Page 1
GSERIES
EPA Certified Wood
Burning Furnaces
OPERATION AND
MAINTENANCE
MANUAL
By SteelTech Inc.
Version 5
UL 2523-2009
CAN/CSA B366.1-2011
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2 HeatmasterSS G Series Furnace Operating Manual
Page 3
GSERIES
CONTENTS
WARRANTY AND SAFETY
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water Treatment And Testing . . . . . . . . . . . . . . . . . . . . . 5
Water Treatment Policy . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Operating Levels . . . . . . . . . . . . . . . . . . . 5
Test Parameters and What They Mean . . . . . . . . . . . . . . . . 5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FURNACE INSTALLATION GUIDE
Furnace Specication Charts . . . . . . . . . . . . . . . . . . . . . . 7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clearance To Combustibles . . . . . . . . . . . . . . . . . . . . . . 7
Furnace Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit Foot Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Indoor Installation (Smokeless Loading Option Only) . . . . . . . 9
Chimney Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 10
Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring And Hydronic Lines . . . . . . . . . . . . . . . . . . . . . . 11
Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RETAIN THIS MANUAL FOR
FUTURE REFERENCE
DO NOT THROW AWAY
CANADA
SteelTech Inc.
Box 158
Winkler MB. R6W 4A5
Canada
Ph. (204) 325-9792
Fax (204) 325-9803
USA
SteelTech Inc.
Box 373
Walhalla ND. 58282
Ph. (877) 325-9792
Fax (204) 325-9803
Info@heatmasterss.com
www.heatmasterss.com
OPERATING THE FURNACE
Furnace Components . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filling The Furnace With Water. . . . . . . . . . . . . . . . . . . . 15
Firing The Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wood Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Loading The Furnace (Smokeless Loading ) . . . . . . . . . . . . 17
Loading The Furnace (Loading Switch) . . . . . . . . . . . . . . . 18
Operating A Gasication Furnace Requires . . . . . . . . . . . . 19
Controls And Safety Devices . . . . . . . . . . . . . . . . . . . . . 20
How the G Series Gasication Outdoor Furnace Works . . . . . 22
CARE AND MAINTENANCE
Care And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 26
G100 and G200 Electrical Schematic . . . . . . . . . . . . . . . . 29
G400 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . 30
Instructions For Editing Control Settings . . . . . . . . . . . . . . 31
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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 rebox 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 rebrick used in the furnace carries a 2-year
warranty.
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
thermostats, limit switches, pumps, 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 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
modications 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 nish.
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 le 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 verications are on le at SteelTech Inc.’s
ofce.
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.
4 HeatmasterSS G Series Furnace Operating Manual
Page 5
WATER TREATMENT AND TESTING
GSERIES
Water Treatment Policy
To qualify for warranty, water must be tested at a minimum
of once per year and water treatment added when
necessary.
To take a water sample:
Locate your water sample bottle, mailing carton and
mailing label provided to you by your dealer.
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 pouring into a bucket, and let cool before
collecting a sample.
Fill one of the test bottles at least 1/2 to 2/3 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 done (if anything). If any action is necessary, take
another sample and mail it to our test lab again to verify
the recommended changes have been made.
Add the water treatment through the ll pipe located at
the top of the furnace when initially lling 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 ring the furnace and 1:300
after that. Additional treatment may have to be added
for water with more severe properties or for systems with
more chemically demanding requirements.
Recommended operating levels are as
follows:
Conductivity: 100 - 4000 ppm
pH: 8.5 – 10. 5
Nitrates: no less than 730 ppm
Test Parameters and What They Mean
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.
pH
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.
Glycol
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 ush 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.
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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
youown your G Series outdoor furnace. Carefully read
and follow these directions.
DANGER
Do not start the re 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 qualied and trained
should operate this furnace. Improper ring 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 comply
with all applicable local and state laws 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. Consult with local authorities prior to
installation to adhere to local laws and ordinances.
DO NOT OVER FIRE THIS HEATER. Attempts to
achieve heat output rates that exceed the heater
design specications 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
operations, wiring, plumbing and building codes.
All models operate at atmospheric pressure. DO NOT
obstruct, block or plug the overow vent tube in any
way, which is located on top of the furnace.
When installing the furnace, the chimney should
never be connected to a chimney ue serving another
appliance.
DO NOT operate furnace in event of power failure.
Use caution when opening the rebox and ash cleaning
doors. Push the by-pass handle towards the front of the
furnace or push the loading switch and slowly crack the
door open for at least 20 seconds before fully opening
the door.
DO NOT use chemicals or uids to start the re.
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 ues and chimney regularly.
This appliance should not be installed in a location
where a corrosive atmosphere, ammable gas or
vapour, combustible dust or combustible bers may
be present. If ammables are present in the building,
ensure ducts, vents and doorways between the rooms
are sealed so as to not allow vapours or bers to travel
to the appliance.
CAUTION
DO NOT start or operate furnace without checking the
heating uid. The furnace must be lled until heating
uid 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.
ATTENTION: DO NOT CONNECT THIS UNIT TO A
CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
6 HeatmasterSS G Series Furnace Operating Manual
Page 7
GSERIES
FURNACE INSTALLATION GUIDE
Installation should be performed by a qualied installer and must comply with all requirements of the agency having
jurisdiction.
