HeatMaster 2021 G Series Owner's Manual

G
OPERATION AND
O
MAINTENANCE
MANUAL
EPA Certified Wood
Burning Furnaces
By SteelTech Inc.
Version 8
UL 2523-2009
CAN/CSA B366.1-2011
1
CONTENTS
RETAIN THIS MANUAL FOR
FUTURE REFERENCE
WARRANTY AND SAFETY
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTENTS
DO NOT THROW AWAY
Water Treatment And Testing . . . . . . . . . . . . . . . . . . . . . 5
Water Treatment
. . . . . . . . .
WARRANTY
ANDPolicy
SAFETY
Recommended Operating Levels . . .
Limited Warranty
Test Parameters and What They Mean
Water Treatment And Testing
Safety Precautions . . . . . . . . . . . .
Water Treatment Policy
. . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . 5
3
. . . . . . . . . . . . . . . . 5
4
. . . . . . . . . . . . . . . . 6
4
Recommended
Operating Levels
FURNACE INSTALLATION
GUIDE
4
Test Parameters and What They
. .Mean
. . . . . . . . . . . . . . . .4 . . . . 7
Safety
Precautions
Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 . . . . 7
ClearanceINSTALLATION
To Combustibles
. . . . . . . . . . . . . . . . . . . . . . 7
FURNACE
GUIDE
Furnace Specification
Foundation .Charts
. . . . . . . . . . . . . . . . . . . . . .6 . . . . 8
Furnace
Unit Foot Prints . . . . . . . . . . . . . . . . . . . . . . . . . .6 . . . . 8
Location
Trench . . To
. .Combustibles
. . . . . . . . . . . . . . . . . . . . . . . . . . .6 . . . . 8
Clearance
Indoor Installation
Furnace
Foundation(Smokeless Loading Option Only) . . .7 . . . . 9
Chimney
Installation . . . . . . . . . . . . . . . . . . . . . . .7 . . . 10
Unit
Foot Prints
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .7 . . . 11
Trench
WiringInstallation
And Hydronic Lines . . . . . . . . . . . . . . . . . . .8 . . . 11
Indoor
DomesticInstallation
Hot Water . . . . . . . . . . . . . . . . . . . . . . .9 . . . 13
Chimney
Combustion
10
OPERATINGAir
THE FURNACE
Wiring And Hydronic Lines
10
Furnace Components . . . . . . . . . . . . . . . . . . . . . . . . . 14
Domestic Hot Water
12
Filling The Furnace With Water. . . . . . . . . . . . . . . . . . . . 15
OPERATING
THE FURNACE
Firing The Furnace
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wood Quality.
. . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . 16
Furnace
Components
Loading
Furnace
(Smokeless
Loading ) . . . . . . . . 14
. . . . 17
Filling
TheThe
Furnace
With
Water
CANADA
RETAIN SteelTech
THIS MANUAL
FOR
Inc.
FUTURE
REFERENCE
Box 158
Winkler MB. R6W 4A5
DO NOT Canada
THROW AWAY
Ph. (204) 325-9792
CANADA
Fax (204)
325-9803
SteelTech Inc.
Box
158
USA
SteelTech
Inc.4A4
Winkler, MB R6W
Box 373
Canada
Walhalla
58282
Ph. (204)ND.
325-9792
Ph. (204)
(877) 325-9792
Fax:
325-9803
Fax (204) 325-9803
USA
[email protected]
SteelTech Inc.
www.heatmasterss.com
Box 373
Walhalla ND, 58282
Ph. (877) 325-9792
Fax: (204) 325-9803
[email protected]
www.heatmasterss.com
Loading
Furnace (Loading Switch) . . . . . . . . . . . 14
. . . . 18
Firing
TheThe
Furnace
. . . . . . . . 15
. . . . 19
Wood Quality
ControlsThe
AndFurnace
Safety Devices
. . Loading)
. . . . . . . . . . . . . . . 16
. . . . 20
Loading
(Smokeless
Operating A Gasification Furnace Requirements
. 17
. . . . 22
Controls
AndMAINTENANCE
Safety Devices
18
CARE AND
How the G Series Gasification Outdoor Furnace Works
20
Care And Maintenance . . . . . . . . . . . . . . . . . . . . . .
CARE AND MAINTENANCE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Care
And Maintenance
Electrical
Troubleshooting . . . . . . . . . . . . . . . . . .21
. .
Cleaning
Your
Furnace
22
G100000 and G7000 Electrical Schematic
. . . . . . . . . . . . . .
. . 23
. . 24
. . 26
. . 29
.................
Troubleshooting
23
G10000 Electrical Schematic
. . . . . . . . . . . . . . . . . . . . . . 30
Electrical
Troubleshooting
Instructions For Editing Control Settings . . . . . . . . . .25
. . . . 31
G Series Electrical Schematic
28
Instructions For Editing Control Settings
29
Combustion Tuning Basics
33
Home Network Connection
36
Hardwired Connection
Finding an IP Address for Your Furnace
36
37
Addressing Your Furnace
39
Viewing Your Furnace in a Web Browser
40
3
2
LIFETIME LIMITED WARRANTY
SteelTech Inc. warrants to the original owner of the
G Series outdoor furnace that it is free from defects in
workmanship and material, which could cause a leak or
malfunction of the firebox or water jacket, and against
corrosion (if the instructions in the owners manual for
water treatment and maintenance are followed) for the life
of the furnace towards the purchase of a new HeatMasterSS
furnace, in the following pro-rated schedule.
Warranty Schedule
Coverage in the initial 5 years is 100%
• Year 6 - 7 is 50%
• Year 8 - 9 is 40%
• Year 10 - 15 is 30%
• Year 16 to life is 10%
• All firebrick used in the furnace carries a 2-year
warranty.
• Firebox door has a warranty of 5 years at 100%.
In addition, all steel including housing, legs, etc. have a
pro-rated warranty for a period of 10 years with coverage
reducing by 10% per year. Any parts not manufactured
by SteelTech Inc. that are used on the furnace - such as
controls, limit switches, heat exchangers - carry their own
manufacturer’s warranty. SteelTech Inc. will not be liable
for the cost of shipping, replacement or repair of these
parts.
If warranty requires removing or replacing of the furnace or
a part on the furnace, SteelTech Inc. is not responsible for
the cost of plumbing, replacement of antifreeze or water
treatment, shipping cost or any other cost other than the
replacement component or furnace.
SteelTech Inc. always has the right to decide if a part or
3
furnace will be repaired or replaced and will not be liable for
any cost not authorized by a SteelTech Inc. representative.
SteelTech Inc. does not warranty any damage caused due
to negligence and deterioration due to lack of proper
ongoing maintenance, physical damage caused by abuse
or freeze up, power surges or unauthorized work or
modifications to the furnace.
SteelTech Inc. is not liable for any damage or cost which
may occur from or during the operation of the furnace
or damage incurred due to any heating system failure.
The purchaser assumes all responsibility for the care,
maintenance, and safe operation of the furnace including
adding of approved boiler treatment or water. SteelTech
Inc does not warrant door gaskets, exterior paint or finish.
To qualify for warranty all instructions must be followed
in the operator’s manual, water must be tested and
maintained a minimum of once per year, and warranty
registration must be on file at SteelTech Inc. within 30 days
of purchase along with a copy of the original invoice. No
warranty can be approved unless the warranty registration
and water test verifications are on file at SteelTech Inc.’s
office.
The warranty can be voided by operating the furnace in a
manner inconsistent with the owner’s manual. SteelTech
Inc. reserves the right to change conditions or warranty at
any time.
GSERIES
WATER TREATMENT & TESTING
WATER TREATMENT POLICY
To qualify for warranty, water must be tested at a minimum
of once per year and water treatment added when
necessary.
RECOMMENDED OPERATING LEVELS ARE AS
FOLLOWS:
To take a water sample:
Conductivity: 100 - 4000 ppm
pH: 8.5 – 10. 5
Nitrates: no less than 730 ppm
• Locate your water sample bottle, mailing carton and
TEST PARAMETERS AND WHAT THEY MEAN
mailing label provided to you by your dealer.
pouring into a bucket, and let cool before collecting a
Conductivity
Conductivity is a measurement of minerals in your furnace
water. While it is common to have minerals in water, in
excess minerals can cause many problems in hydronic
systems including scaling and corrosion.
sample.
pH
• Open the boiler drain located at the bottom of the rear
cabinet of the furnace for 10-15 seconds or until the water
runs clear. CAUTION: Water is hot! Use extreme care when
• Fill one of the test bottles at least 1/2 full. Fill out the
mailing label, provided with the test bottle, completely,
including your email address, the model number and the
serial number of your furnace. Make sure to note if the
furnace water contains any antifreeze or additional
chemicals.
• Place bottle in the tube. Attach top part of the label to
sample bottle and bottom part to the outside of mailing
tube. Mail to our testing lab. Results can take up to 4
weeks to receive and up to 8 weeks if no email address is
on hand at HeatMasterSS.
• You will receive a water test report outlining what must be
pH is a measurement of alkalinity (hard or soft water).
For outdoor furnace water and the water treatment used
in outdoor furnaces, it is better to have your water a little
harder than softer (recommended pH range is 8.5-10) as
the active ingredients in the water treatment neutralize
harder water easier than softer water.
Nitrates
Nitrates tested for are a measurement of how much water
treatment is in the water. Nitrates measured are active units
of water treatment available to neutralize harmful elements
in your furnace water. Nitrates also act to neutralize harmful
bacteria that may build-up in the furnace water over time.
done (if anything). A week after making the recommended
Glycol
changes to your water, send in another sample to verify
Inhibited glycol provides anti-corrosion elements and
freeze protection for outdoor furnaces and is compatible
with Outdoor Furnace Water Treatment. Because outdoor
furnaces are open to the atmosphere systems and will have
fresh water added occasionally, oxygen is always entering
the system and will break down the glycol over time to
create glycolic acid which will harm your furnace system.
When this happens you will be required to drain and flush
your furnace system.
It is always suggested to use 100% virgin glycol instead
of recycled glycol as it will break down much sooner and
create glycolic acid.
the fluid has adequate protection.
Add the water treatment through the fill pipe located at
the top of the furnace when initially filling the furnace with
water or after testing, if needed. Ensure that all drains are
closed. It is recommended that water treatment is added
at a 1:200 ratio when initially firing the furnace and after
that. Additional treatment may have to be added for water
with more severe properties or for systems with more
chemically demanding requirements.
Heatmasterss G Series Furnace Operating Manual
4
SAFETY PRECAUTIONS
Read and understand all precautions before operating
the furnace. This furnace needs a periodic inspection for
proper operation. It is against federal regulations to operate
this furnace in a manner inconsistent with operating
instructions in this manual. Save these instructions. Retain
this manual as long as you own your G Series outdoor
furnace. Carefully read and follow these directions.
DANGER
Do not start the fire with or burn garbage, gasoline, naphtha,
engine oil or other inappropriate materials. Only competent
persons with a sound understanding of this heating method
that are qualified and trained should operate this furnace.
Improper firing could result in personal injury and/or
damage to the unit and void warranty.
ATTENTION
• USE APPROVED FUELS ONLY!
• The person(s) operating this furnace, must operate it in a
way that will comply with all applicable local and state
laws, and or other requirements.
• The person(s) operating this furnace is responsible to run
it in such a way so that it does not cause a public or
private nuisance.
