Polar Furnace G2-PLUS, G2, G3 Owner's Manual

Heater Setup

Owner’s Manual for G2, G2-Plus & G3

G-Class

Outdoor Wood Furnace

Wood Moisture Requirements

See Section 8.2 of this Manual

The G-Class indoor/outdoor hydronic heater by Polar Furnace is listed by Intertek to the applicable portions of the following standard: ASTM E 2618-10 and/or EPA Method 28 WHH or EPA Method 28 WHH-15 and ASTM E2515-2011. The G-Class G2-Plus indoor/outdoor hydronic heater by Polar Furnace is also listed by Intertek to the applicable portions of the following standard: CSA B415.1-10. The G-Class indoor/outdoor hydronic heater by Polar Furnace is listed by CSA group to the applicable portions of the following standards: UL 2523 Standard for Solid Fuel-Fired Hydronic Heating Appliances, Water Heaters and Boilers and CAN/CSA-B366.1-11 Solid-Fuel-Fired Central Heating Appliance. The G-Class is CSA and UL certiﬁed for indoor or outdoor installation. Indoor installations must satisfy CSA CAN/CSA-B365 installation code for solid fuel burning appliances as well as any other applicable standards or regulations. The G-Class includes one 2-foot stainless steel insulated chimney section. Use only stainless steel solid fuel chimneys speciﬁed by Polar Furnace to extend the chimney.

To obtain a French translation of this manual, please contact your dealer or visit www.polarfurnace.com. (Pour obtenir une traduction française de ce manuel, s’il vous plaît contacter votre revendeur ou visitez www.polarfurnace.com.)

Speciﬁcations

8-Hour Output Rating Btu/hr 66 897 108 982 142 533

8-Hour Average Efﬁciency

Manufacturer’s Rated Heat

Output Capacity

Output Range Btu/hr 0 to 160 000 0 to 180 000 0 to 200 000

Annual Efﬁciency Rating

Speciﬁcations subject to change without notice

*This heater is U.S. ENVIRONMENTAL PROTECTION AGENCY certiﬁed to comply with 2015 particulate emission standards. Not approved for sale after May 15, 2020. Under speciﬁc test conditions, this heater has been shown to deliver heat at rates shown for the respective model above. **This heater is U.S. ENVIRONMENTAL PROTECTION AGENCY Certiﬁed to comply with 2020 particulate emission standards using cord fuel. Under speciﬁc test conditions, this heater has been shown to deliver heat at rates shown for the respective model above.

Performance is a product of the combustion rate, combustion efﬁciency and heat exchange efﬁciency of a single fuel load. Results may vary because of many additional factors including wood species, wood quality, wood quantity and moisture content of the wood used. Efﬁciencies are determined under the same test conditions using higher heating value, lower heating value and annual fuel utilization efﬁciency (AFUE). This wood heater has a manufacturer-set minimum low burn rate that must not be altered. It is against federal regulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual.

U of M G2* G2-Plus** G3*

lower/higher

heating value (%)

Btu/hr 160 000 180 000 200 000

lower/higher

heating value (%)

76.5/71.2 87.2/81 80.5/74.8

71.6/66.5 78.7/73.1 77.9/72.3

DO NOT OVERFIRE THIS HEATER. Attempts to achieve heat output rates that exceed heater design speciﬁcations can result in permanent damage to the heater. Any person(s) operating a hydronic heater must comply with all applicable laws, including but not limited to local ordinances. Improper use or failure to maintain the hydronic heater may cause nuisance conditions. The person(s) operating a hydronic heater is/are responsible for operation in a manner that does not create a nuisance condition. Meeting the setback distance and stack height recommendations from the manufacturer and requirements in applicable State and local regulations may not always be adequate to prevent nuisance conditions in some areas due to terrain or other factors. Operating and maintaining an outdoor furnace may not be suitable to every individuals’ abilities or lifestyles. Be sure to review the Owner’s Manual for the appliance with your dealer prior to purchasing or operating this heater.

IMPORTANT: Read and fully understand this manual prior to installing and/or operating a Polar Furnace heater. 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.

Owner’s manual for Polar Furnace models: G-2 & G-3

POLAR FURNACE G-CLASS HEATER WARRANTY (v. 15-1)

The longevity of your G-Class heater will depend on how well the heater is maintained and if the wood burned in the unit meets the wood moisture requirements speciﬁed in the owner’s manual. With proper operation, proper maintenance and proper wood quality your new furnace will last a long time. Be sure to understand and follow the operational and maintenance instructions included in the owner’s manual.

