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					                 ACME FURNACE COMPANY




                  INSTALLATION
                      AND
             OPERATING INSTRUCTIONS

                        FOR

                   THE ACME
                 OUTDOOR WOOD
                BURNING FURNACE


                  Manufactured by
                Black Creek Welding
                 Shelbina, Missouri


                  Built for Quality
                  Sold with Pride
               For a "Greener World"
Revision A                1             01/26/09
                              ACME FURNACE COMPANY



 INTRODUCTION

 Thank You and congratulations on the purchase of your new ACME Outdoor Wood (or Coal)
 Burning Furnace!

 We at ACME Furnace Company applaud, support and encourage you in your efforts to
 be environmentally friendly and make this a "Greener World".

 With the purchase of this ACME Furnace, you will soon realize the high degree of
 craftsmanship and reliability that are found in every hand built furnace.

 We realize the importance in providing you, the customer, with this user and maintenance
 manual, which will allow you to use your furnace under the best possible conditions, optimize
 savings and increase its operating life. WE STRONGLY RECOMMEND THAT YOU READ IT
 CAREFULLY AND FOLLOW INSTRUCTIONS COMPLETELY.

 Once again, Thank You for purchasing an ACME Outdoor Wood (or Coal) Burning Furnace.

 THIS MANUAL INCLUDES IMPORTANT SAFETY INFORMATION


 ACME Furnace Company, LLC
 Macon, Missouri
 660-699-3845 or 660-651-5017




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                              ACME FURNACE COMPANY



 GENERAL INFORMATION

 Specifications

 Type of fuel - Wood and coal only
 For outdoor use only
 Electrical Rating - 115 VAC / 60 HZ / 1 PH
 15 AMP Breaker

 Clearance to Combustibles

 Top, Rear, Sides: 18"
 Chimney Connector: 18"
 Always use a double or triple-wall pipe when going through any kind of roof with at least 6" to
 2 feet of clearance from any combustibles (depending on the type of flu pipe). Check with the
 manufacturer for their recommendations!
 Front: 10 feet, with the door facing away from the structure.
 Flooring: Non-Combustible

 Furnace Features

 * 60" X 72" X 92" tall, 235,000 BTU, 235 gallon water tank, heats 5,500 square feet, 2,000 lb
 shipping weight


  Description            Width            Depth                       Height (approx.)
  36" cylinder            36"              34"                  26" + 10" for Ash Compartment




                        All specifications subject to change at any time.



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                               ACME FURNACE COMPANY

 SAFETY PRECAUTIONS

 Do not operate this equipment for other than its intended purpose nor in accordance with the
 instructions contained in this manual and all other instructions accompanying the furnace.
 It is important to observe safety precautions to protect yourself from possible injury.
 This furnace must be wired by a qualified electrician in accordance with the National Electrical
 Code.
 Never use any type of petroleum product, petroleum based product, charcoal starter, lighter
 fluid, lantern fuel, kerosene or any other flammable accelerant to start your furnace. KEEP
 ALL SUCH LIQIUDS AWAY FROM FIREPLACE WHEN IT IS IN USE.
 Keep anti-freeze, which is flammable, away from the furnace. Only use non-toxic anti-freeze.
 Test anti-freeze and other chemicals annually. The use of treated wood (painted, treated, etc.)
 and any other salvaged material that can emit noxious gases into the environment and are
 corrosive towards the components of the appliance is NOT ALLOWED and eliminates the
 rights of guarantee.
 DO NOT BURN GARBAGE, HOUSEHOLD WASTE OR YARD WASTE. In most areas, this is
 illegal. The furnace is designed to burn seasoned cordwood and coal. Burning other materials
 can reduce the life of the furnace and will void your warranty. Always open the ash door
 (bottom) before you open the firebox door (top). Open loading door - pausing momentarily
 between the first latch and the safety latch to allow any combustion gases to burn off.
 DO NOT OPERATE THE FURNACE WITH THE DOOR OR ASH RECEPTACLE DOOR
 OPEN. Always latch the doors securely. If the ash door is open for any extended period of
 time, other than for cleaning, it will cause over-firing of the fireplace and boiling.
 Always use proper care when installing, operating and maintaining the furnace.
 Always use protective gloves and glasses and be aware that hanging and loose clothing do
 not catch fire!
 Do not modify the furnace. Do not substitute repairs that can be provided by your dealer,
 distributor, or Manufacturing Company (Black Creek Welding).

