Greenwood Frontier CX Installation And Operation Manual

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Page 2 Installation and Operation SAVE THESE INSTRUCTIONS READ THIS MANUAL AND KEEP IT NEAR THE FURNACE FOR REFERENCE V 1.9 © 2013 Greenwood Clean Energy, Inc All Rights Reserved For the latest information about your Greenwood Frontier CX refer to www.GreenwoodUSA.com/support.php...
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Page 5: Table Of Contents
7. Wire the Furnace .............................. 17 CHIMNEY INSTALLATION ............................ 18 Chimney Size ................................ 18 Connecting to an Existing Chimney Flue ........................ 18 Connecting to a New Factory‐made Chimney ...................... 20 Supplying Make‐up Air .............................. 21 Measuring and Adjusting the Draft .......................... 22 References .................................. 22 PLUMBING INSTALLATION ............................ 23 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 1...
Page 6: Table Of Contents
Safe Practices ................................ 4 3 Heat Transfer Fluid ............................... 4 3 Heat Exchanger Cleaning .............................. 4 4 Annual Shutdown Maintenance ........................... 4 5 System Flush ................................. 4 5 TROUBLESHOOTING ............................... 4 6 WARRANTY ................................ 5 0 Page 2 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 7: Appliance Identification
(To identify your serial number, see nameplate location on page 5.) Dealer Name: ____________________________________________________________ Address: ________________________________________________________________ Phone: _____________________________ Installer Name: ___________________________________________________________ Address: _________________________________________________________________ Phone: _____________________________ Installation Date: _________________________________________________________ © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 3...
Page 11: Introduction
Greenwood Clean Energy. With proper installation and maintenance, this furnace will provide years of low cost heat for your home. To insure correct installation and safe operation of your Greenwood Frontier hydronic furnace, you should: 1. Hire a Greenwood approved licensed heating contractor to install the furnace and integrate it with your heating system.
Page 12: Air Flow Through The Furnace
6. Exhaust Zone: Exhaust gases leave the boiler at temperatures of 200 – 450 F (93 C to 205 depending on firing rate. Side View of Air Flow through the Frontier CX Page 8 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 13: Fluid Flow Through The Furnace
1. The circulator pushes fluid around the boiler loop. 2. Fluid temperature is monitored by the Greenwood Boiler Management System. The intelligent control adjusts the burn rate of the furnace, balancing a clean burn heat demand.
Page 14: Specifications
(17 kW). On these days the boiler will need reloading every 8 hours. On average winter days (35,000 BTU/hr, 10kW), the boiler requires reloading approximately every 12 hours. Page 10 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 15: Greenwood Frontier Cx Component Identification
SPECIFICATIONS Greenwood Frontier CX Component Identification See Piping Section for piping component identification © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 11...
Page 16: Installation Preparation
INSTALLATION PREPARATION Installation Requirements Checklist Your Frontier Series should be installed by a Greenwood approved heating contractor who is thoroughly familiar with gas, oil, and solid fuel hydronic heating appliances. Also, be sure to comply with local building codes, fire codes and other regulations when installing the hydronic furnace.
Page 17: Unpack And Inspect The Furnace
(some of the items will be found stowed inside the firebox). If you observe any damage or find any items missing, please contact your Greenwood Dealer. Each unit is wired for 115 volt operation. Items shipped with the product include: ©...
Page 18: Unload The Furnace
INSTALLATION PREPARATION Additional items typically ordered and packaged with the Frontier CX. Other parts required for your boiler and distribution system installation will be determined by your installer and may arrive with the furnace or be shipped separately. Note: These are diagrams of furnace components which are shipped with the unit. Additional parts and configuration used for installation will be determined by your installer.
Page 19: Locate The Furnace
Mechanical Code 913, 6-4 in states where applicable. The Frontier CX may be installed on a combustible floor provided that the bottom heat shield (shipped with the boiler) is installed and the floor is protected from spillage of burning fuel particles by a noncombustible surface (such as masonry, cement, or sheet metal) placed: (1) Underneath the furnace;...