G100 G200 G400
Heat Output Range 18,000 -120,000 BTU/hr 32,000 - 214,000 BTU/hr 47,000 - 350,000 BTU/hr
Furnace Size (W x H x L) 38 x 57 x 77 53 x 70 x 84 54 x 82 x 89
Furnace Weight 1300 lbs 2400 lbs 3000 lbs
Firebox Dimensions 19 x 20 x 30 28 x 30 x 36 30 x 42 x 40
Chimney Size 6” 6” 8”
Water Capacity 100 gallons 195 gallons 250 gallons
8 Hour Average Efciency Using
Higher Heating Value of Wood
U.S. ENVIRONMENTAL PROTECTION AGENCY Certied to comply with the 2015 particulate emission standards. Not approved for
sale in the United States after May 15, 2020
Annual Efciency rating is calculated using the weighted average test results from the emission test reports for each model.
Efciency is determined by dividing the total input, using the higher heating value of wood (8700 BTU/lb) by the average heat output
is taken off of the furnace.
LOCATION
Where you install the furnace will have an effect on the
efciency of your furnace. Although the furnace is very well
insulated, installing the furnace outdoors will mean some
heat loss at the furnace. The furnace will have less heat loss
when installed indoors away from the elements that can
cause heat loss.
Maintain an adequate clearance of buildings and
combustibles.
Do not place or store wood within stove installation
clearances or within the space required for charging
and ash removal.
75.8% 79.0% 74.8%
Do not store combustible fuels in the same room as the
furnace.
Pile and store wood under shelter.
For indoor installations where fans are used in the fuel
storage area, they should be installed so as to not create
any negative pressure in the room where your furnace is
burning.
Contact all governing authorities in your area prior to
installation.
When choosing the location of your furnace you should
consider prevailing wind direction, distance from home
and wood storage for refueling.
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)
Side Walls & Rear 6”
Front (Loading door) 24”
6”
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FURNACE FOUNDATION
67.457”
48” concrete
37.013”
Footprint dimensions are shown below.
Inspect the ground conditions where you intend to
install your furnace.
A cement pad of 4-6” thickness should be used.
Cement pads should be a little bigger than the actual
furnace. You 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
not less than 6” wide x 10” long and 3” thick. Place your
48” concrete
work space
(optional)
48” concrete
work space
(optional)
20.603”
50.109”
42.187”
G200
G100
27.606”
12.999”
blocks so the legs will stand at the center of the blocks.
The furnace may be installed on a combustible oor
provided a noncombustible material such as metal or
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 rebox and lower combustion chamber
doors.
work space
(optional)
30.106”
14.609”
55.408”
62.08”
G400
43.892”
48” concrete
work space
(optional)
48” concrete
work space
(optional)
30.687”
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 of the trench bottom.
Most insulated underground pipes have room for electrical wire in it. If it
does not, place an electrical supply at the bottom of the trench and cover
with 6 inches of dirt.
A minimum of R8 insulation value is recommended and a water-tight vapor
barrier such as PVC pipe or drain tile to encase your insulation is a must.
NOTE: If you are installing your water lines under an area where vehicles
will cross, you should increase your depth of the trench and use a schedule
pipe over your lines to reduce the pressure generated on the lines.
8 HeatmasterSS G Series Furnace Operating Manual
44.018”
48” concrete
work space
(optional)
Page 9
INDOOR INSTALLATION (with Smokeless Loading Option Only)
GSERIES
IMPORTANT: The furnace must be equipped with the
Smokeless Loading Option to install the appliance in a
building.
IMPORTANT: A re may be caused by the following:
Improper installation. To reduce the risk of re, follow all
local codes and these installation instructions carefully.
Storing ammables 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-tting 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 ue serving another
appliance. Make sure the chimney, ue pipe, and draft
inducer fan stay clean and in good condition at all times.
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,
replaces, vents and solid fuel burning appliances in the
USA or CSA B365 installation code for solid fuel burning
appliances and equipment in Canada.
The recommended chimney and collar adapters are listed
below.
Furnace Chimney Size
G100 6”
G200 6”
G400 8”
This is a forced air 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 IS
ESPECIALLY IMPORTANT AT THE END OF THE HEATING
SEASON TO MINIMIZE CORROSION DURING THE
SUMMER MONTHS CAUSED BY ACCUMULATED ASH.
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CHIMNEY INSTALLATION
10 ft. (3 m)
or less
2 ft. (0.6 m)
minimum
Ridge
Chimney
3 ft. (0.9 m)
minimum
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.
We recommend that chimneys being installed on our
products be installed by professionals who are certied in
the USA by NFI (National Fireplace Institute) or in Canada
by WETT (Wood Energy Technology Transfer).
Draft problems may occur because of incorrect chimney
installation.
IMPORTANT: The furnace room must never be in a
negative pressure condition. Negative pressure could result
in smoke in the room.
Make sure to follow these simple rules below to ensure
proper performance and safety.
The chimney must be connected using a double wall
stainless steel chimney and connector.
Use only components intended for the brand and
model of chimney you are using. Never substitute
parts from other chimney brands or fabricate your own
components.
To be safe and effective, the chimney must be
installed exactly in accordance with the manufacturer’s
instructions.
Use a direct exit whenever possible. A vertical exit with
no elbows is always the safest and most trouble-free
installation.
Maximum chimney installation height is 15 ft.
Maximum horizontal installation from the furnace to the
exhaust exit is 3 ft.
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.
45-degree elbows and tees cannot be used.
Elbows should never be installed in oor joists or roof
attic entries.
Shields should be used whenever going through oors,
attics, and roofs to keep the wood and insulation from
getting too hot and possibly catching re.
Make sure to follow local building codes.
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.