 Failure to heed these warnings may result in personal injury and/or damage.

 CALL BEFORE YOU DIG THAT DITCH!
 Disposal of Ashes
 OPEN THE ASH DOOR FOR HE DISPOSAL OF ASHES. ASHES SHOULD BE PLACED IN A METAL
 CONTAINER WITH A TIGHT FITTING LID. THE CLOSED CONTAINER OF ASHES SHOULD BE
 PLACED ON A NON-COMBUSTIBLE FLOOR OR ON THE GROUND. ALL COMBUSTIBLE MATERIALS
 SHOULD BE DISPOSED OF BY BURIAL IN SOIL OR OTHERWISE DISPERSED, THEY SHOULD BE
 RETAINED IN THE CLOSED CONTAINER UNIT UNTIL ALL CINDERS HAVE THOROUGHLY COOLED.

 All installation and operation must follow Federal, Provincial, State and Local Codes



Revision A                                       4                                         01/26/09
                               ACME FURNACE COMPANY

 LIFETIME LIMITED WARRANTY

                            Year 100% On-Site Warranty!
             Plus, a Lifetime and 40 Year Warranty on roof and siding!
 We have a 5 Year On-Site warranty against leaks on the furnace – NOT prorated.

 We also have a 20 Year warranty against leaks on the furnace – Parts and Labor.

 Electrical components such as the fan, thermostat and pump and the door and grates have a
 one-year manufacturer’s warranty.

 We don’t have ship the furnace back to us, like some companies demand. Instead, we send a
 professional repairman to perform on-site repairs.

 a) Years 6 – 20 on the life of your furnace are prorated as follows:
 b) Year 6 - 90%
 c) Year 7 - 80%                                  We will give you the percentage discount
 d) Year 8 - 70%                                   on the repair or off a replacement boiler.
 e) Year 9 - 60%                                   The furnace will be repaired or replaced,
 f) Year 10 - 50%                                  whichever is less expensive.
 g) Year 11 - 40%                                  Shipping not included.
 h) Year 12 - 14 - 30%                             No cash or surrender value.
 i) Year 15 - 20 - 20%
 j) Year 21 to forever - 10%

 The cost of the service call is not covered after 5 years.

 The life of your furnace depends upon proper maintenance. With proper maintenance, your
 furnace can give you 25 – 30 plus years of dependable service.

 You MUST test your water annually and retain results for possible review by ACME Furnace
 Company (upon request) to support warranty claims, in some instances.

 Water samples must be submitted to a professional water testing lab. If there is not a water
 testing lab near your home, a “Water Sample Analysis Kit” can be purchased for your
 convenience. Recommended source:

 Wood Boiler Solutions

 Phone: 920-382-6498
 Website: http://www.diswebsites.com/woodboilersolutions/store.cfm




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                                ACME FURNACE COMPANY

 The following tests are performed and interpreted to ensure mineral levels which are harmful
 to carbon steel are within acceptable limits;

 Nitrite, pH, total dissolved solids, bio test, iron, glycol concentration/level (if applicable) and
 total hardness.

 Recommendations provided by the test lab MUST be followed.

 Exclusions

      1. Disasters, breakdown or faulty operation linked to:
          In adequate relation between the nominal power of the equipment and the heat
            requirements of the premises;
          A faulty installation or faulty connections;
          Damage to the thermostat through overheating due to intensive use;
               o The ash box door is left open
               o The ventilation convection fan is left off with high fires
          Failure to clean out ash;
               o Moisture combined with ash will eat through a furnace in short order and
                   WILL NOT be covered under warranty
          An insufficient or excessive draft;
          Incorrect use;
          Burning non-compatible fuels, destructive and/or damp fuels (treated wood, etc..)
          Burning other than non-treated, non-painted wood or coal;
          Damage caused from burning coal is not covered under the warranty
          Consumption exceeding the use limits;
          A lack of maintenance; not adding the recommended chemicals, water treatment
            and rust inhibitor;
          Any modification, transformation inside the appliance;
          Transport and installation.

      2. Transport and packaging cost.
      3. All costs not previously accepted by Black Creek Welding.
      4. Costs and deterioration due to the non-use of the equipment.
      5. The cost of any incidentals or consequential damage, including the loss of anti-freeze
         and/or water treatment.
      6. Warped grates or door (grates and door always warp over time due to high heat).
      7. Door seal gasket
      8. The guarantee starts on the date of delivery. The invoice showing the delivery date is
         the only document valid for the guarantee.




