Heatmaster G Series User manual
UL 2523-2018
CAN/CSA B366.1-2011
Version 10
OPERATION AND
MAINTENANCE
MANUAL
EPA CERTIFIED WOOD
BURNING FURNACES
G
32 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
CONTENTS
WARRANTY AND SAFETY
Lifetime Limited Warranty .................................................................................................................x
Water Treatment And Testing ...........................................................................................................x
Water Treatment Policy .....................................................................................................................x
Recommended Operating Levels......................................................................................................x
Test Parameters and What They Mean ............................................................................................x
Safety Precautions.............................................................................................................................x
FURNACE INSTALLATION GUIDE
Furnace Specications Charts ..........................................................................................................x
Location..............................................................................................................................................x
Clearance To Combustibles ..............................................................................................................x
Furnace Foundation...........................................................................................................................x
Unit Foot Prints ..................................................................................................................................x
Trench .................................................................................................................................................x
Indoor Installation..............................................................................................................................x
Chimney Installation ..........................................................................................................................x
Combustion Air ..................................................................................................................................x
Wiring And Hydronic Lines ................................................................................................................x
Domestic Hot Water...........................................................................................................................x
OPERATING THE FURNACE
Furnace Components ........................................................................................................................x
Filling The Furnace With Water .........................................................................................................x
Firing The Furnace .............................................................................................................................x
Wood Quality ......................................................................................................................................x
Loading The Furnace (Smokeless Loading).....................................................................................x
Operating A Gasication Furnace Requirements.............................................................................x
Controls And Safety Devices.............................................................................................................x
How The G Series Gasication Outdoor Furnace Works.................................................................x
CARE AND MAINTENANCE
Care And Maintenance ......................................................................................................................x
Cleaning Your Furnace.......................................................................................................................x
Troubleshooting .................................................................................................................................x
Electrical Troubleshooting.................................................................................................................x
G Series Electrical Schematic ...........................................................................................................x
Editing Control Settings.....................................................................................................................x
Combustion Tuning Basics ...............................................................................................................x
Home Network Connection...............................................................................................................x
Hardwired Connection.......................................................................................................................x
Finding An IP Address For Your Furnace..........................................................................................x
Addressing Your Furnace ..................................................................................................................x
Viewing Your Furnace In A Web Browser .........................................................................................x
RETAIN THIS MANUAL
FOR FUTURE REFERENCE
DO NOT THROW AWAY
CANADA
HeatMaster Furnaces Inc.
Box 158
Winkler, MB R6W 4A4
Canada
Phone: (204) 325-9792
Fax (204) 325-9803
USA
HeatMaster Furnaces Inc.
Box 373
Walhalla ND, 58282
USA
Phone: (877) 325-9792
Fax (204) 325-9803
www.heatmasterss.com
F21-685
LIFETIME LIMITED WARRANTY
HeatMaster Furnaces 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.
• Firebox door has a warranty of 5 years at 100%.
In addition, all steel including housing, legs, etc. have a pro-
rated warranty for a period of 10 years with coverage reducing
by 10% per year. Any parts not manufactured by HeatMaster
Furnaces Inc. that are used on the furnace - such as controls,
limit switches, heat exchangers - carry their own manufacturer’s
warranty. HeatMaster Furnaces 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, HeatMaster Furnaces 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. HeatMaster Furnaces
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 HeatMaster Furnaces Inc. representative.
HeatMaster Furnaces 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.
HeatMaster Furnaces 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. HeatMaster Furnaces 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 HeatMaster Furnaces 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 the HeatMaster Furnaces Inc. oce.
The warranty can be voided by operating the furnace in a manner
inconsistent with the owner’s manual. HeatMaster Furnaces
Inc. reserves the right to change conditions or warranty at any
time.
54 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
WATER TREATMENT AND TESTING
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 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 HeatMaster Furnaces Inc.
• You will receive a water test report outlining what must be
done (if anything). A week after making the recommended
changes to your water, send in another sample to verify the
uid has adequate protection.
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. Additional treatment may
have to be added for water with more severe properties or for
systems with more chemically demanding requirements.
WATER TREATMENT POLICY
Conductivity: 100 - 4000 ppm
pH: 8.5 - 10.5
Nitrites: 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.
Nitrites - Nitrites tested for are a measurement of how much
water treatment is in the water. Nitrites measured are active units
of water treatment available to neutralize harmful elements in your
furnace water. Nitrites 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.
RECOMMENDED OPERATING LEVELS
SAFETY PRECAUTIONS
Read and understand all precautions before operating the
furnace. This furnace needs a periodic inspection for proper
operation. It is against federal regulations to operate this
furnace in a manner inconsistent with operating instructions
in this manual. Save these instructions. Retain this manual as
long as you own your G Series outdoor furnace. Carefully read
and follow these directions.
DANGER
Do not start the 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 operate it in
away that will comply with all applicable local and state
laws, and or other requirements.
• The person(s) operating this furnace is responsible to run
it in such a way so that it does not cause a public or private
nuisance.
• DO NOTOVER FIRETHIS 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 NOTobstruct,
block or plug the rooftop overow vent tube in any way.
