PORTAGE & MAIN ML30 User manual

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PORTAGE & MAIN
WOOD-FIRED OUTDOOR WATER FURNACE
INSTALLATION AND OPERATION MANUAL
MODELS ML30, ML36, & ML42
PLEASE SAVE THESE INSTRUCTIONS AND REFER TO THEM FOR SAFETY AND
EFFICIENT PREFORMANCE.

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Table of Contents
Page
Letter to Customer ...................................................................................................3
The P & M Outdoor Water Furnace System ................................................................4
Location ..................................................................................................................4
Placement ...............................................................................................................5
Chimney ..................................................................................................................5
Clearances ...............................................................................................................5
Pipe Trench .............................................................................................................5
Water Fill-up.............................................................................................................6
Corrosion Control .....................................................................................................6
Electrical Connections ...............................................................................................7
Starting –Up ............................................................................................................7
Setting ....................................................................................................................7
Operating Instructions ..............................................................................................8
Saving Tips ..............................................................................................................8
Creosote Control ......................................................................................................8
Ash Disposal ............................................................................................................9
Safety Warnings ......................................................................................................9
Maintenance / Fan & Damper Lid Assembly ...........................................................9-10
Connection to Heating System ................................................................................11
Schematic #1 ........................................................................................................12
Schematic #2 ........................................................................................................13
Schematic #3 ........................................................................................................14
Schematic #4 ......................................................................................................... 15
Wiring Diagram ......................................................................................................16
Controls Functions ............................................................................................. 17-19
Troubleshooting......................................................................................................20
Warranty ................................................................................................................21
Warranty Card ........................................................................................................ 21
Notes & Records .....................................................................................................22

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PORTAGE & MAIN WOOD OUTDOOR WATER FURNACE
Manufactured by
Piney Manufacturing Ltd.
Box 130, Piney, MB
R0A 1K0,
Canada
Thank you for purchasing a Portage & Main Outdoor Water Furnace which has been tested
and approved by the Canadian Standard Association (CSA MC231278).
Please observe the instructions contained in this Manual and affixed to the unit to enjoy the
full benefits of heating your home, other buildings and your domestic water in a safe and efficient
way. We also recommend that you consult and comply with your local electrical, pluming and fire
codes, which override these instructions. We have also included some maintenance procedures and
tips that will ensure efficient, economic and trouble-free operation.
For more information regarding the installation, operation and maintenance of this unit, please
contact us or your nearest dealer.
Piney Manufacturing Ltd.

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THE PORTAGE & MAIN OUTDOOR WATER FURNACE
The Portage & Main Outdoor Water Furnace is safe and highly efficient, conveniently installed
outside your house to give you the comfort you desire all year round using the oldest and most
environmentally friendly fuel of all: WOOD.
This unique system has a fire pot and heat exchanger which are totally immersed in a water
jacket that keeps its components from overheating and warping. The front door is insulated and
built of heavy gauge material to eliminate warping. The multi-pass heat exchanger is designed to
extract useful heat from the flue gases before they exit through the insulated stainless steel
chimney.
The water temperature is maintained at the desired level by automatic controls. The heated
water is pumped to the house and the other buildings by means of individual circulating pumps
through an individual underground loop for each building or application.
The heating loop will provide the required amount of heat to your house or building,
regardless of your existing heating systems as described later on. You can also add a water-to-
water heat exchanger to your system to provide you with all your domestic hot water
requirements to increase your fuel savings considerably.
The Portage & Main Outdoor Water Furnace is equipped with a fan for forced combustion air
to modulate the burning rate as required, and with safety instruments that would prevent the
water from overheating or boiling.
Please follow the instructions contained in this Manual to enjoy the comforts of heating with
wood in a safe manner.
LOCATION
The ideal location for the P & M Outdoor Water Furnace should be:
Outside your residence for safety and lower insurance rates.
In a separate structure such as your garage, shop or shed.
Away from storage of wood, chemicals and other flammable materials.
Not less than fifty (50) feet from main residence and other buildings. Not less that twenty-five
(25) feet from bushes
Downstream of prevailing winds relative to main residence.
On the side of pipe entry to residence.