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                                  ACME FURNACE COMPANY

 BEST BURN PRACTICES

      1.     Read and follow all operating instructions supplied by the manufacturer.
      2.     FUEL USED: You may burn any hard wood (or softwood), as well as pallets that have
             been split up and coal, but never burn driftwood, painted, stained or pressure or/and
             chemically treated wood. Never use the following; trash, plastics, gasoline, rubber
             naphtha, household garbage, material treated with petroleum products (particle board,
             railroad ties and pressure treated wood), leaves, paper products, and cardboard. If you
             burn softwood, the wood will burn faster and you will have to clean the creosote and
             chimney more often.
      3.     LOADING FUEL: For a more efficient burn, always add wood before the wood has
             burned out. Most often it can be loaded in the morning and at night. Load coal before
             wood. See next page.
      4.     STARTERS: Do not use lighter fluids, naphtha, gasoline or chemicals.
      5.     LOCATION: It is recommended that the furnace be located with due consideration to
             the prevailing wind direction. Chimney height can be easily extended with 5.5”
             stovepipe. You can get downdrafts if the furnace is too close to a building.
                 We recommend a distance of at least 100 feet if prevailing winds blow towards
                    any other residence not ser4ved by the furnace. It is also recommended that the
                    stack be at least 2 feet higher than the eave line of that residence.
                 If located more than 100 feet, but no more than 150 feet to any residence, it is
                    recommended that the stack be at least 50% of the eave line of that residence ,
                    plus and additional 2 feet.
                 If located more than 150 feet, but no more than 200 feet to any residence, it is
                    recommended that the stack be at least 25% of the height of the eave line of that
                    residence, plus an additional 2 feet.




                            CHIMNEY HEIGHT RELATIVE TO NEAREST DOWNWIND NEIGHBOR


 The chimney can easily be extended with standard 5.5” stove pipe to any height necessary,
 with zero adverse affect on performance. In fact, it may even draft better. Always use at least
 a double wall pipe when going through any kind of roof. The chimney should extend at least 2
 feet higher than any portion of a building within a horizontal distance of 100 feet. You can get
 downdrafts if the furnace is too close to a building.

 6. Always remember to comply with all applicable federal, state and local codes and laws.



Revision A                                           7                                       01/26/09
                               ACME FURNACE COMPANY


 WOOD RECOMMENDATIONS

 Burn only cordwood that has been seasoned for 12 – 18 months. Burning unseasoned wood is
 wasteful and inefficient, using much of the combustion energy to boil off the excess moisture.
 It also puts a lot of moi9sture into the ash “pan” which makes it corrosive. Ideally, the wood
 should be split to aid in seasoning and should be approximately 25% moisture content by
 weight. However, whole rounds burn well and are cheaper. Rounds will have to be dried
 longer.
 The following are general guidelines for wood selection;
     Hardwoods burn better than softwoods (mix them if you need to burn softwood).
     Larger pieces burn better and longer than small pieces.
     25% moisture content is optimum. Drier is always better.
 Higher moisture content wastes energy boiling off water. Wood with a lot of moisture can
 cause more smoke than the chimney can dispose of. It also puts a lot of moisture into the ash
 “pan”, which makes an extremely corrosive mixture. Ash corrosion is NOT covered by the
 warranty.
 Lower moisture content (very dry, old woods) burns rapidly and inefficiently.

 BURNING COAL
 We recommend that you burn a coal and wood mixture. Keep the ash receptacle and firebox
 clean, as coal is very corrosive. You may want to place firebrick in the bottom of the furnace.
 Damage from burning coal is NOT covered under the warranty.

 ABOUT YOUR FURNACE
 How does an outdoor furnace heat my home?
 The ACME outdoor wood furnace is designed to save the most energy and provide the most
 comfortable heating available. It heats by heating a firebox surrounded by a steel tank filled
 with water. The furnace is basically a safe non-pressurized boiler with an atmosphere vent.
 This hot water is then circulated through underground hot water pipes (Pex Pipe) to a water
 coil (heat exchanger) installed inside your existing central duct system.
 If you have a boiler, a water-to-water heat exchanger is used. The ACME furnace can be
 connected to virtually any existing pressurized or no-pressurized boiler, Hydronic or radiant
 heating system that operates at 180 degrees or less. It will not work with steam systems.

