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Polar Electro G2 Owner's Manual

Outdoor wood furnace setup 1 wood moisture requirements see section 8.2 of this manual g-class
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G-Class
Heater Setup
Outdoor Wood Furnace
Owner's Manual for G2, G2 Plus & G3
Wood Moisture Requirements
See Section 8.2 of this Manual
1
For service and support on your Polar Furnace contact your local dealer

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Summary of Contents for Polar Electro G2

  • Page 1 G-Class Heater Setup Outdoor Wood Furnace Owner’s Manual for G2, G2 Plus & G3 Wood Moisture Requirements See Section 8.2 of this Manual For service and support on your Polar Furnace contact your local dealer...
  • Page 2 ASTM E 2618-10 and/or EPA Method 28 WHH or EPA Method 28 WHH-15 and ASTM E2515-2011. The G-Class G2-Plus indoor/outdoor hydronic heater by Polar Furnace is also listed by Intertek to the applicable portions of the following standard: CSA B415.1-10. The G-Class indoor/outdoor hydronic heater by Polar Furnace is listed by CSA group to the applicable portions of the following standards: UL 2523 Standard for Solid Fuel-Fired Hydronic Heating Appliances, Water Heaters and Boilers and CAN/CSA-B366.1-11 Solid-Fuel-Fired Central Heating Appliance.

  • Page 3: Warranty Details

    POLAR FURNACE G-CLASS HEATER WARRANTY (v. 15-1) The longevity of your G-Class heater will depend on how well the heater is maintained and if the wood burned in the unit meets the wood moisture requirements specified in the owner’s manual. With proper operation, proper maintenance and proper wood quality your new furnace will last a long time.
  • Page 4 NOTICE: To activate this warranty, the white copy of the warranty activation form (page 5) as well as a copy of the original bill of sale (invoice) must be mailed to the Polar Furnace address above within thirty (30) days of furnace delivery to end user. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 5: Warranty Activation Form

    POLAR FURNACE MFG. INC. WARRANTY (v.15-1) ACTIVATION FORM—DOWN DRAFT HEATER WARRANTY REGISTRATION FORM Customer’s Name:____________________________ Dealership Name: ___________________________ Address:____________________________________ Address: __________________________________ City, State/Prov. Code:_________________________ City, State/Prov. Code:_______________________ Phone: (____)________________________________ Serial No.___________________________________ Date of Purchase: ____________/_______/_______ DELIVERY CHECKLIST _____ Review owner’s manual. _____ Identify safety hazards &...

  • Page 7: Table Of Contents

    Table of Contents Warranty Details Warranty Activation Form Table of Contents Introduction Warnings & Cautions Responsible Ownership Heater Components Safety Heater Setup Heater Controls Operating the Heater Maintaining the Heater Water Testing & Treatment Heater Model Specifications Electrical Diagrams G-Class Parts Plumbing For service and support on your Polar Furnace contact your local dealer...

  • Page 8: Introduction

    Our commitment is to provide you with the best possible wood burning technology. As part of this commitment, we make improvements to our products on a regular basis as we strive to make them even Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 9: Warnings & Cautions

    Warnings & Cautions 2.1 !!WARNING!! A person operating a hydronic heater must comply The manufacturer does not recommend burning with all applicable laws or other requirements such treated or contaminated wood (i.e. railroad ties or as state or provincial laws or regulations and local pressure treated lumber).
  • Page 10 Some level of carbon monoxide is being generated in all stages of the combustion process regardless of the fuel. Continued on next page..Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 11: Responsible Ownership

    Several precautions must be taken to minimize the risk of carbon monoxide poisoning especially when the G-Class is installed in a building: • First, run the furnace in the most efficient manner possible to reduce the production of carbon monoxide. Use well seasoned, dry wood and establish the correct operating draft as laid out in these operating instructions to help limit CO emissions.

  • Page 12: Heater Components

    Rear Bottom Access Panel—Plumbing Hookup, Air Damper Setting Work Light (inside outer door) Rear Top Access Panel—Suction Fan Access, Electrical Access Overflow/Fill Pipe Lifting Hook Main Outer Door Loading Door Ignition Door Front Bottom Cleanout Door Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 13: Safety

    Safety 5.1 !! WARNING !! Maintain minimum distances between heater and combustibles. (Refer to section 6.6) 5.2 !! WARNING!! Develop and implement a clearly formulated plan of 5.5 The Combustion Fans Have what to do in the event of a chimney fire. Just Shut Off Once the heater reaches the point where the water 5.3 !! WARNING!!