• DO NOT OVER FIRE THIS HEATER. Attempts to achieve
heat output rates that exceed the heater design
specifications can result in permanent damage to the
heater.
WARNING
• All installations and operations of your furnace must
follow state, provincial, and local laws pertaining to
• DO NOT operate furnace in event of power failure. Use
caution when opening the firebox and ash cleaning doors.
Push the by-pass handle towards the back of the furnace
and slowly crack the door open for at least 20 seconds
before fully opening the door.
• DO NOT use chemicals or fluids to start the fire.
Risk of Fire:
• DO NOT operate with fuel loading or ash removal doors
open.
• DO NOT store fuel or other combustible material within
marked installation clearances.
• Inspect and clean flues and chimney regularly.
• This appliance should not be installed in a location
where a corrosive atmosphere, flammable gas or vapour,
combustible dust or combustible fibers may be present.
If flammables are present in the building, ensure ducts,
vents and doorways between the rooms are sealed so as
to not allow vapours or fibers to travel to the appliance.
CAUTION
• DO NOT start or operate this furnace without confirming
adequate heating fluid level.
• The furnace must be filled until heating fluid comes out
the vent pipe on top of the furnace.
• Check for buried cables and utility lines before digging the
trench to your furnace.
• For safety and proper temperature control keep all doors
closed during operation.
• Hot Surfaces: Keep children away. Do not touch during
operation.
operations, wiring, plumbing and building codes.
• All models operate at atmospheric pressure. DO NOT
obstruct, block or plug the rooftop overflow vent tube in
any way.
• When installing the furnace, the chimney should never be
connected to a chimney flue serving another appliance.
5
Heatmasterss G Series Furnace Operating Manual
ATTENTION: DO NOT CONNECT THIS UNIT TO A
CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
GSERIES
GSERIES
FURNACE INSTALLATION GUIDE
Installation should be performed by a qualified installer and must comply with all requirements of the agency having
jurisdiction.
FURNACE INSTALLATION GUIDE
G4000
G7000
Heat
Output Range
jurisdiction.
16,500 - 110,000 btu/hr
TBD
Heat Output
Furnace
WeightRange
18,000
32,000 - 214,000 BTU/hr
1448
lbs -120,000 BTU/hr TBD
47,000
TBD - 350,000 BTU/hr
Furnace
Size
(W x H x L)
Firebox
Size
(DepthxWidthxHeight)
x 57
x 77
2338
x 22
x29
53 x 70 x 84
TBD
54
x 82 x 89
TBD
Firebox
Volume
Furnace
Weight
8.51300
ft3 lbs
3000
TBDlbs
Chimney
FireboxSize
Dimensions
6” 19 x 20 x 30
2400 lbs
TBD
TBD
28 x 30 x 36
Water
Capacity
Chimney
Size
8 Hour
Average
Efficiency Using
Water Capacity
HHV
116”
6 USG
TBD
6”
8”TBD
100 gallons
92.9%
195 gallons
TBD
250
gallons
TBD
89.5%
75.8%
TBD
79.0%
TBD
74.8%
68,025 btu/hour
TBD
Furnace Size (WidthxHeightxLength ) 42G100000
x 92 x 62
Annual Efficiency rating Using HHV
Higher Heating Value of Wood
8 Hour Burn Rating
G7000
TBD
G10000
TBD
G10000
TBD
TBD
30
x 42 x 40
TBD
U.S.
ENVIRONMENTAL
AGENCY Certified to comply with the 2020 particulate emission standards.
sale
in the United StatesPROTECTION
after May 15, 2020
Annual Efficiency rating is calculated using the weighted average test results from the emission test reports for each model.
Efficiency is determined by dividing the total input using the heating value of wood (8600BTU/lb)by the actual heat delivered
is taken off of the furnace.
by the furnace.
LOCATION
LOCATION
Where
you
install
furnace
will
have
effect
the
Where
you
install
thethe
furnace
will
have
anan
effect
onon
the
efficiency of your furnace. Although the furnace is very well
insulated, installing the furnace outdoors will mean some
insulated, installing the furnace outdoors will mean some
heat loss at the furnace. The furnace will have less heat loss
heat loss at the furnace. The furnace will have less heat
when installed indoors away from the elements that can
loss
when
installed
cause
heat
loss. indoors away from the elements that
can cause heat loss.
 Maintain an adequate clearance of buildings and
• Maintain
an adequate clearance of buildings and
combustibles.
combustibles.
 Do not place or store wood within stove installation
• Doclearances
not place or
withinrequired
stove installation
orstore
withinwood
the space
for charging
clearances
or within the space required for charging and
and ash removal.
ash removal.
in the
same
room
as the
• Do
Donot
notstore
storecombustible
combustible
fuels
fuels
in the
same
room
as the
furnace.
furnace.
 Pile and store wood under shelter.
• Pile and store wood under shelter.
 For indoor installations where fans are used in the fuel
• For indoor installations where fans are used in the fuel
storage area, they should be installed so as to not create
storage area, they should be installed so as to not create
any negative pressure in the room where your furnace is
any
negative pressure in the room where your furnace is
burning.
 burning.
Contact all governing authorities in your area prior to
• Contact
all governing authorities in your area prior to
installation.
 installation.
When choosing the location of your furnace you should
• When
choosing
the wind
location
of yourdistance
furnace from
you should
consider
prevailing
direction,
home
and woodprevailing
storage for
refueling.
consider
wind
direction, distance from home
 and
Givewood
consideration
to refueling.
any effect on your neighbors.
storage for
• Give consideration to any effect on your neighbors.
CLEARANCES TO COMBUSTIBLES
Whether installing your G SERIES furnace inside a building
or outside, the following clearances to combustibles must
always be followed or damage and personal injury may
result.
DO NOT STORE COMBUSTIBLE FUELS IN THE SAME
SPACE AS THE FURNACE IF INSTALLED INDOORS.
Minimum Clearance to Combustibles
Furnace Roof to Ceiling (Indoor
Installations)
6”
Side Walls & Rear
6”
Front (Loading door)
24”
6
7
FURNACE FOUNDATION
• Footprint dimensions are shown below.
• Inspect the ground conditions where you intend to install
not less than 6” wide x 10” long and 3” thick. Place your
blocks so the legs will stand at the center of the blocks.
• The furnace may be installed on a combustible floor
your furnace.
• A cement pad of 4-6” thickness should be used. Cement
provided a noncombustible material such as metal or
pads should be a little bigger than the actual furnace. You
masonry liner is used in the following areas:
— Underneath the furnace.
— At least 16” in front of the furnace and 8” on each side
of the firebox and lower combustion chamber doors.
can also include a 4’ extra length front and back so you
have a solid working area.
• The furnace can also be placed on 4 cement blocks
46 5/8
43 3/4
46 5/8
43 3/4
37 1/2
34 1/8
Feet (x4)
7
9 1/4
28 5/16
62
74 3/4
6
8
TRENCH
SteelTech Inc. recommends the trench to be 24” to 36” deep, and wide
enough to install your water lines. If possible, have a gradual slope in your
trench to allow drainage away from your lines and out the trench bottom.
Place a properly rated electrical supply cable at the bottom of the trench
and cover with 6 inches of dirt. Install burial rated Cat5 or Cat6 cable or a
conduit to allow networking to be set up with the furnace.
Use an underground insulated pipe product like Rhinoflex, available from
HeatmasterSS, for your best value and longest lasting underground pipe.
NOTE: If you are installing your water lines under an area where vehicles
will cross, you should increase the depth of the trench and use a schedule
pipe over your lines to reduce the pressure generated on the lines.
7
Feet (x4)
Feet (x4)
6
6
21 1/4
G7000
49 7/8
62 5/8
G4000
40 3/4
52 7/8
G10000
10 1/4
14 1/4
18
14 1/4
GSERIES
INDOOR INSTALLATION
IMPORTANT: To reduce the risk of fire, follow all local codes
inducer fan stay clean and in good condition at all times.
and these installation instructions carefully. A fire may be
caused by the following:
The top of the chimney must extend at least 3.0 feet above
the highest point where it exits the roof and be at least 2.0
feet taller than any point of the roof within 10.0 feet. For a
new chimney, use an insulated stainless steel system that
conforms to type HT (High Temperature) requirements of
UL 103 and ULC-S629 and complies with the requirements
of Chapter 11 of NFPA 211, Standard for chimneys,
fireplaces, vents and solid fuel burning appliances in the
USA or CSA B365 installation code for solid fuel burning
appliances and equipment in Canada.
• Improper installation.
• Storing flammables in the same room as the furnace or
wood fuel.
• Not carefully cleaning ash and embers from around the
furnace area after loading or cleaning.
ATTENTION: When installing the furnace in a building,
always make sure that smoke and CO detectors are
properly installed in the same area as the furnace. Outside
combustion air may be necessary if:
• The furnace does not draw steady, smells, rolls out
smoke, is burning poorly or back-drafts or if any of these
symptoms are alleviated by opening a window.
• The building is equipped with a well-sealed vapor barrier
and tight-fitting windows and/or has any powered devices
that exhaust house air.
• There is excessive condensation on windows in the
winter.
• A ventilation system is installed in the building.
Chimney
Note: Incorrect chimney installation will void the warranty.
The chimney on your G Series furnace is a stainless steel
chimney. When installing the furnace, the chimney should
never be connected to a chimney flue serving another
appliance. Make sure the chimney, flue pipe, and draft
The recommended chimney and collar adapters are listed
below.
Furnace Chimney Size
G4000
6”
G7000
6”
G10000
6”
This is a draft induced furnace but it is important that the
chimney has a good draft to further eliminate any smoke
issues.
Note: Using a smaller chimney may cause smoke issues
and using larger chimney may negatively affect furnace
performance.
ATTENTION: CLEANING OF THE HEAT EXCHANGER, FLUE
PIPE, CHIMNEY AND DRAFT INDUCER ARE ESPECIALLY
IMPORTANT AT THE END OF THE HEATING SEASON TO
MINIMIZE CORROSION DURING THE SUMMER MONTHS
CAUSED BY ACCUMULATED ASH.
8
CHIMNEY INSTALLATION
A chimney connector is the double-wall or single-wall
pipe that connects the furnace to the chimney. Chimney
connectors are used only to make the connection from the
stove to the chimney. They will only be used for installations
where chimney extensions are used. For all other
installations, the factory provided chimney can be used.
We recommend that chimneys being installed on our
Double-wall
connectors approved for use with solid-fuel
products be installedCHIMNEY
by professionals
who are certified in
A chimney connector is the double-wall or single-wall
INSTALLATION
burning
appliances
must
be used.
pipe
that
connects
the furnace
to the chimney. Chimney
the USA by NFI (National Fireplace Institute) or in Canada
ATTENTION: Before installing, check with local buildingInformation
connectors
are
used
only
to
make
the connection
from the
on assembling and installing
double-wall
by WETT (Wood Energy
Transfer).
codesTechnology
for information
regarding chimney height and
stove to the chimney. They will only be used for installations
connectors and chimneys is provided by the manufacturer
to adjacent buildings, etc. You may need to
where chimney extensions are used. For all other
Draft problems may distances
occur because
of incorrect chimney
and must
be followed.
Use
chimneys
and
connectors
from
obtain a building permit for the installation of this appliance
installations,
the factory
provided
chimney
can
be used.
installation.
or the chimney.