 A typical water-to-air heat exchanger – much like a small radiator or heater core in a car, is
 installed in your ductwork. When air blows through it, heat is extracted and hot air blows out of
 your vents. You can also use hydronic or radiant heat utilizing Pex Pipe under the floors or in a
 concrete floor or by using radiators or baseboard hydronic heaters.



Revision A                                       8                                        01/26/09
                                  ACME FURNACE COMPANY

 How does an outdoor furnace heat water for household use?
 ACME Furnace utilizes a Side Arm Heat Exchanger mounted to the side of your existing hot
 water heater. Water is supplied to the heat exchanger and is then routed to the side arm
 before returning to the outdoor furnace, eliminating the need for two additional insulated Pex
 lines.
 How do the Thermostat Controls work?
 The outside furnace has a hot water thermostat that senses the water temperature of the unit.
 If the water is not as hot as the thermostat setting, the combustion air blower is automatically
 turned on (building a hotter fire by feeding oxygen to the base of the fire) and remains on until
 the desired (set) temperature is attained.

 PEX PIPE
 Insulated Pex Pipe
 We highly recommend that all Pex Pipe be insulated. You will burn less wood because there
 will be virtually no heat loss through the Pex pipe. ALWALYS bury it below the frost line for
 less heat loss and to avoid freezing. The ground temperature below the frost lone will be 50 –
 55 degrees or more.
 Purchase quality insulated Pex Pipe at a location of your choice.
 Pex Pipe Routing
      1.     Goes to the house heat exchanger.
      2.     Return from the house heat exchanger.
      3.     Power to pump, thermostat and blower.
      4.     Drain
      5.     Thermostat




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                               ACME FURNACE COMPANY


 Number 1 and 2 with arrow shows direction of water flow for built-in hot water coil in furnace.
 All furnaces come with another hookup now for another building, at no cost. More can be
 added when ordering furnace at no cost.

 LOCATION OF FURNACE
 The outdoor furnace should be located at least 10 feet from your home (in accordance with
 most insurance companies), with the door facing away from the house, so that all fire danger
 is removed from our home. We recommend 30 feet or more. The furnace many be installed as
 much as 100 – 120 feet away with the standard pump (or up to 300’ with a bigger pump) and
 still heat your house and hot water easily. The chimney should extend at least 2 feet higher
 than any portion of a building within a horizontal distance of 100 feet.
 If the furnace is located is located more than 100 feet away, you may experience some heat
 loss in the water going to your heat exchanger (and water heater) – about 2 degrees / 100 feet
 of well insulated Pex Pipe. A larger pump than the one supplied is needed for distances over
 120 feet and/or any rise in elevation over 8 feet.
 Locate the outdoor wood furnace where it will be convenient for refueling and wood storage.
 All water and power lines are installed underground between the house and the outside wood
 furnace in a 4” or 6” PVC pipe that is ALWAYS buried below the frost line.
 The furnace should be installed on a 4” thick concrete pad. The furnace should be set on the
 concrete pad with the rear of the furnace 2 – 3 inches from the end of the pad.

             A) It is recommended that the furnace be located with due consideration to any
                neighboring residences and to the prevailing wind direction.
             B) Do not locate an outdoor wood burning appliance within 100 ft of a residence
                not served by the furnace. Follow local and state laws concerning setbacks.
                Please be considerate of neighboring residences, properties, parks, etc.
             C) Review the recommended stack heights on page 9.
             D) Do not locate near any combustible materials, gasoline or flammable liquids or
                gases.
             E) Locate away from dry grassy areas, dry leaves, brush and trees.
             F) Place far enough away from any building to minimize fore danger.
             G) Check with our insurance company and local codes or ordinances.
             H) Do not install in an area where nearby structures or trees might cause
                downdrafts or fires.
             I) Typically, outdoor wood burning furnaces are located 40 to 100 feet down wind
                from the served structure.
             J) Transfer lines in excess of 120 ft may require a larger size pump than the one
                provided with the furnace, especially if there is any incline.
             K) Locate the furnace to allow easy access to wood supply.
             L) To aid in smoke dispersal, extra chimney lengths may be required depending on
                the distance to surrounding structures. See page 9 for additional guidance.
             M) The furnace requires 115 V, 15 amp electrical services to operate.



Revision A                                      10                                        01/26/09
                                   ACME FURNACE COMPANY

 The space between the inside rear of the furnace and the door will allow space for a 4 or 6
 inch water tight PVC pipe with the plumbing and electrical lines, to run directly into the ground.
 We put a large full size door on the back that will allow you easy access for the connection of
 the plumbing and electrical lines.

