C-3-sidewall vent kit - Energy Kinetics

SIDEWALL VENT KIT Installation Instructions

C-3

Product Description Low cost venting alternative with System 2000’s Sidewall Vent.

For Fuel Oil, Natural Gas, or LP/Propane Gas

The Energy Kinetics Sidewall Vent System is available in two different hood styles to accommodate a wide verity of installation requirements and conditions.

The Combined Sidewall Vent Hood serves

two functions with one wall opening. The exhaust of flue gas and the intake of fresh combustion air in one rectangular vent hood body. The exhaust gases pass down a double wall pipe through the welded seam center pipe of the vent hood. The intake air passes outside of the double wall exhaust pipe, which keeps the exterior of the hood cool. The Combined Sidewall Vent Hood can be installed directly into wood construction (combustible) walls.

The Non-Combo Sidewall Vent Hood version is suitable for use only in non-combustible walls, such as cinder block or poured concrete walls. Installation of this unit only requires a 4” diameter hole making installation using a 4-1/2” core bit clean and simple. Intake air must be piped separately with the Non-Combo version.

Energy Kinetics has through the wall and bottom inlet surface mount air inlet screen models available depending on your application.

The design of these units makes them very quiet and very stable in high winds. The outlet ejector nozzle design used on Energy Kinetics Sidewall Vent System Hoods direct the flue

products away from the house or building. The inducers come with a factory-installed positive pressure adapter. The adapter has a silicone gasket built into it,

which eliminates the need to add liquid sealant in the field. Just slide the inducer on and tighten the gear clamp provided.

For applications where the hood must be located in a joist bay, a 3” sealed elbow is included along with a heat shield that attaches to the back of the hood to cover the elbow.

EK1 Combination Hood with Elbow and Elbow Shield & Inducer Shown Assembled

Non-Combo Hood (Vent Only)

Combined Hood (Vent & Inlet)

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Kit 10-0321, EK1 Sidewall Vent Kit, for Premier Oil, Combo Hood Shown Kit Includes: EK1 Combo Vent Hood, EK1 Inducer, 3” Z-Vent Sealed Elbow, Elbow Shield,

Hood Mounting Hardware, 4” Damper, 3” Male PVC Adaptor, Interior Trim Ring, 10oz Cartridge of Silicone Sealant, Installation Instructions

Parts List:

Combo Hood Kits (For use with combustible walls) 10-0311 Option: EK1 Sidewall Vent Kit, for Oil, Combo Hood * 10-0312 Option: EK2 Sidewall Vent Kit, for Oil, Combo Hood, 1.60 gph max * 10-0321 Option: EK1 Sidewall Vent Kit, for Premier Oil, Combo Hood ** 10-0321-G Option: EK1 Sidewall Vent Kit, for Gas, Combo Hood 10-0322 Option: EK2 Sidewall Vent Kit, Premier Oil, Combo Hood, 1.60 gph max ** 10-0322-G Option: EK2 Sidewall Vent Kit, for Gas, Combo Hood, 225 MBH max

Non-Combo Hood Kits (For use with non-combustible walls) 10-0313 Option: EK1 Sidewall Vent Kit, for Oil, Non-Combo Hood * 10-0314 Option: EK2 Sidewall Vent Kit, for Oil, Non-Combo Hood, 1.60 gph max * 10-0323 Option: EK1 Sidewall Vent Kit, for Premier Oil, Non-Combo Hood ** 10-0323-G Option: EK1 Sidewall Vent Kit, for Gas, Non-Combo Hood 10-0324 Option: EK2 Sidewall Vent Kit, for Premier Oil, Non-Combo Hood ** 10-0324-G Option: EK2 Sidewall Vent Kit, for Gas, Non-Combo Hood, 225 MBH max

* Kits include Smart Filter Kit ** Kits Do Not include Smart Filter Kit

Joist Bay Installation Parts 10-0191-E390 3” Z-Vent, Sealed Elbow 10-0191-P33 3” x 3 Ft Long Z-Vent Pipe 10-0215 Air Inlet, Bottom Entry 10-0329 Elbow Shield

Optional Installation Parts 10-0191-45 Flex Connector Kit, 4” Diameter, 5 Foot Long *** 10-0191-410 Flex Connector Kit, 4” Diameter, 10 Foot Long *** 10-0215 Air Inlet, Bottom Entry 10-0497 Air Inlet Screen Only

*** Kits include: 316Ti Titanium S.S. flex connector hose that maybe cut to length in field using snips, two clamps for the flue collar end, and a crimped end that inserts into the four inch flue damper that come with the vent kits.

