if it meets the requirements for one of the zones.
NOTICE: Refer to piping schematic for location of zone circulators.
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 EK3
Frontier contains 7-1/2 gallons of water.
NOTICE: Sizing must consider cold start and hot operation due to system concepts of energy recovery and rapid heat up.
BOILER BYPASS CIRCULATOR
NOTICE: Systems are piped at the factory with the boiler bypass circulator. The bypass circulator piping and
wiring must not be changed from the factory configuration. The bypass circulator runs whenever the burner is
powered for heat and ensures the proper flow rate though the boiler.
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. 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, then anti-freeze should be added. When a
property 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

EK3 Frontier Boiler Manual, Gas Edition 14 August 2022
+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.
PIPING and WIRING DIAGRAMS
All piping and threaded accessory connections should follow good practice using approved joint sealants.
Energy manager
The Energy manager controls one or more zones directly off the boiler and benefit from the Energy manager energy
recovery cycle, such as for large load with multiple zones (5 & 15 zone versions of the Energy manager are available),
primary/secondary injection with multiple boilers, or as a dedicated hot water maker. The Energy manager has built in
condensing protection. Tekmar multiple boiler controls are recommended, for 2, 4, 9, or more boilers.
For piping and wiring boilers with a Energy manager and single zone injection, refer to drawing SYS-08-019. This
drawing shows the factory wiring of the Energy manager boiler.
For piping and wiring boilers with an Energy manager with heat, domestic hot water and injection, refer to drawing SYS-
08-020. The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to the system
junction box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the zone valve end
switches which are fed from the 24VAC lug.
For piping and wiring boilers with an Energy manager with heat and domestic hot water, refer to drawing SYS-08-021.
The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to the system junction
box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the zone valve end switches
which are fed from the 24VAC lug.
For piping and pipe sizing of Primary/Secondary Loops, refer to drawing SYS-04-019.
-
system circulator. Four wire zone valves as shown in drawings SYS-08-020 and 08-021 use end switches to pull in a relay
that starts the system circulator after the zone valve has opened. A bypass installed on the end of the supply and return
headers that is adjusted by a ball valve allows 2 wire zone valves to be used as shown in drawing SYS-08-023.
WIRING and CONTROLS
The Frontier 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
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 voltmeter in at the service outlet located on
the side of the system junction box.
DANGER: Make All Connections with Power Off at Main Circuit Box
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 manual reset low water cut-off is factory installed by Energy Kinetics, either
as a standalone control, or integrated in the DualGard 2450-3
Use Energy Kinetics Smart Thread Sealant P/N 10-0620
POWER SUPPLY: 120 VOLT 60 HZ, 15 Amperes