 The PVC pipe must be buried below the frost line and most jurisdictions require a 2 foot
 minimum depth for the electrical wire.
 After placing your furnace on the concrete pad, you are ready to continue with the installation.
 Preparing Your Furnace
      1. Remove access panel from the rear of the furnace, to make plumbing and electrical
         connections.
      2. Open the protective cover on the side of the blower. Simply swing it open so the inlet is
         exposed ¼ of the way.
      3. The fire should be blazing when the fan is on. It should be just smoldering if the fan is
         off. Quickly crack open the firebox door to see what the fire is doing (leaving the door
         open for any length of time will produce a blazing fire). If you have too hot a fire with
         the fan off, close the cover on the side of the fan a little more. The water should never
         be boiling. If it is, the cover is open too far or there is a downdraft problem.
      4. The plumbing and electrical lines for your furnace must be installed underground in a
         water tight 4” or 6” PVC pipe or use pre-insulated pipe.
      5. A trench must be dug wide enough to accommodate the pipe that you choose. All
         plumbing and electrical lines MUST be run inside the water tight PVC pipe.
      6.     If more than one location is to be heated, then additional PVC with Pex Pipe must be
             installed underground to that location.
      7.     This pipe will run from the rear of the furnace to the location to be heated. Inside the
             water tight pipe a re the water lines and electrical supply wire (# 12/3 W/Ground UF).
      The listing below describes each water line and their function;

      1. One water supply line to heat exchanger , placed into existing heat system. This one is
         attached at the circulating pump. All of these must be 1`” pipe. 1” pipe will give up to
         37% more BTU than ¾ with the same heat exchanger.

      2. One water line from heat exchanger. This line is attached at the nipple at the bottom of
         the furnace to carry cool water back into the water jacket.
      3. One # 12/3 W/Ground UF underground Romex wire.

      4. Tap into existing indoor plumbing for filling the furnace.




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                                ACME FURNACE COMPANY

 Filling The Furnace With Water And Chemicals

 Once your Pex pipe is hooked up, simply turn on the manual fill valve and allow it to fill until
 water runs out the overflow (Shown below). After starting the pump and bleeding the heat
 exchanger, top off the water again. Be sure to open the valve at least once a week during
 heating season to keep the furnace topped off. Failure to do so may result in overheating and
 circulating pump failure.

 Plumbing Parts Needed

    1. You will need 1” Pex Pipe for the main pumps to the heat exchanger.

    The Pex Pipe connected at the bottom of the pump runs to the house and normally runs to
    your heat exchange (water-to-air or water-to-water).

    This will also be your supply line if you have a Hydronic or radiant heating system. A brazed
    plate heat exchanger is recommended between the two systems.

    SharkBite™ fittings are HIGHLY recommended for installing the Pex Pipe.

      1. Install two shut-off valves, one at the return and one at the pump to isolate parts of the
         system as needed.

 Installing The Heat Exchanger In The Plenum Or Ductwork

 If you have air conditioning, the heat exchanger must be installed between the furnace and the
 evaporator coil. Failure to do so may result in freezing of the heat exchanger. If you can’t place
 the heat exchanger between the furnace and the evaporator coil, you must drain the heat
 exchanger annually before using the A/C.

 The heat exchanger must be installed so that it is airtight. No air must be able to flow around it
 or out of the ductwork. Use adhesive backed foam tape (used for insulating doors and
 windows) around the water coil. Use foil tape to seal off the heat exchanger and the hole you
 make, or consult a local HVAC installer or technician.


 Make sure the fittings are easy to get to once it is installed. Ideally, there should be no splices
 in any water lines. If you have to splice two lines together, use SharkBite™ fittings.

 You should be able to find a heat exchanger to fit most popular sizes of plenums. If you can’t,
 you must have your ductwork modified to accept the heat exchanger. This is best left to a
 professional, unless your ductwork is made up of fiber board. In all cases, wear protective
 gear, gloves, glasses and a mask.

 Measure the width of the heat exchanger (Dimension A). Measure the thickness of the heat
 exchanger (Dimension C). See Diagram 1 on next page.



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                                ACME FURNACE COMPANY




                                             Diagram 1

      1. Start by cutting a hole in the side of your ductwork the thickness of the heat exchanger
         (Dimension C) and the full length of the ductwork (Dimension A). See Diagram 2
         below.