Double-wall connectors approved for use with solid-fuel
burning appliances must be used.
Information on assembling and installing double-wall
connectors and chimneys is provided by the manufacturer
and must be followed. Use chimneys and connectors from
the same manufacturer as it helps make the assembly and
installation easy.
Note: When installing a chimney through a roof, telescoping
chimneys can be used to simplify the installation and
eliminate the need to cut individual connector sections.
Consult your local dealer about these special pieces.
Roof Penetrations and Clearances
The basic rule is this: The top of the chimney must clear the
roof penetration point (the upper edge) by at least 3-feet
and must clear anything within a 10-foot radius by at least
2-feet. This includes the peak of the house, parapet, dormer,
chimney, or spire. See (gure 1).
If the chimney terminates beyond 10 feet from the ridge of
the roof, it must clear the upper penetration of the roof by
3-feet. Notice that the ue still terminates 2-feet above the
roof at the 10-foot perimeter.
10 ft. (3 m)
or less
2 ft. (0.6 m)
Ridge
Ridge
minimum
More than
10 ft. (3 m)
10 ft. (3 m)
2 ft. (0.6 m)
minimum
3 ft. (0.9 m)
minimum
Chimney
Height above
any roof surface
with 10 ft. (3 m)
horizontally
3 ft. (0.9 m)
minimum
10 HeatmasterSS G Series Furnace Operating Manual
Chimney
Page 11
GSERIES
COMBUSTION AIR
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.
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. Your
G Series furnace requires 85 CFM (cubic feet/minute).
3. Determine whether the space is ‘conned’ or
‘unconned’ 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 ‘unconned’.
b. If the result is less than 50 CF/1000 BTU per hour,
then consider the space ‘conned’.
4. For an ‘unconned’ space in a conventionally
constructed building, the fresh air inltration 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 ‘conned’ space or an ‘unconned’ 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.
Furnace Connection
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
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
qualied technician.
Power Specications
G100 and G200
Power Supply 120V 1PH 60 HZ
Max Breaker 15 AMP
Running Load 2.5 Amps
Max Accessory Load 9.5 Amps
G400
Power Supply 120V 1PH 60 HZ
Max Breaker 15 AMP
Running Load 6 Amps
Max Accessory Load 6 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.
System Flow Rates
WIRING AND HYDRONIC LINES
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 qualied
technician must perform the electrical portion of the
installation.
See Pages 29-30 for the furnace wiring diagrams.
Due to the high efciency heat exchanger design it
is important to have sufcient water ow through the
furnace. Without adequate ow there may be boiling in
hot spots in the heat exchanger. Stratication may also
result in cool water temperature ow to the buildings.
Optional Re-Circulation Pump
A factory equipped re-circulation pumped, valves and
connections can be purchased with the furnace. With it
installed there will always be enough ow in the tank. The
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Page 12
pump and loop should be plugged in and valves open at
the marked outlet in the rear electrical box whenever the
furnace is in use. The pump automatically shuts itself down
in a “Low Water Alarm” situation. 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.
G100 - Speed #1
G200 - Speed #2
G400 - Speed #3
Note: If the optional factory equipped re-circulation
pump has not been installed, it may be necessary to install
a mixing pump on an unused set of lines to make sure
there is enough ow in the furnace to keep the furnace
from stratifying.
Underground Hydronic Lines
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 lines should
be at minimum of 1” and have a rating of 100 PSI capacity
of 180° F.
Hint: Mark your feed and return lines prior to covering
and allow enough pipe above ground at both ends for
a relaxed connection. Red lines are generally “hot” while
blue lines are usually “cold”.
Interior Connections
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 t your needs. The following are examples of basic
interior connections. Your dealer carries the necessary
parts for installation.
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, an
excessive amount of joints and elbows, etc.
It is also important to install air bleed valves at hight points
in the system to avoid an air lock, especially if these points
are higher than the furnace. Airlocks can restrict system
ow limiting the BTU’s available to your building. They
may also cause your furnace to overheat or stratify leading
to cold water to ow to your building.
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 qualied technician.
Water-To-Water Heat Exchangers
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 in-
line 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 at 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 in 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.
The furnace must be installed without affecting the
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.
The furnace must have provisions for preventing, or
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
function of the controls or rewiring the original boiler.
A wiring interconnection is permitted. The electrical
12 HeatmasterSS G Series Furnace Operating Manual
Page 13
GSERIES
system of both boilers shall be powered from a single
branch circuit without exceptions.
Boiler Safety
Operate the boiler periodically to ensure that it will
operate 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 veried for
acceptable operation before and after installation of the
add-on appliance by a gas tter who is recognized by
the regulatory authority.
Do not connect to any chimney or vent serving a gas
appliance.
Forced Air Furnace (Water-To-Air Exchanger)
The water-to-air heat exchanger must be mounted so that
air blows through the ns (coils). The exchanger should be
mounted below the A/C coil if possible. The exchanger
should be sized to t 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.
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
ring 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 boiler installation example
Installation should comply with requirements of CAN/
CSA-B365, and changes to the installation should comply
with CSA-B139 (for oil-red boilers), C22.1 (for electric
boilers), or CAN/CSA B149.2 (for gas-red boilers).
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.
Example of hookup for a forced air furnace and hot water.