Double-wall
connectors
use with
the same
manufacturer
asapproved
it helpsfor
make
thesolid-fuel
assembly and
burning appliances must be used.
We recommend
that chimneys
being
on our installation
IMPORTANT: The furnace
room must
never be
in ainstalled
negative
easy.
Information on assembling and installing double-wall
pressure condition. Negative pressure could result in smoke
Note: When
installing
a chimney
through
roof, telescoping
the USA by NFI (National Fireplace Institute) or in Canada
connectors
and chimneys
is provided
by theamanufacturer
in the room.
by WETT (Wood Energy Technology Transfer).
and
must
be
followed.
Use
chimneys
and
connectors
chimneys can be used to simplify the installation from
and
ATTENTION: Before installing, check with local building
codes for information regarding chimney height and
distances to adjacent buildings, etc. You may need to obtain
a building permit for the installation of this appliance or the
chimney.
the same manufacturer as it helps make the assembly and
problems
occur
because
of incorrect chimneyeliminate the need to cut individual connector sections.
Make sure to follow Draft
these
simplemay
rules
below
to ensure
installation easy.
installation.
proper performance and safety:
Consult
your
local
dealera chimney
about these
special
pieces.
Note:
When
installing
through
a roof, telescoping
IMPORTANT: The furnace room must never be in a
pressure condition.
pressure could result chimneys can be used to simplify the installation and
• The chimney mustnegative
be connected
using a Negative
double wall
Roof Penetrations
and
Clearances
eliminate the need
to cut
individual connector sections.
in smoke in the room.
•
•
•
•
•
•
•
stainless steel chimney and connector.
Consult
your
about
pieces.
rule
is local
this:dealer
The top
ofthese
the special
chimney
must clear the
Make sure to follow these simple rules below to ensure The basic
Use only components
intended
for and
the safety.
brand and model
proper
performance
roof penetration
point (the
edge) by at least 3-feet
Roof Penetrations
andupper
Clearances
of chimney you are using.
Never
substitute
parts
from
The chimney
must
be connected
using
a double walland must clear anything within a 10-foot radius by at least
The basic rule is this: The top of the chimney must clear the
stainless
steel chimney
connector.
other chimney brands
or fabricate
yourand
own
components.
2-feet.roof
This
includespoint
the (the
peak
of the
house,
parapet,
penetration
upper
edge)
by at least
3-feet dormer,
 Use only
intended
the brand and
and or
must
clear See
anything
within
To be safe and effective,
thecomponents
chimney must
befor
installed
chimney,
spire.
(figure
1).a 10-foot radius by at least
model of chimney you are using. Never substitute
2-feet. This includes the peak of the house, parapet, dormer,
exactly in accordance
with
the
manufacturer’s
parts
from
other
chimney brands or fabricate your own
If the chimney terminates beyond 10 feet from the ridge of
instructions.
components.
If the
terminates
beyond
10 feet from the
of by
the roof,
it chimney
must clear
the upper
penetration
of ridge
the roof
 To be safe
and effective,
the chimney
the
roof,
it
must
clear
the
upper
penetration
of
the
roof
by
Use a direct exit whenever
possible.
A vertical
exit must
withbe
3-feet. Notice that the flue still terminates 2-feet above the
exactly in accordance with the manufacturer’s
no elbows is alwaysinstalled
the safest
and most trouble-free
10 ft. (3 m)
roof atroof
theat10-foot
perimeter.
the 10-foot
perimeter.
or less
instructions.
installation.
 Use a direct exit whenever possible. A vertical exit with
10 ft. (3 m)
lessm)
2 ft.or(0.6
Maximum chimney installation
height
15 ft.
Any
height
no elbows is always
theissafest
and
most
trouble-free
minimum
3 ft. (0.9 m)
SS
installation.
longer than 15 ft. must be approved by Heatmaster
Ridge
minimum
2 ft. (0.6 m)
 Maximum chimney installation height is 15 ft.
minimum
office.
3 ft. (0.9 m)
Ridge
minimum
 Maximum horizontal installation from the furnace to the
Maximum horizontal installation from the furnace to the
exhaust exit is 3 ft.
exhaust exit is 3 ft. Maximum 8 ft run from elbow to elbow, but keep as short
Chimney
Maximum 8 ft run from
elbow to elbow, but keep as short
as possible.
 Never use an elbow with a greater than 30-degree bend.
as possible.
Chimney
45-degree elbows and tees cannot be used.
Never use an elbow with a greater than 30-degree bend.
More than

Height above
10 ft. (3 m)
any roof surface
45-degree elbows and
tees cannot be used.
attic entries.
with 10 ft. (3 m)
10 ft. (3 m)
• Elbows should never
 be installed in floor joists or roof
•
9
•
attics, and roofs to keep the wood and insulation from
attic entries.
Shields should be used whenever going through floors,
 Make sure to follow local building codes.
attics, and roofs to keep the wood and insulation from
getting too hot and possibly catching fire.
10 local
Heatmaster
G Series Furnace Operating Manual
Make sure to follow
buildingSScodes.
Ridge
Ridge
More than
10 ft. (3 m)
2 ft. (0.6 m)
10 ft. (3 m)
minimum
horizontally
Height above
any roof surface
with 10 ft. (3 m)
horizontally
3 ft. (0.9 m)
minimum
2 ft. (0.6 m)
minimum
3 ft. (0.9 m)
minimum
Chimney
Chimney
GSERIES
Combustion Air
Furnace Connection
Fireplaces, other furnaces, clothes dryers, exhaust fans,
and other appliances all draw air from the room in which
they are located. Your G Series furnace adds to that
draw, making it important to ensure there is an adequate
source of fresh air to offset these demands. Otherwise, a
negative pressure may be created in the room and starve
combustion in the furnace.
• Connections to the furnace are clearly marked.
• Return (from the house) are the top ports.
• Supply (to the house) are the bottom ports.
• The installation of isolation valves at both ends of the
1. Determine the volume of space (cubic feet) in the room.
Include in the calculation adjacent rooms and areas not
closed off by doors. Volume (CF) = Length (ft) x Width (ft)
x Height (ft).
2. Determine the air input requirements of all appliances in
the space. Add the BTU output of all appliances and round
the total to the nearest 1000 BTU per hour.
3. Determine whether the space is ‘confined’ or
‘unconfined’ by dividing the total volume of the room by the
total input requirements for all appliances in the room.
a. If the result is equal to or greater than 50 CF/1000
BTU per hour, then consider the space ‘unconfined’.
b. If the result is less than 50 CF/1000 BTU per hour,
then consider the space ‘confined’.
4. For an ‘unconfined’ space in a conventionally
constructed building, the fresh air infiltration through
cracks around windows and doors NORMALLY provides
adequate air for combustion and ventilation, and therefore
no additional make-up air is required.
5. For a ‘confined’ space or an ‘unconfined’ space in a
building with unusually tight construction, an additional
source of make-up air is required. Please consult an HVAC
professional to determine the best way to supply make-up
air for this type of installation.
WIRING AND HYDRONIC LINES
pump is recommended as well as a valve at the return
line. This will allow you to shut off the water supply if
repairs or additional heating components are added to
the system.
• Your main power is connected to the junction box at
the back of the furnace and should be connected by a
qualified technician.
Power Requirements
Power Supply
120V 1PH 60 HZ
Max Breaker
15 AMP
Running Load
2.5 Amps
Max Accessory Load
9.5 Amps
Building Connections
It is important to have a hole large enough to accommodate
the water lines, insulation, and a protective sleeve through
the wall. Attention to sealing this point on both sides is also
important
Re-Circulation Pump
Your G Series furnace comes factory equipped with a
recirculation pump, maximizing the heat storage in your
furnace and supplying even temperatures and flow
throughout the tank.
ATTENTION:
This pump should only be plugged in after your furnace has
been filled with your heating fluid.
• All wiring must conform to local codes.
• Use an electrical wire (rated and approved) for
underground installations. This wiring can be placed
in the same trench below the water lines. A qualified
technician must perform the electrical portion of the
installation.
• See Page 27 for the furnace wiring diagrams.
10
The pump should be plugged in and recirculation loop
valves open whenever the furnace is in use. Under no
circumstances should this pump or piping be used to
service distribution piping to buildings. The outlets provided
for distribution should be connected to separate pumps
and piping properly sized for their respective heat load
requirements. The circulation pump has three speeds and
should be set according to the model of the furnace.
system flow limiting the BTU’s available to your building.
This may also lead to your furnace overheating and cause
temperature swings in the water feeding the house.
G4000 - Speed #2,
Water-To-Water Heat Exchangers
G7000 - Speed #3,
G10000 - Speed #3.
Underground Hydronic Lines
Rhinoflex pipe by HeatmasterSS is your best value for long
lasting underground pipe with the most efficient insulation
used in insulated pipe resulting in minimal heat loss
between your furnace and building. Contact your local
dealer to purchase.
Hydronic lines (hot water heating lines), whenever buried or
encased in cement should not be spliced. Take the
necessary steps to ensure they stay dry. This ensures that
minimal heat loss occurs. Supply and return piping should
be sized according to the flow and pressure drop required
by each building. Piping should have a minimum rating of
100 PSI at 180 F.
Hint: To easily identify supply and return lines, Rhinoflex
Insulated pipe includes one pipe with a black stripe and one
pipe blank.
Interior Connections
11
DISCLAIMER: The following information in the interior
connections are examples and suggestions only. When
installing a furnace and its parts it is best to consult your
local dealer or a qualified technician.
To maintain pressure in an existing boiler system while
using an outdoor furnace, a water-to-water heat exchanger
is used. The water-to-water exchanger is installed inline on
the return side of the existing pressurized boiler system.
Flat Plate Exchanger for Pressurized Boiler Systems
Flat plate exchangers are used with pressurized systems
such as boilers. The flat plate transfers heat in to the water
in the boiler return line pressurized system while keeping
the two systems separate. Because an outdoor furnace
is an open system (not pressurized) and the system tied
in to this type of application is pressurized, it allows both
systems to stay the same while being operational. The
water supplied by the outdoor furnace will heat the water
in the pressurized system while the present heat source in
the pressurized system (such as a boiler) can be used as
a backup heat source in case of an emergency or need for
additional heat. When connecting the furnace to an existing
pressurized boiler system:
• The furnace must not be installed so that it interferes with
normal heat delivery of the existing boiler system.
You may require either a water-to-water (tube and shell or
plate) or a water-to-air exchanger (rad) to transfer heat
energy from the hot water your furnace has produced. Your
plumber or dealer can design and install a system to best fit
your needs. The following are examples of basic interior
connections. Your dealer carries the necessary parts for
installation.
• The furnace must be installed without affecting the
It is important to note that when installing your piping
system in your building that you should avoid installation
methods that cause too great a restriction in the piping
system. Examples of this are reducing pipe size, and an
excessive amount of joints and elbows, etc.
• The furnace must have provisions for preventing, or
operation of the electrical and mechanical safety controls
of the original boiler.
• The furnace must provide for a changeover from one fuel
to the other without requiring manual adjustment of any
controls or components other than the thermostats.
adequate water capacity within the boiler to prevent
damage from loss of circulation due to electrical power
failure.