Page 20: Install The Combustible Floor Heat Shield
4. Install the Combustible Floor Heat Shield The Combustible Floor Heat Shield (part no. F100304) shipped with the Frontier CX is required to be attached when the appliance is installed on a combustible floor. The Heat Shield slides through the side front openings of the unit’s skids.
Page 21: Plumb The Furnace
INSTALLATION PREPARATION 6. Plumb the Furnace You can plumb your Greenwood Frontier to meet almost any heating need in the home. You can:  Supplement an existing radiant or forced-air central heating system;  Produce domestic hot water;  Heat your home, greenhouse, garage, outbuilding, basement or swimming pool;...
Page 22: Chimney Installation
Flue Diameter The flue adapter that ships with the Frontier CX can be used with a 5” (127mm) or 6” (152mm) diameter flue. A 6” flue will require use of a stove pipe reducer such as the 24 gauge 6” to 5” Imperial Stove Pipe Reducer sold by Ace Hardware (Product UPC 0634672300069).
Page 23 When attaching the connector pipe to the chimney, do not push it into the chimney (it may plug the chimney and impede the draft). The following illustration shows proper installation. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 19...
Page 24: Connecting To A New Factory-Made Chimney
(0.9m) above the highest point where it exits the roof and be at least 2.0 feet (0.6m) taller than any point of the roof within 10.0 feet (3.04m). Page 20 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 25: Supplying Make-Up Air
Fireplaces, other furnaces, clothes dryers, exhaust fans, and other appliances, all draw air from the room in which they are located. The Greenwood Frontier adds to that draw, so it is important to make sure there is an adequate source of fresh air to offset these demands. Otherwise, you may create negative pressure in the room and starve combustion in the furnace.
Page 26: Measuring And Adjusting The Draft
4. American Society of Mechanical Engineers (www.asme.org) *Note – Greenwood Clean Energy provides these supplier references for your convenience only. We do not endorse the vendor, the equipment they sell, or their prices. Other suppliers may offer similar or identical components and we encourage you to comparison shop.
Page 27: Plumbing Installation
Fill the boiler and lines, add boiler treatment and freeze protection, and purge the system of air. 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.
Page 28: Hydronic System Configuration
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.
Page 31: Nonstandard Installs
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,...
Page 32: Fluid Testing And Treatment
Proper fluid quality management is essential to protect your investment and longevity of Greenwood boilers. Before filling the boiler with water, draw a sample of the supply water to be used and send it to a Greenwood authorized lab for testing (see below). The sample will be analyzed and specific recommendations made for appropriate water treatment.
Page 33 RhoGard 925-40 is a 40% propylene mixture with D.I. water that eliminates water quality issues and removes all uncertainty covering water quality, freeze, corrosion and scale protection. The above products are non-hazardous for shipping. They can ship UPS for small quantities. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 29...
Page 34: Wiring
FW1) Frontier CX Hydronic Conditioning Manifold: The Taco 007 circulator requires connection to a grounded 115, 60-cycle power source. The pump should not be powered until the system is filled with fluid. (See...
Page 36: Power Outage And Overheat Protection
The Thermsafe system, which is controlled by the Greenwood Boiler Management logic, shuts down combustion and enables gravity fed cooling through the expansion tank when the power goes out or the outlet temperature rapidly rises beyond the set point.
Page 37: Universal Power Supply
Clean Burn algorithm. Note: On-Demand Zone functionality is not active in some Frontier CX boilers. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 33...
Page 38: Auxiliary Wiring For Heat From A Backup Furnace Or Boiler
Most operators want their existing central furnace or boiler to fire whenever there is insufficient output from the Greenwood Frontier (i.e., the fire dies down and no one is available to stoke it). This automatic switching between systems can be enabled by use of an additional aquastat and relay (note: these components are not included with the furnace).
Page 39: Operating The Frontier