13
Page 14
LIFT HOOK
WATER LEVEL FLOAT
EZ CLEAN HANDLE
OPTIONAL
SMOKELESS
LOADING HANDLE
FIREBOX DOOR
DAMPER COVER
OPTIONAL SIGHT
GLASS VIEWING
PORT
DRAFT INDUCER FAN
COLD WATER
RETURN OUTLETS
HOT WATER SUPPLY
OUTLETS
14 HeatmasterSS G Series Furnace Operating Manual
PUMP PLUG IN
AND MAIN POWER
SWITCH
LEAD IN POWER BOX
OPTIONAL
CIRCULATION PUMP
FURNACE DRAIN
VALVE
Page 15
OPERATING THE FURNACE
GSERIES
FILLING THE FURNACE WITH WATER
Your furnace has a vent pipe that protrudes through the
roof which is used to ll the furnace with water.
CAUTION: Do not re the furnace until it is lled with
water. Allow the furnace to run for 2 days and check the
system water levels and ttings for leaks. Take your initial
water sample at this time and be sure that it is sent in for
testing.
IMPORTANT: To properly maintain your furnace, test your
water every year. Water treatment may need to be added
or your furnace may need to be drained and ushed and
water treatment added. For information on acquiring this
product refer to your local dealer.
Hint: It is recommended that a ll valve is installed inline in
the building you’re heating with a shut-off valve or oneway check valve (Check local codes for proper installation)
to prevent back-ow.
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
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
level falls to a low level, rst check
your water temperature before
lling with water again.
FIRING THE FURNACE
These furnaces have been specically designed to burn
wood and as such are not intended for burning any other
fuels such as rubber, material treated with petroleum
products, leaves, paper products, cardboard, plastic or
garbage. Burning these fuels in your furnace will result in
the warranty of the furnace being voided.
BURN WOOD ONLY: Load carefully or damage may
result. On starting an initial re, use kindling wood and
paper, if required. Add heavier fuel gradually until a
suitable re is achieved. The furnace will continue to feed
an air supply to the re until your temperature control
reaches set point. TIP: Develop and keep a bed of ashes
in the rebox to keep coals lit during periods of idle. It is
common for the re to go out during idle when rst red
in the fall. The ashes will help to insulate the coals and
keep them lit.
Note: Your furnace is equipped with a low temperature
cut off feature. Anytime the water temperature drops
below 140 Degrees F, (including your rst initial ring of
the furnace), you will need to activate the low-temperature
bypass function. The black button (labeled Cold Start) is
located on the control panel. When pushed, the furnace
will allow the fan to turn on to start your re.
ATTENTION: On the initial startup, the water jacket will
reach what is called the “dew point”. This causes sweating
inside the rebox which may last a couple of days and is
normal.
15
Page 16
WOOD QUALITY
This furnace is designed to burn natural wood only. Higher
efciencies 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.
Keep in mind the diameter of wood you use, especially
with the G100. Using wood that is no larger in diameter
than 6” will give you a better, more even burn. For the
G200 and G400, a larger diameter of wood can be used
but do not exceed 8”. 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 in
the rebox.
DO NOT BURN:
1. Garbage.
2. Lawn clippings or yard waste.
3. Materials containing rubber (including tires).
4. Materials containing plastic.
5. Waste petroleum products, paints or paint thinners
and asphalt products.
6. Materials containing asbestos.
7. Construction or demolition debris.
8. Railroad ties or pressure-treated wood.
9. Manure or animal remains.
10. Salt-water driftwood or other previously salt water
saturated materials.
11. Unseasoned materials.
12. Paper products, cardboard, plywood or
particleboard.
Using a moisture meter to test your wood
You can use a moisture meter to test how wet your wood
is. A moisture meter will measure the moisture content of
a piece of wood by inserting the metal prongs into the
grain of the wood. The moisture content will be displayed.
To get an accurate reading make sure to use a high-
quality moisture meter, split the wood and take at least 2-3
readings from different points of the wood.
Storing wood
Store your wood pile under an open-ended shelter to
avoid rain and snow buildup on the pile. Keeping 3 sides
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.
The prohibition against burning these materials does
not prohibit the use of re starters made from paper,
cardboard, saw-dust, and similar substances for the
purpose of starting a re in an affected wood heater.
Burning these materials may result in a release of toxic
fumes or render the heater ineffective and cause smoke.
Typically it takes at least 12 months to properly season
wood. Seasoned wood looks dark or gray when
compared to green wood - but if you split a piece of
seasoned wood - it’s WHITE on the inside. It has cracks
running through each piece, and a lot of little cracks on
the inner rings. Unseasoned wood has a wet, fresh looking
center, with lighter wood near the edges or ends which
have been exposed since cutting. When rewood is very
fresh, the bark will be tightly attached.
16 HeatmasterSS G Series Furnace Operating Manual
Typical moisture meter
Page 17
LOADING THE FURNACE - SMOKELESS
LOADING HANDLE
WARNING: Risk of re ashback. 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 rebox door within 15 or more
minutes of the furnace reaching temperature or when the
rebox 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. Pull the Smokeless Loading Handle towards the front.
This will open the smoke bypass so no smoke or ame
exits the rebox door when you open it.
2. Crack the rebox door open to the safety catch for at
least 15 seconds to allow the air draft to build out the
chimney and prevent blow-back.
3. Open the door slowly while standing behind the door.
GSERIES
1
2
4. Use your ash rake to knock charred wood down and
bank hot coals away from the slot and toward the
edges of the rebox.
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 19.
7. Close the rebox door.
8. Close the smoke bypass by pushing the Smokeless
Loading Handle over center all the way to the back of
the furnace to the closed position.