Replacement Parts 10-0330 EK1 Inducer Only 10-0331 EK2 Inducer Only

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Air Box Kit

Important Installation Notes

Please read and follow these instructions carefully. Your installation time will be shortened and proper system performance will be assured.

All combustion requires an adequate air supply. Modern construction, electric heat homes and even older homes that have been sealed to reduce heat loss, can starve the burner of adequate air. Other exhaust devices within the home (clothes dryers, bathroom fans, kitchen fans, fireplaces or even wood stoves) can deplete air supply or create negative pressure within the structure.

NOTE: The sidewall vent must only be installed on System 2000 boilers that include an air box and piping for supplying outside combustion air, to provide a balanced flue for dependable operation. The balanced flue will prevent the reversal of flue products and discharge into the home when the inducer shuts down.

CAUTION: 1. The System must be installed by a qualified installer in accordance with

applicable local codes or in their absence, in accordance with ANSI Z223.1/NFPA No.54-National Fuel Gas Code; NFPA No.70-National Electrical Code; ANSI/NFPA No. 31 and No.211. "Qualified Installer" shall mean an individual who is properly trained and licensed.

2. The installer should attach a tag to the inducer with the following information: name, phone number, date of installation, signature.

3. Plan the vent system layout to avoid the possibility of accidental contact with concealed wiring or plumbing inside of walls.

4. The inducer must be inspected annually to ensure safe and proper operation. Inspection points should include:

(a) MOTOR: The motor has sealed ball bearings and does not require lubrication. (b) FAN: Fan must be clear of soot, ash, or any other coating that affects balance, rotation, or airflow. Remove all

foreign material before operating.

The fuel supply must be clean, fuel lines tight with flare fittings only, and fuel at proper temperature, which will permit clean light off. Cold fuels (below 50°F) can cause sooting on light off. Preferably, pipe fuel units’ single pipe, to allow fuel to warm up in burner location. Outside tanks and cold fuel may require fuel additives, electric heat tape tracing or nozzle line heaters. Sidewall Vent Limitations

This System 2000 Sidewall Vent is to be installed only with the System 2000 boiler. Oil supply must be installed with Energy Kinetics Smart Filter or equivalent. Maximum input for #2 fuel oil is, 1.0 GPH for EK1 and 1.6 GPH for the EK2. Maximum input for gas is 150,000 BTU/Hr for the EK1 and 225,000 BTU/Hr for the EK2. It is suitable for gross flue gas temperatures under 450°F (measured at the inducer inlet) and over 212°F (measured at the hood outlet). Check the temperature at the outlet after five minutes of operation during setup and again after at least 15 minutes, allowing the flue gas temperature to stabilize.

The sidewall vent system must be carefully installed, adjusted and maintained. It should be annually checked and adjusted if necessary.

The conventional chimney can absorb, unseen, the many things that can go wrong with a combustion system such as poor ignition or atomization, improper air adjustment, accumulation of pet hair or lint on the inlet shutter, component malfunctions, contamination of fuel, improper setup or installation, etc.

With Sidewall venting, the effect of these conditions can result in an exhaust that may contain odors or incompletely burned fuel (soot). These flue products, while still effectively discharged outside the home, may cause discoloration to siding or areas immediately surrounding the vent. The flue by-products may be corrosive and can cause damage to nearby objects such as condensers, playground equipment, landscaping, shrubs, etc. The exhaust may emit odors similar to a poorly tuned car exhaust. This would normally not be apparent when discharged from a chimney well above the roofline.

No one can guarantee that at all times the exhaust will be without a trace of odor or soot for all the reasons described above which may be beyond the control of the homeowner, manufacturer, installer or service company.

Periodic cleaning of the area around the vent may be required if the appearance is objectionable in the view of the homeowner, and this cannot be the responsibility of the manufacturer, installer or service company.

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1. Location

The hood or exhaust pipe should be located so that proper clearances are maintained, according to local code. Per Standard for the Installation of Oil-Burning Equipment NFPA 31 & National Fuel Gas Code NFPA 54 ANSI Z223.1, the flue gas outlet termination of a direct vent application with an input over 50,000 Btu/hr shall be located at least 1 ft from any door, window, or air inlet to the structure (Energy Kinetics recommends 4 ft as a minimum whenever possible). Note that the Energy Kinetics sidewall vent (power vent) kit, when properly installed on an Energy Kinetics boiler, meets the definition of a ‘direct vent appliance’ as used in NFPA 31 & NFPA 54. Regardless of input, the flue gas outlet terminal and air intake shall be located at least 1 ft above grade or expected snow level. Both the vent hood and air intake must be at least 5 ft from any supply tank vents.