• The furnace must be installed without changing the
It's important to design your system in a way, that allows
the water returning to your furnace to remain above 130°F
function of the controls or rewiring the original boiler. A
It is also important to install air bleed valves at high
points in the system to avoid an air lock, especially if these
points are higher than the furnace. Airlocks can restrict
of both boilers shall be powered from a single branch
wiring interconnection is permitted. The electrical system
circuit without exceptions.
GSERIES
Boiler Safety
Forced Air Furnace (Water-To-Air Exchanger)
• Operate the boiler periodically to ensure that it will operate
The water-to-air heat exchanger must be mounted so that
air blows through the fins (coils). The exchanger should
be mounted below the A/C coil if possible. The exchanger
should be sized to fit existing duct-work and should
produce about as many BTU’s as the existing heat source.
An exchanger that produces too many BTU’s will result in
uneven heat and the fan stopping too quickly while a heat
exchanger that is undersized will not produce the necessary
BTU’s. The heat exchanger can also be placed into the cold
air portion of the duct-work but it is not recommended
because some furnaces have an overheat shut off if the fan
overheats as a result of blowing hot air instead of cold air.
satisfactorily when needed.
• Do not relocate or bypass any of the safety controls in the
original boiler installation.
• The operation of the boiler must be verified for acceptable
operation before and after installation of the add-on
appliance by a gas fitter who is recognized by the
regulatory authority.
• Do not connect to any chimney or vent serving a gas
appliance.
It is important that the warm-air supply-duct system is
constructed of metal in accordance with NFPA 90B-1993,
2-1.1. If the outlet-air temperature of a central furnace
exceeds 250 degrees F (121 degrees C) when it is tested in
accordance with the requirements for simultaneous firing in
56.4.1 and 56.4.2 of the standard. It is also important that
the plenums installed to the furnaces are constructed of
metal in accordance with NFPA 90B-1993, 2-1.3.
Overhead fan coil installation example
Installation should comply with requirements of CAN/
CSA-B365, and changes to the installation should comply
with CSA-B139 (for oil-fired boilers), C22.1 (for electric
boilers), or CAN/CSA B149.2 (for gas-fired boilers).
Example of hookup for a forced air furnace and hot water.
DOMESTIC HOT WATER
Flat plate exchanger systems used to pre-heat domestic
water tanks are generally more reactive to hot water
demands then tube and shell systems. However, tube and
shell exchangers hold up better when hard water is present.
12
EZ CLEAN HANDLE
CONTROL PANEL
WATER LEVEL FLOAT
FIREBOX DOOR
SMOKELESS
LOADING HANDLE
COMBUSTION
CHAMBER
DRAFT INDUCER FAN
COLD WATER
SUPPLY OUTLETS
TOP AIR CONTROL
DAMPER
RECIRCULATION PUMP
PUMP PLUG IN MAIN POWER
SWITCH LEAD IN POWER BOX
HOT WATER SUPPLY
OUTLETS
BOTTOM AIR
CONTROL
DAMPER
FURNACE DRAIN
VALVE
13
Heatmasterss G Series Furnace Operating Manual
GSERIES
OPERATING THE FURNACE
Filling the Furnace With Water
Your furnace has a vent pipe that protrudes through the
roof which is used to fill the furnace with water.
GSERIES
Filling the furnace with the inline valve pushes all the air
towards the furnace and out of the vent. Because this
furnace is an open system it is normal that water will have
to be added annually, depending on the circumstances (6 to
10 gallons is not unusual).
Hint: If any part of the system is higher than the furnace
a bleeder
shouldwith
be the
used
to make sure all air is
Fillingvalve
the furnace
inline
valve pushes all the air towards
removed.
OPERATING THE FURNACE
CAUTION: Do not fire the furnace until it is filled with water.
Allow the furnace to run for 2 days and check the system
water levels and fittings for leaks. Take your initial water
FILLING THE FURNACE WITH WATER
sample at this time and be sure that it is sent in for testing.
Your furnace has a vent pipe that protrudes through the
the furnace and out of the vent.
IMPORTANT: To properly maintain your furnace, test your
ATTENTION:
water level
BecauseYour
this furnace
is an open
water every year.
Water
treatment
may
need
to
be
added
or
will
rise
as
the
temperature
of the
system
it
is
normal
that
water
CAUTION:
will
have
to
be
added
annually,
your furnace water.
may need
befurnace
drained
flushed
Allowto
the
to and
run for
2 daysand
andwater
check the water rises and fall as the water
depending
on the
circumstances.
treatment added. For information on acquiring this product
temperature
falls.
If your
water
(6
to
10
gallons
is
not
unusual).
water
sample
at
this
time
and
be
sure
that
it
is
sent
in
for
refer to your local dealer.
level falls to a low level, first check
testing.
If any
part of thebefore
system is
your Hint:
water
temperature
Hint: It is rec ommended that a fill valve is installed inline in
higher
than
the
furnace
a bleeder
IMPORTANT: To properly maintain your furnace, test your
filling with water again.
the building you’re heating with a shut-off valve and oneway
water every year. Water treatment may need to be added
check valve (Check local codes for proper installation)
water treatment added. For information on acquiring this
to prevent back-flow.
product refer to your local dealer.
Hint:
the building you’re heating with a shut-off valve or oneway check valve (Check local codes for proper installation)
valve should be used to make sure
all air is removed.
ATTENTION: Your water level
will rise as the temperature of the
water rises and fall as the water
temperature falls. If your water
your water temperature before
Note: Your furnace is equipped with a low temperature cut
off feature. Anytime the water temperature drops below 140
These furnaces have been specifically designed to burn
F, (including your first initial firing of the furnace), you will
wood and asFIRING
such are THE
not intended
for burning any other
FURNACE
needintothe
activate
low-temperature
bypass
function.
fall. Thethe
ashes
will help to insulate
the coals
and The
fuels such as rubber, material treated with petroleum
silver
button
(labeled
Cold
Start)
is
located
on
the
control
keep them lit.
products, leaves, paper products, cardboard, plastic or
wood and as such are not intended for burning any otherpanel. When pushed, the furnace will allow the fan to turn
Note: Your furnace is equipped with a low temperature
garbage. Burning these fuels in your furnace will result in
fuels such as rubber, material treated with petroleum
on
to
start
your fire.
cut
off feature.
Anytime the water temperature drops
the warranty of the furnace being voided.
Firing the furnace
products, leaves, paper products, cardboard, plastic or
Burning
these fuels
in your furnace
will result inATTENTION: On the initial startup, the water jacket will
BURN WOODgarbage.
ONLY: Load
carefully
or damage
may result.
the furnace), you will need to activate the low-temperature
the warranty of the furnace being voided.
Cold Start)
is
reachbypass
what function.
is calledThe
theblack
“dewbutton
point”.(labeled
This causes
sweating
On starting an initial fire, use kindling wood and paper, if
WOOD
ONLY: Load
carefully
or damage
located
on the which
controlmay
panel.
When
pushed,
furnace
the firebox
last
a couple
of the
days
and is
required. AddBURN
heavier
fuel gradually
until
a suitable
fire is may inside
achieved. The furnace will continue to feed an air supply to
paper, if required. Add heavier fuel gradually until a
the fire until your temperature control reaches set point.
TIP: Develop reaches
and keep
bed of
ashes
in the
keep
setapoint.
TIP:
Develop
andfirebox
keep ato
bed
of ashes
coals lit during periods of idle. It is common for the fire to
go out during idle when first fired in the fall. The ashes will
help to insulate the coals and keep them lit.
normal.
ATTENTION: On the initial startup, the water jacket will
reach what is called the “dew point”. This causes sweating
normal.
Heatmasterss G Series Furnace Operating Manual
15
14
WOOD QUALITY
This furnace is designed to burn natural wood only. Higher
efficiencies and lower emissions generally result when
burning air-dried seasoned hardwoods (15-25% moisture
content) as compared to softwoods or too green and
freshly cut hardwoods.
WOOD QUALITY
Keep in mind the diameter of the wood you use. Using
wood that is no larger in diameter than 6” will give you a
better, more even burn. For anything over 6” diameter it
may be best to split the log. Smaller, split wood will season
faster, burn better and will be easier to load and stack into
the firebox.
in mind meter
the diameter
of your
woodwood
you use, especially
Using Keep
a moisture
to test
with the G100000
. Using wood that is no larger in diameter
You can
use
a moisture
testeven
how
wetFor
your
This furnace is designed to burn natural wood only. Higher
than
6” will
give you ameter
better,to
more
burn.
thewood
is. Your
G-Series
furnacea came
with a moisture
meter.
G7000
and G10000,
larger diameter
of wood can
be used
DO NOT BURN: burning air-dried seasoned hardwoods (15-25% moisture but do not exceed 8”. For anything over 6” diameter it
Take a piece of firewood, split it and check the moisture
content) as compared to softwoods or too green and
may be best to split the log. Smaller split wood will season
on a freshly split surface. The moisture meter pins should
1. Garbage. freshly cut hardwoods.
faster, burn better and will be easier to load and stack in
2. Lawn clippings or yard waste.
3. Materials containing
DO NOTrubber
BURN:(including tires).
4. Materials containing
plastic.
1. Garbage.
2. Lawn
clippings
or yard
5. Waste petroleum
products,
paints
or waste.
paint thinners
be pressed into the grains of the wood, parallel to the
wood grains. Make sure to take at least 2-3 readings from
Using a moisture meter to test your wood
different points of the wood.
3. Materials containing rubber (including tires).
and asphalt products.
6.
7.
8.
9.
10.
You can use a moisture meter to test how wet your wood
A moisture meter will measure the moisture content of
Storingis.wood
a piece of wood by inserting the metal prongs into the
Store your
pile under
an open-ended
to avoid
grain wood
of the wood.
The moisture
content willshelter
be displayed.
4. Materials
containing plastic.
To snow
get an buildup
accurate reading
makeKeeping
sure to use
high- open will
rain and
on the pile.
3 asides
Materials containing
asbestos.
quality moisture meter, split the wood and take at least 2-3
5. demolition
Waste petroleum
products, paints or paint thinners
allow the
sun and wind to season the wood. Do not keep
Construction or
debris.
readings from different points of the wood.
and asphalt products.
the
wood
in a woodshed or under a tarp during the summer
Railroad ties or pressure-treated wood.
6. Materials containing asbestos.
Storing
wood
as the moisture
that evaporates from the wood will have
Manure or animal remains.
7. Construction or demolition debris.
Store
nowhere
toyour
go. wood pile under an open-ended shelter to
Salt-water driftwood
or other
salt water
avoid rain and snow buildup on the pile. Keeping 3 sides
8. Railroad
ties orpreviously
pressure-treated
wood.
saturated materials.
9. Manure or animal remains.
11. Unseasoned materials.
10. Salt-water driftwood or other previously salt water
saturated materials.
12. Paper products, cardboard,
plywood or
open will allow the sun and wind to season the wood. Do
not keep the wood in a woodshed or under a tarp during
the summer as the moisture that evaporates from the
wood will have nowhere to go.
particleboard.11. Unseasoned materials.
12. Paper products, cardboard, plywood or
particleboard.
The prohibition against burning these materials does not
prohibit the use ofThe
fireprohibition
starters made
paper,
cardboard,
againstfrom
burning
these
materials does
saw-dust, and similar substances for the purpose of
and similar substances for the
starting a fire in ancardboard,
affected saw-dust,
wood heater.