3
4
17
Page 18
LOADING THE FURNACE - LOADING
SWITCH
WARNING: Risk of re ashback. 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 rebox door within 15 or more
minutes of the furnace reaching temperature or when the
rebox 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. Locate the switch on the side of the furnace to the left
of the control box. Pressing it will activate the draft fan
to run for 5 minutes so smoke or ame does not exit
the rebox door when opened or while loading.
2. Crack the rebox door open to the safety catch for at
least 15 seconds to allow the air draft to build out the
chimney and prevent blow-back.
3. Open the door slowly while standing behind the door.
1
4. Use your ash rake to knock charred wood down and
bank hot coals away from the slot and toward the
edges of the rebox. 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 the following page.
7. Close the rebox door.
Note: The loading switch has an automatic 5-minute timer
and will automatically shut the fan off after 5 minutes. If a
second cycle is needed (unlikely), press the loading switch
again to start a new loading cycle.
WARNING: Risk of re:
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 ues and chimney regularly.
Remove ashes regularly.
2
3
CAUTION: Hot surfaces, Keep children away and do not touch during operation.
18 HeatmasterSS G Series Furnace Operating Manual
Page 19
OPERATING A GASIFICATION FURNACE
REQUIRES:
1. Use seasoned wood: It is always recommended to
use dry seasoned wood (15-25% moisture, seasoned
1-2 years) when operating a gasication furnace with a
minimal mix of green wood. If required to burn green
or wet wood, always mix with a higher ratio of dry or
seasoned wood.
2. Stacking: Using the illustration to the right, rst stack
your primary wood on the coal bed in the rebox so
that as the wood gasies and burns, the wood above
it falls on top of the coal bed at the bottom of the
rebox to continue the gasication process. Stack your
secondary wood around the primary wood to ll the
rebox, if necessary.
3. Log Sizing: For ideal operation, log sizing should not
exceed 8” in diameter. Exceeding the recommended
sizing may result in doming (which only allows for
the bottom and/or inside core of the log to burn) or
bridging (the wood “hangs up” in the rebox and
separates from the coal bed). Pieces of wood larger
than 8” should be split into smaller size pieces for use
in gasication furnaces.
GSERIES
Improper wood sizing, stacking or excessive moisture
content in the wood may result in the re going out,
improper burning, and extensive creosote buildup not
allowing for efcient burning of the wood and eventual
furnace malfunction.
For more information on wood quality, follow these links:
EPA’s Burnwise Program - http://www.epa.gov/burnwise
How to Use a Moisture Meter (Video) -
http://www.youtube.com/watch?v=jM2WGgRcnm0
Split, Stack, Cover and Store (Video) -
http://www.youtube.com/watch?v=yo1--Zrh11s
19
Page 20
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
Your HeatMasterSS G Series furnace uses a factoryprogrammed control to maintain your water temperature
by using an air damper control and draft inducer fan.
The control is located around the corner to the left of
the rebox door and requires no user programming or
changes. The control displays the water temperature in
your furnace, the damper air percentage and any active
alarms.
Note: A timer has been programmed into the control to
re 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.
Air Damper
The damper air percentage is the amount of air being
drawn through the furnace to stoke the re. This feature
keeps your furnace burning clean and hot while keeping
your water temperature in the preferred range. The
damper is located beneath the rebox loading door and
is a mechanical part that opens or closes the air injection
port.
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 damper
through the furnace. The fan should be on whenever the
air damper percentage is above 0% or when the smoke
bypass is open.
Note: Be sure to close the bypass once you have nished
loading the furnace and closed the rebox 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.
Loading Switch (Base Model)
Unless equipped with a Smokeless Loading Handle,
your furnace has a run switch to make loading safer. If
the furnace is not running when you go to load, turn on
the loading switch. The draft fan will turn on for up to 5
minutes to reduce the smoke spillage while loading.
High Limit Switch
The high limit cut off switch is used to ensure the furnace
does not cause damage via runaway re. It acts as a
safety switch by cutting power off to the fan if the water
temperature rises above 190 degrees F. If the high limit
switch trips, it will have to cool off to about 140 F before
turning on again.
Alarm LED Light
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 re the furnace from a cold start
(First ring the furnace or when the water temperature has
gone low).
Smokeless Loading Handle (Optional)
Use the Smokeless Loading Handle whenever the rebox
loading door is open. The bypass handle is located on
the side of the furnace and opens a direct exit out of the
rebox through the chimney whenever pulled towards
the front of the furnace. This will allow you to check your
rebox, fuel and load your furnace without smoke blowing
out of the rebox loading door.
20 HeatmasterSS G Series Furnace Operating Manual
Page 21
GSERIES
ALARM LED LIGHT
FAN BREAKER
FURNACE ON/OFF
BUTTON
COLD START
BUTTON
SMOKELESS
LOADING HANDLE
(OPTIONAL)
AIR DAMPER
FURNACE CONTROL
DRAFT
INDUCER
FAN
LOADING SWITCH
21
Page 22
HOW THE G/GS SERIES GASIFICATION OUTDOOR FURNACE WORKS
SteelTech Inc. is proud of its reputation for producing
innovative outdoor heating methods and our G Series
outdoor furnaces are continuing that trend. They operate
more efciently with fewer emissions than other outdoor
furnaces. The HeatMasterSS G Series wood furnaces use up
to 50% less wood to create the same heat.
How It Works
Wood gas is generated in a high-temperature reaction
(>700º F) between the wood and a limited amount of
oxygen. The heat and lack of oxygen “bakes” the wood,
causing the gases in the wood to release in the form of
carbon monoxide, hydrogen and carbon dioxide.