Polar Furnace Mfg. Inc. (The Company) warrants the water jacket and ﬁre chamber of the heater identiﬁed herein to be free from leaks during normal use for a period of 4 (four) years from the date of original purchase to the original purchaser of this heater. From year 1 (one) through year 4 (four) The Company will cover the cost of repairing any leaks in the ﬁre chamber and water jacket onsite or at our factories including materials, parts, travel, shipping and labor.

Electric and electronic components as well as high temperature refractory and the heater housing are limited to a 12 month 100% replacement warranty including parts, shipping, travel and labor. Only the manufacturer at the address on this certiﬁcate will determine, in its sole and absolute discretion, all warranty issues. Any repair work claimed under warranty must be approved in writing by The Company prior to any repairs being started.

If repair is not feasible for any reason as judged by The Company, our obligations under this warranty are limited to providing a replacement heater per the following schedule. For the 15 year warranty period the following prorated replacement charge will apply.

Schedule of Charges for Replacement of the Complete Heater.

From 1 through 2 years Company’s then current list price less 100% From 3 through 4 years Company’s then current list price less 100% From 5 through 6 years Company’s then current list price less 60% From 7 through 10 years Company’s then current list price less 25% From 11 through to 15 years Company’s then current list price less 10%

All replacement heaters are FOB our factory unless otherwise speciﬁed in this warranty. The warranty period on any replacement heater is from the date of the sale of the original heater.

General Conditions of this Warranty.

The warranty registration form, delivery checklist, and customer acceptance must be completely ﬁlled in and signed by the customer and dealer and submitted to The Company for this warranty to be valid. The warranty contained herein shall be voided if the heater is not installed, operated and maintained as instructed in the owner manual. Using wood that does not meet the wood moisture requirements detailed in the owner’s manual voids this warranty. The heater must never be pressurized; pressurizing the heater voids this warranty. The boiler protection valve must be maintained as described in the owner’s manual and failure to properly maintain the boiler protection valve voids this warranty. A properly qualiﬁed tradesperson/s should supervise or perform all installations. If the chimney needs be extended an appropriately certiﬁed and approved insulated chimney system must be used. The insulated chimney is not covered under this warranty. This warranty is void if the chimney

installation does not meet all of the installation requirements detailed in the owner’s manual. Your dealer may charge you for a service call to do warranty work. Parts will be replaced on an even exchange basis. Polar Furnace heaters are not intended to be the only source of heat. A backup system should be in place to prevent resultant damage due to a lack of heat. This warranty is limited to defective parts repair and/or replacement only and excludes any incidental and consequential damages. Door seals, door insulation, light bulbs, ﬁre tending tools, heat shields, Strong Wall liner, hearth plates and any other wear items are not covered under this warranty. High temperature refractory materials are warranted for 1 year under this warranty. In use, small cracks can occur in high temperature refractory and will not affect the performance of the heater. Damage caused by abuse, accidents, improper use, improper installation, excess creosote buildup, overheating, freezing, corrosion, negligence, accidents in transit, and pressurization are not covered under this warranty. Damage resulting from modiﬁcations or alterations will not be covered under this warranty. If the serial number on the equipment is defaced, altered or removed this warranty is void. Damage caused by burning ﬂammable materials (such as petroleum products) or any other material besides properly prepared wood will void this warranty. Only nontoxic antifreeze that meets and/or is approved per all applicable regulations and standards may be used. The Company will not be responsible for any environmental damages or charges resulting from use of toxic and or unapproved types of antifreeze. Antifreeze will breakdown over a period of time and therefore should be tested annually to ensure adequate freeze protection. Always dispose of antifreeze per federal, state, provincial, local or any applicable laws and regulations. Loss of antifreeze under any situation and condition is not covered under this warranty. The Company is not responsible for replacement of water, water treatment, antifreeze, removal, disposal, costs of transportation, or shipping charges unless otherwise speciﬁed in this warranty. Warranty does not cover any plumbing components, boiler piping, valves, controls or any other component or system external to the boiler package. WARNING, The Company will not warranty the inside of the ﬁre box due to ash corrosion. Rotation of ashes and/or removal of ashes from the ﬁre chamber must be performed as per the operator manual instructions. WARNING, The Company will not warranty the water jacket due to corrosion from corrosive or improperly treated water. An appropriate water treatment must be added and maintained and receipt retained for proof of use to establish any warranty claims. We will not be liable to any contingency beyond our control including war, strikes, ﬂoods, government restrictions or short supply of material. We will not be liable for any labor cost, except above schedule. This warranty replaces and supersedes any and all other warranties, expressed or implied, directly and or indirectly whether at law, common law, equity and/or statute and constitutes the only warranty of The Company and the only liability of The Company. This warranty constitutes the entire agreement between the parties with respect to the subject matter and supersedes all prior agreements, negotiations, discussions, undertakings, representations, warranties and understandings, whether written or verbal. This Warranty is governed by, and is to be construed and interpreted in accordance with the laws of Manitoba and the federal laws of Canada applicable in Manitoba. The purchaser and The Company each irrevocably agree to submit to the jurisdiction of the courts of Manitoba. The Company’s limitation of liability pursuant to any warranty shall be equivalent in all respects to the sum of $1.00.