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RECOMMENDATION
We recommend a hot water circulation loop that will dissipate at least 10% (ten percent) of the
estimated heat output of the water furnace in the event that circulation is reduced because of
electrical power failure. This loop shall be such that it can only be made inoperative by a deliberate
manual action. The minimum pipe to be used should be 18mm (.75 inch) in diameter.
PLACEMENT
We recommend a concrete or cement (noncombustible) slab for placing the P & M Outdoor Water
Furnace. The slab should be at least four (4) inches thick, sixty (62) inches wide and sixty (60) inches
long.
CHIMNEY
We recommend the use of insulated stainless steel pipe as a stack to minimize creosote formation. A
six (6) inch pipe is recommended for Model ML30 and an eight (8) inch pipe for Models ML36 and
ML42. The stack should extend at least four (4) feet above the building where the Outdoor Water
Furnace is located.
CLEARANCES
The Outdoor Water Furnace should be placed in a location where it can always get a significant
amount of fresh air. This is important for the water furnace to operate efficiently, and to have good
combustion.
The minimum installation clearances to combustible materials are:
Back & Sides: Twelve (18) inches(46 cm)
Front: Forty-eight (48) inches(122 cm)
Top Eighteen (18) inches(46 cm)
Flue Pipe: Eighteen (18) inches(46 cm)
Note: Adequate space should also be left around the outdoor water furnace in addition to the
required clearances for servicing and maintenance.
PIPE TRENCH
Pre-insulated pipes such as lOGSTOR Dual Pex Flex, properly sized for circulation requirements
are recommended to convey the hot water from the outdoor water furnace to each building.
The piping should be laid in a flat trench eighteen (18) inches to thirty six (36) inches deep. If
high water table is encountered, the trench may be shallower, traffic permitting. It is to your
advantage to be down deeper at the boiler/furnace especially as it makes the bend easier.
Use of water tight insulation is recommended as all Styrofoam will absorb water to the point it
becomes very poor insulation. Use only in high dry well drained areas if using at all.
All plumbing must be done according to applicable local codes.

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WATER FILL-UP
After installing the P & M Outdoor Water Furnace in place and connecting to it the supply and
return pipe(s) to and from the various buildings to be heated, IN ACCORDANCE WITH
APPLICABLE LOCAL CODES, the heating installation is ready to be filled with water.
Before filling the P & M Outdoor Water Furnace with water, make sure all valves are in
“closed” position, and unused supply and return outlets on the front of the outdoor water
furnace are tightly capped.
A permanent water supply to the Outdoor Water Furnace is recommended by tapping into the
water mains and connecting it to the top of the Outdoor Water Furnace through a manually
operated shut-off valve.
Add water until the entire heating installation is filled and the level gauge on top of the
outdoor water furnace shows full.
Before starting the outdoor water furnace make sure the entire heating installation is properly
vented to facilitate the circulation of water in the heating loop(s).
Ensure water trap and discharge pipe are properly installed and unobstructed to release any
pressure build-up in the outdoor water furnace.
CORROSION CONTROL
To control corrosion in the Portage & Main Outdoor Water Furnace we recommend the following:
1. Always use certified boiler treatment. Submit water sample for testing annually through your
dealer. Keep your records.
2. Always maintain the proper water level.
3. Add a commercially available antifreeze solution to the water in the order of thirty (30) per
cent, during the initial water fill-up. (Optional)
4. When adding large make-up water quantities to compensate for evaporation and to maintain
proper water level, use the same ratio of antifreeze solution to the make-up water. For smaller
make-up water quantities, no antifreeze solution is required.
5. If sedimentation occurs after the initial few weeks, the water should be treated chemically to
adjust its pH level. Consult your dealer for water analysis and treatment.
6. Keep ashes to minimal. Do not burn garbage.
7. Always maintain adequate water level. If level drops occasionally, check for leaks or boiling of
hot water and refer to the Troubleshooting Section.
8. Make sure the outdoor water furnace is properly grounded.
9. Remove ashes when outdoor water furnace is not used
10.Cover the chimney during off-season to prevent rainwater from entering the firepot.
11.Clean the firepot during the off-season.
12.Clean the heat exchanger with the cleaning tool provided with the outdoor water furnace,
through the cleaning door located above the wood-loading door.