The wood gas mixture that is created in the rebox then
gets forced through the base of the re along with any
ash that would come with it and burned at temperatures
around 2000º F in the gasication chamber. This creates a
very hot, very clean burn helping you get the most out of
your fuel. After the gas is burned, heat is extracted to the
water jacket using the heat exchange tubes.
Normal exit temperatures of the exhaust are 200-300º F.
The most notable indicator of effective gasication is the
lack of smoke exiting the chimney. However, many times
you will see white exhaust that dissipates quickly, which is
steam from the wood in the rebox.
The gasication process creates longer burn times
and can reduce wood consumption as much as 50%
compared to a standard outdoor furnace.
22 HeatmasterSS G Series Furnace Operating Manual
Page 23
CARE AND MAINTENANCE
GSERIES
To obtain the high level of performance of your furnace,
certain maintenance procedures are required periodically.
On a daily basis:
Ensure that all doors are closed and sealing properly.
Adjust if necessary.
Check for creosote buildup in the rebox and lower
combustion chamber. Some creosote buildup along
the walls, door jamb, and rebox door is normal.
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
properly. The fan should turn on when the furnace calls
for heat. The control display should be functional and
keep the water temperature between 160° and 180° F.
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 (if installed)
is closed. The handle should be facing towards the back
of the furnace.
On a weekly basis:
Check for creosote build up in the heat transfer tubes
and chimney using the access panel on the rear of the
furnace.
WARNING: Always keep the rebox door open when
removing ash from the lower combustion chamber.
Remove ash from the lower combustion chamber in
the horseshoe refractory brick and both sides, carefully
using your ash rake.
Dispose of ashes in a metal container away from the
stove and wood pile.
On a monthly basis:
Inspect air inlet for creosote build up or blockage.
Depending on the type and quality of wood being
used, ash removal from the rebox may be necessary.
For optimal performance, the ash bed in the rebox
should not exceed 6-8”. If you are burning a wood fuel
that leaves quite a bit of ash you may need to clean your
rebox out every 2-4 weeks to continue to get optimal
performance from your furnace.
Check the fan motor and wheel for creosote buildup.
The motor and wheel can be easily removed by
unplugging the wires to the fan and loosen the nuts on
the stainless steel plate.
On a seasonal basis when the furnace is not in
use, you will have to:
Remove all ashes and excess creosote from the rebox,
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, scuff the surface where the seal is placed
with sandpaper and re-apply high temp silicone. Lay
berglass rope over silicone and let bond for at least 24
hours before using the furnace again.
Cover the chimney and crack open the bottom door
enough to allow air movement and reduction of
condensation within the rebox.
Make sure your water tank is full and have your water
treatment tested and adjusted to manufacturer’s
specications. See page 5 for exact specications.
Tighten your rebox door by adjusting the hinges on
each side of the door.
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-tting lid. The closed container should be placed
on a non-combustible oor or on the ground well away
from all combustible materials before nal disposal. If
the ashes are disposed of by burial in soil or otherwise
locally dispersed, they should be retained in the closed
container until all cinders have thoroughly cooled.
23
Page 24
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 ue of a slow-burning re. As a
result, creosote residue accumulates on the ue lining.
When ignited, this creosote makes an extremely hot re.
The chimney and chimney connector should be inspected
at least twice a month during the heating season to
TROUBLESHOOTING
determine if a creosote buildup has occurred. If creosote
has accumulated it should be removed to reduce the risk
of a chimney re.
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
TROUBLESHOOTING TO ENSURE
PROPER BURNING AND AIR FLOW
If your furnace is not producing enough heat, is smoking
while burning, there is no exhaust coming from the
chimney or there is a general concern on how well it
is functioning you can conrm functionality using this
process:
1. Remove damper cover located below the rebox door
and ensure the damper is opening the metal disc
when the furnace is calling for heat and closing when
the furnace is satised.
2. Use a light piece of paper (like receipt paper) and
hold it up to both of the openings in the metal disc.
The paper should suction to the opening. If it is not,
there is an airow issue in the furnace that should be
diagnosed by your dealer.
3. Make sure the ash bed is not so high as to block air
holes in the panels on the sides of the rebox.
4. Check to ensure the slot at the bottom of the rebox is
completely open.
5. Check to ensure all ash from the lower combustion
chamber is removed and there are no blockages.
Make sure ash from the middle, both sides and behind
the brick are cleaned.
6. Inspect top chamber of furnace and heat exchange
tubes for blockage.
— Is there wet creosote build up? If there is, inspect
the bypass plate to ensure it is seated properly to
seal against the ange
— Do the spirals in the heat exchange tubes have full
movement up and down?
— Is there creosote build up in the fan housing or in
the fan wheel?
Clean any creosote found by scraping it off.
7. Check chimney for blockage, inspecting all the way
down into the furnace. Clean out any blockage.
More than likely, if there is a problem with the furnace
burn or air ow, you will nd it by checking these things.
If the actuator damper plates do not open or close
as they should and the power in the furnace is
acting appropriately:
1. Remove the bracket, spring, and motor to get at the
damper plates.
2. Remove plates and clean off any creosote, ice, dirt, etc.
For additional lubrication, a light coating of automatic
transmission uid can be applied.
3. Re-install and test for function.
If the furnace is running but fails to bring water up to
temperature:
1. Check re.
2. Check for power at the furnace. Make sure control is
running with no errors or alerts.