• 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 back of the furnace
and slowly crack the door open for at least 20 seconds
before fully opening the door.
• DO NOT use chemicals or 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 this furnace without conrming
adequate heating uid level.
• 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 ue serving another appliance.
76 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
FURNACE INSTALLATION GUIDE
Installation should be performed by a qualied installer and must comply with all requirements of the agency having jurisdiction.
G4000
Heat Output Range
Furnace Size* (L” x W” x H”)
Furnace Weight
Firebox Size (D” x W” x H”)
Firebox Volume
Chimney Size
Water Capacity
8 Hr Average Eciency Using HHV
Annual Eciency Rating Using HHV
8 Hr Burn Rating
*height to top of lift hook
16,500 - 110,000 btu/hr
59 x 41 x 81
1448 lbs
23 x 22 x 29
8.5 ft3
6”
116 USG
92.9%
89.5%
68,025 btu/hr
G7000 G10000
42,000 - 300,000 btu/hr
81 x 50 x 84.5
2484 lbs
42 x 29 x 33.5
23.6 ft3
6”
274 USG
89.24%
88%
194,946 btu/hr
29,400 - 210,000 btu/hr
69 x 50 x 84.5
2035 lbs
29 x 29 x 33.5
16.3 ft3
6”
234 USG
86.9%
80.7%
129,866 btu/hr
U.S. ENVIRONMENTAL PROTECTION AGENCY Certied to comply with the 2020 particulate emission
standards. Annual Eciency rating is calculated using the weighted average test results from the
emission test reports for each model. Eciency is determined by dividing the total input using the
heating value of wood (8600BTU/lb) by the actual heat delivered by the furnace.
LOCATION
Where you install the furnace will have an effect on the eciency
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.
• 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.
Furnace Roof to Ceiling (Indoor Installations 6”
FURNACE FOUNDATION
• 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. Concrete
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 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.
Side Walls & Rear 6”
Front (Loading Door) 24”
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.
98 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
TRENCH
HeatMaster Furnaces Inc. recommends the trench to be 24” to
36” deep, and wide enough to install your water lines. If possible,
have a gradual slope in your trench to allow drainage away from
your lines and out the trench bottom.
Place a properly rated electrical supply cable at the bottom of
the trench and cover with 6 inches of dirt. Install burial rated
Cat5 or Cat6 cable or a conduit to allow networking to be set
up with the furnace.
Use an underground insulated pipe product like Rhinoex,
available from HeatMasterSS, for your best value and longest
lasting underground pipe.
NOTE: If you are installing your water lines under an area where
vehicles will cross, you should increase the depth of the trench
and use a schedule pipe over your lines to reduce the pressure
generated on the lines.
IMPORTANT: To reduce the risk of re, follow all local
codes and these installation instructions carefully. A re
may be caused by the following:
• Improper installation.
• 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 carbon monoxide
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.
INDOOR INSTALLATION
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
G4000 6”
G7000 6”
G10000 6”
This is a draft induced furnace but it is important that the
chimney has a good draft to further eliminate any smoke issues.
Note: Using a smaller chimney may cause smoke issues
and using larger chimney may negatively affect furnace
performance.
ATTENTION: Cleand of the heat exchanger, ue pipe,
chimney and draft inducer are especially important at the
end of the heating season to minimize corrosion during
the summer months caused by accumulated ash.
1110 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
CHIMNEY INSTALLATION
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. Any height
longer than 15 ft. must be approved by HeatmasterSS oce.
• 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.
Figure 1
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.
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.
10ft (3m) or less
Ridge
2ft (0.6m)
minimum 3ft (0.9m)
minimum
Chimney
10ft (3m)
More than 10ft (3m)
Ridge 2ft (0.6m)
minimum
Chimney
3ft (0.9m)
minimum
Height above
any roof surface
within 10ft (3m)
horizontally
1312 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
Re-Circulation Pump
Your G Series furnace comes factory equipped with a
recirculation pump, maximizing the heat storage in your furnace
and supplying even temperatures and ow throughout the tank.
ATTENTION: This pump should only be plugged in after
your furnace has been lled with your heating uid.
The pump should be plugged in and recirculation loop valves
open whenever the furnace is in use. Under no circumstances
should this pump or piping be used to service distribution
piping to buildings. The outlets provided for distribution should
be connected to separate pumps and piping properly sized for
their respective heat load requirements. The circulation pump
has three speeds and should be set according to the model of
the furnace.
G4000 - Speed #2
G7000 - Speed #3
G10000 - Speed #3
Underground Hydronic Lines
Rhinoex pipe by HeatMasterSS is your best value for long
lasting underground pipe with the most ecient insulation used
in insulated pipe resulting in minimal heat loss between your
furnace and building. Contact your local dealer to purchase.
Hydronic lines (hot water heating lines), whenever buried or
encased in cement should not be spliced. Take the necessary
steps to ensure they stay dry. This ensures that minimal heat
loss occurs. Supply and return piping should be sized according
to the ow and pressure drop required by each building. Piping
should have a minimum rating of 100 PSI at 180 F.
Hint: To easily identify supply and return lines, Rhinoex
Insulated pipe includes one pipe with a black stripe and one
pipe blank.