EK3 Frontier Boiler Manual, Gas Edition 15 August 2022
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 gas orifice size is used.
4. Verify electrode and flame sense rod settings.
5. Verify the burner settings for air band position. (see "Gas Burner Settings" Table).
6. Gas supply is connected to burner. Gas supply lines and shut-off valves are open.
7. Gas lines are purged.
8. Verify operating gas pressure at inlet of gas valve.
9. Flue pipe properly connected from unit to chimney. All joints are secured and sealed.
10. Combustion air supply is available and sufficient. (See “Combustion Air”)
11. 
(to right of burner) for use as the overfire sampling location.
START UP PROCEDURE
Turn on system supply switch and burner supply switch. The Energy manager lights should come on briefly, the
circulator relay should close briefly, and then the Energy manager should only show one red light next to 'power'.
1. 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.
2. Check for burner light off. If gas piping is not well purged, then several starts may be required to clear air from gas
piping.
3. 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.
4. NOTICE: Perform carbon monoxide test immediately after light off. If the carbon monoxide exceeds 400 ppm air-
free after one minute of operation, shut off boiler immediately and repeat "Prepare for Start Up" checklist. (See
“Air-free method of measuring CO”)
5. Once the boiler heats up and reaches temperature, Energy manager 
zone(s) calling for heat.
6. Allow system to run about 15 minutes before testing and recording burner operation. (See "Gas Burner Operation")
The AIR-FREE METHOD of MEASURING CO
Air-free measurement of CO takes account of the amount of excess air by incorporating an adjustment to the as-
measured ppm value, thus simulating air-free (oxygen-free) conditions in the combustion gases. To do this, a reading
of oxygen (O2) or carbon dioxide (CO2) percentage is taken from the combustion gases along with the as-measured
CO reading. This can be done with a meter having the capability of measuring CO and O2 or CO2 percentage, or it
can be done with two different meters, one measuring CO ppm and one measuring O2 or CO2 percentage.
If air-free CO is determined with a single meter, an integral electronic chip calculates the air-free level from as-
measured CO ppm and O2 percentage.
If two meters are used, the equations below can be used to determine the air-free level of CO in a combustion gas
sample. For natural gas or propane, using as-measured CO ppm and O2 percentage:
CO AFppm = 20.9 x CO ppm
20.9-O2
For propane, using measured CO ppm and CO2percentage:
.
CO AFppm = 14 x CO ppm
CO2
For natural gas, using measured CO ppm and CO2percentage:
COAfppm =12.2 x CO ppm
CO2
Where:
CO AFppm = Carbon monoxide, air-free ppm
CO ppm = As-measured combustion gas carbon monoxide ppm
O2= Percentage of oxygen in combustion gas, as a percentage
CO2= Percentage of carbon dioxide in combustion gas, as a percentage.

EK3 Frontier Boiler Manual, Gas Edition 16 August 2022
GAS BURNER OPERATION
NOTICE: For reliable operation, set Air-Fuel mixture conservatively based on installation conditions.
Carbon dioxide, Oxygen, and Carbon Monoxide readings should be taken through 1/4" test port in front jacket opening
just to right of burner (see FIG. 5A). Sample tube must extend at least six (6) inches into front cover to obtain accurate
readings. A test port is provided for the flue box (see FIG. 5A) to measure draft loss.
NOTICE: For accurate efficiency calculations, measure flue gas temperature in flue pipe at flue outlet. Flue box and
over fire temperatures may be higher than flue gas temperature measured in the flue pipe.
Note: When Air Box is used, CO2/O2must be checked with air box cover in place.
AFTER 15 MINUTES RUNNING, CHECK AND RECORD:
1.  - minimum.
2 CO2
 9.7 Min / 10.7 Max
 8.6 Min / 9.2 Max
3. O2
 4.5 Min / 6.0 Max
 4.5 Min / 5.5 Max
4. STACK TEMPERATURE  350oto 450oF
5.  Must be less than 400 ppm air-free
Draft over fire with a chimney should be -0.02" to 0.12" w.c.
If not, recheck chimney, chimney base and flue pipe for blockage or clean out door openings.
1. DANGER: Verify proper operation of the automatic reset high limit aquastat:
a. Remove all heat and hot water calls (No input lights on left side of manager).
b. Turn System switch off, then remove red sensor lead from the left side quick connect.
c. Restore power. The 100od start
momentarily.
d. At approximately 205oF to 215oF, the high limit aquastat should shut off burner.
2. DANGER: Verify proper operation of the manual reset high limit aquastat:
a. Remove all heat and hot water calls (No input lights on left side of manager).
b. Turn System switch off, then remove red sensor lead from the left side quick connect.
c. Change the manual reset high limit aquastat from 220oF down to 200oF
c. Restore power. The 100o
momentarily.
d. At approximately 190oF to 200oF, the manual reset high limit aquastat should shut off burner.
e. Turn off power, reset the aquastat to 220oF and reconnect the red sensor lead.
3. 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.
4. NOTICE: Check that each thermostat operates proper zone.
5. Verify flame failure lockout of Carlin 60200FR burner control
a. Install a hose barb fitting in the gas train manifold pressure tap and connect with a hose to a U-tube
manometer.
b. Close the main manual gas valve and turn the combination gas valve knob to ON.
c. Turn on power to System 2000 boiler and adjust a thermostat to call for heat.
d. Burner motor will start. The burner control will run the burner motor for 30 seconds (pre-purge), and then start
the ignitor. Approximately one second later, the gas valve will open. (The manometer should show low (about
 pressure, because the main manual gas valve is closed.)
e. After the end of the Trial For Ignition period, the burner control will lockout and turn on the red LED. The
ignitor will shut off and the gas valve will close. Turn off power and adjust the thermostat to stop the call for
heat.
f. If lockout does not occur, replace the burner control.