                                             Diagram 2


      2. Slide the heat exchanger into the hole for a test fit. Ideally, the tubes (D & E) should
          stick out of the plenum. The header and tubes (F) can stick out of the plenum as well, if
          necessary. As long as the whole coil surface (B) is in the plenum, you should be good,
          even if a little more of the header, (F) and (G), sticks out. See Diagram 1 on the
          previous page. While test fitting, try to determine how much tape is needed around it. A
         different amount (thickness) may be needed on different sides. You can purchase
         different thicknesses of tape so that it will fit and seal properly.
      3. Place foam tape around the outside of the heat exchanger to seal it off so that it fits
         tight and air can’t blow by it.
      4. The heat exchanger needs to be installed so it won’t move around. The easiest way is
          to use a right angle (“L” shaped) metal braces, approximately the length of the heat
          exchanger. See Diagram 3 on next page.

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                               ACME FURNACE COMPANY




                                            Diagram 3

 Below (Diagram 4) is what the braces would look like. Very simple. Rivet or screw into place.




                                            Diagram 4

 Slide the heat exchanger carefully into the plenum to check the fit again. If all looks good, you
 can seal off the ends of the heat exchanger and the hole you made in the plenum with foil tape
 made for ductwork.

 Installing a Heat Exchanger that is Longer than the Plenum

 You can install a heat exchanger in a plenum that is smaller than the length of the heat
 exchanger, as follows;

      1. Cut the red line vertically (from top to bottom) in the center of the plenum. See
         Diagram 5 below.
      2. Cut the red lines horizontally at the top and bottom of the plenum, about 2 inches out
         from each side of the vertical center cut (4 inches total). See Diagram 5 on next page.




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                               ACME FURNACE COMPANY




                                            Diagram 5

 Bend the metal back from the vertical center cut to slightly past 90 degrees. See Diagram 6
 below.




                                            Diagram 6

 Slide the heat exchanger through the front hole to the back hole, so that it protrudes front and
 back. Ideally, the core of the heat exchanger will be entirely within the plenum.

 Crimp the sheet metal to the edge of the heat exchanger (this is item G in Diagram 1).
 Using channel locks to crimp it makes a very nice professional looking installation. This not
 only forms a virtually air tight seal, but it also supports the heat exchanger as well.


 Bleeding a Heat Exchanger

 We recommend a “T” fitting and ball valve to allow bleeding from the heat exchanger once the
 system is pumping.

 Insufficient Air Flow Through Plenum

 You can attain 10 – 11% higher BTU outputs with 37 – 50% higher CFM of air flow. If you
 need more air flow, the pulleys (if used) can usually be changed on the fan and/or motor to
 give a higher fan speed.
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                               ACME FURNACE COMPANY

 Many furnaces have 2 variable speed fans, utilizing the high speed for A/C, which can be
 beneficial here. Please consult a furnace specialist about this.

 How to Prevent the Water From Freezing

 As long as there is a fire, the water won’t freeze in the outdoor furnace.

 The pipes that are underground won’t freeze if they are below the frost line, as the ground
 temperature is 50 degrees or more.

 Connection of Power to the Furnace

 We recommend that a junction box be installed with 4 plugs in outlets. This will allow you to
 plug in up to 3 pumps plus the draft blower.

 Route the black, white and ground wires by the thermostat to the blower, breaking the black
 wire and connecting to each terminal on the thermostat. This will allow control of the blower by
 the thermostat.

 Wiring Running to the House

 12/3 W/Ground from the breaker box inside your home with 15 amp breaker to the junction
 box inside the furnace.

 Hooking Up the Outdoor Furnace to an Existing Boiler

 Again, we need to use a heat exchanger to transfer heat from the outdoor furnace to the boiler
 or hydronic system so that the two systems remain isolated from each other. A water-to-water
 plate heat exchanger is used in this type of system. See Diagram 7 below.




                                             Diagram 7

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                                   ACME FURNACE COMPANY

 The 2 systems are totally isolated from each other so that the existing hydronic system (usually
 pressurized) remains undisturbed and functions exactly as it did before. All pumps and controls remain
 the same. The system’s return water goes through the heat exchanger and gets reheated before entering
 the existing boiler.

 The water circulates from the outdoor furnace, to the heat exchanger, out the top of the heat exchanger
 and back to the return on the outdoor furnace. Water that circulates through the furnace is never
 circulated through the home’s hydronic system or visa versa.