• 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 Page 33 for the furnace wiring diagrams.
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.
WIRING AND HYDRONIC LINES
Power Requirements
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.
Power Supply 120V 1PH 60HZ
Max Breaker 15 AMP
Running Load 2.5 Amps
Max Accessory Load 9.5 Amps
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, and an excessive amount of joints
and elbows, etc.
It’s important to design your system in a way, that allows the
water returning to your furnace to remain above 130°F.
It is also important to install air bleed valves at high points in
the system to avoid an air lock, especially if these points are
higher than the furnace. Airlocks can restrict system ow
limiting the BTU’s available to your building. This may also lead
to your furnace overheating and cause temperature swings in
the water feeding the house.
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 inline on the return
side of the existing pressurized boiler system.
Flat Plate Exchanger for
Pressurized Boiler Systems
Flat plate exchangers are used with pressurized systems such
as boilers. The 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 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 system
of both boilers shall be powered from a single branch
circuit without exceptions.
1514 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
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.
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).
Overhead fan coil installation example
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.
DOMESTIC HOT WATER
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.
Example of hookup for a forced air furnace and hot water.
1EZ Clean Handle
2Control Panel
3Smokeless Loading Handle
4Water Level Float
5Firebox Door
6Combustion Chamber
1
2
3
4
5
6
7Draft Inducer Fan
8Top Air Control Damper
9Recirculation Pump
10 Cold Water Return Inlets
11 Pump Plug in Main Power
Switch Lead in Power Box
12 Hot Water Supply Outlets
13 Bottom Air Control Damper
14 Furnace Drain Valve
7
8
9
14
13
12
10
11
1716 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
OPERATING THE FURNACE
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 wate 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 and 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 F,
(including your rst initial ring of the furnace), you will need
to activate the low-temperature bypass function. The silver
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.
WOOD QUALITY
This furnace is designed to burn natural wood only. Higher
eciencies 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.
DO NOT BURN:
• Garbage.
• Lawn clippings or yard waste.
• Materials containing rubber (including tires).
• Materials containing plastic.
• Waste petroleum products, paints or paint thinners
and asphalt products.
• Materials containing asbestos.
• Construction or demolition debris.
• Railroad ties or pressure-treated wood.
• Manure or animal remains.
• Salt-water driftwood or other previously salt water
saturated materials.
• Unseasoned materials.
• Paper products, cardboard, plywood or particleboard.
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.
Keep in mind the diameter of the wood you use. Using wood
that is no larger in diameter than 6” will give you a better, more
even burn. For anything over 6” diameter it may be best to split
the log. Smaller, split wood will season faster, burn better and
will be easier to load and stack into the rebox.
Using a Moisture Meter to Test Your Wood
You can use a moisture meter to test how wet your wood is.
Your G-Series furnace came with a moisture meter. Take a
piece of rewood, split it and check the moistur on a freshly
split surface. The moisture meter pins should be pressed into
the grains of the wood, parallel to the wood grains. Make sure
to 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
Typical Moisture Meter
1918 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
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 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:
• Push the Smokeless Loading Handle towards the back of
the furnace. This will open the smoke bypass so no smoke
or ame exits the rebox door when you open it.
• Crack the rebox door open to the safety catch for at least
15 seconds to allow smoke to exit the chimney and prevent
blow-back.
• Open the door slowly while standing behind the door.
• Use your ash rake to knock charred wood down and level
the coal bed.
Hint: If there is a minimal coal bed left, use the ash
rake to rake through the ash bed to stir up the hot coals
underneath the surface. Lay small pieces of wood on top
of the coals before loading larger pieces of wood.
• Make sure the air slot in the refractory brick is clear.
• Load wood carefully using the information and diagram on
page 17.
• Close the rebox door.
• Close the smoke bypass by pulling the Smokeless Loading
Handle over center all the way to the front of the furnace to
the closed position.
1
2
3
4
(1) Primary
(2) & (3) Secondary
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, 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. Neatly stack your wood side to
side, across the burn slot. This promotes good airow
throughout the wood pile and helps reduce bridging as the
wood burns. Reload your furnace before the wood falls
below the bottom of the door frame.Throwing wood into
the rebox in a disorganized manner causes bridging and
poor combustion.
3. Log Sizing: For ideal operation, log sizing should not
exceed 6” 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 6” should be split into smaller
size pieces for use in gasication furnaces.
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 ecient
burning of the wood and eventual furnace malfunction.
WARNING: Risk of Fire
• Do not operate with fuel loading or ash removal doors open.
• Do not store fuel or other combustible material within
marked installation clearance.
• Inspect and clean ues and chimney regularly.
• Remove ashes regularly.
CAUTION: Hot surfaces. Keep children away and do not
touch during operation.
EPA’s Burnwise Program
https://www.epa.gov/burnwise
How to Use a
Moisture Meter (Video)
https://youtu.be/jM2WGgRcnm0
Split, Stack, Cover,
and Store (Video)
https://youtu.be/yo1--Zrh11s
For more information on wood quality, follow these links:
2120 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
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.
The control on this furnace will self regulate, operating the air
controls regardless of the required burn rate.