Polar Furnace Mfg. Inc.

Box 159. Sperling, Manitoba. R0G 2M0

PH: 1-204-626-3485 FAX: 1-204-626-3326

NOTICE: To activate this warranty, the white copy of the warranty activation form (page 5) as well as a copy of the original bill of sale (invoice) must be mailed to the Polar Furnace address above within thirty (30) days of furnace delivery to end user.

Owner’s manual for Polar Furnace models: G-2 & G-3

POLAR FURNACE MFG. INC.

WARRANTY (v.15-1) ACTIVATION1 FORM—DOWN DRAFT HEATER

WARRANTY REGISTRATION FORM

Customer’s Name:____________________________ Dealership Name: ___________________________

Address:____________________________________ Address: __________________________________

City, State/Prov. Code:_________________________ City, State/Prov. Code:_______________________

Phone: (____)________________________________

Serial No.___________________________________ Date of Purchase: ____________/_______/_______

DELIVERY CHECKLIST

_____ Review owner’s manual.

_____ Identify safety hazards & demonstrate proper

operation.

_____ Review warranty and service requirements.

_____ Explain requirement that properly seasoned wood

_____ Explain required maintenance schedule.

_____ Review and explain Boiler Protection Valve

Maintenance (Manual Section 14.4)

must be used. (review manual section 8.2)

_____ No warranties are validated unless this form and

registration are completed and returned.

CUSTOMER ACCEPTANCE

I have inspected the Polar Furnace heater with the customer and reviewed all items on the delivery checklist. I have thoroughly instructed the customer on the equipment identiﬁed herein and thoroughly reviewed the operator’s manual. The customer has accepted responsibility for the operation and maintenance of the product identiﬁed herein.

Date: ________________________________ Dealer’s Rep. Signature: ___________________________

The dealer rep. and I have inspected my new Polar Furnace heater and reviewed all items on the delivery checklist. The dealer rep. has reviewed the operator’s manual with me and has thoroughly instructed me on the equipment herein. I assume full responsibility for the operation and maintenance of the product identiﬁed herein.

Date: ________________________________ Owner’s Signature: ______________________________

A nominal fee may be charged for service calls. All sales are ﬁnal. Heater approved for use with well-seasoned wood only. Suitability of use is the customer’s decision. The customer is responsible for ensuring conformance to local bylaws and regulations. A backup heating system is strongly recommended.

White—Polar Furnace copy Yellow—Dealer copy Pink—Customer copy

To activate this warranty, the white copy of this warranty registration form as well as a copy of the original bill of sale (invoice) must be mailed to

Polar Furnace Mfg. Inc., Box 159, Sperling MB, R0G 2M0 within 30 days of delivery of furnace to end user.

Table of Contents

A. Warranty Details 3

B. Warranty Activation Form 5

C. Table of Contents 7

1. Introduction 8

2. Warnings & Cautions 9

3. Responsible Ownership 11

4. Heater Components 12

5. Safety 13

6. Heater Setup 14

7. Heater Controls 21

8. Operating the Heater 24

9. Maintaining the Heater 30

10. Water Testing & Treatment 36

11. Heater Model Speciﬁcations 37

12. Electrical Diagrams 38

13. G-Class Parts 39

14. Plumbing 45

For service and support on your Polar Furnace contact your local dealer

Introduction

The Polar Furnace G-Class Heaters are wood-ﬁred, downdraft, hydronic heaters. The downdraft burning design allows for controlled combustion of wood which results in far lower smoke and particulate emissions and higher efﬁciency when compared to other designs.

1.1 !! NOTICE !!

The Warranty Activation form is located on page 5. This form must be thoroughly completed and the white copy returned to Polar Furnace Mfg. Inc. to ensure product support and warranty activation.

G-Class heaters are tested and approved by CSA

INTERNATIONAL to

CSA/CSA-366.1-M91 and UL2523

G-Class heaters are tested to EPA test Method 28

WHH and are EPA Phase II qualiﬁed.