Burning these materials
may result in a release of toxic
Burning these materials may result in a release of toxic
fumes or render the
heater
ineffective
andineffective
cause smoke.
fumes or render
the heater
and cause smoke.
Typically it takes atTypically
least 12
months
to
properly
season
it takes at least 12 months to properly season
wood.looks
Seasoned
looks
dark or
gray when
wood. Seasoned wood
darkwood
or gray
when
compared
compared
to
green
wood
but
if
you
a piece of
to green wood - but if you split a piece of seasonedsplit
wood
seasoned wood - it’s WHITE on the inside. It has cracks
- it’s WHITE on the inside. It has cracks running through
running through each piece, and a lot of little cracks on
each piece, and a lot
little
cracks
on the inner
rings.
theof
inner
rings.
Unseasoned
wood has
a wet, fresh looking
nearcenter,
the edges
or ends which
Unseasoned woodcenter,
has awith
wet,lighter
freshwood
looking
with
lighter wood near the edges or ends which have been
fresh, the bark will be tightly attached.
exposed since cutting. When firewood is very fresh, the bark
will be tightly attached.
16
15
HeatmasterSS G Series Furnace Operating Manual
Heatmasterss G Series Furnace Operating Manual
Typical moisture meter
GSERIES
LOADING THE FURNACE - SMOKELESS LOADING
HANDLE
WARNING: Risk of fire flashback. Follow these instructions
carefully or personal injury may result.
It is always best to load your furnace when it is low on wood.
DO NOT open the firebox door within 15 minutes of the
furnace reaching temperature or when the firebox is full of
wood.
To reduce condensation and creosote formation, load only
enough wood to last 12-16 hours.
Before opening any door to the furnace:
1. Push the Smokeless Loading Handle towards the back of
the furnace. This will open the smoke bypass so no smoke
or flame exits the firebox door when you open it.
2. Crack the firebox door open to the safety catch for at least
15 seconds to allow smoke to exit the chimney and
prevent blow-back.
3. Open the door slowly while standing behind the door.
4. Use your ash rake to knock charred wood down and level
the coal bed.
Hint: If there is a minimal coal bed left, use the ash rake to
rake through the ash bed to stir up the hot coals underneath
the surface. Lay small pieces of wood on top of the coals
before loading larger pieces of wood.
5. Make sure the air slot in the refractory brick is clear.
6. Load wood carefully using the information and diagram on
page 17.
7. Close the firebox door.
8. Close the smoke bypass by pulling the Smokeless Loading
Handle over center all the way to the front of the furnace
to the closed position.
Heatmasterss G Series Furnace Operating Manual
16
GSERIES
OPERATING A GASIFICATION FURNACE
REQUIRES:
OPERATING A GASIFICATION FURNACE REQUIRES:
1. Use seasoned wood: It is always recommended to
1. Use Seasoned Wood: It is always recommended to use
use dry seasoned wood (15-25% moisture, seasoned
dry seasoned wood (15-25% moisture, seasoned 1-2 years)
when operating
a gasification
furnace to
with
a minimal
minimal
mix of green
wood. If required
burn
green mix
green
wood.
If required
toaburn
green
orofwet
orofwet
wood,
always
mix with
higher
ratio
drywood,
or
always
mix
with
a
higher
ratio
of
dry
or
seasoned
wood.
seasoned wood.
Stacking: Using the illustration to the right, stack your
2. 2.
Stacking:
primary wood on the coal bed in the firebox so that as the
wood gasifies and burns, the wood above it falls on top
it of
falls
topbed
of the
coalbottom
bed at of
thethe
bottom
of to
thecontinue
theoncoal
at the
firebox
the gasification process. Neatly stack your wood side to
side, across the burn slot. This promotes good airflow
throughout the wood pile and helps reduce bridging as
theSizing:
wood burns.
Reload
your furnace
before
the not
wood
3. Log
For ideal
operation,
log sizing
should
falls below the bottom of the door frame.Throwing
exceed 8” in diameter. Exceeding the recommended
wood into the firebox in a disorganized manner causes
sizing may result in doming (which only allows for
bridging and poor combustion.
the bottom and/or inside core of the log to burn) or
3. Log Sizing: For ideal operation, log sizing should not
separates
the coal Exceeding
bed). Pieces
ofrecommended
wood larger sizing
exceed 6”from
in diameter.
the
than
should
be split into
smaller
pieces
for bottom
use
may8”result
in doming
(which
only size
allows
for the
and/or inside core of the log to burn) or bridging (the wood
“hangs
up” sizing,
in the firebox
and
from the coal bed).
Improper
wood
stacking
or separates
excessive moisture
Pieces of wood larger than 6” should be split into smaller
improper
burning,
creosote
buildup not
size pieces
forand
useextensive
in gasification
furnaces.
Improper
wood sizing, stacking, or excessive moisture
furnace
malfunction.
content in the wood may result in the fire going out, improper
burning, and extensive creosote buildup not allowing
for efficient burning of the wood and eventual furnace
malfunction.
For more information on wood quality, follow these links:
WARNING: Risk of fire:
• Do not operate with fuel loading or ash removal doors open.
• Do not store fuel or other combustible material within marked
installation clearance.
• Inspect and clean flues and chimney regularly.
• Remove ashes regularly.
CAUTION: Hot surfaces. Keep children away and do not touch
during operation.
EPA’s Burnwise Program - http://www.epa.gov/burnwise
How to Use a Moisture Meter (Video) For more information on wood quality, follow these links:
http://www.youtube.com/watch?v=jM2WGgRcnm0
EPA’s Burnwise Program - http://www.epa.gov/burnwise
Split, Stack, Cover and Store (Video) How to Use a Moisture Meter (Video) http://www.youtube.com/watch?v=jM2WGgRcnm0
http://www.youtube.com/watch?v=yo1--Zrh11s
Split, Stack, Cover and Store (Video) http://www.youtube.com/watch?v=yo1--Zrh11s
19
17
Heatmasterss G Series Furnace Operating Manual
GSERIES
CONTROLS AND SAFETY DEVICES
This wood furnace has a manufacturer-set minimum low
burn rate that must not be altered. It is against federal
regulation to alter this setting or otherwise operate this
wood heater in a manner inconsistent with operating
instructions in this manual.
Furnace Control
Note: Be sure to close the bypass once you have finished
loading the furnace and closed the firebox door. The control
has a timer that will shut the furnace down if the bypass
has been open for 5 minutes.
CAUTION: Do not open any door before opening the
Smokeless Loading Handle. Damage to the furnace and
personal injury may result.
Your HeatMasterSS G Series furnace uses a factory
programmed control to maintain your water temperature by
using air damper controls and draft inducer fan. The control
is located around the corner to the left of the firebox door
and requires no user programming or changes. The control
displays the water temperature in your furnace, the air
damper postions, and any active alarms.
High Limit Switch
Note: A timer has been programmed into the control to fire
the furnace for 3 minutes after 90 minutes of idling and for
3 minutes every 30 minutes after that. This timer will help to
keep your coal bed lit during idle periods. The timer settings
can be adjusted. See the timer settings section.
Alarm LED Light
Top/Bottom Air Dampers
The damper air percentage is the amount of air being
drawn through the furnace to fuel the fire. This feature
keeps your furnace burning clean and hot while keeping
your water temperature in the preferred range. The
dampers are located in the rear cabinet and are mechanical
parts that open or close the air injection ports.
The high limit cut off switch is used to ensure the furnace
does not cause damage via runaway fire. It acts as a
safety switch by cutting power off to the fan if the water
temperature rises above 195 degrees F. If the high limit
switch trips, it will have to cool off to approximately 160 F
before turning on again.
The LED alarm light is located on the front left corner
of the furnace and will blink red if the furnace smoke
bypass is open, the furnace is low on water or if the water
temperature is too low or too high. It is intended to warn the
user of potential problems.
Cold Start Button
The button is located on the control panel in the top right
corner. Press the button to bypass the low-temperature
function of the control to fire the furnace from a cold start
(First firing the furnace or when the water temperature has
gone low).
Draft Inducer
The draft inducer fan is located at the rear of the furnace on
the top and is used to draw air from the air dampers
through the furnace. The fan should be on whenever the
furnace is in a heating cycle or when the smoke bypass is
open.
Smokeless Loading Handle
Use the Smokeless Loading Handle whenever the firebox
loading door is open. The bypass handle is located on the
side of the furnace and opens a direct exit out of the firebox
through the chimney whenever pushed towards the rear of
the furnace. This will allow you to check your firebox, fuel
and load your furnace without smoke blowing out of the
firebox loading door.
18
COLD START
BUTTON
FURNACE CONTROL
ALARM LED LIGHT
FAN BREAKER
FURNACE ON/
OFF SWITCH
19
Heatmasterss G Series Furnace Operating Manual
SMOKELESS
LOADING HANDLE
G
SERIES
HOW THE G/GS SERIES GASIFICATION OUTDOOR FURNACE WORKS
SteelTech Inc. is proud of its reputation for producing
ash that would come with it and burned at temperatures
innovative outdoor heating methods and our G Series
The wood gas mixture that is created in the firebox is then
HOW THE G SERIES GASIFICATION OUTDOOR
outdoor furnaces are continuing that trend. They operate drawn
verythrough
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clean burn helping you get the most out of
the base of the fire along with any ash that
FURNACE WORKS
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would
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How
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How It The
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carbon
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(>700ºmonoxide,
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SS
oxygen. The heat and lack of oxygen “bakes” the wood,
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carbon monoxide, hydrogen and carbon dioxide .
After the gas is burned, heat is extracted to the water jacket
using
exchange
tubes.
lackthe
ofheat
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Normal
exhaust
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arethat
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Thequickly,
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exhaust
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notable indicator of effective gasification is the lack of
smoke exiting the chimney. However, often you will see
white exhaust that dissipates quickly, which is steam from
and can reduce wood consumption as much as 50%
the wood in the firebox.
compared to a standard outdoor furnace.
The gasification process creates longer burn times and can
reduce wood consumption as much as 50% compared to a
standard outdoor furnace.
Heatmasterss G Series Furnace Operating Manual
22
HeatmasterSS G Series Furnace Operating Manual
20
CARE AND MAINTENANCE
To obtain the high level of performance of your furnace,
certain maintenance procedures are required periodically.
• Check the fan motor and wheel for creosote buildup. The
On a Daily Basis:
motor and wheel can be easily removed by unplugging
• Ensure that all doors are closed and sealing properly.
the wires to the fan and loosen the nuts on the stainless
Adjust if necessary.
steel plate.
combustion chamber. Some creosote buildup along the
On a seasonal basis when the furnace is not in use, you
will have to:
walls, door jamb, and firebox door is normal.
• Remove all ashes and excess creosote from the firebox,
• Check for creosote buildup in the firebox and lower
• Check water level.
• Clean heat exchange tubes by aggressively pushing and
pulling the lever back and forth at least 5 times.
• Check to make sure the fan and controls are functioning
lower combustion chamber, heat exchange tubes and
chimney.
• Check all gasket seals to make sure they are sealing. To
replace, remove the old seal and residue from the door,
properly. The fan should turn on when the furnace calls
scuff the surface where the seal is placed with sandpaper
for heat. The control display should be functional and
and re-apply high temp silicone. Lay fiberglass rope over
keep the water temperature within the cut-in and cut-out
silicone and let bond for at least 24 hours before using
settings you have the control set to.
the furnace again.
