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