  • Page 14: Heater Setup

    2’ of extension. Either 1pc x 2’ or 2pcs x 1’). Left Side 1” Right Side 6” • Chimney rain cap. 2” Chimney 6” • Distribution pipe finishing duct (diagram 14.2 of manual). Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 15: Chimney Requirements

    SECTION 6: HEATER SETUP Consult with your insurance company to ensure all applicable standards and local codes. No other that the boiler to building clearances are acceptable. appliance should be connected to the chimney unless Failure to do so may void insurance. The manufacturer allowed by the local code authority.
  • Page 16 Polar Furnace • pH must be within the allowable range of 7.0 - suggests using softened water. 9.9. (See section 10.5 for instructions on how to determine pH) Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 17 SECTION 6: HEATER SETUP 6.10 Filling the Water Jacket will fill with water showing the level of the water in the water jacket. If the level is in the red, “ADD” zone, add water until the level reaches the green, “FULL” 6.10.1 !! WARNING !! zone.
  • Page 18 2. Ensure moisture content of wood is 24% or lower. Lower moisture content will reduce condensation. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 19 SECTION 6: HEATER SETUP G-Class Foundation Drawing Diagram 6.12–Foundation Pad Recommendations For service and support on your Polar Furnace contact your local dealer...

  • Page 21: Heater Controls

    Heater Controls 7.1 Controls Overview while the second aquastat is the high temperature shutdown. This prevents overheating of the system if the control aquastat fails for any reason. One switch The heater’s controls include: 2 aquastats turns the combustion cycle on and off. The second located inside the rear top access panel, 2 switch is used to turn the heater’s front-access work switches and a temperature gauge located on...
  • Page 22 Place the new fuse in position and push the tab operation. The control aquastat should not be set back into position. lower than 180˚F. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 23 SECTION 7: HEATER CONTROLS 7.4 Primary Air & Secondary Air Controls Diagram 7.2–Air Controls Note: Refer to pages 32 and 33 for General Air Gate Adjustment Guidelines Item Feature Function Description Gate Adjustment Spring loaded lever can be pulled slightly sideways and moved upwards or Lever downwards to set how far the air gate opens.

  • Page 24: Operating The Heater

    Diagram 8.2–Seasoned, Split Wood: checking visible, indicates wood has been split and stacked under a roof without side walls for one year will usually season to within the acceptable seasoned. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 25: Wood Burning

    SECTION 8: OPERATING THE HEATER For more information, visit the following links on the web: • EPA’s Burnwise Program Website (lots of good wood burning information): http://www.epa.gov/burnwise • Video about how to properly Split, Stack, Cover and Store Wood: http://www.youtube.com/watch?v=yo1--Zrh11s •...
  • Page 26 Lay the heat output will be reduced. first few pieces into the bottom of the fire chamber Flue Brush Large ash tool Small ash tool Ash Shovel Diagram 8.5–Cleaning Tools Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 27: Disposal Of Ashes

    SECTION 8: OPERATING THE HEATER 8.6 Managing the Ash/Coal Bed In a fractional load-type situation, fill the chamber only with as much wood as needed to provide heat After using the heater for several days you will notice for the next 10-12 hours. For example, if a half a buildup of ash and coals at the bottom of the fire chamber load of wood is needed to provide heat for chamber.
  • Page 28 If the heat exchanger and fan blade and fan housing are not coated in black the Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 29 SECTION 8: OPERATING THE HEATER heater is not smoking and the visible cloud is condensation. 8.14.3 Secondary Flame Characteristics How well the heater is burning can be gauged by viewing the orangey-yellow secondary flame through the peep hole in the front bottom door. During optimal combustion this flame will have at least some blue flame in it.

  • Page 30: Maintaining The Heater

    Maintaining the Heater Proper maintenance of the heater is important to away from the walls and primary air holes regularly insure reliable, efficient and safe operation of the using the Large Ash Tool (Section 8.1). If the ash at heater. Proper maintenance will also help insure longer the bottom of the fire chamber builds up more than service life of the heater.
  • Page 31 SECTION 9: MAINTAINING THE HEATER the inner access cover, remove the inner access cover, !! DANGER !! - EXTREMELY HIGH remove the quick pins to remove the turbulators. TEMPERATURES OCCUR INSIDE FRONT Brush until clean. BOTTOM CLEAN-OUT DOOR. ALLOW HEATER TO COOL BEFORE COMPLETING Caution: MAINTENANCE DESCRIBED BELOW.
  • Page 32 The release on the front Primary Air Supply Ports are about 4 inches deep. control connector is on the back side of the connector and hidden from view. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 33 SECTION 9: MAINTAINING THE HEATER Power Control Once unplugged, thread both cables back into the Connector Connector electrical controls area. Next, remove the thumb screw(s) (see diagram 9.3 –item #5) securing the cooling shroud in place and remove the fan cooling shroud (see diagram 9.3–item #4).
  • Page 34 G2 Part # 100048 heater. The life expectancy of these items varies greatly G2-Plus Part # 101085 depending on my factors including maintenance level, G3 Part # 100047 Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 35 SECTION 9: MAINTAINING THE HEATER 9.10 Maintaining the Fan Fan Problem Cause of Problem Troubleshooting/Corrective Measures Fan is making a loud Fan is contacting inside surface of -remove and adjust fan blade on shaft to give more noise furnace clearance to surface being contacted. -fan has buildup of dust on one side of the fan making it unbalanced.