Furnace Control
Your HeatMasterSS G Series furnace uses a factory
programmed control to maintain your water temperature by
using air damper controls and draft inducer fan. The control
is located around the corner to the left of the rebox door and
requires no user programming or changes. The control displays
the water temperature in your furnace, the air damper postions,
and any active alarms.
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.
Top/Bottom Air Dampers
The damper air percentage is the amount of air being drawn
through the furnace to fuel the re. This feature keeps your
furnace burning clean and hot while keeping your water
temperature in the preferred range. The dampers are located
in the rear cabinet and are mechanical parts that open or close
the air injection ports.
Draft Inducer
The draft inducer fan is located at the rear of the furnace on
the top and is used to draw air from the air dampers through
the furnace. The fan should be on whenever the furnace is in a
heating cycle or when the smoke bypass is open.
Smokeless Loading Handle
Use the Smokeless Loading Handle whenever the 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 pushed towards the rear 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.
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.
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 195 degrees F. If the high limit switch trips, it will have to
cool off to approximately 160 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).
The “Cold Start” button can also be used to manually start a heat cycle as long as the temperature is below the “Set Water Temp”
temperature. To start a manual heat cycle press and hold the “Cold Start” button for 3 seconds.
1
Furnace Control
2
Cold Start Button
3
Fan Breaker
4Furnace On/Off Switch
5Alarm LED Light
6Smokeless Loading Handle
1
2
3
4
6
5
2322 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
HOW THE G SERIES GASIFACATION OUTDOOR FURNACE WORKS
Heatmasterss is proud of its reputation for producing innovative
outdoor heating methods and our G Series outdoor furnaces are
continuing that trend. They operate more eciently 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 (>700˚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 is then drawn
through the base of the re along with any ash that would come with
iit and is burned at temperatures around 2000˚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 exhaust temperatures are 200-300˚F. The most notable
indicator of effective gasicatioon is the lack of smoke exiting
the chimney. However, often yoouo 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.
CARE AND MAINTENANCE
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 within the cut-in and cut-out settings
you have the control set to.
• Check for embers or ashes laying on the ground around
the furnace and dispose of them.
• Make sure all covers and guards are in place securely.
• Make sure the Smokeless Loading Handle is closed. The
handle should be angled towards the front of the furnace.
On a Weekly Basis:
WARNING: Always keep the rebox door open when
opening the lower combustion chamber door.
Using the service tools supplied, remove ash from the lower
combustion refractory tubes, side, and rear chambers. Dispose of
ashes in a metal container away from the stove and wood pile.
See Cleaning Tools on page 26.
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 get optimal performance.
• 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 furnace is not in use:
• 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
2524 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
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 4 for exact specications.
• If necessary adjust the hinges on each side of the doors to
maintain a good seal.
Other maintenance:
• All covers and guards must be in place at all times, except
for maintenance or service.
• Care for the exterior of your furnace is minimal.
• The user must wash and remove ash and creosote
regularly.
• Ashes should be placed in a metal container with a
tighttting lid. The closed container should be placed on
a noncombustible 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.
• HeatMasterSS carries a full line of parts for your furnace
including pumps, ttings and heat exchangers. For more
information on our parts, please contact your local
HeatMasterSS dealer.
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 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
CLEANING YOUR FURNACE
Tool #1
Has a round edge that is meant to be used to clean out the round
ports (A) in the refractory.
The straight edge can be used as a general scraping and cleaning
edge.
This tool is also good for your daily wood poking and re
management tool.
Tool #2
This tool is to be used to pull ash out from the area to the right of
the bottom refractory (B). This tool allows you to reach to the back
and behind the refractory to pull out ash.
Tool #3
This tool is meant to be used, to get a better handle on the
Refractory plug and thread out this plug.
WARNING. Threading out this plug should only be done
after the furnace has been allowed to cool down.
CLEANING TOOLS
A
B
Tool #1 Tool #2 Refractory Plug Tool #3
2726 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
TROUBLESHOOTING
If your furnace is showing signs of poor combustion such
as smoking while burning, little to no exhaust coming from
the chimney, longer than normal heating cycles, or there is
a general concern of functionality, use these step by step
instructions to assist in troubleshooting.
Is the control calling for heat? Status = Heating Cycle/Cold
Start Mode. See the Control Settings section of this manual.
Is the draft fan running in the rear cabinet? If not, consult
the Draft Fan troubleshooting section in this manual.
In the rear cabinet, inspect the top and bottom air dampers
to ensure they are opening and closing as indicated by the
control. If not, refer to the actuator troubleshooting section.
Use a light piece of paper (like receipt paper) and hold it up to the
openings in the damper plates. The paper should be drawn to
the openings. If it is not, there is an airow issue in the furnace.
Remove the top and bottom air box covers and inspect
for blockage. Use receipt paper to check for air ow in the
top and bottom air ducts. If there is not a visible blockage
but there is not adequate airow in the ducts inspect the
air channels within the rebox.
Make sure the ash bed is not so high as to block air holes
in the panels on the sides of the rebox.
Make sure the holes in the air channels are clear. If
necessary, remove, clean, and replace the air channels.
Inspect the burn slot in the rebox oor. Remove any
blockage that may be present.