 Starting a Fire

 Use small pieces of split kindling together with crumbled newspaper or cardboard, adding larger pieces
 as the flame grows. Remember, the smaller and drier the better.

 If it is Difficult to Start the Fire, These are the Reasons it Might Be;

 Not enough air: Make sure the fan is on and/or open the ash door.
 Bad kindling: See Starting a Fire.
 Down Draft / Cold Chimney: Heat up the chimney by twisting some newspapers into a torch and hold
                                it up into the stove until the draft is reversed.
 Boiling Water: Draft for fan in back of the furnace is open too far. Try reversing input and output, with
                pump at bottom of furnace.

 Testing

 This should be done when the furnace and heat exchanger are first installed so that you will know that
 the water flow is like in your system, for future reference.

 Perform these steps on a new furnace:

      1. After the furnace has been filled and running, separate the 2 valves shown above at the Pex Pipe
         between them, after turning off both valves so that water won’t drain out.

      2. Insert the left plastic valve and pipe in a 5 gallon bucket. Open he valve and turn on the pump
         by turning on the furnace (raising the thermostat will do this, if necessary).

      3. Record the amount of time it takes to fill the 5 gallon bucket. If it is 45 seconds, for example,
         write that figure down on the inside of the furnace with a permanent marker near the valve for
         future reference. Turn off the plastic valve.

      4. Disconnect the Pex line at the pump output. Install a short piece of Pex Pipe or washing machine
         hose about 4 – 6 feet long and insert the pipe/hose into a bucket. Turn on the pump by turning
         on the furnace.

      5. Record the amount of time it takes to fill the 5 gallon bucket. If it is 35 seconds, for example,
         write that figure down on the inside of the furnace, nest to the pump for future reference. Turn
         the pump off.


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                                    ACME FURNACE COMPANY

 Maintenance

      1. CLEAN OUT ASH: Ash and/or coal corrosion IS NOT COVERED under warranty.

      2. CREOSOTE: When wood is burned slowly, it produces tar and other organic vapors which
                   combine with moisture to form creosote. The creosote vapors condense in the
                   relatively cool chimney flue of a slow burning fire. As a result, creosote residue
                   accumulates on the flue lining. When ignited, this creosote makes an extremely
                   hot fire.

                            The chimney should be inspected at least once a month during the heating
                            season to determine when a creosote buildup has occurred. When creosote has
                            accumulated, it needs to be removed to reduce the risk of a chimney fire.

                            All creosote and ash must be cleaned from the firebox twice a year, preferably
                            halfway though the heating season and immediately after the heating season.

 Door Seals
 We recommend keeping creosote build-up clear of the door seal to ensure proper fit. This will not all
 creosote to stick to the seal. If installing new seal, use 3/8” fiberglass rope and high temperature silicone
 to seal in place.

 End of Season

            Power: Turn off power supply at the appropriate circuit breaker
            Chimney: Clean and inspect chimney. Cap the chimney to keep rain water out.
            Firebox and Ash Receptacle: Remove ashes, soot, and hardened deposits from the
             firebox by using a putty knife or wire brush. Coat inside of firebox with a light coat of
             motor oil to protect the steel during the off season.
            Doors: Oil door hinges and latches.
            Plumbing: Ensure fittings on both ends of tubing are tight at all locations.
            If anti-freeze is not being used: The water jacket must be drained and flushed yearly
             right before each heating season. Always dispose of anti-freeze according to state and
             local codes. The water testing company will advise if you can leave the old water in.

 Trouble-shooting:
 Poor Water Flow or Little or No Heat:

      1.      Check to make sure that the furnace is full of water. Simply open the valve on the front
              until water flows out of the overflow tube.

      2.      Make sure you have a good fire.

      3.      Make sure that the water is hot. You can check this at the drain on the stove or at the
              pump by removing the Pex Pipe and turning on the pump.

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                                   ACME FURNACE COMPANY

      4.     Watch the fan to see if it comes on when the water temperature drops in the furnace.
             You can test the fan by connecting the two wires at the thermostat together AFTER
             TURNING OFF THE POWER.
             If the fan comes on when you connect the two wires, but it won’t come on by itself
             when the water temperature drops, you need to replace the thermostat.
             In most cases, the flap on the side of the fan should only be open 1/4 to 1/3.
      5.     Turn off both valves so that water won’t drain out. Separate the two valves at the Pex
             Pipe between them.
      6.     First open the right shut-off valve with the large handle. If water flows out freely, then
             you know that there isn’t a blockage there. Close the valve.