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ELECTRICAL CONNECTIONS
The Portage & Main Outdoor Water Furnace is factory-wired and is ready for connecting it to
an AC/120V/60 Hertz supply
ALL ELECTRICAL CONNECTIONS SHALL BE WIRED ACCORDING TO APPLICABLE LOCAL
CODES.
Make sure outdoor water furnace (and metallic water lines, if used) is well grounded to avoid
pitting in the water jacket.
STARTING-UP
Before starting-up observe the SAFETY WARNINGS contained in this Manual.
Make sure the Outdoor Water Furnace, circulating loops and existing heat exchangers or
baseboard heaters are full of water and properly vented.
Ensure the circulating pump(s) is properly installed according to manufacturer’s instructions.
Failure to do so could void the Warranty.
Load the outdoor water furnace with wood only to fill three-quarters (3/4) of the firepot. Use
kindling wood to start the fire. DO NOT USE ANY FLAMMABLE LIQUIDS TO START THE FIRE.
Always turn the power off before loading the appliance with wood or opening the firing door.
Keep firing and ash pit doors tightly closed at all times for safety when outdoor water furnace
is in use.
Inspect the chimney and make sure it is clear from any obstructions.
Set the aquastat to the highest temperature setting on the dial (180 F) as described under
SETTING. When the water temperature reaches this set point, the control will turn the
combustion fan off to close the air damper at the bottom of the outdoor water furnace.
When the combustion fan is shut down turn the setting dial down to a range of 140 F to 170
F. If the weather is mild, turn the dial further down to a range of 120 to 140 F.
Now turn the circulating pump(s) on and leave it on at all times.
Before leaving the Outdoor Water Furnace location, make sure that:
1. The water level is adequate.
2. The wood loading door is tightly closed.
3. The ash pan door is tightly closed.
4. The area around the outdoor water furnace is clear from any combustible materials.
SETTING
The Portage & Main Outdoor Water Furnace is equipped with a digital display immersion type
aquastat controller which operates in response to water temperature changes.
To set the temperature at the desired level, go to page 19 of this manual.

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OPERATING INSTRUCTIONS
1. Portage & Main Outdoor Water Furnace may be connected to an existing boiler system. Burn
natural wood only
2. To avoid damage load wood carefully. Always shut off power before opening firing door or
loading the appliance with wood. Unlatch firing door allow ten seconds for smoke to dissipate
before opening door fully.
3. Do not use chemical substances or liquid fuels to start or enhance the fire.
4. Do not burn garbage, liquid fuels, engine oil, naphtha or other flammable materials, which
may cause a fire or an explosion.
5. Shut off the outdoor water furnace in case of a runway fire.
6. Clean the heat exchanger regularly to remove accumulated creosote and ash. Flue pipe and
chimney need to be cleaned periodically.
7. Clean the Outdoor Water Furnace and cap the chimney at the end of each heating season to
minimize corrosion during summer months.
8. Always maintain the Outdoor Water Furnace, flue pipe and chimney in good condition.
9. Do not load the Outdoor Water Furnace with wood during an electrical power failure. Do not
leave fire door open. Do not use firing, ash or damper doors to manually regulate combustion.
10.For safety do not store any fuel or combustible materials within the installation clearance of
the outdoor water furnace.
11.Keep firing and ash pan doors tightly closed at all times for safety.
12.Always keep the grates at the bottom of the firepot clean and free from ash to allow maximum
combustion air to enter the firepot.
SAVING TIPS
1. Keep the circulating pump(s) on all the time to maintain a comfortable environment and avoid
temperature swings and settling of suspended matter in the water.
2. Maintain a regular wood-loading schedule to keep the Outdoor Water Furnace operating under
steady-state conditions.
3. Lower the temperature setting to 120 –140 F (depending on your need) during milder
weather for maximum efficiency and savings.
4. Turn the circulating pump(s) on occasionally during summer to minimize pump seizure.
CREOSOTE CONTROL
Creosote is formed when wood is burned at a slow rate. Condensation of creosote vapors
occurs in the chimney which is relatively cooler than the Outdoor Water Furnace. This causes
creosote to form a lining inside the chimney.
Accumulations of creosote when ignited may result in chimney fires.
We recommend inspecting the chimney once a month during the heating season and removal
of creosote linings to reduce chimney fire hazards.
Morning high temperature firing of boiler for up to ten (10) minutes twice a week will eliminate
most of the soggy creosote in the heat exchanger and chimney. This is achieved by opening
the ash pan door during the high temperature-firing period. The ash pan door should be
closed immediately after this high temperature firing to prevent overheating of the outdoor
water furnace and water boiling away to an unsafe level.