3. Check fan for operation.
4. Check that the damper is open to allow air injection.
24 HeatmasterSS G Series Furnace Operating Manual
Page 25
GSERIES
5. Check if the furnace is properly gasifying by opening
the bottom door to the Lower Combustion chamber.
A ame should be visible only for a short time after
opening the door and glowing embers should be
present. Keep arms, legs, and head at least 3 feet from
the opening.
6. Ensure that the air slot in the rebox refractory is clear
to allow proper burning.
7. Check fuel type. Poor quality fuel will not provide as
many BTU’s as high-quality fuel.
8. Check water level of the furnace.
9. Check for creosote blockage in the chimney and heat
exchange tubes.
10. Check to ensure all pumps in the system are running.
11. Check to make sure there are no leaks, hot/wet spots
on your ground or breaks in the pipe or ttings which
may cause the pipe to be saturated and lose its
insulation value.
12. 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 ow in the water
tank. (See next topic).
13. 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:
1. Check to be sure the recirculation pump (if equipped)
and the buildings pumps are operating properly and
that the valves in the circulation loop are open to allow
ow. The circulation piping should be hot from top to
bottom.
2. Check system for ow:
— Check to ensure all pumps in the system are
running and none are turned the wrong way.
— Check lter cartridge for ow blockage (if installed).
— Check for air in the system at the exchanger by
bleeding off.
— Check for closed valves to ensure water ow.
3. If no obvious ow 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 lls up. You should be able to calculate
the ow rate in that line. Do this for each line coming
off of the furnace to calculate furnace ow rate.
If the furnace water and the building supply lines
are hot but buildings do not have heat:
1. Check to ensure all pumps in the system are running.
2. Check lter cartridge for ow blockage (if installed).
3. Check for air in the system at the exchanger by
bleeding off.
4. Check for closed valves to ensure water ow. Check
Temperature of water exiting the 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 the furnace overheats:
1. Close all air inlets and doors on the furnace.
2. Retrieve as much heat as possible from the system by
turning thermostats up and opening windows until
furnace cools down.
3. Check that all doors are closing properly and that door
gasket is completely sealing.
4. Check that the damper plate is opening and closing
properly. It should be completely closed when the
furnace temperature is over 180° F.
5. Check water level.
6. Check to ensure all pumps in the system are running.
If there is a runaway or chimney re:
1. Make sure the rebox and lower combustion chamber
doors are tightly closed.
2. Close all combustion air inlets on the furnace.
If the furnace has shut down:
1. Check to ensure that the unit has power.
2. Check to ensure the furnace On/Off switch is in the On
position.
3. Check the water temperature (furnace has a high
temperature cut off of 190° F and turns on again
at 140° F).
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4. Check control for errors that may have shut the
furnace down.
5. If all checks have not corrected the problem have a
technician check the control panel.
If the furnace has an excessive amount of creosote:
1. Check to ensure the furnace is sized accurately
according to heat demand. If the furnace is oversized
it will idle and cause this.
If there is a power failure:
1. Open all ow-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 ow-check valves and will continue to operate
normally without electricity.
2. It is important to remember that the heating systems
cannot dispose of a great deal of heat without the
circulator(s) running. Avoid over-ring!
DO NOT LOAD LARGE AMOUNTS OF SOLID FUEL
INTO THE FURNACE!
Fire the furnace cautiously until you are able to
determine how quickly the heating system is able to
absorb the heat being produced by the furnace.
3. When the power has returned, reset all ow-check
and zone valves and resume normal operation of the
system.
If there is smoke leaking out of the door:
1. Check to ensure the door is sealing properly.
2. If the seal is worn out it will have to be replaced.
3. 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.
2. Check moisture content in your wood fuel. Moisture
content over 30% may cause creosote buildup.
Recommended moisture content in your wood fuel is
15-25%.
3. Remove the access panel at the rear of the furnace
and inspect the bypass door for smoke leakage.
4. If the chimney and/or heat exchange tubes become
plugged with creosote it will be necessary to scrape
the creosote out to obtain a proper burn in the rebox.
You are having to ll the furnace with water more
than once a week or more than a few gallons of
water per week and there is no obvious explanation:
1. Check the temperature settings and gasket on the
door and lower combustion chamber door to ensure
the furnace is not over temperature and steaming.
If water temperature reaches levels over 200° F the
water will steam and water loss will occur.
2. Check the perimeter of the furnace for water puddles
collecting or dripping from the furnace.
3. Check all plumbing in the system to ensure there are
no leaks.
4. If these checks have not provided an answer call your
dealer.
ELECTRICAL TROUBLESHOOTING
Electrical troubleshooting should always be done by a
qualied technician.
High Limit Switch:
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 pole of the switch. If the furnace was over 195° F.
and the switch has opened the water will need to cool
down to approximately 140° F. before it will close and
26 HeatmasterSS G Series Furnace Operating Manual
allow power through once again.
If the furnace has not overheated (190° F+) but there is
still power on only one pole of the switch, the switch is
faulty and should be replaced.
If there is no power on either pole 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
poles of the power supply rocker switch. The switch has
power in, neutral, and power out poles. During normal
Page 27
GSERIES
operation, there should be power at the power in and
power out poles.
If there is only power on one of the poles check to make
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 high limit 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 lit the power supply is
working.
If there is no 24 volts DC check for power on the INPUT
terminals (this should be 115V AC).
If there is 115V AC on the INPUT terminals but not
24V DC on the OUTPUT terminals the power supply is
faulty and should be replaced. Check for possible short
circuits in the 24V DC wiring that may have caused the
power supply to fail.