  • Page 36: Water Testing & Treatment

    10.4 Nitrite Treatment 10.4.1 Initial Nitrite Treatment Follow the instructions in with the Initial Treatment Kit included with the heater to initially treat the water. Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 37: Heater Model Specifications

    Heater Model Specifications Heater Specifications Specifications* U of M G2-Plua A x B x Overall Height x Width x Length 72 x 36.5 x 63.5 76 x 40 x 69.5 80 x 42.5 x 69.5 C-inch Weight 2200 2650 2750...

  • Page 38: Electrical Diagrams

    Electrical Diagram G Series Wiring Schematic Hi Limit Aquastat Controller Light. Light Fans Door Switch White 3 amp Slow Blow fuse 1 2 3 4 N N N Relay Relay ECM Suction Fan Primary Actuator Suction Fan 120 Volt Wiring ECM Suction Fan Control Wiring White Secondary Actuator...

  • Page 39: G-Class Parts

    G-Class Replacement Parts NOTE: Only replace parts and components with original Polar replacement parts. With Polar original replacement parts in your furnace, you are using parts designed to work with and fit perfectly with each other. Installing non-original parts voids the warranty. Parts shown may be different from actual furnace.
  • Page 40 SECTION 13: G-Class Replacement Parts Diagram 13.2—Air Gate Assembly Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 41 SECTION 13: G-Class Replacement Parts Diagram 13.3—G2 Ceremics Assembly Diagram 13.4—G2-Plus Ceremics Assembly For service and support on your Polar Furnace contact your local dealer...
  • Page 42 SECTION 13: G-Class Replacement Parts Diagram 13.5—G3 Ceremics Assembly Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 43 SECTION 13: G-Class Replacement Parts Diagram 13.6—Housing Components For service and support on your Polar Furnace contact your local dealer...
  • Page 44 SECTION 13: G-Class Replacement Parts Diagram 13.7—Fan Assembly Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 45: Plumbing

    Plumbing The hydronic system is used to distribute heat from or factory support regarding other means of protecting an outdoor wood furnace to where it is needed and the G-Class against cold return and maintaining can range in complexity from very simple to quite minimum required flow.
  • Page 46 Differentials as high as 40 F are acceptable on G-Class furnaces equipped with the Supply/Return Manifold. Consult with your dealer or the factory before selecting a pump for your distribution loop(s). Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...

  • Page 47: Safety Instructions

    SECTION 14: Plumbing 14.4 Boiler Protection Valve 14.2.4 Distribution Pipe Finishing Duct Maintenance 4 flat pieces are shipped inside each furnace (See “as shipped” in Diagram 14.3). The pieces are bent by The Connect-EZ assembly includes a boiler hand into a u-shape as shown in the diagram above. protection valve which is an important component in 2 pcs combine to form a rectangle.
  • Page 48 Consult with your dealer and/or local heating professionals to create a hydronic heat distribution system best suited to your requirements. Diagram 14.5–Boiler Protection Valve Cut-Away Diagram 14.7–Valve Wrench Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 49 SECTION 14: Plumbing Diagram 14.8– Open System Basic Install Diagram 14.9– Closed System Basic Install For service and support on your Polar Furnace contact your local dealer...
  • Page 50 SECTION 14: Plumbing Backup Boiler Diagram 14.10– Closed System Large System/ Multiple Stories Install Backup Boiler Diagram 14.11– Multiple Buildings Install Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 51 __________________ Your Notes __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ For service and support on your Polar Furnace contact your local dealer...
  • Page 52 Your Notes __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ __________________ Owner’s manual for Polar Furnace models: G2, G2 Plus & G3...
  • Page 54 Polar Furnace Mfg. Inc. Box 159. Sperling, Manitoba. R0G 2M0 For service and support on the Polar Furnace heater contact your local dealer. Printed in Canada Revision 5.0 ( July 2016)

This manual is also suitable for:

G2 plusG3

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