EK3 Frontier Boiler Manual, Gas Edition 17 August 2022
Energy Manager Use the Energy Manager control with one or more zones directly off the boiler is needed and
benefit from the Energy Manager energy recovery cycle, such as for large load with multiple zones (5 10 & 15
zone versions of the Energy Manager are available), primary/secondary injection (5 10 & 15 zone ERC Controls
are available) with multiple boilers, or as a dedicated hot water maker. The Energy Manager has built in
condensing protection. Tekmar multiple boiler controls are recommended, for 2 or more boilers.
For piping and wiring boilers with a Energy Manager and single zone injection, refer to drawing SYS-08-019. This
drawing shows the factory wiring of the Energy Manager boiler.
For piping and wiring boilers with a Energy Manager with heat, domestic hot water and injection, refer to drawing
SYS-08-020. The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to
the system junction box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the
zone valve end switches which are fed from the 24VAC lug.
For piping and wiring boilers with a Energy Manager with heat and domestic hot water, refer to drawing SYS-08-
021. The factory wiring must be field modified per this drawing. The blue leads from the 24V relay mounted to the
system junction box must be moved. One from Z1 lug to the Circ lug and the other one wired in parallel with the zone
valve end switches which are fed from the 24VAC lug.
For piping and pipe sizing of Primary/Secondary Loops, refer to drawing SYS-04-019.
-
system circlator. Four wire zone valves as shown in drawings SYS-08-020 and 08-021 use end switches to pull in a
relay that starts the system circulator after the valve has opened. A bypass installed on the end of the supply and
return headers that is adjusted by a ball valve allows 2 wire zone valves to be used as shown in drawing SYS-08-023.
WIRING and CONTROLS
The Frontier 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. All wiring for installations in Canada must be
done in accordance with the Canadian Electrical Code, Part I.
ELECTRICAL CONNECTION - 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 voltmeter in at the
service outlet located on the side of the system junction box.
DANGER: Make All Connections with Power Off at Main Circuit Box
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 manual reset low water cut-off is factory installed by Energy
Kinetics, either as a standalone control, or integrated in the DualGard 2450-3.
POWER SUPPLY: 120 VOLT 60 HZ, 15 Amperes

EK3 Frontier Boiler Manual, Gas Edition 18 August 2022
PREPARE FOR START UP
DANGER: MAKE CERTAIN THE FOLLOWING REQUIREMENTS HAVE BEEN SATISFIED BEFORE START UP:
12. The boiler and piping are completely filled with water.
13. Re-check wiring to ensure that it is correct and in accordance with appropriate wiring diagrams and codes.
14. Verify that proper nozzle is used and installed correctly.
15. Verify electrode settings.
16. Verify the burner settings for air band position and head position (see "Oil Burner Settings" Table).
17. Oil supply is connected to burner. Oil supply lines and shut-off valves are open.
18. CAUTION: DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR ANY OIL CONTAINING GASOLINE.
19. Fuel pump and fuel lines are purged.
20. Verify operating oil pressure at gauge port.
21. Flue pipe properly connected from unit to chimney. All joints are secured and sealed.
22. Combustion air supply is available and sufficient. (See “Combustion Air”)
23. Adjust valve in domestic hot water circuit under circulator approximately ¾ of the way open.
24. 

