Heatmaster G400s, G100s, G200s Operation And Maintenance Manual

G100s, G200s, G400s

EPA Certified Wood Burning Furnaces

OPERATION AND MAINTENANCE MANUAL

Model:

By SteelTech Inc.
Version 3

Serial No.:

UL 2523-2009
CAN/CSA B366.1-2011

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Contents

Warranty and Safety

Warranty Registration & Delivery Form ....Front Insert

Warranty Details .............................4

Water Treatment And Testing ...................5

Safety Precautions............................6

Cautionary Markings.......................... 7

Furnace Installation Guide

Specifications ...............................8

Location ...................................8

Clearances To Combustibles....................8

Furnace Foundation ..........................9

Trench .....................................9

Wiring And Hydronic Lines ..................10-13

Operating The Furnace

Filling The Furnace With Water ................. 14

Firing The Furnace...........................14

Wood Quality, Testing and Storage .............15

Loading The Furnace ........................16

Operating A Gasification Furnace ..............17

How to clean the shaker system ................ 18

Controls And Safety Devices .................18-19

How the GS-Series Gasification

Outdoor Furnace Works ......................20

Care And Maintenance ....................21-22

Troubleshooting

Troubleshooting To Ensure Proper

Burning And Air Flow ......................22-24

Electrical Troubleshooting ...................24-26

G100 And G200 Electrical Schematic ............27

G400 Electrical Schematic..................... 28

Instructions for Editing Control Settings........... 29

RETAIN THIS MANUAL FOR

FUTURE REFERENCE

DO NOT THROW AWAY

CANADA

SteelTech Inc.

Box 158

Winkler Mb. R6W 4A5

Canada

Ph. [phone]

Fax [phone]

USA

SteelTech Inc.

Box 373

Walhalla Nd 58282

Ph. [phone]

Fax [phone]

[e-mail]

www.heatmasterss.com

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4

LIMITED WARRANTY

SteelTech Inc. warrants to the original owner of the
GS 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 toward 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-Life is 10%

• All firebrick used in the furnace carries a 2 year
warranty.

In addition, all steel components 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 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 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 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 Ind. 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 violated by operating the furnace
in a manner inconsistent with the owner’s manual

SteelTech Inc. reserves the right to change conditions
of warranty at any time.

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WATER TREATMENT AND TESTING

Water Treatment Policy

To qualify for warranty, water must be tested a
minimum of once per year and water treatment added
when necessary.

To take a water sample:

1. Locate your water sample bottle, mailing carton
and mailing label provided to you by your dealer.

2. Open the boiler drain located at the bottom of
the rear of the furnace for 10-15 seconds or until
the water runs clear. CAUTION: Water is hot! Use
extreme care or a bucket to run water into and let
cool before collecting sample.

3. Fill one of the test bottles at least 1/2 to 2/3 full.

4. Fill out the mailing label provided with the test
bottle completely, including your email address, the
model number and serial number of your furnace.
Make sure to note if the furnace water contains any
antifreeze or additional chemicals.

5. Attach top part of label to sample bottle and
bottom part to outside of mailing tube. Place bottle
in tube.

6. 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 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 be added at a 1:200 ratio when
initially firing 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 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 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.

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SAFETY PRECAUTIONS

Read and understand all precautions before operating
the furnace.

This wood heater needs periodic inspection and
repair for proper operation. It is against federal
regulations to operate this wood heater in a manner
inconsistent with operating instructions in this manual.

Save these instructions. Retain this manual as
long as you own your GS SERIES outdoor furnace.
Carefully read and follow these directions.

DANGER

Do not start fire with or burn garbage, gasoline,
naptha, engine oil or other inappropriate materials.
Only competent persons with a sound understanding
of this heating method should operate this furnace.
Improper firing could result in personal injury and/or
damage to the unit and void warranty.

ATTENTION

• BURN WOOD ONLY. LOAD FUEL CAREFULLY OR
DAMAGE MAY RESULT

• The person(s) operating this furnace must comply
with all applicable local and state laws or other
requirements,

• The person(s) operating this furnace are
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 OVERFIRE 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 GS SERIES
product 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 overflow vent tube
in any way, which is located on top of the boiler.

• When installing the furnace, the chimney should
never be connected to a chimney flue serving
another appliance

• Do not operate furnace in event of power failure

• Use caution when opening firebox and ash
cleaning doors. Crack door open using the safety
catch for at least 20 seconds before opening door.
Stand behind the door when opening it.

• 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

CAUTION

• Do not start or operate furnace without checking
heating fluid. Furnace must be filled until heating
fluid comes out of vent pipe on the 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.

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Cautionary Markings

Images on this page not to scale

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FURNACE INSTALLATION GUIDE

Installation should be performed by a qualified installer and will comply with all requirements of the agency
having jurisdiction.

G100s G200s G400s

Max BTU Output 120,000 BTU/hr 210,000 BTU/hr 350,000 BTU/hr

Heat Output (8 Hour Burn) 47,772 BTU/hr 111,315 BTU/hr 180,409 BTU/hr

Furnace Size (W x L x H) 38 x 58 x 79 52 x 70 x 88 52 x 82 x 92

Furnace Weight 1088 lbs 1840 lbs 2480 lbs

Firebox Dimensions (W x L x H) 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 Efficiency Using
Higher Heating Value of Wood

75.8% 79.0% 74.8%

LOCATION

Where you install the furnace will have an affect on
the efficiency 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 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.

• Pile and store wood under shelter.

• 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 for any effect on your
neighbors.

CLEARANCES TO COMBUSTIBLES

When installing your GS SERIES furnace, the following
clearances to combustibles must always be followed
or damage and personal injury may result:

Minimum Clearance to Combustibles

Furnace Roof to Ceiling (Indoor
Installations)

6”

Side Walls & Rear 6”

Front (Loading door) 24”

**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 higher heating value of wood (8700 BTU/lb), by the
average heat output taken off of the furnace.

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FURNACE FOUNDATION

• Footprint dimensions are in the illustration to the
right.

• Inspect the ground conditions that you intend to
install your furnace on.

• A cement pad of 4-6” in thickness should be used.
Cement pads should be a little bigger than the
actual furnace. You can also include about 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 blocks so the legs will stand on
the center of the blocks.

• The furnace may be installed on a combustible
floor 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 firebox and lower combustion
chamber doors.

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 pipe has room for
electrical wire in it. If it does not, place electrical
supply in bottom of 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.

50.112”

43.895”

12.999” 27.609”

55.412”

48” concrete

work space

(optional)

48” concrete
work space
(optional)

62.161”

44.012”

67.400”

48” concrete

work space

(optional)

48” concrete
work space
(optional)

14.609”

30.106”

37.013

30.687”

20.603”

42.187”

48” concrete

work space

(optional)

48” concrete
work space
(optional)

G100s

G200s

G400s

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LEAD IN
POWER BOX

HOT WATER
SUPPLY OUTLETS

FURNACE
DRAIN VALVE

H.E TUBE CLEANING ACCESS

COLD WATER
RETURN OUTLETS

DRAFT INDUCER FAN

LIFT HOOK

CONTROL BOX

WATER LEVEL FLOAT

FIREBOX DOOR

DAMPER COVER

LOWER
COMBUSTION
CHAMBER

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