A flat plate heat exchanger is used when the system requires isolating:

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1 Technical Bulletin #4 PLUMBING CONFIGURATIONS The Frontier Series provides a steady flow of high-temperature heat transfer fluid to various devices in your hydronic heating system, including hot water tanks and heaters, baseboard or free-standing radiators, radiant panels, in-floor radiant heat loops, and many other devices. You can install the Frontier Series as your primary or supplemental source of heat to an existing or new hydronic or forced-air central heating system. The Frontier Series is designed and pre-configured for easy installation in combination with the Frontier CX Hydronic Conditioning Manifold and the Thermsafe Overheat Protection Kit. This hydronic equipment, engineered specifically for the Frontier Series, eliminates much of the time and expense typically required to install a boiler while ensuring optimum heat transfer, flow rates, temperatures, and safety. (See piping diagrams below). Frontier CX Hydronic Installation System Components Frontier CX The Frontier Series CX is certified to operate as an atmospheric system. While having the highest quality welds, the heat exchanger is not an ASME certified pressure vessel Atmospheric Expansion Tank (Dealer provided) ThermSafe TM Overheat Cooling System (Dealer installed kit) Frontier CX Hydronic Conditioning Manifold (Factory pre-installed) Out > < In Steps to connect the hydronic system: 1. Connect the distribution loop to the supply and return ports of the factory installed Hydronic Conditioning Manifold (See piping and wiring diagrams below) 2. Connect Expansion Tank and the ThermSafe TM Overheat Cooling System. The ThermSafe kit makes this easy. (See piping and wiring diagrams below) 3. Fill the boiler and lines, add boiler treatment and freeze protection, and purge the system of air. 4. Ensure sufficient demand is available in the distribution loop and buffers to absorb 100,000 Btu (29.3kw)/hr with a full load and 60,000 Btu (17.58kw)/hr with a partial load. Integrate the Frontier CX On-Demand-Zone relay functionality where needed. Your Frontier Series hydronic system is now ready to operate. NOTE: The Frontier Series operates independently or as an add-on to an existing central furnace or boiler. If used as an add-on, the home system must be in good operating condition; meet all local building codes, ordinances, and safety standards; and be installed with required controls and in accordance with appropriate standards of the National Fire Protection Association. Greenwood Clean Energy, Inc 1 of 5

2 Hydronic System Configuration The Frontier Series Hydronic Conditioning Manifold (Part No ) ensures a consistent flow rate through the internal heat exchanger and protects the boiler from condensation caused by low return temperatures. The Hydronic Conditioning Manifold may be piped with the installer provided atmospheric expansion tank connected on either the right or left side of the manifold (as shown in Schematic FP3A and FP3B). The tank does double duty as both expansion tank and reservoir for the ThermSafe Overheat Cooling System (Part No ). NOTE: All plumbing schematics shown in this section are for illustration purposes only. Actual systems may require control and safety devices not shown in these illustrations. Consult your Greenwood certified home heating and plumbing professional for home heating system design and installation. Flat Plate Heat Exchangers Q: When should I use a Flat Plate Heat Exchanger? A: Flat plate heat exchangers are used to transfer heat between one circulation system and another. A mixture of propylene glycol and water flows through the manifold on the furnace side of the flat plate heat exchanger. This fluid does not mix with the fluid flowing through the distribution side of the heat exchanger. A flat plate heat exchanger is used when the system requires isolating: 1. Pressure differences. 2. Fluid differences. Greenwood Clean Energy, Inc 2 of 5