1.2 Product Feature Variation

Our commitment is to provide you with the best possible wood burning technology. As part of this commitment, we make improvements to our products on a regular basis as we strive to make them even better. Although a concerted effort is made to keep this manual as up-to-date regarding any changes to our products, there may be noticeable differences. If clariﬁcation of any part of this manual is needed, don’t hesitate to contact your local Polar Furnace dealer or contact Polar Furnace directly.

1.3 Save These Instructions!

Keep this manual for as long as you own the Polar Furnace heater. Read and understand these instructions before installing or operating this heater.

Owner’s manual for Polar Furnace models: G-2 & G-3

Warnings & Cautions

2.1 !!WARNING!!

A person operating a hydronic heater must comply with all applicable laws or other requirements such as state or provincial laws or regulations and local ordinances.

The manufacturer does not recommend burning treated or contaminated wood (i.e. railroad ties or pressure treated lumber).

2.2 !!WARNING!!

All installations and operations must follow the applicable federal, provincial, state, and local codes for wiring, plumbing, chimney installation, chimney extension (if required) and ﬁring of this unit. When the relevant local codes differ from this manual, the local codes take precedence.

2.3 !!WARNING!!

Strictly maintain the following clearances around the heater to any combustibles including fuel storage. Front—24”, Right—6”, Left—1”, Rear—6”, Top—2”, Flue—6”.

2.4 !!WARNING!!

This heater is designed to burn natural wood only. Higher efﬁciencies and lower emissions generally result when burning air-dried seasoned hardwoods as compared to softwoods or to green or freshly cut hardwoods. DO NOT BURN: unclean wood, unseasoned wood, garbage, tires, lawn clippings, leaves, brush trimmings or general yard waste, materials containing asbestos, materials containing lead, mercury or other heavy toxic metals, materials containing plastic, waste petroleum products, paints and paint thinners, asphalt products, chemicals, coal, glossy or colored paper, construction and demolition debris, plywood, particleboard, salt water driftwood and other salt water saturated materials, manure, or animal carcasses. Burning these materials may lead to the release of toxic fumes or render the heater ineffective and cause smoke. Burning these materials can cause irreparable damage to your heater which is not covered under warranty.

2.5 !!WARNING!!

Burn wood only! Dry seasoned wood is preferable.

2.6 !!WARNING!!

All Polar Furnace heaters operate at atmospheric pressure. DO NOT, in any way, obstruct, block or plug the overﬂow/ﬁll pipe located on top of the heater. DO NOT install a pressure relief valve. This boiler should not be connected to an existing heating system unless a water to water or water to air heat exchanger is used.

2.7 !!WARNING!!

Use of a rain cap with an approved spark arrestor is required.

2.8 !!WARNING!!

Most Polar Furnace heaters are installed outdoors. All ﬁre clearances on page 15 should be observed. Always keep area around and in front of ﬁre door cleared from combustible materials. DO NOT store fuel within clearances listed on label.

2.9 !!WARNING!!

Polar Furnace heaters are CSA certiﬁed for outdoors and indoors. When used indoors, special care must be taken to ensure the installation conforms to local installation requirements. Plan for makeup air, ventilation of smoke when opening door, chimney clearances and heights, and clearances from combustibles. Consult local professionals. Field installations must satisfy CSA CAN/CSA-B365 installation code for solid fuel burning appliances as well as any other applicable standards or regulations. If extended chimney height is needed, use an insulated chimney system.

2.10 !!WARNING!!

Installation should be completed by appropriately qualiﬁed personnel.

For service and support on your Polar Furnace contact your local dealer

SECTION 2: WARNINGS & CAUTIONS

2.11 !!WARNING!!

Never let small children play near or tamper with the heater. Only responsible adults should operate the heater. Outer surfaces may be hot during operation. Ensure children do not touch heater.

2.12 !!WARNING!!

Always open the load door slowly while standing well back and behind the door. Open the outer door and wait one minute before opening inner doors. Do not look directly into the ﬁre chamber until at least 60 seconds after opening the load door. Failure to do so may result in serious injury from ﬂashbacks.

2.13 !!WARNING!!

Keep fuel door tightly closed during operation.

2.14 !!WARNING!!

In case of a runaway ﬁre, disconnect the heater from the electrical supply and ensure all doors are closed. Check to ensure the air supply gates are not stuck open. Check aquastat settings. Add water to ensure that the heater is not low on water.

2.16 !!WARNING!!

Be concerned about ground water and insulate the distribution pipes to avoid excessive wood consumption.

2.17 !!WARNING!!