• Check for embers or ashes laying on the ground around
the furnace and dispose of them.
• Make sure all covers and guards are in place securely.
• Make sure the Smokeless Loading Handle is closed. The
handle should be angled towards the front of the furnace.
On a Weekly Basis:
WARNING: Always keep the firebox door open when
opening the lower combustion chamber door.
Using the service tools supplied, remove ash from the lower
combustion refractory tubes, side, and rear chambers.
Dispose of ashes in a metal container away from the stove
and wood pile.
See Cleaning Tools on page 22.
On a monthly basis:
21
every 2-4 weeks to get optimal performance.
• Cover the chimney and crack open the bottom door
enough to allow air movement and reduction of
condensation within the firebox.
• Make sure your water tank is full and have your water
treatment tested and adjusted to manufacturer’s
specifications. See page 4 for exact specifications.
• If necessary adjust the hinges on each side of the doors
to maintain a good seal.
Other maintenance:
• All covers and guards must be in place at all times, except
for maintenance or service.
• Care for the exterior of your furnace is minimal.
• The user must wash and remove ash and creosote
regularly.
• Ashes should be placed in a metal container with a tight-
• Inspect air inlet for creosote build up or blockage.
• Depending on the type and quality of wood being used,
fitting lid. The closed container should be placed on a
ash removal from the firebox may be necessary. For
all combustible materials before final disposal. If the
optimal performance, the ash bed in the firebox should
ashes are disposed of by burial in soil or otherwise locally
not exceed 6-8”. If you are burning a wood fuel that leaves
dispersed, they should be retained in the closed container
quite a bit of ash you may need to clean your firebox out
until all cinders have thoroughly cooled.
Heatmasterss G Series Furnace Operating Manual
non-combustible floor or on the ground well away from
GSERIES
Creosote - Formation, and Need for Removal:
When wood is burned slowly, it produces tar and other
organic vapors, which combine with expelled moisture
to form creosote. The creosote vapors condense in the
relatively cool chimney flue of a slow-burning fire. As a
result, creosote residue accumulates on the flue lining.
When ignited, this creosote makes an extremely hot fire.
The chimney and chimney connector should be inspected
at least twice a month during the heating season to
determine if a creosote buildup has occurred. If creosote
has accumulated it should be removed to reduce the risk of
a chimney fire.
CAUTION: Make certain that all electrical power to the
furnace and components is shut off. It can be washed using
water and a mild nonabrasive cleaner suitable for painted
surfaces.
ATTENTION: Avoid direct water pressure
CLEANING YOUR FURNACE
CLEANING TOOLS
Tool #1
• Has a round edge that is meant to be used to clean out
the round ports (A) in the refractory.
• The straight edge can be used as a general scraping and
cleaning edge.
• This tool is also good for your daily wood poking and fire
management tool.
Tool #2
• This tool is to be used to pull ash out from the area to the
right of the bottom refractory (B). This tool allows you to
reach to the back and behind the refractory to pull out
ash.
Tool #3
• This tool is meant to be used, to get a better handle on
the Refractory plug and thread out this plug. WARNING.
A
Threading out this plug should only be done after the
B
furnace has been allowed to cool down.
Tool #1
Tool #2
Refractory
Plug
Tool #3
Heatmasterss G Series Furnace Operating Manual
22
TROUBLESHOOTING
TROUBLESHOOTING TO ENSURE PROPER
BURNING & AIR FLOW
If your furnace is showing signs of poor combustion such
as smoking while burning, little to no exhaust coming from
the chimney, longer than normal heating cycles, or there is
a general concern of functionality, use these step by step
instructions to assist in troubleshooting.
• Is the control calling for heat? Status = Heating Cycle/
Cold Start Mode. See the Control Settings section of this
manual.
• Is the draft fan running in the rear cabinet? If not, consult
the Draft Fan troubleshooting section in this manual.
• In the rear cabinet, inspect the top and bottom air
• Do the spirals in the heat exchange tubes have full
movement up and down? If not inspect the linkage for
damage. Flush the heat exchanger tubes with water to
loosen them if necessary.
• Remove and inspect the draft fan. Clean the fan and
housing if there is creosote or other build up present.
• Inspect the chimney for restrictions and clean if
necessary.
More than likely, if there is a problem with the furnace burn
or air flow, you will find it by checking these things.
dampers to ensure they are opening and closing as
The furnace is running but fails to bring the water
temperature up to setpoint:
indicated by the control. If not, refer to the actuator
• Confirm good combustion by following the steps in the
troubleshooting section.
• Use a light piece of paper (like receipt paper) and hold
previous section.
• Check if the furnace is properly gasifying by opening the
it up to the openings in the damper plates. The paper
bottom door to the Lower Combustion chamber. A flame
should be drawn to the openings. If it is not, there is an
should be visible only for a short time after opening the
airflow issue in the furnace.
door and glowing embers should be present. Keep arms,
• Remove the top and bottom air box covers and inspect
legs, and head at least 3 feet from the opening. Check
for blockage. Use receipt paper to check for air flow in the
fuel type. Poor quality fuel will not provide as many BTU’s
top and bottom air ducts. If there is not a visible blockage
as high-quality fuel.
but there is not adequate airflow in the ducts inspect the
air channels within the firebox.
• Make sure the ash bed is not so high as to block air holes
in the panels on the sides of the firebox.
• Make sure the holes in the air channels are clear. If
• Check water level of the furnace.
• Check to ensure all pumps in the system are running.
• Is the piping between the furnace and buildings properly
insulated? Has the insulation become wet from
groundwater or a leaking pipe or fitting? Wet insulation
necessary, remove, clean, and replace the air channels.
around the piping will cause significant heat loss to the
Inspect the burn slot in the firebox floor. Remove any
ground.
blockage that may be present.
• Check the water temperature coming back to the furnace,
• Remove the burner plug and inspect the right and left
this temperature should be above 130° F. If this return
burn tubes. Clean as necessary. Always replace the
temperature is below 130° F there maybe a problem in
burner plug for operation.
your building's heat design.
• Inspect and clean the areas to the left and rear of the
refractory using the service tools provided with your
•
23
inspect the smoke by-pass plate for leakage and adjust
as necessary.
furnace.
Remove the flue access cover and inspect that area for
possible blockage. If the area is sticky with creosote,
• Check the temperature of water exiting furnace, entering
the building being heated and before and after each heat
exchanger. Large temperature drops signal large
consumption of the BTU’s produced by the furnace. If
there is a large difference in the water at the top of the
tank and the water coming from the supply outlet there is
not enough flow in the water tank. (See next topic).
GSERIES
• If everything is functional, call your dealer.
If the water temp on the control is hot (170-180° F or
higher) but the water temp in the supply line is cool:
• Check to be sure the recirculation pump and the building
pumps are operating properly and that the valves in the
circulation loop are open to allow flow. The recirculation
piping should be hot from top to bottom.
• Check system for flow:
» Check to ensure all pumps in the system are running
and none are turned the wrong way.
» Check filter cartridge for flow blockage (if installed).
» Check for air in the system at the exchanger by
bleeding off.
» Check for closed valves to ensure water flow.
• If no obvious flow issues arise from above system
checks, turn off pumps on each line, close ball valves on
the return lines. Remove the return line and turn the pump
on again. Dump water in a 5-gallon bucket and time how
fast it fills up. You should be able to calculate the flow
rate in that line. Do this for each line coming off of the
furnace to calculate furnace flow rate.
If the furnace water and the building supply lines are hot
but buildings do not have heat:
• Check to ensure all pumps in the system are running.
• Check filter cartridge for flow blockage (if installed).
• Check for air in the system at the exchanger by bleeding
off.
• Check for closed valves to ensure water flow. Check
Temperature of water exiting the furnace, entering
• Check that the damper plate is opening and closing
properly. It should be completely closed when the
furnace temperature is over 180° F.
• Check water level.
• Check to ensure all pumps in the system are running.
If there is a runaway or chimney fire:
• Make sure the firebox and lower combustion chamber
doors are tightly closed.
• Close all combustion air inlets on the furnace.
If the furnace has shut down:
• Check to ensure that the unit has power. Is the Main
Power switch in the rear electrical box in the ON
position?Is there power at the rear receptacles? Is the
rocker switch illuminated? Ensure that the rocker switch
on the control panel is in the on position.
• Check the water temperature (furnace has a high
temperature cut off of 190° and turns on again at 140°).
• Check the control screen for errors that may have shut
the furnace down.
• If all checks have not corrected the problem have a
technician check the control panel.
If there is a power failure:
• Open all flow-check and zone valves in the system.
Depending on the system design, this may allow
convective circulation.
Note: This does not apply to gravity systems, as they have
no flow-check valves and will continue to operate normally
without electricity.
• It is important to remember that the heating systems
the building being heated and before and after each
cannot dispose of a great deal of heat without the
heat exchanger. Large temperature drops signal large
circulator(s) running. Avoid over-firing!
consumption of the BTU’s produced by the furnace.
Fire the furnace cautiously until you are able to determine
If the furnace overheats:
• Close all air inlets and doors on the furnace.
• Retrieve as much heat as possible from the system
by turning thermostats up and opening windows until
furnace cools down.
• Check that all doors are closing properly and that door
gasket is completely sealing.
how quickly the heating system is able to absorb the heat
being produced by the furnace.
• When the power has returned, reset all flow-check and
zone valves and resume normal operation of the system.
If there is smoke leaking out of the door:
• Check to ensure the door is sealing properly.
• If the seal is worn out it will have to be replaced.
Heatmasterss G Series Furnace Operating Manual
24
• The door may need to be adjusted. To do this loosen the
door latch bearings and nuts on the door hinge and set the
door so it seals tightly against the door jamb.
Re-tighten once the door is in place.
If the furnace has an excessive amount of creosote:
• Check to ensure the furnace is sized accurately according
to heat demand. If the furnace is oversized it will idle and
cause this.
• Check moisture content in your wood fuel. Moisture content
over 30% may cause creosote buildup.
creosote out to obtain a proper burn in the firebox.
You are having to fill the furnace with water mo e than once
a week or more than a few gallows of water per week and
there is no obvious explanation:
• Check and confirm that the temperature set-point is not
higher than 180 F. Hotter water temperatures will cause
increased evaporation.
» Check the gaskets on the upper and lower firebox
doors. Air leaks in door gaskets will allow continued
combustion and potential overheating.
• Check the perimeter of the furnace for water puddles
Recommended moisture content in your wood fuel is 1525%.
• Remove the access panel at the rear of the furnace and
inspect the bypass door for smoke leakage.
• If the chimney and/or heat exchange tubes become
collecting or dripping from the furnace.
• Check all plumbing in the system to ensure there are no
leaks.
• If these checks have not provided an answer call your
dealer.
plugged with creosote it will be necessary to scrape the
TROUBLESHOOTING
ELECTRICAL TROUBLESHOOTING
Electrical troubleshooting should always be done by a
qualified technician.
poles of the power supply rocker switch. The switch has
power in, neutral, and power out poles. During normal
operation, there should be power at the power in and power
out poles.
High Limit Switch:
• If there is only power on one of the poles, check to make
Alarm High Limit should be displayed on the control screen.