3 Pi ping Schematics (3) Atmospheric Expansion Tank must be positioned higher than any other point in the atmospheric piping loop. Tank size: 5 gal minimum fluid; 10 gal minimum tank volume. Vent Pipe (min. 1" diameter) (2) ThermSafe Overheat Cooling Assembly with Air Vent and Taco Zone Sentry, 2 way, Normally Open. Drawing shows system piping concept only. Installer is responsible for system design and compliance with local codes. NOTES: 1. The Hydronic Conditioning Manifold maintains a constant flow rate hydraulically separate from the distribution system. Distribution system piping should carry a flow rate of 10 to 30 GPM through the supply and return ports of the Frontier CX boiler loop. 2. The boiler loop must be piped to not develop excessive pressure in any portion of the boiler system. The Hydronic Conditioning Manifold s pressure relief valve opens at 30PSI. 3. The overheat cooling system piping is positioned above the boiler and designed to promote natural thermal circulation of the water in the event of a power failure. Greenwood Frontier Series Atmospheric System: Expansion Tank Piped Right FP 3A FPC03A ANDD Water level should be maintained 1" above the top of the Overheat Cooling assembly inlet. The base of the Tank must be at least 4 inches above the top of the Frontier CX to provide sufficient NPSH (net positive suction head) to prevent cavitation of the circulator. (1) Frontier CX Hydronic Conditioning Manifold May be piped direct or through a flat plate heat exchanger. Circulator Ball Valve Elbow must be at the high point of the vertical rise. Horizontal distance between the elbow and the expansion tank should be less than 6 feet. Available as an Overheat Cooling Kit to be installed by the installer Fluid Level Sight Glass Factory preinstalled Isometric View H Supply Port Return Port C Vent Pipe Outlet (must be unthreaded) Boiler Drain for filling and draining the system. (4) Distribution System Greenwood Clean Energy, Inc 3 of 5

4 (2) ThermSafe Overheat Cooling System Assembly with Air Vent and Taco Zone Sentry, 2 way, Normally Open. Elbow must be at the high point of the vertical rise. Horizontal distance between the elbow and the expansion tank should be less than 6 feet. Available as an Overheat Cooling Kit to be installed by the installer Fluid Level Sight Glass Vent Pipe (min. 1" diameter) (3) Atmospheric Expansion Tank must be positioned higher than any other point in the atmospheric piping loop. Tank size: 5 gal minimum fluid; 10 gal minimum tank volume. Water level should be maintained 1" above the top of the Overheat Cooling assembly inlet. The base of the Tank must be at least 4 inches above the top of the Frontier CX to provide sufficient NPSH (net positive suction head) to prevent cavitation of the circulator. (4) Distribution System May be piped direct or through a flat plate heat exchanger. Circulator Ball Valve H C (1) Frontier CX Hydronic Conditioning Manifold Supply Port Return Port Factory preinstalled Boiler Drain for filling and draining the system. Vent Pipe Outlet (must be unthreaded) Isometric View Greenwood Frontier Series Atmospheric System: Expansion Tank Piped Left Drawing shows system piping concept only. Installer is responsible for system design and compliance with local codes. NOTES: 1. The Hydronic Conditioning Manifold maintains a constant flow rate hydraulically separate from the distribution system. Distribution system piping should carry a flow rate of 10 to 30 GPM through the supply and return ports of the Frontier CX boiler loop. 2. The boiler loop must be piped to not develop excessive pressure in any portion of the boiler system. The Hydronic Conditioning Manifold s pressure relief valve opens at 30PSI. 3. The overheat cooling system piping is positioned above the boiler and designed to promote natural thermal circulation of the water in the event of a power failure. FP 3B FPC03B ANDD Greenwood Clean Energy, Inc 4 of 5

5 Nonstandard Installs Q: If the Frontier CX is installed without the factory mounted Hydronic Conditioning Manifold and Overheat Cooling Kit what piping and components are required? The Frontier CX Hydronic Conditioning Manifold and ThermSafe TM Overheat Cooling Kit simplifies the installation by including many of the components that typically must be installed in the boiler loop. The Hydronic components are custom designed for the Frontier Series, factory calibrated and preset to ensure optimum performance. For the rare situation in which the Frontier CX is installed without the install package (this will void the warranty without prior approval in writing from Greenwood Clean Energy), the installer must design, source, and install components to meet the following requirements: Hydronic System Functionality Frontier CX with install package Without install package Requirements Frontier Series Boiler Control System Outlet temperature monitoring Inlet temperature monitoring Flow switch cabling ThermSafe TM Overheat Cooling connection ready On-Demand Zone connection ready Boiler loop circulation X Flow rate stability X Taco 007 circulator or equivalent UL rated cirulator and piping to ensure 10 GPM (+- 2 GPM) flow rate Hydraulic separation of boiler and distribution loops Air elimination X Air vent Pressure relief X Atmosheric venting, pressure relief valve Fluid fill X Boiler drain Low temperature protection X Thermostatic 3-way 1" mixing valve Cavitation protection X Low fluid protection X Power failure and overheat protection X Boiler loop design that ensures sufficient head at the circulator inlet McDonnel & Miller FS-251 flow switch or equivalent UL rated device Taco 1" normally open Zone Sentry valve, power supply, gravity loop design, and piping Greenwood Clean Energy, Inc 5 of 5