The secondary combustion chamber, heat exchanger and areas above and below the heat exchanger should be cleaned regularly to remove accumulated creosote and ash.

2.18 !!WARNING!!

Cleaning the ﬁrebox, ﬂue pipes, chimney, heat exchanger and fan is especially important at the end of the heating season to minimize corrosion. All accumulated ash MUST be removed.

2.19 !!WARNING!!

Care should be taken to avoid potential smoke problems. Downdraft heaters can smoke if not operated as per recommendations or without properly prepared wood. Be a responsible neighbor and use properly seasoned ﬁrewood. Use a chimney extension if required.

2.15 !!WARNING!!

DO NOT operate heater unless the water level gauge shows that the water jacket is in the “Full” range.

2.20 !!Alert: Monitoring Smoke and Carbon Monoxide!!

During the combustion process, the presence of smoke is a strong indicator that the fuel is not being consumed efﬁciently. Smoke is created when the combustion air supply to the fuel load is inadequate to burn all the gases and particulate being released as the wood is consumed. This is why it is important to establish the correct draft with the furnace/chimney system. One of the byproducts of poor combustion is carbon monoxide, a colourless, odourless, and tasteless gas that is toxic when inhaled and which can be fatal depending on concentration levels and exposure time. Note that although carbon monoxide is produced during poor combustion that might also create smoke (as described above), high levels of carbon monoxide may be produced in the absence of smoke. For example, this could take place when a wood ﬁre has been reduced to the coal state and the draft starts to reduce as less heat is available to keep the chimney warm. Some level of carbon monoxide is being generated in all stages of the combustion process regardless of the fuel.

Continued on next page....

Owner’s manual for Polar Furnace models: G-2 & G-3

Several precautions must be taken to minimize the risk of carbon monoxide poisoning especially when the G-Class is installed in a building:

• First, run the furnace in the most efﬁcient manner possible to reduce the production of carbon monoxide. Use well seasoned, dry wood and establish the correct operating draft as laid out in these operating instructions to help limit CO emissions.

• Second, Building Pressure—if the combustion air for an appliance (i.e., the wood furnace) comes from within the same building in which the appliance is located, there will be a tendency for the internal building pressure to become negative. Adequate mechanical ventilation must be supplied to the building to neutralize the building pressure, otherwise there is a risk of reversing the ﬂow of exhaust ﬂue products back into the building. These ﬂue products may not only come from the wood furnace but also from other combustion appliances in the building.

• Thirdly, Smoke Alarms and Carbon Monoxide Detectors—Smoke alarms and carbon monoxide detectors are not only important tools for protecting the inhabitants of a building, but they are mandated in many jurisdictions. Although these items should be located on every level of a building there are two locations that are of prime importance. The ﬁrst is in the sleeping areas of the building, and the second is in the location where the combustion process is taking place. Check with local codes for details on alarm/detector requirements. Carefully follow installation instructions included with the purchase of your Smoke Alarm and Carbon Monoxide Detector(s).

Responsible Ownership

3.1 Safety First!

• Be safety conscious.

• Clear ground around heater.

• Use non-combustible cement blocks, patio blocks or cement base under heater.

• Install the rain cap on the chimney. Use an approved spark arrestor.

• Use a good quality pipe for hot water distribution.

• ALWAYS HIRE APPROPRIATELY QUALIFIED INSTALLERS!

3.2 Minimize Smoke Emissions. Burn Wisely.

• Be considerate of your neighbours when operating your furnace. If you use your furnace in the summer months, ensure that your chimney exhaust is not adversely affecting any neighbours with open windows.

• Consider prevailing wind direction when choosing a site location for the heater.

• Water can be piped a long distance with minimal heat loss. This is a good option to avoid smoke related problems.

• Don’t burn garbage. Burn only well-seasoned ﬁrewood.

Heater Components

Diagram 4.1–Heater Components

Item # Description

1 Heat Exchanger Access Cover

2 Chimney Hookup

3 Waterjacket Temperature Gauge (On some models, check inside Main Outer Door)

4 Furnace ON/OFF Switch, Work Light ON/OFF Switch

5 Water Level Sight Gauge

6 Heat Exchanger Cleaning Actuator Lever (Easy Sweep)

7 Heat Exchanger Bottom Cleanout

8 Rear Bottom Access Panel—Plumbing Hookup, Air Damper Setting

9 Work Light (inside outer door)

10 Rear Top Access Panel—Suction Fan Access, Electrical Access

11 Overﬂow/Fill Pipe

12 Lifting Hook

13 Main Outer Door

14 Loading Door

15 Ignition Door

16 Front Bottom Cleanout Door

Owner’s manual for Polar Furnace models: G-2 & G-3

5.1 !! WARNING !!