Remove the burner plug, inspect right and left burn tubes. Clean
as necessary. Always replace the burner plug for operation.
TROUBLESHOOTING TO ENSURE PROPER BURNING & AIR FLOW
Inspect and clean the areas to the left and rear of the
refractory using the service tools provided with your furnace.
Remove the ue access cover and inspect that area for
possible blockage. If the area is sticky with creosote, inspect
the smoke by-pass plate for leakage and adjust as necessary.
Do the spirals in the heat exchange tubes have full
movement up and down? If not inspect the linkage for
damage. Flush the heat exchanger tubes with water to
loosen them if necessary.
Remove and inspect the draft fan. Clean the fan and
housing if there is creosote or other build up present.
Inspect the chimney for restrictions and clean if necessary.
More than likely, if there is a problem with the furnace burn
or air ow, you will nd it by checking these things.
The furnace is running but fails to bring the water
temperature up to setpoint:
Conrm good combustion by following the steps in the
previous section.
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. Check
fuel type. Poor quality fuel will not provide as many BTU’s
as high-quality fuel.
Check water level of the furnace.
Check to ensure all pumps in the system are running.
Is the piping between the furnace and buildings properly
insulated? Has the insulation become wet from groundwater
or a leaking pipe or tting? Wet insulation around the piping
will cause signicant heat loss to the ground.
Check the water temperature coming back to the furnace,
this temperature should be above 130° F. If this return
temperature is below 130° F there maybe a problem in
your building’s heat design.
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).
If everything is functional, call your dealer.
If the water temp on the control is hot (170-180° F or
higher) but the water temp in the supply line is cool:
Check to be sure the recirculation pump and the building
pumps are operating properly and that the valves in the
circulation loop are open to allow ow. The recirculation
piping should be hot from top to bottom.
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.
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:
Check to ensure all pumps in the system are running.
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. 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:
Close all air inlets and doors on the furnace.
Retrieve as much heat as possible from the system
by turning thermostats up and opening windows until
furnace cools down.
Check that all doors are closing properly and that door
gasket is completely sealing.
2928 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
Check that the damper plate is opening and closing
properly. It should be completely closed when the furnace
temperature is over 180° F.
Check water level.
Check to ensure all pumps in the system are running.
If there is a runaway or chimney re:
Make sure the rebox and lower combustion chamber
doors are tightly closed.
Close all combustion air inlets on the furnace.
If the furnace has shut down:
Check to ensure that the unit has power. Is the Main Power
switch in the rear electrical box in the ON position?Is
there power at the rear receptacles? Is the rocker switch
illuminated? Ensure that the rocker switch on the control
panel is in the on position.
Check the water temperature (furnace has a high
temperature cut off of 190° and turns on again at 140°).
Check the control screen for errors that may have shut
the furnace down.
If all checks have not corrected the problem have a
technician check the control panel.
If there is a power failure:
Open all 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.
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! 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.
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:
Check to ensure the door is sealing properly.
If the seal is worn out it will have to be replaced.
The door may need to be adjusted. To do this loosen the
door latch bearings and nuts on the door hinge and set
the door so it seals tightly against the door jamb. Re-
tighten once the door is in place.
If the furnace has an excessive amount of creosote:
Check to ensure the furnace is sized accurately according
to heat demand. If the furnace is oversized it will idle and
cause this.
Check moisturecontent in yourwood fuel. Moisturecontent
over 30% may cause creosote buildup. Recommended
moisture content in your wood fuel is 15-25%.
Remove the access panel at the rear of the furnace and
inspect the bypass door for smoke leakage.
If the chimney and/or heat exchange tubes become
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 gallows of water per
week and there is no obvious explanation:
Check and conrm that the temperature set-point is
not higher than 180 F. Hotter water temperatures will
causeincreased evaporation.
Check the gaskets on the upper and lower rebox
doors. Air leaks in door gaskets will allow continued
combustion and potential overheating.
Check the perimeter of the furnace for water puddles
collecting or dripping from the furnace.
Check all plumbing in the system to ensure there are no leaks.
If these checks have not provided an answer call your dealer.
ELECTRICAL TROUBLESHOOTING
Electrical troubleshooting should always be done by a
qualied technician.
High Limit Switch:
Alarm High Limit should be displayed on the control
screen. Using an electrical testing meter check for power
on both poles of the high limit switch. If the furnace
temperature is above 195° F. the switch should be OPEN
and there should only be power on one side of each
switch. 24V DC on the red and 115V AC on the black. If
the furnace was over 195° F. and the switch has opened
the water will need to cool down to approximately 150° F.
before it will close and allow power through once again.
If the furnace has not overheated (195° F+) but there is
still power on only one side of the switch, the switch is
faulty and should be replaced.
If there is no power on either side of each switch, check
for power at the main power switch at the rear of the
furnace.
Control power supply switch:
Using an electrical testing meter check for power on both
poles of the power supply rocker switch. The switch has
power in, neutral, and power out poles. During normal
operation, there should be power at the power in and
power out poles.
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 rear main power switch.
24V DC Power Supply:
Using an electrical testing meter check for DC voltage at
the OUTPUT terminals.