The vent terminal shall not be installed closer than 3 ft from an inside corner of an L-shaped structure and must be at least 1 ft from the soffit of the roof of the structure.

V e n t h o o d m u s t b e a t le a s t 1 ft. to th e s id e o f a n y d o o rs o r w in d o w s(E n e rg y K in e tic s re co m m e n d s 4 ft m in im u m w h e n e ve r p o ss ib le )

V e n t h o o d m u s t b e a t le a s t 3 ft. fro m in s id e c o rn e rs . R e co m m e n d 1 0 ft.

V e n t h o o d m u s t b e a t le a s t 1 ft. a b o ve g ra d e

V e n t h o o d m u s t b e a t le a s t 4 ft. b e lo w

w in d o w s th o u g h n o t re co m m e n d e d !

V e n t h o o d m u s t b e a t le a s t 1 ft. a b o ve d o o rs a n d w in d o w s

V e n t h o o d m u s t b e a t le a s t 7 ft. a b o ve p u b lic w a lkw a ys

A ir in ta ke m u s t b e lo ca te d o n sa m e w a ll a n d w ith in 2 0 in . o f ve n t h o o d o r o n sa m e w a ll a n d a b o ve sn o w le ve l w h e n m o re th a n 2 0 in . fro m ve n t h o o d .

R e co m m e n d e d C le a ra n ce s : E xh a u s t p ro d u c ts co n ta in su lfu r w h ich ca n a ffe c t m e ch a n ica l e q u ip m e n t, m e ta l o b je c ts a n d ve g e ta tio n .

B o th th e ve n t h o o d a n d th e a ir in ta ke m u s t b e a t le a s t 5 ft fro m a n y su p p ly ta n k ve n ts .

V e n t h o o d m u s t b e a t le a s t 1 ft. b e lo w th e s o ffit o f ro o f o f th e s tru c tu re .

Figure 1

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energy

SYSTEM 2000ENERGY MANAGER

ERGYETICS

TO OPEN FRONT COVER

KINEN

WARNING

14" MaxWall

Thickness

READ

Combustible

Non-Combustible

Joist Bay

Flue Damper

READ

ENERGY KINETICS

SYSTEM 2000

FRONTIERÒ

Figure 2

Combination Vent Hood Clearance to Combustibles:

With flue gas temperatures under 450°F at the inlet of the inducer, the combination Vent Hood is suitable for zero clearance to combustibles on top, bottom, sides and front of the hood. The air intake of the hood must be used to supply combustion air. When the 90° sealed elbow is used, the elbow shield is suitable for use in the same size bay opening as the Combination Vent Hood. The inducer must be installed directly to the elbow. Additional Recommendations Are:

1.1 The vent hood inducer should be above the boiler flue outlet. A minimum vertical height of 4 feet is preferred. This provides for some natural drafting of the boiler. See Figure 2.

1.2 With modern and/or tightly constructed houses, it may be necessary to insulate the body of the vent hood to help prevent it from condensing.

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2. Installation of Vent Hood/ Inducer/Flue Damper

The Combination Vent Hood p/n: 10-0325 (EK1) & 10-0326 (EK2) is suitable for passage through both combustible and non-combustible walls. Maximum wall thickness is approximately 14" but depends on piping, inducer location, and wall configuration.

When it is not practical or possible to make an opening large enough in a non-combustible wall, a vent only style hood p/n: 10-0327 (EK1) & 10-0328 (EK2) that requires a 4” diameter opening is available. A separate air inlet is required with the vent only style hood. For an EK1, air intake of 2" PVC can be run for a maximum total distance of 20 feet with up to five elbows or up to 40 feet and five elbows using 3” PVC. EK2’s require 3" PVC pipe with a maximum total distance of 20 feet with up to 5 elbows or up to 40 feet and 5 elbows using 4” PVC. 2.1 The air inlet must be located on the same side of the building and should be

within 20” of the exhaust from the vent hood. It must be above expected snow levels when more than 20” from the vent hood. It should be clear of obstructions. The air inlet may be installed as close as 6" from the exhaust hood and preferably slightly above. The air inlet must be at least 60” from any supply tank vents. Make sure you have the correct sidewall vent hood and inducer for your application. The System 2000 EK1 Boiler requires the hood with the smaller, 4-1/2” wide ejector nozzle and the inducer with the black housing. The System 2000 EK2 Boiler requires the hood with the larger, 6” wide ejector nozzle and the silver inducer.