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ASH DISPOSAL
Ashes should be removed from the Outdoor Water Furnace regularly or they will block the flow
of combustion air from the damper.
Ashes should be stored in metal containers with tight lids and kept in an area free of
combustible materials until finally disposed.
Do not dispose of ashes while embers are still hot.
Check local by-laws for ash disposal. Wood ash can be used to reduce soil acidity or as a
fertilizer for the garden.
SAFETY WARNINGS
Never leave children un-attended near the boiler.
Never add water when outdoor water furnace temperature is close to 212 f as it
may result in steam flashing.
Never perform any service or maintenance work before water temperature drops
below 100 f.
DO NOT store combustible materials or liquids near the Outdoor Water Furnace.
DO NOT burn any materials other than natural wood.
DO NOT use flammable liquids or materials to start or to enhance the fire.
DO NOT leave wood loading door open or unlatched.
DO NOT open the loading door too quickly to avoid blowbacks which could cause sever burns.
ALWAYS check water level, aquastat and damper setting for a proper and safe operation.
DO NOT touch any part on the front of the Outdoor Water Furnace, which is insinuated to
avoid skin burns.
ALWAYS store ashes in tightly covered metal containers away from combustible materials.
Always turn the circulating pump(s) on when burning scraps of wood in the summer to
prevent system from overheating.
MAINTENANCE
Portage & Main Outdoor Water Furnace is designed to operate for many years with the least
amount of maintenance. Good housekeeping practices and observance of the instructions
contained in this Manual would assist you in maintaining the outdoor water furnace in good
and safe working conditions.
ALWAYS SHUT OFF THE POWER SUPPLY prior to performing any service or maintenance work.
Refer to the SAETY WARNINGS and OPERATING INSTRUCTIONS prior to performing any or
maintenance work.
If circulating pump(s) is seized due to a prolonged shutdown, removed the screw in the center
of the motor and turn the motor shaft with a screwdriver to loosen it.

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The damper lid on the blower fan has to be manually adjusted to the desired amount of air required.
This is done simply by moving the air flow adjuster. This blower fan assembly should not be altered
in anyway for increased fire.