25. CAUTION: All covers, enclosures, and guards must be maintained in place at all times, except during
maintenance and servicing.
26. CAUTION: Do not start burner unless the front door is closed and the nuts have been properly tightened.
27.
ENERGY MANAGER
Install Energy Manager
The 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 prewired quick connectors fastened to the front of the junction box by two cable
ties. Cut the two cable ties and discard. Fasten the Energy Manager to the junction box with the four corner screws. Slide
the two quick connectors onto the Energy Manager. Label each zone on the manager, using the adhesive labels supplied.
Low Voltage Wiring
Energy Manager Operates Only On 24 Volts 60 HZ Power
WARNING: Make All Connections With Power Off at Main Circuit Box
Typical low voltage wiring diagrams for the Energy Manager are shown along with piping schematics near the back of
this manual (refer to table of contents). Thermostats must be located on inside walls away from cold drafts, windows or heat
from fireplaces
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 Energy 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
Be
sure to verify 24VAC output from all transformers.
The Energy Manager is designed to heat domestic water and up to four (4) heating zones. Use Energy Kinetics supplied
zone valves with four wire connections. For more than four heating zones, use Energy Kinetics expanded 10 or 15 zone
Energy Manager, or call Energy Kinetics for alternatives.
START UP PROCEDURE
7. Turn on system supply switch and burner supply switch. The Energy Manager lights should come on briefly, the
circulator relay should close briefly, and then the Energy Manager should only show one red light next to 'power'.
8. The hot water tank aquastat should call for heat, if not, adjust a thermostat to call for heat. Burner and bypass circulator
should come on at the same time. If not, check primary control and reset it if necessary.
9. 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.
10. On light off, water temperature and chimney temperature will start to rise. A slight odor is common on initial light off as
combustion flame former and converter surfaces warm for the first time.
11. NOTICE: Perform smoke test immediately after light off. Smoke test should show yellow after initial one minute of
operation due to the combustion flame former sizing heating up. If the smoke test shows dark grey or black after one
minute of operation, shut off boiler immediately and repeat "Prepare for Start Up" checklist.
12. As Unit reaches temperature, Energy Manager 
first start up, this will usually be the hot water storage tank zone.) Once boiler water temperature reaches 160o180o
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.
13. Allow system to run about 15 minutes before testing and recording burner operation. (See "Oil Burner Operation")
14. CAUTION: Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when
the combustion flame former is very hot.
15. CAUTION: NEVER BURN GARBAGE OR PAPER IN THE UNIT, AND NEVER LEAVE COMBUSTIBLE MATERIAL
AROUND IT.

EK3 Frontier Boiler Manual, Gas Edition 19 August 2022
INSTALL ENERGY MANAGER
The 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 Energy Manager to the junction box with the four
corner screws. Slide the two quick connectors onto the Energy Manager. Label each zone on the manager, using the
adhesive labels supplied.
Five Zone Display Manager
The Display Manager is an Energy Manager that is equipped with an LCD display, and four pushbutton keys.
With the exception of the Fuel Type (oil/gas) and Venting (chimney/inducer) options, all setup options are selected
through option screens via the display and keys. The Fuel Type and Venting options can be viewed, but not set, in the
option screens. These two options can only be set using the physical dip switches on the bottom of the Manager
board.
To access the option screens, you must first ensure the manager is powered; if the manager is powered, the blue
key to wake the display.
Use the UP/DOWN keys to view additional menu screens.Use the ENTER/ESC keys to enter/exit submenus. The
ENTER key is also used to change options from the option screens.
How to Use Self-Guided On-Screen Prompts To Edit Options
From the system status screen, press the DOWN key twice, or until the
Option Setup (edit) menu screen is displayed. Press the ENTER key to enter into the option screens. From there,
use the UP/DOWN keys to view each option. Use the ENTER key to change the selected option.







-
-

















 

Setting features are self-guided through on-screen prompts