2.2 Use the inside wall cover plate as a template to locate the vent hood location on the exterior of the structure. (Note: See code requirements listed on page 2 and refer to Figures 1 and 2).

2.2 Cut opening through wall 1/2" larger (1/4” per side) than the inside opening of the wall cover plate to facilitate easy installation. The excess opening can be filled with a spray foam type insulation.

2.3 Apply an exterior rated sealant to the back of the mounting flange to seal the penetration. Slide hood through opening from outside. The hood should pitch down toward the outside slightly.

2.4 Fasten the vent hood to the exterior through the four mounting holes using the hardware provided. 2.5 Install the inside wall cover plate and fasten to the inside wall using the four mounting holes. 2.6 For the air intake on EK1 Boilers, use 2” PVC piping with a maximum length of 20 feet and 5 or less 90 degree

elbows or use 3” PVC piping with a maximum length of 40 feet and 5 or less 90 degree elbows. 2.7 For the air intake on EK2 Boilers, use 3” PVC piping with a maximum length of 20 feet and 5 or less 90 degree

elbows or use 4” PVC piping with a maximum length of 40 feet and 5 or less 90 degree elbows. Note: The Combination Sidewall Vent intake is designed to accept a 3” PVC male adapter. If 2” or 4” PVC piping is used, the appropriate bushing or adaptor is required, to be supplied by installer. If intake in the body of the Sidewall vent will not be used, then purchase the non-combo version of the vent hood and the separate air intake screen. 2.8 The inducer must be separately supported, preferably with the use of springs, a shock cord or similar material to

prevent structural transmission of any motor vibration. 2.9 Connect a 4” flue pipe to the boiler flue outlet using a flue pipe reducer. On side flue boilers, use a reducing tee with

bottom clean-out cover. EK1 Top & Side Flue outlet 5” EK1 Frontier outlet 4” EK2 Top & Side Flue outlet 7” EK2 Frontier outlet 6”

2.10 4” flue pipe may be used for runs up to 30 feet with four or less 90-degree elbows (fifty foot equivalent length). Single wall 24 gauge, galvanized flue pipe is suitable if adequate clearance exists from combustible materials; otherwise, properly insulated flue pipe must be used. If flue pipe is a long run (over ten feet), or exposed to reduced temperatures, it must be insulated to prevent flue gas condensation.

CAUTION: Temperature of the flue gases at nozzle exit should be measured (212º F Min) to ensure that condensation of flue products does not occur in the vent hood or the flue pipe. Double wall vent pipe can be used as an insulating chase, such as L-Vent or B-Vent.

2.11 Flue damper shall be installed in the 4” line as close to the inducer as practical and must be fully sealed with silicone. Flue sections between the inducer and the flue damper are subject to a much higher negative pressure. Locating the flue damper directly on the inlet of the inducer maximizes the effectiveness and stability of the venting configuration.

EK2 Hood (Large Nozzle)

EK2 Inducer (Silver)

EK1 Inducer (Black)

EK1 Hood (Small Nozzle

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2.12 ALL FLUE GAS JOINTS UNDER NEGATIVE PRESSURE MUST BE PROPERLY SEALED WITH SILICONE SEALANT, OTHERWISE, A REDUCTION IN FAN CAPACITY WILL OCCUR. SEAL ALL JOINTS, SUCH AS FROM THE BOILER FLUE COLLAR TO PIPE, BETWEEN PIPE SECTIONS, BETWEEN PIPE AND ELBOWS, BETWEEN PIPE AND DAMPER, AND BETWEEN DAMPER AND INDUCER. BE SURE TO TIGHTEN FRONT AND REAR BOILER COVERS, IF NEEDED.

2.13 The inducer should be mounted directly to the vent hood. If this is not possible due to code or space requirements, a sealed 3” Z-Vent elbow, (EK P/N: 10-0191-E390) and an elbow shield is included with the kit. If needed, straight lengths of 3” x 3’ long Z-Vent are available (EK P/N: 10-0191-P33) also. All joints must be designed and rated for over 5.0” W.C. positive pressure. The connection points between the inducer and hood must be sealed by a gasket or with a silicone or a high temperature equivalent.