If there is 24 volts DC across the terminals and the green
LED on the front is illuminated the power supply is working.
If there is not 24 volts DC check for 115V AC power on
3130 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
the INPUT terminals. If there is no power check for power
at the control power switch.
If there is 115V AC on the INPUT terminals but not 24V DC
on the OUTPUT terminals, remove the 24V DC terminal
strip from the power supply and test for 24V DC on the
output pins. If there is not, the power supply is faulty and
should be replaced. If there is power on the pins with the
terminal strip removed then it is likely that there is a short
circuit in the 24V DC wiring. Locate and repair the issue
and re-install the terminal strip.
Fan Motor Breaker:
If the fan motor breaker has tripped check the fan for
proper operation before resetting the breaker. Remove and
inspect the fan motor & wheel to conrm it is turning freely.
Siemens LOGO Control: (with display)
Using an electrical test meter to check for 24V DC power
across the “L+” and “M-“ terminals.
If there is 24V DC power at the terminals but the display
remains blank the control is faulty and should be replaced.
If there is not 24V DC power at the terminals, check for
power output at the power supply.
Low Water Cut Off Switch:
Check to be sure there is enough water in the tank of the
furnace by removing the 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.
Use an electrical test meter to check for voltage across
the “M-“ and “I1” terminals on the Siemens LOGO control.
If the low water switch is satised (closed) there should
be 24V DC.
If there is no voltage, power off the furnace, remove the
Low Water Switch wiring from the control 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. Remove 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.
By-Pass Door Switch:
Test the By-Pass Switch using an electrical test meter.
Measure the voltage across the “M-“ and “I2” terminals
on the Siemens control. There should be 24 VDC when
the bypass is in the CLOSED position.
If there is no power across those terminals, isolate the
switch wiring and perform a continuity test on the switch
in the open and closed positions. The circuit should be
“open” when the by-pass is OPEN and “closed” when the
by-pass is CLOSED
If this is not the case the switch must be inspected. Check
that the switch is wired to the correct terminals and that
the magnet is within 1/2” of the sensor when the bypass
is in the closed position. If this is all working well but there
is no continuity across the switch when the By-Pass is
CLOSED then the switch is faulty and should be replaced.
Cold Start Button:
The cold start button will override the low temperature shut
down feature of this furnace. It should be pressed once to
allow the furnace to operate when in a cold start situation.
If the screen is ashing “Low-Temperature Alarm” and the
Cold Start Button is depressed, the Furnace Status should
change to “Cold Start Mode”. This message will remain
until the furnace has heated past it’s programmed cut in
temperature and the mode changes to “Heating Cycle”.
If the button is depressed and the “Low-Temperature
Alarm” continues, the circuit should be tested using an
electrical testing meter. Check for voltage between the
“M-“ and “I3” terminals on the Siemens control when the
button is DEPRESSED. There should be 24V DC across
those terminals only when the button is depressed.
If there is no power present, isolate the switch from the
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:
Inspect the top and bottom damper plates for
proper operation. The target damper position (%) is
indicated on the control screen. If the damper plate
is not in the position targeted by the control inspect
the plate for creosote, ice, or other build-up. Loosen
and clean the plates if necessary.
To remove the damper plates remove the two
actuator mounting bolts. Remove the actuator and
the damper plate should slide off the shaft. If the
plate is stuck, pry it off and clean as necessary.
The damper plates may be lubricated with a light
coating of automatic transmission uid if necessary.
If the damper plate is not stuck but the actuator will
not turn test the electrical at the actuator.
The “mode” selector should be set to mode 3.
Remove the screw in the electrical cover of the
actuator. Pull and wiggle gently on the cover to
remove it from the actuator. Take care not to damage
the electrical pins in the plug.
To test for proper operation the furnace should be
powered on and calling for heat. The display should
indicate the target Top and Bottom Air %. In this state,
you may test for power across terminals 1 & 2 on the
actuator. There should be 24V DC across those terminals.
If there is no power across terminals 1 & 2 then conrm
there is power at the Siemens control. If there is no
power at the control check the power supply (see Power
Supply Section). The control signal to the actuator can be
tested from terminal 2 to 3. There should be 2-10V DC.
The actuator position can be conrmed by testing the DC
voltage across terminals 2 and 5 on the actuator. It should
be 2 to10V DC depending on the position of the actuator.
If the damper plate is not stuck and there is power
and communication from the control, the damper
actuator is faulty and should be replaced. Please
consult your local dealer for assistance.