Maintain minimum distances between heater and combustibles. (Refer to section 6.6)

5.2 !! WARNING!!

Develop and implement a clearly formulated plan of what to do in the event of a chimney ﬁre.

5.3 !! WARNING!!

Keep area around heater clear of combustibles.

5.4 Flashbacks

5.4.1 !! CAUTION !!

ALWAYS KEEP BODY AND FACE WELL AWAY FROM LOAD DOOR, ACCESS DOORS AND CLEANOUT DOORS WHILE OPENING THEM. FAILURE TO DO SO CAN RESULT IN SERIOUS BODILY INJURY FROM FLASHBACKS.

When opening any access panels on the heater there is danger of ﬂashbacks. It is important to understand what causes ﬂashbacks before operating the heater. Read the following explanations carefully and be sure to understand what ﬂashbacks are before attempting to operate the heater.

Safety

5.5 The Combustion Fans Have Just Shut Off

Once the heater reaches the point where the water temperature is high enough, the controller shuts off the combustion fans. When the fans stop blowing, actuators also close off the air supply openings. This stops any new air and oxygen from getting into the ﬁre chamber. At this point the ﬁre chamber is still extremely hot. The heat in the ﬁre chamber continues to bake the wood which continues to break down into combustible smoke and gases. Without oxygen, these combustible, hot gases do not burn off but accumulate in the ﬁre chamber. When a door is opened, fresh air and oxygen mix with the hot combustible gases which then ignite and explode. Always keep face and body

well away when opening the load door, ignition door, bottom and side cleanout doors.

5.6 Hot Surfaces

Some surfaces on the boiler get hot. Always wear protective leather gloves when working on or around the heater, when loading the heater or when performing maintenance on the heater.

5.4.2 Cause of Flashbacks

The root cause of ﬂashbacks is the accumulation of oxygen-starved hot gases inside the ﬁre chamber. These gases cannot combust without oxygen. Opening the load door allows fresh air and oxygen to mix with the hot gases causing them to ignite and explode.

5.4.3 Conditions Causing Flashbacks

There are some combustion conditions that greatly increase the risk of ﬂashbacks. It is important to understand these conditions. It is important to note

that ﬂashbacks can occur whenever any of the front heater doors are opened and are not limited to the conditions described below.

5.7 Smoke Inhalation / Eye Irritation

Burning wood produces smoke. Avoid inhaling smoke. Whenever there is smoke, wait until it has cleared before proceeding to load the heater or performing maintenance work.

5.8 !! DANGER !!

NEVER PRESSURIZE THIS HEATER! NEVER block or obstruct the overﬂow/vent pipe located on the roof of the heater (item #11 on page 12). Pressurizing this heater could result in very serious injury and damage to the heater and property!!

Heater Setup

6.1 !! NOTICE !!

All installation work must be completed by appropriately qualiﬁed personnel and must conform to all applicable standards, regulations and local codes (e.g. CAN/CSA-B365 Installation Code for Solid Fuel Burning Appliances).

6.2 Heater Delivery

Wash the heater immediately following delivery to remove salt and dirt from shipping. Inspect the heater for shipping damage. If damaged, make note of it on carrier shipping paperwork.

6.3 Unpacking

Several items are shipped with each furnace. These components are located inside the main ﬁre chamber and the rear bottom access panel. They include:

• Owner’s Manual.

• Distribution pipe ﬁnishing duct (diagram 14.2 of manual).

• Anti-Condensation Valve (diagram 14.5 of the manual).

• Stack Temperature Gauge (diagram 6.1 of the manual).

6.4 Indoor Installation

Polar Furnaces are CSA & UL certiﬁed for both indoor and outdoor installation. However, care must be taken whenever a heater is near or inside a building. When installed indoors, proper air supply is required for combustion and ventilation. Continuous air supply is mandatory. Installation must conform to all applicable codes and standards. Consult a heating professional.

• Ash shovel (diagram 8.5 of manual).

• Small ash tool (diagram 8.5 of manual).

• Small ash scoop (diagram 8.5 of manual).

• Poker (diagram 8.5 of manual)

• Flue brush (handle and brush may ship separated from each other and may need to be assembled) (diagram 8.5 of manual).

• Initial boiler treatment kit.

• Anti-evaporation cap (diagram 6.2 of manual).

• Insulated chimney pipe extension (total of at least 2’ of extension. Either 1pc x 2’ or 2pcs x 1’).