2.14 Listed clearance from combustibles for smoke pipe/inducer is 9". This may be reduced by use of spaced metal or non-combustible fireboard as permitted by NFPA 31, NFPA 211, and applicable local codes.

CAUTION: The inducer and vent hood for EK1 have been designed to work together. The inducer and vent hood are different for the EK2. The EK1 inducer is BLACK and uses the 4 ¼” wide ejector nozzle. The EK2 inducer is SILVER and uses the 6” wide ejector nozzle. Do not use EK1 inducer with an EK2 vent hood or vice versa, the system will not function properly.

1834"

28 916" 3 3

16"

514"

812"

7"

914"

10"

4X Ø 14"

EK-1 Nozzle* = 414"

EK-2 Nozzle* = 6"

4" Ø 3"

Phantom Lines Indicate 90° Sealed Elbow and Shield

14" Wall ThicknessMax

Side

Bottom

Front* Nozzles mount to hoods using #10-32 S.S. Screws

25 916"

1614"

1"

1"

Ø3"

1614"

301316"

14" Wall ThicknessMax

Side358"

21 316" End of Exhaust

Inlet Tube

1214"

712"

23 316"

1"

331116"

4"

121116"

41316"115

16"

Flue Damper

Inducer

Alternate Inducer Mounting Position Using Sealed Elbow & Elbow Shield

Rear

Air Inlet Ø3" PVC

181116"

4"

3078"

618"

Non Combustible Wall Vent Hood

6"

READ

READ

Figure 4

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TRANSFORMERPOWER LEADS

WHITEWHITE

WHITE

WHITE

BLA

CK

WH

ITE

OU

TLET

BLA

CK

GR

EEN

GR

EEN

SWITCHSYSTEM

#14

WH

ITE

#14

GR

EEN

WH

ITE

BLAC

K

#14

BLA

CK

HOT

NEUTRALGROUND

BLA

CK

RED

BLA

CK

POWER (HOT)TT

TO BURNERNEUTRAL

DOOR SWITCH

BLACKBLACKBLACK

RED

RE

D

BURNERSWITCH

WH

ITE

RE

D

OR

ANG

E

BLA

CK

GR

EEN

BLU

E

-24 V

-B2-B1-IND

-ZHW

-CIRC

(GREEN)

(BLUE)(WHITE)(BLACK)(RED)

(ORANGE)

120 VAC POWER IN

BLAC

K

BLA

CK

BLACK

BLACK

R

120VCIRCIND CIRCBURNGND PWRXFMR

LA

INDCIRCHW

HW MAIN

MAIN CIRCBURNER

24V1

V

TUEN

02 VACHWIND 24 CIRC

OUTPUT CABLE FROMDIGITAL MANAGER

RIGHT SIDE

HIGH LIMIT AQUASTAT

MAIN CIRC

DOMESTIC HOTWATER CIRC

INDUCER FAN

GROUNDSCREW

MANUAL RESETHIGH LIMIT AQUASTAT

Figure 5B – Frontier Boiler

3.0 Wiring 3.1 The Energy Manager output can handle hot water, 4 heating zones, plus the inducer output with one (1) 50VA

transformer. Additional outputs require an additional transformer for either the expanded Energy Manager, or for zones using zone valves with end switches. Refer to boiler manual for details.

3.2 Install the inducer relay provided with the Sidewall Vent Kit into the plug-in base labeled IND on the relay board. Be careful to insert the male spade connections of the relay properly between the female contacts in the relay socket. Connect "hot" leg of the inducer to 120V IND and "neutral" leg to 120V NEUTRAL. The 24V connection is already factory wired (see red and green wires). Refer to the wiring diagram on the boiler junction box.

NOTE: 1) Inducer Relay comes taped to the Vent Hood 2) Inducer Relay is NOT included with the Inducer & Vent Hood Upgrade.

3.3 A two-wire conductor BX/Greenfield is fed to the inducer. It must be supported and installed at a proper distance from the flue pipe.