OPERATING THE FRONTIER CX Control System The integrated Greenwood® Boiler Management System is a micro-processor based controller that continuously optimizes boiler performance. The control system is designed to ensure safe operating conditions and to initiate an automatic shut-down in the event of an error. The control panel on the front of the unit operates the system.
Page 41: Building Your First Fire
DO NOT completely fill the firebox with wood. Too much fuel, coupled with low demand for heat from your central heating system, may cause the furnace to over-heat or operate less cleanly. A Greenwood Frontier is more efficient than most other wood burning © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 42: Key Operating Guidelines
Once the fire is burning briskly (5-10 minutes), press the “SmokeGuard” button on the control panel before opening the firebox door to add small to medium-sized logs to the fire. Use care not to smother the fire. Page 38 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 43: Loading Wood Into The Firebox
Note: Temperature indicator lights on the control panel change refueling guided by the refractory between water temperature (constant light) and refractory temperature (flashing light) every 5 seconds. temperature indicator lights on the control panel. (See chart.) © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 39...
Page 44: What Wood To Burn
Then, cut the wood to the largest width that will fit through the firebox door and the length of your firebox. The larger the log, the longer the fire will hold. Page 40 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 45: Heat Content Of Wood By Species
2,669 17.1 Pine, Norw ay Pine, Pitch 2,669 17.1 Pine, Ponderosa 2,380 15.2 2,236 14.3 Pine, Western Spruce 2,100 14.5 Spruce, Black 2,482 15.9 Tam arack 3,247 20.8 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 41...
Page 46: Ash Removal
VERY HOT. Wear protective clothing, leather hearth gloves and eye protection whenever you work around the open firebox door. Page 42 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 47: Maintenance
Do not confuse it with Ethylene Glycol, more commonly known as automotive antifreeze, which is odorless, sweet to the taste; and HIGHLY TOXIC. DO NOT use Ethylene Glycol in your furnace. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 43...
Page 48: Heat Exchanger Cleaning
Before you start, all fire and coals in the firebox should be extinguished and cooled. Remove the top panel of the Frontier CX. Use a 5/16” socket wrench to remove the self-tapping screws and lift off the cover to expose the insulation.
Page 49: Annual Shutdown Maintenance
(available at most HVAC distributors and home improvement stores). Replace the fluid with a new mix of boiler treatment, propylene glycol (if utilized) and water. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 45...
Page 50: Troubleshooting
The firebox is out of fuel. If the Load the firebox with fuel. Frontier Series has burned through it's fuel, the control panel ‘warning’ status will light and the Page 46 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 51 Insufficient draft--refer to the Call your dealer and consult with a Chimney section in the manual. chimney professional for cleaning, Blockages in the flue or chimney. proper design and installation. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 47...
Page 52 (late spring and early fall) reduce the amount of wood placed in the load chamber. During these low demand periods a full firebox provides reduced performance. (continued on next page) Page 48 © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9...
Page 53 Clean Energy dealer for an normal wear and tear on the furnace. They do not affect the not affect furnace performance or inspection. safety or performance of the unit. life. © 2013 Greenwood Clean Energy, Inc All Rights Reserved V1.9 Page 49...
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Page 55 1. The complete model and serial number of the Boiler. Greenwood for one year from the verifiable date of purchase of the 2. Proof of purchaser’s required periodic maintenance, the installation Boiler.
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Page 58 Greenwood Frontier CX Hydronic Furnace: Installation and Operation V1.9; Issue Date: September, 2013 Part No D100100 Printed in USA GREENWOOD CLEAN ENERGY, INC 13429 SE 30 Street, Suite A, Bellevue, WA 98005 USA © 2013 Greenwood Clean Energy, Inc All Rights Reserved...

Greenwood Frontier CX Installation And Operation Manual

Table of Contents

Appliance Identification

Safety

Introduction

Specifications

Installation Preparation

1 Unpack and Inspect the Furnace

2 Unload the Furnace

3 Locate the Furnace

4 Install the Combustible Floor Heat Shield

5 Install the Chimney Flue

6 Plumb the Furnace

7 Wire the Furnace

Chimney Installation

Plumbing Installation

Wiring

Operating the Frontier

Maintenance

Troubleshooting

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