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CONNECTION TO HEATING SYSTEMS
The P & M Heating System is versatile and can be connected to any existing or new heating system
and/or domestic water system as described below. The corresponding schematics are provided
as a guideline only. ALL CONNECTINS MUST BE EXECUTED ACCORDING TO LOCAL PLUMBING
AND ELECTRICAL CODES.
1. EXISTING FORCED AIR SYSTEM
All you need is to install a water-to-air heat exchanger in your existing furnace plenum (on the
supply side) to keep your house as comfortable as you desire using a separate thermostat. Your
existing furnace would be used as a back up when required. (Refer to Schematic #1)
2. EXISTING WATER BASEBOARD SYSTEM
A water-to-water heat exchanger will be required to replace your existing boiler and provide you
with all the comfort you require. Your existing boiler would be used as a back up when required.
(Refer to Schematic #2). Another alternative would be to convert your existing system into an “open
system” with the assistance of an expert in heating system.
3. NEW WATER BASEBOARD SYSTEM
You will not need any heat exchangers in this case as the Portage and Main Heating System is
directly connected to the baseboard system to keep your house warm and comfortable. (Refer to
Schematic #3)
4. DOMESTIC WTER HEATER AND HEATING SYSTEM
You can enjoy more energy savings and running hot water during the heating season by
connecting your domestic water heater to the Portage & Main Heating System through a sidearm
water heater. (Refer to Schematic #4). We would caution you, however, that creosote may increase
during summer due to lowered heat demand. but if additional heat could be used elsewhere, then
creosote formation would be reduced.

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13

14

15

16
Ground
GroundLine 1
Nuetral
160
Green
Switch
Fan
Wiring Diagram

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The A419 control functions
Set point (SP) establishes the temperature value at which the equipment is switched on or
off, depending on the user selected mode of operation. Set point range is -30 to
212˚F or -34 to 100˚C (in 1-degree increments). Set at 175 degrees to 185 degrees F.
If Set point mode is set to cut-in, set point is the temperature value at which the control closes
the Normally Open (N.O.) contacts. If Set point mode is set to cutout, set point is the temperature at
which the N.O. contacts open.
Differential (DIF) established the difference in temperature between the cut-in value and
cutout value. The differential is set relative to Set point and may be set from 5 to 10 F˚ or C˚ (in 1 –
degree increments).
Anti-Short Cycle Delay (ASD) established the minimum time that the outplay relay remains
de-energized before the next on-cycle. The ASDdoes not allow the output relay to re-energize until
the programmed time delay has elapsed. The delay is activated when the control is first turned on
and every time an on-cycle ends. When the delay is activated, the LCD alternately flashed the senor
temperature and ASD. The ASD range is 0 to 1 minutes DO NOT ADJUST from factory settings.
Sensor Failure Operation (SF) establishes how the A419 control’s output-relay operates
the equipment in the event of a sensor or sensor wiring failure. The user may select to run the
equipment continuously or to shut it down. When the control detects a sensor circuit failure, the LCD
flashes SF alternately with OP (if the sensor circuit is open), or SH (If the sensor circuit is shorted).
Before indicating a failure, the control implements a 1-minute delay, which allows verification of
failure condition and avoids nuisance failure indications.
Temperature Offset (OFS) establishes a set secondary Set point and Differential values
that may be invoked to control an application when a circuit is closed between the binary input (BIN)
and common (COM) terminals (and BIN appears on the display). See Figure 3. Offset range is 0 to
50F˚ or C˚ (in 1-degree increments). A typical application might use a switching time clock to invoke
night-setback temperature settings.
IMPORTANT: Make sure the Touchpad Lock jumper is installed (unlocked) before
attempting to adjust the A419 control functions.
Changing the A419 Control Temperature Units
The A419 control is factory set to display Fahrenheit temperature. To change to Celsius, press
Up and Down (arrows) simultaneously. Press them again to display Fahrenheit units. Verify that the
control is displaying the desired temperature units before setting the Setpoint.