3332 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
L+ M I1 I2 I3 I4 I5 I6
Q1 Q2 Q3 Q4
24V DC Inputs
Outputs
PLC 6ED1052-1MD00-0BA8
I7 I8
1
2
3
4
5
Top Air
Damper Mode 3
Water
Temp
Sensor
L
Draft
Fan
N
Cold
Start
Low
Water
Cut-off
High
Limit
+
_Alarm
Light
Live
Neutral
G-Series Wiring Diagram
Ground
120V AC Power Supply
Power Supply -120V 1PH 60 HZ
Max Breaker - 15 AMP
Running Load –2.5 Amps
Max Accessory Load –9.5 Amps
* Use Copper Conductors Only *
Revision 4.3
Yellow –1
Yellow –2
Red –3
Black –4
Blue - 5
O2 Sensor Board
6–24V +
7–24V -
8–0-10V DC
9 -
Load/
ByPass
Switch
N/O
COM
PWR
T-OUT
COM
NEG
SEN
EXC
RTD Circuit Board
Fan
Breaker
Power
Switch
120V AC
Input
+- -
24V DC
2.5A
Output
L N
Power Supply
6EP1332-5BA00
Main Power Switch
+ -
24V DC Bus
1
2
3
4
5
Bottom Air
Damper Mode 3
M- L+ M-
M1 I1
Analog Module
6ED1055-1MM00-0BA2
U2 M2U1
L+
I2
O2 Sensor
Ethernet
Port
G-Series Wiring Diagram
Colour Copy of Wiring Diagram
PCL Module
EDITING CONTROL SETTINGS
To edit temperature, differential, timer and low temperature cut off
settings follow these instructions:
• To change control settings press the down arrow
repeatedly until you reach the desired screen.
• To edit the settings on the screen press and hold the
“ESC” key until a black box appears on a variable.
• Use the up/down arrow keys to toggle to different
variables on the screen.
• Press the OK button to adjust the highlighted setting
• Use the left/right arrows keys to navigate to the
appropriate character.
• Use the up/down arrow keys to adjust the value of
the character.
Note: The values are always in minutes, seconds, or degrees
Fahrenheit and always positive “+”.
• Press the “OK” key to save your changes and adjust
other settings.
• Press the “ESC” key to close the black box and
toggle between screens.
• Press the “UP” arrow repeatedly to return to the run
screen.
The following is a breakdown of the
information displayed on your control panel.
Furnace Status (run screen)
This screen displays the primary status information at a
glance.
The 2nd line displays the current status mode of the furnace.
Heat Cycle, Idle, Timer Cycle, or Cold Start Mode. Current
water temperature, oxygen level, and damper positions are
also indicated.
Furnace Run Time
Total Hours displays the accumulated time the furnace has
been in a heating cycle.
Trip Hours is a resettable hour meter. IE: You might want
to reset this trip meter at the start of your heating season
to keep track of hours run in a season. Reset the meter by
changing the reset option to “on”
3534 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
Service Reminder
The “Service Reminder” allows you to set a service reminder
for yourself, at the interval you choose. Set the “Interval Time”
in hours. The “Time Remaining” line, allows you to see how
much time is left before your service reminder will appear.
Water, Differential Settings
Set Water Temp is the temperature at which the furnace will
turn off at the end of a heating cycle.
Differential is how many degrees the water will loose before
the furnace turns on to reheat the water.
Idle Timer Settings
This timer can be used to keep the coal bed alive during
long idle periods. Once the furnace shuts down at the end
of the heating cycle the initial timer will start (Factory Set
Delay - 1 hour and 30 minutes). Once this Delay time has
passed the furnace will start the fan and open the dampers
to provide air to the coal bed for the set On Time (3 Minutes
and 0 Seconds). After this rst cycle the control will run the
On Time cycle every Off Time (30 minutes and 0 seconds).
Set Low Temperature Shut Down
When the furnace water cools below this setpoint, it will
assume the rebox is empty and will shut down to conserve
heat.
By-Pass Door Is Open
Opening the smoke by-pass will activate the draft fan for a
maximum of 5 minutes. If more time is needed the by-pass
must be closed and opened again. Operating the smoke
by-pass for extended periods of time may over heat the fan
motor causing premature failure.
Top Damper
Max Open % - The maximum allowable open position for the
primary air intake for normal operation. This is adjusted to
optimize amount of combustion air according to the type,
size , and moisture content of the fuel. Min Cls % - The
minimum allowable position for the primary air intake during
normal operation. This is adjusted according to the fuel
type, size, and moisture. This setting establishes the lowest
possible burn rate of the furnace.
Control Options
o2 Optimize – A feature reducing the primary air in the event
that o2 level is lower than set point. o2 Limiting – A feature
reducing the primary air if the o2 level is higher than set
point. MAXAIR – A feature active during Cold Start Mode
that drives the primary air damper to the full open position
for faster warm up. Modulation – Allows the primary damper
to regulate combustion air according to water temperature.
Bottom Damper
Set o2 % - The target oxygen level in the furnace exhaust.
This is set according to fuel quality. Recommended settings
range from 4% for premium dry fuel up to 8 % for low quality
high moisture fuel. Max Open % - Maximum allowable open
position for the secondary air inlet. Typically 100% as this
is regulated by the o2 sensor. Min Cls % - The minimum
allowable for the secondary air inlet. Off Delay – The amount
of time the bottom secondary air damper is allowed to
remain active after the furnace has cycled off. This helps to
reduce emissions in idle.
3736 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
o2 Bypass
o2 Bypass – In the event that your oxygen sensor fails, you
can enable this “o2 bypass” option, allowing you to continue
using the furnace till the oxygen sensor problem has been
resolved. Warning: Do not operate your furnace with this
option enabled for extended periods of time.