DPSTBURNERSERVICESWITCHU

HWCIRC

HIGH LIMIT AQUASTAT

WATER CIRC

INDUCER FANDOMESTIC HOT

MAIN CIRC

GROUNDSCREW

#14

BLA

CK

WHITEWHITE

GREEN

WHITE

WHITE

#14

WH

ITEO

UTLE

T

#14

GR

EEN

BLACK

BLACK

BLA

CK

#14

GR

EEN

GND XFMRPWR IND

L

RA

T

IND

DOOR SWITCH

GROUND (GREEN)POWER (RED/WHITE)POWER-LIMIT (BLACK)

TO BURNER

TT

NEUTRAL (WHITE)

RED/WHITE

BLACK

BLACKBLACK

RED

BLACK

BLAC

K

MAIN CIRC

CIRCMAINBURNHW

CIRC 120V

BURNER

RED

/WH

ITE

RED

/WH

ITE

BLA

CK

RED

IND

NEUTRAL 120 VAC POWER IN

HOTGROUND

SWITCHSYSTEM

WH

ITE

#14

WH

ITE

#14

GR

EEN

#14

BLA

CK

BLAC

K

0

NE

V

12

RED

POWER LEADSTRANSFORMER

(ORANGE)

(RED)(GREEN)

(WHITE)(BLUE)

(BLACK)

OR

ANG

E

BLAC

K

CIRCVACHW 24 24V

BLU

E

GR

EEN

BLA

CK

WH

ITE

BLA

CK

RIGHT SIDEDIGITAL MANAGER

OUTPUT CABLE FROM

-B1

-CIRC-B2

-ZHW

-IND-24 V

Figure 5C – Frontier EZ-Gas

GROUND N

LIMITHIGH

AQUASTAT

OUTLET YELLOW- 2 Cond. WH

ITE

BLAC

K

BLAC

K

WH

ITE

(NE

UTR

AL)

SWITCHN/C

PUFF CELLCAD

INDUCER HW MAINCIRCFAN CIRC

TTFFTO BURNER

RED

(HO

T)

GND

WHITEWHITE

SCREW

LGR

EEN

WH

ITE

BLAC

K UT

AR

E

120V

BLACK

INDXFMRPWR HWCIRC CIRC

MAINBURN

BLA

CK

BLAC

K

RED

BURNERMAIN CIRC

HWCIRC

IND

BLAC

K

RED

OUTPUT CABLE FROMNEUTRAL 120 VAC POWER IN

POWER LEADSTRANSFORMER

SWITCHSYSTEM

BLACK

GR

EEN

WH

ITE

BLAC

K

12

V0

BLACK

WHITE

WH

ITE

GR

EEN

BLAC

K

HOTGROUND

OR

ANG

E

(WHITE)(BLACK)

WH

ITE

IND 24 CIRCVACHW

RED

GR

EEN

BLU

E

SWITCH

24V

BLACKBLK

BLACK

BURNER

(BLUE)

(ORANGE)

(RED)(GREEN)

RIGHT SIDEDIGITAL MANAGER

-B1-B2-CIRC

-24 V-IND

-ZHW

Figure 5A – Standard Boiler

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4. Digital Manager Option Switch Settings 4.1 The Digital Energy Manager must have Option Switch 2 set to "ON" ("OFF" is setting for a chimney). 4.2 When the burner shuts off, the inducer will stay on for a period of 3 to 10 minutes to purge the flue products from

the boiler. Option Switch 3 is temperature based and will turn the inducer off after the boiler return drops to a certain temperature. Option Switch 4 regulates the minimum time the inducer will stay on.

Option Switch 3

Option Switch 4

Minimum Purge Time

Boiler Return Temp.

Maximum Purge Time

OFF OFF 5 Minutes 140°F 10 minutes

OFF ON 3 Minutes 140°F 8 minutes

ON OFF 5 Minutes 120°F 10 minutes

ON ON 3 Minutes 120°F 8 minutes

Inducer Purge Time Options The recommended settings are

"OFF", allowing a 5 minute minimum purge time (after 5 minutes, the

inducer will turn off when the boiler return temperature drops to 140°F).

5. Air Flow and Burner Setup 5.1 Adjust the damper located at the inlet of the inducer to set the over fire draft in the boiler to between -0.10 and -

0.12 inches H2O, with the burner running, allowing at least ten minutes for sufficient warm up. The inducer has excess fan capacity and the damper must be throttled to adjust the running draft in the boiler.

5.2 NOTE: TAKE ALL READINGS WITH AIR BOX COVER IN PLACE AND AIR INTAKE PIPING CONNECTED. The inlet piping and elbows add extra resistance to air flow, requiring the damper to be adjusted to compensate for the inlet piping. Measure the over fire draft with the air box cover in place and adjust the damper accordingly.

5.2 If needed, adjust burner air shutter for CO2/O2 levels indicated for conditions described in the Owner Installation Manual. Check for clean burning. Record settings in the spaces provided on the “Check Off Procedure” page.

