Frontier Oil Heat – PN 10-2021 – October 2021 - 14 -
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 EK1
Frontier contains 2-1/2 gallons of water and the EK2 Frontier contains 4 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 LINE AND VALVE
NOTICE: Systems are piped at the factory with the boiler bypass line and bypass ball valve. The bypass
valve must be at least partially open for the boiler to operate properly.
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. NOTICE: AIR VENT CAP SHOULD REMAIN OPEN DURING
INITIAL PURGING. Each zone should be purged until a steady stream of water without air passes out of purge hose.
Vent all radiation. The cap used on the air vent, is a hygroscopic safety air vent cap and should be made hand tight after
purging the system. It will allow air to vent but seal tight once contact with water is made.
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.
Pipe capacities 1” Copper pipe .044 gal. per foot EK1 2.5 gals
¾” Copper pipe .025 gal. per foot EK2 4.0 gals
Example: 500’ ¾ copper pipe holds 12.5 gals @ 30% solution add 3.75-gals antifreeze
EK1 boiler holds 2.5 gals @ 30% solution add .75-gals antifreeze
System total 15 gallons @ 30 % add 4.5-gals antifreeze
Note: Use refractometer for calculation of actual concentration or test strips
WINTERIZING
NOTICE: If the SYSTEM 2000 Boiler may be exposed to freezing temperatures, such as a vacation home shut down
for the winter, then anti-freeze should be added. When a home 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
+8F, 40% to -8F, 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 shutoff if the burner is shut down for an extended period of time.
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