Alarm - Low Water
The water level sensor is indicating the water level is below
the safe operating level in the reservoir. Add water to clear
the alarm. Top off the uid level once the uid is back up to
normal operating temperature.
Warning - Cold Start
During a “Cold Start”, If your furnace temperature hasn’t
climbed 20 degrees in the rst hour of operation, this error
warning will appear. The furnace will continue running,
the warning is simply telling you that the temperature isn’t
climbing as fast as expected. To clear the warning, press the
cold start button.
Alarm - By-pass Open Over-time Shut Down
Opening the smoke by-pass will activate the draft fan for a
maximum of 5 minutes. If more time is needed, the by-pass
must be closed and opened again. Operating the smoke
bypass for extended periods of time may overheat the
fanvvvmotor causing premature failure.
Warning - o2 Bypass
Warning, telling you that your furnace has the o2 sensor
bypass enabled. Do not operate your furnace with this option
enabled for extended periods of time.
Alarm – Low Temperature Shut Down
The water temperature has dropped below the Low
Temperature Shut Down setpoint. The furnace shuts down
to conserve heat assuming the rebox is empty and needs
to be reloaded.
Alarm – High Temperature
The high temperature limit switch has been activated (195
F). The furnace will remain off until the water cools to
approximately 160 F.
Software Version
The control software version currently installed. Software
updates are periodically released offering improved function
and features. Please contact your dealer for the latest
version available.
3938 HeatMasterSS G Series Furnace Operating Manual HeatMasterSS G Series Furnace Operating Manual
COMBUSTION TUNING BASICS
**IMPORTANT** Changing these parameters can affect the performance and operation of your furnace adversely. Changing
these parameters should only be done under the guidance of your Heatmaster dealer. Make small changes at a time and
allow a few days of operation after making a change, observing the furnace to see if you’ve made a positive change.
Suggested starting points for varying wood moisture levels. See the instructions on page 15 to accurately test wood moisture levels.
Factory Defaults
Wood Moisture 26-35%
Top Damper Max 75%
Top Damper Min 50%
o2 Setpoint 6%
Wood Moisture 15-25%
Top Damper Max 65%
Top Damper Min 40%
o2 Setpoint 4%
Wood Moisture less than 15%
Top Damper Max 60%
Top Damper Min 40%
o2 Setpoint 6%
Top Damper
This screen gives you the option to change your maximum
open and minimum closed parameters for the top damper on
your furnace.
The Top Damper defaults are the settings the furnace was tuned
with using a variety of wood species and burning conditions.
These parameters adjustable, allowing the customer to tune
the furnace for conditions that we might not have been able to
simulate at the factory.
Max Open %
Note: When your Furnace Status (rst screen) shows the Top
Air %, it is showing the percentage of this Max Open %. For
example: when you see that the Top Air % on your Furnace
Status screen is at 100%, the damper will be open to the 70%
that you see/set in this Top Damper screen.
You may benet from increasing the Max Open parameter in
the following scenarios:
• If your furnace is installed at a higher altitude ( >2000ft
above sea level)
• The furnace is struggling to achieve target water
temperature.
• If you are burning wood that is wetter than the ecommended
15% - 25%
• If you nd the furnace is consistently smoking during burn
cycles.
Make small changes at a time (+/- 5%) and allow a few days of
operation after making a change, observing the furnace to see
if you’ve made a positive change.
You may benet from decreasing the Max Open parameter in
the following scenarios:
• Your wood is split very small, under 4” cross section.
• Your wood is exceptionally dry, below 15% moisture.
• Your stack temperatures are regularly above 300F during
burn cycles.
Min Cls %
During normal operation, when the furnace’s temperature is
climbing and the temperature is getting close to the Set Water
Temp, the furnace will start to modulate slowing the burn rate.
This allows the furnace to burn at a more eciently and have a
softer, cleaner shut down. This Min Cls % is the minimum amount
that the top damper will close during this modulation period.
You might want to increase this parameter in the following
scenarios:
• If you see that the furnace is regularly smoking while the
top air is at the minimum position.
• You want the furnace to burn at a higher rate right up to the
set temperature.
You may want to decrease this parameter in the following
scenarios:
• The furnace is signicantly overshooting the set
temperature. Lowering the minimum damper setting will
low the furnace down more toward the end of a burn cycle.
• You want to allow for a lower modulation rate
Bottom Damper
This screen gives you the option to change your…
• Oxygen (o2) setpoint
• Bottom Damper, maximum open and minimum closed
• Off delay for the bottom damper
The Bottom Damper defaults are the settings the furnace
was tuned with using a variety of wood species and burning
conditions.
These parameters are adjustable, allowing the customer to
tune the furnace for conditions that we might not have been
able to simulate at the factory.
The bottom damper is supplying secondary air to the lower
grate of the furnace. Working together with the oxygen sensor,
it targets the oxygen level set in this screen.
Set o2 %
This parameter allows you to set the target oxygen level in the
exhaust of the furnace. In general, the lower the level of oxygen
that you can maintain while burning clean, the more ecient
your furnace can operate.
Burning seasoned hardwoods at 15%-25% moisture, you may
be able to burn clean with an o2 setpoint as low as 3%-5%.
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