5.3 Re-check draft over fire, adjust inducer for between -0.10 and -0.12 inches H2O. Recheck CO2/O2 and do a smoke test.

5.4 Lock adjustment on flue damper mechanism and burner air inlet shutter.

6. Safety Inspection Check 6.1 Start and stop burner several times to verify clean light-off, burner operation, and inducer post purge sequence. 6.2 Verify that the burner shuts off when the over fire draft goes positive due to a blocked vent or inducer malfunction. 6.2.1 If the boiler is equipped with the Classic Manager or a non-Carlin primary control, disconnect the black power lead

at the inducer. Start the burner with the inducer power turned off. The positive pressure inside the boiler will open the puff switch in about one minute, which will interrupt the yellow cad cell wire, causing the primary control to lockout.

6.2.2 If boiler is equipped with the Digital Manager and the Carlin primary control, with the burner and inducer running turn off Manager dip switch #2. This will turn off the inducer, causing positive pressure in the boiler, opening the puff switch in less than a minute, which will interrupt the yellow cad cell wire, causing the Carlin primary control to recycle. The Carlin control will attempt to restart the burner, the positive pressure inside the boiler will hold the puff switch open, interrupting the yellow cad cell wire, and then the Carlin primary control will lock out at the end of trial for ignition.

6.3 After performing the blocked vent test, be sure to reconnect the black power lead at the inducer, or turn Manager dipswitch #2 back on.

Record readings on check off list (page C-14).

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Concept

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Venting

D

Diagnostics

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Digital M

anager F

Classic M

anager G

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iring-General

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System

Piping

J D

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Maintenance

C-12

Blocked Air Inlet Installation Kit for Sidewall Vent Kits for Boilers with Gas Burners All Gas Fired System 2000 Frontier boilers with gas burners that are sidewall vented require Energy Kinetics Sidewall Vent Kit for Gas Burners. (Note: gas fired boilers vented by chimney and all oil fired boilers DO NOT require the blocked air intake kit.) This kit includes a second Puff Switch that is field installed to an inside surface of the air frame used on Energy Kinetics Sealed Air Inlet Boxes. The second Puff Switch in the kits for gas burners is an added safety device which shuts off the gas burner to prevent the burner from producing excessive amounts of Carbon Monoxide in the event that the air inlet to the burner were to become blocked. The Kits include all the same components listed with the Sidewall Vent Kits for use with oil burners, plus the following items: Second Puff Switch Harness Assembly Piece of ¼” O.D. Copper Tubing 2 Tek Screws 1 Crimp Nut 2 vinyl thread protectors Installation Instructions: 1. Start by making sure all power is turned OFF to the system. 2. Attach the Puff Switch on inside surface of the air frame so that it is at least ¾” below the top edge using the 2 tek

screws provided. 3. Check to ensure that there is no interference with the air box cover by reinstalled after mounting. 4. Next install the copper tube to the puff switch by slipping it up through the same grommet that the flexible conduit

passes through in the bottom of the air frame. 5. Form an offset in the copper tubing so that it reaches the rear port on the puff switch. The rear port monitors the air

pressure outside of the air box while the front port monitors the pressure inside air box. NOTE: IT IS IMPORTANT THAT THE COPPER TUBE IS INSTALLED IN THE REAR PORT ONLY IN ORDER TO

FUNCTION PROPERLY. 6. Remove the junction box cover on the new Puff Switch by loosening the two screws on the front and remove the

knock-out in the box 7. Install the end of the harness with the two spade terminals into this opening and Install one terminal under each of

the two terminal screws on the Puff Switch. 8. Loosen the screw on the junction box located on the burner air prover (far left of burner) and remove the cover. 9. Remove the knock-out at the rear of the air prover junction box and install the other end of the harness. 10. Loosen the terminal screw for the lead with the spade terminal on it. (This is the violet wire that comes from the Puff

Switch mounted on the front cover of the boiler and comes in from harness that enters through the grommet on the bottom of the air frame, then to the bottom of the air prover junction box.

11. Cut this terminal off and strip the insulation back around ½” and twist this wire together with the stripped wire on the new harness and install the crimp nut supplied with the kit.

12. Install the other wire with the spade terminal from the new harness to the now empty screw terminal on the air prover and tighten the screw.

13. Install junction box covers and test. Test Procedure: Install sealed air box cover making sure it is latched and that the reset plug is installed. Open air inlet piping as close to the burner as possible and block the air inlet with your hand or a piece of tape. Give a zone call to the system manager and turn the power on. After a 30 second pre-purge and a 6 second try for ignition (TFI), the primary must lock out.