Using an electrical testing meter check for power on both
poles of the high limit switch. If the furnace temperature is
above 195° F. the switch should be OPEN and there should
only be power on one side of each switch. 24V DC on the
red and 115V AC on the black. If the furnace was over 195°
F. and the switch has opened the water will need to cool
down to approximately 150° F. before it will close and allow
power through once again.
• If the furnace has not overheated (195° F+) but there is
still power on only one side of the switch, the switch is
faulty and should be replaced.
• If there is no power on either side of each switch, check
for power at the main power switch at the rear of the
furnace.
Control power supply switch:
Using an electrical testing meter check for power on both
25
sure the switch is in the “on” position.
• If the switch is “on” and there is only power on one pole
the switch is faulty and should be replaced.
• If there is no power on either the power in or the power
out pole check for power at the rear main power switch.
Siemens 24V DC Power Supply:
• Using an electrical testing meter check for DC voltage at
the OUTPUT terminals.
• If there is 24 volts DC across the terminals and the
green LED on the front is illuminated the power supply is
working.
• If there is not 24 volts DC check for 115V AC power on
the INPUT terminals. If there is no power check for power
at the control power switch.
If there is 115V AC on the INPUT terminals but not 24V DC
GSERIES
on the OUTPUT terminals, remove the 24V DC terminal strip
from the power supply and test for 24V DC on the output
pins. If there is not, the power supply is faulty and should be
replaced. If there is power on the pins with the terminal strip
removed then it is likely that there is a short circuit in the
24V DC wiring. Locate and repair the issue and re-install the
terminal strip.
Fan Motor Breaker:
• If the fan motor breaker has tripped check the fan for
proper operation before resetting the breaker. Remove
and inspect the fan motor & wheel to confirm it is turning
freely.
Siemens LOGO Control: (with display)
• Using an electrical test meter to check for 24V DC power
across the “L+” and “M-“ terminals.
• If there is 24V DC power at the terminals but the display
remains blank the control is faulty and should be replaced.
• If there is not 24V DC power at the terminals, check for
power output at the power supply.
Low Water Cut Off Switch:
Check to be sure there is enough water in the tank of the
furnace by removing the float assembly and looking in the fill
pipe.
• If the water level is low add enough to raise the water level
so the float level shows full.
• If the water level is full and the Low Water Alarm is
flashing on the screen you will need to test the low water
switch.
• Use an electrical test meter to check for voltage across
the “M-“ and “I1” terminals on the Siemens LOGO control.
• If the low water switch is satisfied (closed) there should be
24V DC.
• If there is no voltage, power off the furnace, remove the
may be cleaned up, tested and re-installed. If it is faulty it
should be replaced.
By-Pass Door Switch:
Test the By-Pass Switch using an electrical test meter.
Measure the voltage across the “M-“ and “I2” terminals on
the Siemens control. There should be 24 VDC when the bypass is in the CLOSED position.
• If there is no power across those terminals, isolate the
switch wiring and perform a continuity test on the switch
in the open and closed positions. The circuit should be
“open” when the by-pass is OPEN and “closed” when the
by-pass is CLOSED
• If this is not the case the switch must be inspected. Check
that the switch is wired to the correct terminals and that
the magnet is within 1/2” of the sensor when the bypass
is in the closed position. If this is all working well but there
is no continuity across the switch when the By-Pass is
CLOSED then the switch is faulty and should be replaced.
Cold Start Button:
The cold start button will override the low temperature shut
down feature of this furnace. It should be pressed once to
allow the furnace to operate when in a cold start situation.
If the screen is flashing “Low-Temperature Alarm” and the
Cold Start Button is depressed, the Furnace Status should
change to “Cold Start Mode”. This message will remain
until the furnace has heated past it’s programmed cut in
temperature and the mode changes to “Heating Cycle”.
If the button is depressed and the “Low-Temperature Alarm”
continues, the circuit should be tested using an electrical
testing meter. Check for voltage between the “M-“ and
“I3” terminals on the Siemens control when the button
is DEPRESSED. There should be 24V DC across those
terminals only when the button is depressed.
• If there is no power present, isolate the switch from the
Low Water Switch wiring from the control then check for
control and wiring and check for continuity across the
continuity across the switch.
switch. There should be continuity only when the button
• If the switch has continuity, re-install the wires in their
original positions and power up the furnace. The Low
Water Alarm should disappear from the screen.
• If the switch does not have continuity, drain the furnace
enough so that the water level is below the low water
switch. Remove and inspect the switch. If it is dirty it
is depressed. If not, the button is faulty and should be
replaced.
Damper Actuator:
» Inspect the top and bottom damper plates for proper
operation. The target damper position (%) is indicated
on the control screen. If the damper plate is not in the
26
position targeted by the control inspect the plate for
creosote, ice, or other build-up. Loosen and clean the
plates if necessary.
» To remove the damper plates remove the two actuator
on and calling for heat. The display should indicate the
target Top and Bottom Air %. In this state, you may test for
power across terminals 1 & 2 on the actuator. There should
be 24V DC across those terminals.
mounting bolts. Remove the actuator and the damper
• If there is no power across terminals 1 & 2 then confirm
plate should slide off the shaft. If the plate is stuck, pry it
off and clean as necessary.
there is power at the Siemens control. If there is no power
» The damper plates may be lubricated with a light
Section). The control signal to the actuator can be tested
coating of automatic transmission fluid if necessary.
» If the damper plate is not stuck but the actuator will not
turn test the electrical at the actuator.
» The “mode” selector should be set to mode 3.
» Remove the screw in the electrical cover of the
actuator. Pull and wiggle gently on the cover to remove it
from the actuator. Take care not to damage the electrical
pins in the plug.
To test for proper operation the furnace should be powered
27
Heatmasterss G Series Furnace Operating Manual
at the control check the power supply (see Power Supply
from terminal 2 to 3. There should be 2-10V DC. The
actuator position can be confirmed by testing the DC
voltage across terminals 2 and 5 on the actuator. It should
be 2 to10V DC depending on the position of the actuator.
» If the damper plate is not stuck and there is power and
communication from the control, the damper actuator is
faulty and should be replaced. Please consult your local
dealer for assistance.
GSERIES
INSTRUCTIONS FOR EDITING CONTROL SETTINGS
To edit temperature, differential, timer and low temperature
cut off settings follow these instructions:
• To change control settings press the down arrow
repeatedly until you reach the desired screen.
• To edit the settings on the screen press and hold the “ESC”
key until a black box appears on a variable.
• Use the up/down arrow keys to toggle to different
variables on the screen.
• Press the OK button to adjust the highlighted setting
• Use the left/right arrows keys to navigate to the
• Use the up/down arrow keys to adjust the value of the
character.
Note: The values are always in minutes, seconds, or degrees
Fahrenheit and always positive “+”.
• Press the “OK” key to save your changes and adjust other
settings.
• Press the “ESC” key to close the black box and toggle
between screens.
• Press the “UP” arrow repeatedly to return to the run screen.
appropriate character.
The following is a breakdown of the information displayed on your control panel.
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Furnace Status (run screen)
Furnace Run Time
This screen displays the primary status information at a
Total Hours displays the accumulated time the furnace has
glance.
been in a heating cycle.
The 2nd line displays the current status mode of the furnace.
Trip Hours is a resettable hour meter. IE: You might want to
Heat Cycle, Idle, Timer Cycle, or Cold Start Mode.
reset this trip meter at the start of your heating season to
Current water temperature, oxygen level, and damper
keep track of hours run in a season.
positions are also indicated.
Reset the meter by changing the reset option to “on”
Heatmasterss G Series Furnace Operating Manual
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Water, Differential Settings
Set Low Temperature Shut Down
Set Water Temp is the temperature at which the furnace will
When the furnace water cools below this setpoint, it will
turn off at the end of a heating cycle.
assume the firebox is empty and will shut down to conserve
Differential is how many degrees the water will loose before
heat.
the furnace turns on to reheat the water.
Idle Timer Settings
By-Pass Door Is Open
This timer can be used to keep the coal bed alive during long
Opening the smoke by-pass will activate the draft fan for a
idle periods. Once the furnace shuts down at the end of the
maximum of 5 minutes. If more time is needed the by-pass
heating cycle the initial timer will start (Factory Set Delay - 1
must be closed and opened again. Operating the smoke
hour and 30 minutes). Once this Delay time has passed the
by-pass for extended periods of time may over heat the fan
furnace will start the fan and open the dampers to provide
motor causing premature failure.
air to the coal bed for the set On Time (3 Minutes and 0
Seconds). After this first cycle the control will run the On
Time cycle every Off Time (30 minutes and 0 seconds).
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Top Damper
Bottom Damper
Max Open % - The maximum allowable open position for the
Set o2 % - The target oxygen level in the furnace exhaust.
primary air intake for normal operation. This is adjusted to
This is set according to fuel quality. Recommended settings
optimize amount of combustion air according to the type,
range from 4% for premium dry fuel up to 8 % for low quality
size , and moisture content of the fuel. Min Cls % - The
high moisture fuel. Max Open % - Maximum allowable open
minimum allowable position for the primary air intake during
position for the secondary air inlet. Typically 100% as this is
normal operation. This is adjusted according to the fuel type,
regulated by the o2 sensor. Min Cls % - The minimum
size, and moisture. This setting establishes the lowest
allowable for the secondary air inlet. Off Delay – The amount
possible burn rate of the furnace.
of time the bottom secondary air damper is allowed to
remain active after the furnace has cycled off. This helps to
reduce emissions in idle.
Control Options
Software Version
o2 Optimize – A feature reducing the primary air in the event
The control software version currently installed. Software
that o2 level is lower than set point. o2 Limiting – A feature
updates are periodically released offering improved
reducing the primary air if the o2 level is higher than set
function and features. Please contact your dealer for the
point. MAXAIR – A feature active during Cold Start Mode
latest version available.
that drives the primary air damper to the full open position
for faster warm up. Modulation – Allows the primary damper
to regulate combustion air according to water temperature.
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Heatmasterss G Series Furnace Operating Manual
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Alarm - Low Water
Alarm – Low Temperature Shut Down
The water level sensor is indicating the water level is below
The water temperature has dropped below the Low
the safe operating level in the reservoir. Add water to clear
Temperature Shut Down setpoint. The furnace shuts down
the alarm. Top off the fluid level once the fluid is back up to
to conserve heat assuming the firebox is empty and needs
normal operating temperature.
to be reloaded.
Alarm - By-pass Open Over-time Shut Down
Alarm – High Temperature
Opening the smoke by-pass will activate the draft fan for a
The high temperature limit switch has been activated (195
maximum of 5 minutes. If more time is needed, the by-pass
F). The furnace will remain off until the water cools to
must be closed and opened again. Operating the smoke by-
approximately 160 F.
pass for extended periods of time may overheat the fan
motor causing premature failure.
Heatmasterss G Series Furnace Operating Manual
32
COMBUSTION TUNING BASICS
**IMPORTANT** Changing these parameters can affect the performance and operation of your furnace adversely. Changing these
parameters should only be done under the guidance of your Heatmaster dealer. Make small changes at a time and allow a few days of
operation after making a change, observing the furnace to see if you’ve made a positive change.
Suggested starting points for varying wood moisture levels. See the instructions on page 15 to accurately test wood
moisture levels.