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Setting the A419 Control Set point Value
To view and adjust Set point, follow these steps:
1. Press and hold MENU (about 2 seconds) until the display flashes SP.
2. Press MENU again to display the existing set point value.
3. Press Up or Down (arrows) to change the set point value.
4. Press MENU again to save the new value. The display returns to the sensed
temperature.
Note: If no setup entry is made for 30 seconds, the control reverts to the (normal)
temperature display.
IMPORTANT: If MENU is not presses after changing the set point value, the control reverts
the preciously programmed set point value.
MENU
-10
BIN
F
*
Temperture
Offset Indicator
Temperture
Offset Indicator
Operating Mode
Indicator
Liquid Crystal
Display
Menu Button
Down Arrow
Key
Up Arrow
Key
Output Relay
Status Indicator
LED
*
Figure 6: Liquid Crystal Display, Touchpad, and LED Indicator
Settings on the Other A419 Control Functions
To set the Differential, Anti-short Cycle Delay, Temperature Offset, or Sensor failure operation,
use the following method.
1. Press and hold Menu until the display changes to flashing SP. (This takes about 2
seconds.)
2. Press Up or Down (arrows) repeatedly until the desired function is displayed.
(See Table 3.)
3. Press Menu to display the functions current value.
4. Press Up or Down (arrows) until the desired value is displayed.
5. Press MENU to save the new value. The display returns to the sensor
temperature.
IMPORTANT: If MENU is not pressed after changing the settings, the new settings are no
saved and the control reverts to the previously programmed setting values.

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NOTE: If no setup entry is made for 30 seconds, the control reverts to the (normal)
temperature display.
NOTE: Any saved A419 control settings are non-volatile and remain in the control’s memory
during power interruptions.
IMPORTANT: Do not set Setpoint and Differential values which (when totaled) fall out of
A419 control’s Set point range (-30 to 212 ˚F [-34 to 100˚C]). The control will not function properly if
Cut-in or Cutout values are outside of the control’s Set point range.
Checkout
Before applying power, make sure installation and wire connections are corrects for your
application. Then power, operate and observe the system and A419 control for at least three
complete operating cycles before leaving the installation.
Table 3: Display Symbols, control Function, Ranges, Unites, Values, and Factory Settings
Display
Symbol
Control
Function
Range –Units/Value
Factory Set
Value
SP
Setpoint*
-30 to 212 - ˚F (-34 to 100 - ˚C)
30
dIF
Differential*
1 to 30 –(F˚ or C˚ in 1-degree
increments)
5
ASD
Anti-short cycle
Delay
0 to 12 –(in 1-minute increments)
1
OFS
Temperature
Offset
0 to 50 (F˚ or C˚ in 1-degree increments)
0
SF
Sensor Failure
Operation
(No range) –0 = output relay de-
energized
1= output relay energized
1
F or C
Temperature
Units
(No range) - F˚ or C˚
F˚
BIN
Temperature
Offset Indicator
(No range) –BIN is displayed and the
A419 control operates on the secondary
setpoints when the circuit between the
BIN and COM terminals is closed.
N/A
Snowflake or
flame picture
Cooling or
Heating Mode of
Operation
(No range) –A Snowflake (Cooling Mode)
is displayed when the Jump1 jumper is
removed. A Flame (Heating Mode) is
displayed when the Jump1 jumper is
installed.
Snowflake
(Cooling Mode)
*The sum of the Setpoint and Differential values must be within the Setpoint range, or the
control may not function properly.

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TROUBESHOOTING
TOO LITTLE HEAT
- Fire is out
-Low water level or water leaks
- Power failure
- Circulating pump failure
- Air traps in system
-Fan is not running
- Add wood/build fire
- Check leaks then add water
- Check electrical circuits
- Check pump
- Vent system
-Inspect fan/replace
TOO MUCH HEAT
- Draft damper stuck in open
position
- Air leaking through wood door
- Aquastat malfunction
- Thermostat inside house
malfunction
- Ash door not shut tight
- Clean, lube and reinstall
- Clean metal to metal surfaces
- Check aquastat
- Check thermostat
- Check gasket on ash door
WATER BOILING
-Fan running constantly
- Aquastat malfunction
- Wood door open
- Damper lid stuck open
- Aquastat malfunction
- Check aquastat
- Close door tightly
- Clean, lube and reinstall
CREOSOTE BUILDUP
- Air leaking through wood door
- Chimney not insulated or
damaged
- Burning high pitch bearing wood
(Pine, Balsam)
- Clean metal to metal surfaces
- Insulate or repair chimney
insulation
- Use mix of dry and harder wood
(Poplar, Birch, Tamarack)
TROUBLE
POSSIBLE CAUSE
SOLUTION