If there is not 115V AC on INPUT terminals check for
power at the Control Power Switch.
Fan Motor Breaker:
If the fan motor breaker has tripped check the fan for
proper operation before resetting the breaker.
If there is not 115V AC power on the input lead to
the fuse holder, check for power at the Control Power
Supply.
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 oat assembly and looking in the
ll pipe.
If the water level is low add enough to raise the water
level so the oat level shows full.
If the water level is full and the Low Water Alarm is
ashing on the screen you will need to test the low
water switch.
Using an electrical testing meter check for voltage
across the “M-“ and “I1” terminals on the Siemens
control. If the low water switch is satised (closed) there
should be 24V DC.
If there is no voltage, power off the furnace, isolate the
low water switch from the control and the wiring, then
check for continuity across the switch.
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 and inspect the switch. If it is dirty it may be
cleaned up, tested and re-installed. If it is faulty it should
be replaced.
Loading Switch
To test the Loading Switch use an electrical testing
meter and measure the voltage across the “M-“ and “I2”
terminals on the Siemens control. There should be 24 VDC
on both terminals when the switch is in it’s normal state.
It should have 24V DC on one side when the switch is
pressed.
Siemens LOGO Control: (with display)
Using an electrical testing meter check for 24V DC power
By-Pass Door Switch:
To test the By-Pass Switch use an electrical testing
meter and measure the voltage across the “M-“ and “I2”
terminals on the Siemens control. There should be 24 VDC
when the by-pass 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
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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
cut off 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 ashing “Low-Temperature Alarm” and
the Cold Start Button is depressed, the alarm should be
replaced with “Cold Start Override”. This message will
ash until the furnace has heated past it’s programmed cut
in temperature.
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
control and wiring and check for continuity across the
switch. There should be continuity only when the button
is depressed. If not, the button is faulty and should be
replaced.
Damper Actuator:
The “mode” selector should be set to mode 5.
To test for proper operation the furnace should be
powered on and calling for heat. The display should
indicate the Air Damper %. In this state, you may test for
power across terminals 1 & 2 on the actuator. There should
be 24V DC across those terminals.
If there is no power across terminals 1 & 2 then check
that there is power at the Siemens control. If there is
no power at the control check the #1 fuse and replace
if necessary. When the control is opening the damper
there should be 24V DC across terminals 2 and 3 on
the actuator. When the control is closing the damper
there should be power across terminals 2 and 4 on the
actuator. When the control is holding a steady position
there should only be power across terminals 1 and 2.
The actuator position can be conrmed by testing the
DC voltage across terminals 2 and 5 on the actuator. It
should be between 2 and 10V DC depending on the
position of the actuator. If the damper plate is stuck or
frozen to back plate, pry them apart. This should break
them loose and the actuator should move freely. If the
plates were stuck they should be removed and cleaned.
If the plates are not stuck or frozen and there is power
and communication the actuator is faulty and should be
replaced.
28 HeatmasterSS G Series Furnace Operating Manual
Page 29
G100 and G200 Electrical Schematic
GSERIES
29
Page 30
G400 Electrical Schematic
30 HeatmasterSS G Series Furnace Operating Manual
Page 31
INSTRUCTIONS FOR EDITING CONTROL SETTINGS
GSERIES
To edit temperature, differential, timer and low
temperature cut off settings follow these instructions:
To access the programming press the down arrow
repeatedly until the programming screen appears.
Note: If the Low-Temperature Alarm is on, DO NOT
push the cold start button.
Use the up and down arrow keys to toggle between
settings screens.
To edit the settings on the screen press and hold the
“ESC” key until the rst value is highlighted.
Use the up/down arrow keys to toggle to different
settings on the screen.
Press the OK button to adjust the highlighted setting.
Use the left/right arrows keys to navigate to the
appropriate character.
Use the up/down arrow keys to adjust the value of the
character. Note: The values are always in minutes or
degrees Fahrenheit.
Press the “OK” key to save your changes and adjust
other settings.
Press the “ESC” key to be able to toggle between
screens.
Press the “UP” arrow repeatedly to return to the run
screen.
The following screens will be available to edit:
Temperature Settings
Timer Settings
The Timer settings are designed to help keep the coal
bed alive in the rebox during periods of idle.
The On Delay controls how many minutes the furnace
will idle before turning the fan on.
On Time controls how many minutes the furnace will
burn for when the Timer function is activated.
Off Time controls how many minutes before the next
Timer function is activated.
Note: This only activates after the furnace completes a
burn cycle and brings the furnace up to temperature.
If the furnace is required to turn on because the water
temperature has fallen below the differential setting, the
Timer Settings will reset to the On Delay Timer.
Low Temperature Shut Down
There is a low-temperature function programmed into the
control to shut the furnace down if the water temperature
falls below the temperature set in the programming. This
is done to preserve the heat in the water if the furnace has
stopped burning.
The Set Temp Function controls how hot the water in
the water jacket is heated to.
The Differential controls how many degrees the water
will lose before the furnace turns on to heat the water.
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Page 32
HeatMasterSS carries a full line of high-quality
parts for your furnace including pumps, ttings
and heat exchangers. For more information
on our parts or to arrange product installation
please contact your local HeatMasterSS dealer.
Heatmaster
Box 158
Winkler, Manitoba, Canada
R6W 4A5
Phone: (204) 325-9792
Fax: (204) 325-9803
Toll Free: 1-877-325-9792
Email: info@heatmasterss.com
SS
heatmasterss.com
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