• Chimney rain cap.

6.5 Electrical Requirements

Electrical Rating: 120V AC, 6 amps, 60Hz. Installation must meet federal, provincial and local codes and must be completed by qualiﬁed personnel only. Wire must be rated and approved for direct burial if is to be included in the same trench as the water lines. Heater power connection box is located inside the rear access panel. Minimum supply conductor ampacity is 15 amps. Maximum over current device is

15 amps. Use copper conductors only.

6.6 Heater Fire Clearances

All G-Class Heaters are CSA and UL approved to the following ﬁre clearances. No combustibles should be stored within these measurements. Front 24” Back 6” Left Side 1” Right Side 6” Top 2” Chimney 6”

Owner’s manual for Polar Furnace models: G-2 & G-3

SECTION 6: HEATER SETUP

Consult with your insurance company to ensure that the boiler to building clearances are acceptable. Failure to do so may void insurance. The manufacturer assumes no liability in the event of damages to personnel or buildings.

6.7 Chimney Requirements

The chimney is a very important component in the successful operation of the G-Class heater. A good chimney provides a continuous, dependable draft to ensure proper operation of the heater. If your furnace is installed indoors, a continuous draft is especially important to pull the exhaust gases out of the building. The entire chimney exhaust system must be designed to prevent possible soot build up, insufﬁcient draft, and condensation. Chimneys are very prone to draft and creosote related problems when they have diameters that are too large, are insufﬁciently insulated, or when they have dents and bends. Incorrect chimney installation will void the warranty.

The heater must be connected to a factory-built chimney that must be designed for solid fuel appliances, must be 6” in diameter, and must be UL103 or ULC-S629 listed. Chimneys that do not meet these requirements MUST NOT be used for any part of the chimney system. Never use black stove pipe or uninsulated double wall chimney pipe for any part of the chimney system. The chimney connection on the G-Class heater will work best with the Security Chimney ASHT+ 6” chimney system. Other chimney systems can be used, but strictly follow the chimney installation instructions for making a connection. If a short piece of stove pipe is used to make the connection, the stove pipe must be as short as possible and must be insulated using suitable blanket insulation. A dripless adaptor must be used at the connection between the boiler and the factory-built chimney. The top of the chimney must be at least 3 feet above the top of the roof penetration level and at least 2 feet above any portion of the roof within a 10 foot diameter measured horizontally.

Always follow the chimney manufacturer’s installation instructions when installing and supporting a chimney. All chimneys and connections must conform to

all applicable standards and local codes. No other appliance should be connected to the chimney unless allowed by the local code authority. Consult your local inspector for chimney requirements and install the heater in accordance with all applicable codes.

6.7.1 Chimney Draft

When measuring draft, ensure that there is a ﬁre in the ﬁre chamber, the fan has been on for at least 10 minutes and the water temperature in the boiler is above 160˚F. This ensures the chimney is at proper operating temperature. Breech draft is the draft near the connection point to the furnace and should be measured within 6” from the top roof panel of the heater. Minimum breech draft is .02” water column. Maximum breech draft is .14” water column. Strong winds blowing across the top of a chimney (especially a chimney which has a strong natural draft) can cause the G-Class heater to continue ﬁring when the fan has switched off. This can cause the furnace to overheat. If there is excessively high draft or an irregular draft, a draft regulator must be used.

6.7.2 Draft Regulator

Whenever the breech draft exceeds .12” water column, a draft regulator must be installed. The diameter of the draft regulator used must be equal to or larger than that of the chimney connector and should be installed as close as possible to the boiler. If one draft regulator is not sufﬁcient to bring the draft below .10” water column, a second draft regulator may be required. After installing a draft regulator, the draft must always be measured on the boiler side of the draft regulator. The draft regulator adjustment should be made with a vacuum gauge if possible. If the damper is adjusted during warm weather, an adjustment may be required during cold weather.

6.7.3 Off Cycle Draft

A slight but measurable draft during the off cycle is required. The draft must persist for at least 30 minutes after the fan has switched off. A draft during the off cycle moves a very small amount of fresh air through the heater which evacuates moisture laden air from

SECTION 6: HEATER SETUP

the primary ﬁre chamber. In some conditions a reverse draft or back draft may occur during the off cycle. This may be the case if the boiler is installed near a very tall building or near a high hill or if the chimney is improperly installed and/or terminates on the side of a building. A back draft must be remedied and stopped. If a back draft is suspected or detected, consult with your dealer or local HVAC professional to determine a possible solution. Lack of a draft and/or back drafting during the off cycle is one possible cause of water condensating and accumulating inside the primary air delivery channels during the off cycle.