      7.     Insert the plastic valve and pipe in a 5 gallon bucket. Open the valve. Turn on the
             pump by turning on the furnace (raising the thermostat if necessary).

      8.     Record the amount of time it takes to fill the 5 gallon bucket. Turn off the plastic valve.
             Compare that figure to the one you wrote down on the inside of the furnace, near the
             valve, when it was installed. If the figures are the same or very close to it, you can
             assume that the pump is working properly and that there aren’t any blockages.
             However, you may have a heat exchanger with a coating of minerals on it, such as
             lime. This will need to be cleaned as it will inhibit heat transfer.

      9.     If the figures are lower than original, proceed to step 10 and find out why the flow is so
             low.

      10. Remove the pump and open the valve above it. If water flows freely, you know that
          there is no blockage there. If good proceed with next step.

      11. Disconnect the Pex line at the pump output. Install a short piece of hose or Pex
          Pipe, about 4 – 6 feet long and insert the pipe into a bucket. Turn on the pump by
          turning on the furnace (raising the thermostat if necessary).

      12. Record the amount of time it takes to fill the 5 gallon bucket. Turn off the plastic valve.
          Compare that figure to the one you wrote down on the inside of the furnace, near the
          valve, when it was installed. If the figures are lower, you know there is a problem with
           the pump.

      13. At this point, you should have been able to determine if the flow rate is good at all
          points and where the problem might be or if there is a blockage.

      14. If you have a fire and the water is hot and circulating without restriction and the furnace
          fan is on, you should have heat. In many cases, air might be trapped in the heat
          exchanger and the bleeding procedure below will need to be performed.

      NOTE: If you have poor draft or a downdraft, heat up the chimney by twisting some
            newspaper into a torch and hold it up into the stove until the draft is
            reversed.
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                                  ACME FURNACE COMPANY

 If the water is boiling:

 Simply close the cover more, on the side of the fan.

 The fire should be blazing when the fan is on. It should be just smoldering if the fan off.

 Quickly crack open the firebox door to see what the fire is doing (leaving the door open any
 length of time will give you a blazing fire).

 If you have too hot a fire with the fan off, close the cover on the side of the fan a little more.
 The water should never be boiling. If it is, the cover is open too far or there is a downdraft
 problem.

 If you still have a boiling problem or you are using too much water, you can move the pump to
 the bottom of the furnace (what is now the return line) and have the return line go to there the
 pump is now.


 Heat Exchanger Cleaning Procedure:

 Recommended: Remove the heat exchanger and take it to a radiator shop for chemical
              cleaning.

 The following is a list of chemicals that may be used to clean the heat exchanger:

            Phosphoric acid
            Muriatic acid (very hazardous)
            Safe-React Formula E – http://www.safe-react.com/formu e.htm
            CLR

 Fill a 5 gallon bucket with Safe-React or CLR per the instructions for dilution, or a 10 – 12%
 solution of Muriatic acid or Phosphoric acid to water.

 Place both supply lines and return lines in bucket with a submersible pup on the supply side.
 You may have to run the pump for three to eight hours. You should be able to see the process
 working as water flows into the bucket.

 Sometimes, reversing the flow can free up deposits encrusted in the heat exchanger.




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                               ACME FURNACE COMPANY

 DISCLAIMER
 All installation, wiring and operation must follow Federal, Provincial, State and local codes,
 ordinances and laws.

 Do Not consider outdoor wood furnaces for built up urban areas.

 The ACME Furnace is not intended to be the only source of heat. Therefore a backup system
 should always be in place and be ready to use.

 A back up generator is HIGHLY recommended so that you can have heat during power
 outages.

 The pump and fan only draw 120 watts together. The furnace fan can draw 1350 watts or
 more on start up. A small 2000 watt generator will power it all and give you extra power for
 lights.

 Do Not Operate under Pressure.

 Keep the overflow tube clean and free of debris, bugs, etc. Do Not close it off. It is supposed
 to steam and release pressure through this tube.

 All electrical and plumbing should be done by qualified personnel and conform to national and
 local building, electrical, plumbing, fire and building codes.

 Manufacturer is not liable for damages to personnel or property for misuse, improper
 installation of equipment or for knowing local installation codes. Owner assumes all
 responsibility for this.




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