C-13

Puff Switch shown mounted and wired

1. Mount the Puff Switch using the 2 tek screws provided. Install approximately ¾” below top of air frame to allow clearance for installation of air box cover.

4. Knock-out removed and harness installed (end with two spade terminals).

5. Remove air prover junction box cover. Loosen screw and remove spade terminal. Cut spade terminal off the wire and strip insulation back.

6. Remove knock-out and install other end of harness from new Puff Switch. Take wire with spade terminal on new harness and install under screw terminal. Twist stripped wires together, one from new harness and one from which spade terminal was cut from and install crimp nut supplied.

2. Insert the ¼” O.D. copper tubing up through grommet in the bottom of the air frame along side the harness that goes to the bottom of the air prover.

3. Form an offset in the tubing so it will line up with the rear port on the new Puff Switch. The ¼” tubing should extend out from the bottom of the air frame at least 1”.

Copper tube

Loosen screw & cut spade terminal from wire

Crimp Nut

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Concept

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-1 O

il Heat Install

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-2 G

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C

Venting

D

Diagnostics

E

Digital M

anager F

Classic M

anager G

W

iring-General

H

System

Piping

J D

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Maintenance

C-14

Installation Check Off Procedure Check Off: 1. BURNER (Must perform these steps prior to inserting Burner)

Oil Nozzle- Correct nozzle and properly tightened Electrode Position Nozzle Location (Proper Setting with Beckett or Other Gauge)

2. INSTALL QUALITY OIL FILTER AT BURNER 3. CHECK HIGH LIMIT AQUASTAT HIGH LOW (Above Burner on Standard, At Rear on Frontier) 215°F 205°F 4. DRAFT INDUCER

A) Mounted at wall as near vent hood as practical B) All flue connections properly sealed with silicone. (Flue collar, flex connecter, inducer connection to hood, and all joints.) C) Wire Fan Motor into 120V IND and 120V Neutral D) Digital Energy Manager Option Switch 2 set to "ON" E) Take Flue sample (Use 1/4" Metal Tube inserted at least 8" through

the Over Fire Test Port at the Puff Switch opening) F) Allow Burner to run 15 minutes before adjusting air settings and damper G) Adjust damper to obtain -0.10 to -0.12 in H20 draft over fire (steady state)

NOTE: Air Box Cover And Air Intake Piping MUST BE IN PLACE WHEN TAKING READINGS.

OIL NATURAL GAS LP Min. Max. Min. Max. Min. Max. Record:

CO2: 10.0% 11.0% 8.6% 9.2% 9.7.% 10.7% CO2 [OR]

O2: 6.2% 7.5% 4.5% 5.5% 4.5% 6.0% O2 5. RECORD TEMPERATURE and SMOKE from BREECH:

Min. Max. Record: Draft Over Fire: -0.10 -0.12 Draft (steady state)______” WC Gross Stack: 450°F Gross Stack Temp.______ °F Hood Outlet: 212°F Hood Outlet Temp ______ °F Smoke Number (Oil Only): 0 Smoke Number ______ Carbon Monoxide (Gas Only) 400ppm CO (Air free) ______%

6. The inducer must be inspected annually to ensure safe and proper operation. Inspection points should include:

(a) MOTOR: The motor has sealed ball bearings and does not require lubrication. (b) FAN: Fan must be clear of soot, ash, or any other coating which affects balance,

rotation, or air flow. Remove all foreign material before operating.

Installed By:

Company: Date:

Installed For:

Address:

C-15

Commonwealth of Massachusetts

♦ This Energy Kinetics gas fired hot water boiler and optional sidewall vent kit has been approved by the Massachusetts Board of Plumbers and Gas Fitters, Approval No. C1-1006-16

♦ When an Energy Kinetics gas fired hot water boiler is installed in the Commonwealth of Massachusetts, the following requirements must be met.

o The Commonwealth of Massachusetts requires that an Energy Kinetics gas fired boiler must be installed by a licensed Plumber or a licensed Gas Fitter.

o The Commonwealth of Massachusetts requires that the licensed Plumber or a licensed Gas Fitter installing the boiler must comply with the following excerpt from “Rules and Regulations - 248 CMR”.

5.08: Modifications to NFPA-54, Chapter 10

(2) Revise 10.8.3 by adding the following additional requirements:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

C-3-sidewall vent kit - Energy Kinetics

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