Factory Defaults
Wood Moisture 26-35%
Wood Moisture 15-25%
Wood Moisture less than 15%
Top Damper Max 75%
Top Damper Max 65%
Top Damper Max 60%
Top Damper Min 50%
Top Damper Min 40%
Top Damper Min 40%
o2 Setpoint 6%
o2 Setpoint 4%
o2 Setpoint 6%
Top Damper
Max Open %
Note: When your Furnace Status (first screen) shows the
Top Air %, it is showing the percentage of this Max Open %.
For example: when you see that the Top Air % on your
Furnace Status screen is at 100%, the damper will be open to
the 70% that you see/set in this Top Damper screen.
You may benefit from increasing the Max Open parameter in
the following scenarios:
• If your furnace is installed at a higher altitude ( >2000ft
This screen gives you the option to change your maximum
open and minimum closed parameters for the top damper
on your furnace.
The Top Damper defaults are the settings the furnace was
tuned with using a variety of wood species and burning
conditions.
These parameters adjustable, allowing the customer to tune
the furnace for conditions that we might not have been able
to simulate at the factory.
above sea level)
• The furnace is struggling to achieve target water
temperature.
• If you are burning wood that is wetter than the
recommended 15% - 25%
• If you find the furnace is consistently smoking during burn
cycles.
Make small changes at a time (+/- 5%) and allow a few days of
operation after making a change, observing the furnace to see if
you’ve made a positive change.
You may benefit from decreasing the Max Open parameter
in the following scenarios:
• Your wood is split very small, under 4” cross section.
• Your wood is exceptionally dry, below 15% moisture.
• Your stack temperatures are regularly above 300F during
burn cycles.
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Heatmasterss G Series Furnace Operating Manual
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During normal operation, when the furnace’s temperature is
climbing and the temperature is getting close to the Set
Water Temp, the furnace will start to modulate slowing the
burn rate. This allows the furnace to burn at a more
efficiently and have a softer, cleaner shut down. This Min Cls
% is the minimum amount that the top damper will close
during this modulation period.
The Bottom Damper defaults are the settings the furnace
was tuned with using a variety of wood species and burning
conditions.
These parameters are adjustable, allowing the customer to
tune the furnace for conditions that we might not have
been able to simulate at the factory.
The bottom damper is supplying secondary air to the lower
grate of the furnace. Working together with the oxygen
sensor, it targets the oxygen level set in this screen.
You might want to increase this parameter in the following
scenarios:
Set o2 %
Min Cls %
• If you see that the furnace is regularly smoking while the
top air is at the minimum position.
• You want the furnace to burn at a higher rate right up to
the set temperature.
You may want to decrease this parameter in the
following scenarios:
• The furnace is significantly overshooting the set temperature.
Lowering the minimum damper setting will slow the furnace
down more toward the end of a burn cycle.
• You want to allow for a lower modulation rate
Bottom Damper
This parameter allows you to set the target oxygen level in
the exhaust of the furnace. In general, the lower the level of
oxygen that you can maintain while burning clean, the more
efficient your furnace can operate.
Burning seasoned hardwoods at 15%-25% moisture, you
may be able to burn clean with an o2 setpoint as low as
3%-5%.
If your fuel is less than desirable, i.e. softwoods, higher
moisture content wood, woods that are very volatile, wood
that is dryer that 15% moisture. You may need to increase
the target o2 as high as 6- 8% to achieve a clean burn.
If you observe your furnace smoking regularly throughout
burn cycles you may have the target o2 too low or too high.
If you are making changes to the o2 setpoint, change by 1%
at a time and observe the change over a period of a few
days.
Max Open %
This screen gives you the option to change your…
• Oxygen (o2) setpoint
• Bottom Damper, maximum open and minimum closed
• Off delay for the bottom damper
The max open percent is the amount that the bottom
damper is allowed to open during the normal on cycle of the
furnace. The bottom damper will open and close
(modulate) as the control targets the oxygen level set on
this screen. This parameter should never need to changed.
Min Cls %
This is the minimum percent the bottom damper is allowed
to close during a burn cycle. Keeping the bottom damper
open at this percentage allows the furnace to maintain
better ignition in the refractory.
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34
Off Delay
o2 Limiting
When your furnace cycles off, it will allow the bottom
damper to continue to operate for the duration of the Off
Delay time. This feature minimizes smoking after shut
down as it is able to burn off the last of the wood gas that
was generated while the furnace was running.
This feature will reduce the top air damper in the event that
the o2 level has exceeded the target by more than 2%. This
reduces the amount of airflow through the furnace to
conserve heat if the firebox is low on wood.
Modulation
Control Options
With this feature turned ON the top damper will modulate
to achieve the target water temperature. When the feature
is OFF, the damper will not modulate unless required by
one of the previously mentioned features.
o2 Optimize
o2 Optimize is a control option that allows the control
system to slow the burn rate in the firebox by turning down
the top air. In the event that the furnace is unable to reach
the target o2 level, it will reduce the top air damper to allow
the target to be achieved. Once the o2 setpoint has been
achieved, the top damper will attempt to return to its target
position as long as the o2 levels remain near set point.
MAXAIR
The MAXAIR option allows the top air damper to bypass
the MAX Open % and run full open during cold start mode
only. This allows for faster warm ups during a cold start.
o2 Limiting
This feature will reduce the top air damper in the event
that the o2 level has exceeded the target by more than 2%.
This reduces the amount of airflow through the furnace to
conserve heat if the firebox is low on wood.
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Heatmasterss G Series Furnace Operating Manual
GSERIES
HOME NETWORK CONNECTION FOR YOUR
HEATMASTER FURNACE
This instruction applies to G-Series furnaces that were
Choose one of the two connection options listed below
manufactured as a part of the 2020 model lineup using the
to setup and access your furnace control from any web
Siemens Logo Control.
browser enabled device on your home network.
1
1A
Hardwired Connection: This is the preferred and recommended method to
connect your furnace to your home network. See page 36 for these.
1B
Wireless Connection: This alternate method requires the installation of a wireless
access device. This is available as part of the HeatMaster Wireless Access Kit. Please
contact your dealer for more information.
2
After you have setup the hardwired connection you will need to next
find an IP address that you can use on your home network. See page 37 for these
instructions.
3
Assign your furnace an IP address. See page 39 for these instructions.
4
Once you have followed these steps you should be able to access your furnace on
your home network via an Internet browser. See page 40 for these instructions.
HARDWIRED CONNECTION
Hardwired LAN Line: This is the preferred method to connect
In the next step you will search your network for an available
your furnace to your home network.
IP address for your furnace. Once you have assigned your
You will need to run and connect a Cat 5 or 6 cable from
furnace control an IP address you will be able to access the
your home router or network switch to the ethernet jack
furnace from any device with a web browser connected to
in the rear cabinet of your furnace. If you need to bury the
your network.
cable make sure it is rated for burial and outdoor use. The
Go to the “Finding your IP address” page in this manual. See
maximum recommended distance that you can run a Cat 5
page 34 for these instructions.
or 6 cable is 328ft.
Heatmasterss G Series Furnace Operating Manual
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FINDING AN IP ADDRESS FOR YOUR FURNACE
These instructions will guide you in finding an available
address on your home network to assign to your
HeatMaster furnace.
Using a windows PC that is running on your home network,
we’ll use the command prompt app. Using the search bar in
the lower left corner of your Windows home screen, enter
the letters “cmd”, and then hit enter as shown in figure 1, the
command prompt app loads.
Figure 1
Next you will see a window similar to the one in figure 2.
Enter the command “ipconfig”. You’ll see a screen with
similar data as shown in figure 3.
Figure 2
Paying attention to the addresses that we’ve highlighted
within the square (in figure 3), you’ll need to take note of
three addresses.
The line “IPv4 Address” is the IP address of the computer
that you are currently working on. The IP address that you’ll
be assigning to your furnace will be in the same range as
this number.
The line “Subnet Mask” is the same Subnet address that
you’ll be assigning to your furnace.
The line “Default Gateway” is an address that you need to
confirm or assign to your furnace.
Note these three addresses, as you’ll need them later.
Continued on page 38.
Figure 3
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Heatmasterss G Series Furnace Operating Manual
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FINDING AN IP ADDRESS FOR YOUR FURNACE (CONTINUED)
In this same window we will ping a few addresses and find
one available to use for your furnace.
Start by pinging your computers IP address that you found
in the previous window (in our case this is 192.168.1.101).
Enter the ping command as shown in the first box in figure
4, using your computers IP address (ping ***.***.**.***.).
The following lines (as shown in the second box in figure 4)
show that the computer is getting a reply from that address,
Figure 4
indicating that this IP address is already in use and can’t be
used for your furnace.
Change the last 3 digits (Figure 5) of your IP address to a
number between 200-250, to ping an address with a higher
number as your router is less likely to assign an address
within this range. Only change the last three numbers in the
Change These
192.168.1.101
Figure 5
address as shown in figure 5.
You may need to try a few different numbers before you will
find an available address. Once you find an IP address that is
available you will see a message saying “Request timed out”,
as shown in Figure 6.
Write down this IP address (in our case 192.168.1.250). This
will be the address we will assign to your furnace in the next
step of this instruction.
Figure 6
Go to the “Addressing Your Furnace” page. See page 39 for
these instructions.
Heatmasterss G Series Furnace Operating Manual
38
ADDRESSING YOUR FURNACE
Now that we have obtained an available IP address, we will
assign this address to the furnace control.
Power on the furnace.
Press the down arrow key repeatedly
Press the ESC key, you should see
to scroll to the last available screen
the screen shown above. We need to
displaying date and time as shown
stop the Logo’s program to make this
above.
IP address change. Select STOP and
Select Yes.
press the OK button.
Select Network.
Select IP Address.
Using the four arrow keys, change
the IP address to the one you found
to be available on your network in
the previous section. Also change
the subnet mask, and the gateway
addresses to match the numbers you
wrote down earlier.
Continued on page 40.
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Heatmasterss G Series Furnace Operating Manual
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ADDRESSING YOUR FURNACE (CONTINUED)
After you have set these three
Select Yes to start the Logo’s program
addresses, scroll back and restart
again.
the furnace by selecting start.
At this point you should be able to access your furnace on your home network.
Go to the “Viewing Your Furnace in a Web Browser”. See below for these instructions.
VIEWING YOUR FURNACE IN A WEB BROWSER
Figure 1
The last step in these instructions is loading and viewing your furnace control system on your computer.
• Load a web browser on a device connected to your home network.
• As shown in figure 1, enter the IP address that you programmed into your furnace control, in our case this
is 192.168.1.250. Enter this in the browser URL and hit enter.
• Leave the name field as Web User.
• Enter the password “heatmaster”, then click “log on”.
Heatmasterss G Series Furnace Operating Manual
40
Figure 2
The Screen that you see in figure 2 should load.
Figure 3
Select the menu option “LOGO! BM” on the left side of the screen.
You can use the control buttons on the screen to navigate the furnace control just as if you were standing at
your furnace.
This page can be accessed from any web browser enabled device connected to your home network.
Bookmark this page in your web browser, allowing you quick access to this page at any time.
41
HeatMasterSS carries a full line of high-quality
parts for your furnace including pumps, fittings
and heat exchangers.For more information
on our parts or to arrange product installation
please contact your local HeatMasterSS dealer.
HeatMasterSS
Box158
Winkler, Manitoba, Canada
R6W 4A4
Phone: (204) 325-9792
Fax: (204) 325-9803
Toll Free: 1-877-325-9792
Email: [email protected]
heatmasterss.com