Diagram 6.1–Stack

Temperature Gauge

6.8 Stack Temperature

Stack temperature is an important factor in the proper functioning of a chimney. e chimney’s maximum stack temperature must never exceed 400˚F. If the chimney temperature exceeds 400˚F, consult with your local dealer or with the factory on how to decrease the maximum stack temperature. e stack temperature must always increase to over 275˚F during every burn cycle. If the stack temperature fails to exceed 275˚F during each burn cycle, consult with your local dealer or with the factory to increase the stack temperature.

6.8.1 Stack Temperature Gauge

A stack temperature gauge is shipped with each G-Class furnace. This gauge must be installed in the chimney within 4” from the point at which the chimney penetrates the rear roof panel. The gauge is installed by sliding it into a small hole drilled through the chimney wall. The stack temperature gauge has a red temperature indicator which shows the maximum temperature measured since the last time the max temperature dial was turned counterclockwise until it contacted the black current temperature indicator.

Notice: Always turn the hand knob very carefully. Only turn the hand knob counterclockwise until the red maximum temperature indicator gently touches the black current temperature indicator.

Additionally, if there are any known issues with the water supply we strongly recommend testing the water to verify that the boiler treatment we supply will provide adequate treatment. Such known issues include:

• high chloride levels (salty taste).

• high iron levels (metallic taste, looks reddish).

• a lot of scaling in the toilet, on shower heat, or in your teapot.

• needing to replace your domestic hot water heater every 2 or 3 years.

• have corrosion on your water taps.

6.9 Water Quality & Treatment

Ensure the water that will be used to ﬁll the water jacket meets at least the following minimum criteria:

• does not have an odor

• is not discolored

• does not discolor after sitting in a container for a number of days.

Owner’s manual for Polar Furnace models: G-2 & G-3

Wood Boiler Solutions (phone: 920-324-2007) are water treatment professionals and they offer water testing service for a reasonable fee. Simply browse to their website (woodboilersolutions.com) and order a water testing service kit to initiate this service. Wood Boiler Solutions will test your water and make a determination if your water supply is suitable for use or not.

SECTION 6: HEATER SETUP

Once the water source is determined to be suitable, begin ﬁlling the water jacket. After adding water for about 5 minutes add the water treatment supplied with your heater. Add the treatment by pouring it into the overﬂow/ﬁll pipe (diagram 4.1, item #11). Refer to section 10 for more information regarding the water treatment kit supplied with your heater.

6.10 Filling the Water Jacket

6.10.1 !! WARNING !!

Do NOT start a ﬁre in the heater before ﬁlling the heater water jacket with water. Starting a ﬁre in the heater without ﬁrst ﬁlling the water jacket can damage or destroy the heater.

6.10.2 !! DANGER!!

Do NOT pressurize this heater since it is designed with an open system type water jacket. Pressurizing the heater could result in damage to the heater, damage to property, and could cause severe bodily injury and even death.

6.11 Using the Water Level Sight Tube

The water level sight tube is located on the side of the heater. To check the water level in the heater turn the valve handle into the vertical position. The sight tube will ﬁll with water showing the level of the water in the water jacket. If the level is in the red, “ADD” zone, add water until the level reaches the green, “FULL” zone. After using the water level sight tube, always turn the handle back into the horizontal position to drain water from the sight tube. Output Settings (V.2)

6.12 Anti-Evaporation Fill Pipe Cap

An anti-evaporation cap ships with each heater (diagram 6.2-Anti-Evaporation Cap). This cap reduces the amount of evaporant escaping the water jacket and helps maintain the water level over long periods of time. The cap is installed into the overﬂow/ ﬁll pipe. To install, slide the stem into the overﬂow pipe. To locate the overﬂow/ﬁll pipe, refer to diagram

4.1, item #11.

6.10.3 !! WARNING !!

This heater is a hydronic heater. This means that it operates by heating water that is inside its water jacket. This water jacket must be ﬁlled with water or a water/ glycol mixture before operating the heater. Filling the water jacket can be achieved by adding water through the overﬂow pipe on top of the heater or by hooking the water supply hose to the drain/ﬁll valve located inside the rear access panel. Alternately, the water jacket can be ﬁlled by adding water into any part of the hot water distribution piping. Fill the heater until the water level is in the green “FULL” zone (See Section 6.11).

Note: Check the water level daily during the ﬁrst few weeks after the heater is installed and used.

Diagram 6.2–Anti-

Evaporation Cap

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Polar Furnace G2-PLUS, G2, G3 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual