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Applications - Specifications - Application notes - Configuration - Safety Notes - Accessories - Warranty - Cost - Drawings - E-brochure

Polar’s Model 30 Exhaust Heat Exchanger converts the waste heat from the engine exhaust into useable heat for hot water, steam, and space heating.

  • Why waste fuel?

  • Why spend more money on a larger generator?

  • Why make your generator work harder and increase maintenance?

  • If you need heating, it makes sense to incorporate our Model 30 exhaust heat-exchanger into your standby or prime power (hybrid solar or wind) system! Relatively simple to add and operates on either AC or DC generators.

  • The Model 30 will typically reduce the exhaust backpressure in most installations and this will improve fuel consumption. 

  •  The Model 30 incorporated with a secondary muffler will create a very quite exhaust.

  • Model 30 is ideal for 10 to 30 Hp engines or 5 to 20 kW generators.

Applications include:
  • Hydronic floor heating.

  • Engine driven carpet, floor, and steam cleaners.

  • Space heating.

  • Eliminates wet exhaust systems for marine generators.

  • Provides heat for absorption air-conditioners.


  • Counter flow Spiral Plate heat exchanger technology.

  • All 304 stainless steel construction.

  • Up to 50,000 Btu/hr heating capacity.  Note that its the horsepower (load) the engine is operating under (not the engine rating) that determines the amount of heat available.

  • Water or water/glycol are typical fluids for heating.

  • 125 psig maximum fluid working pressure.  

  • Water pressure drops at various flow rates are
    • 15 gpm 5 psi

    • 10 gpm  2.0 psi

    • 8 gpm 1.5 psi

    • 5 gpm  0.5 psi

  • The exhaust pressure drop is dependent on gas inlet temperature and water temperature.  Typical pressure drop for an 18 hp engine is under 0.75 psi.  

  • Exhaust gas temperature will be within 100 F of the water exit temperature.

  • Water inlet and outlet fittings are 1” NPT Female

  • Overall dimensions are 18.0 long by 10.375 inches tall by 6.375 inches deep.

  • Weight is 27 pounds dry.

  • Shipping weight is 31 lbs. and container dimensions are 24” X 12” X 10”

Safety Notes:  

Do not pump water (at any temperature) into the heat exchanger if the engine has been operating and there was no water being circulated through the heat exchanger.  Water entering a hot heat exchanger will cause the water to flash to steam and create explosive pressures.  Turn off the engine and allow the heat exchanger to cool down before introducing water into the heat exchanger.

Depending on the application Polar recommends that a thermostat be added to the heat exchanger to either prevent water flowing into a hot heat exchanger and/or shut down the engine.

Incorporate overpressure relief valves into your system.  Point the overpressure discharge into a safe direction.

Be sure to mount the heat exchanger per the installation drawing, the exhaust outlet must be mounted in a down position to allow the gas exhaust condensate (water) to drain. 

On custom installations we recommend that the exhaust manifold pressure be checked.

If the continuous flow of condensate water becomes undesirable then raise the temperature of the water leaving the heat exchanger by dropping the water flow rate through the heat exchanger.  This will raise the temperature of the exhaust gas causing less water to condense.  This task can be accomplished automatically by using a thermostatic valve to regulate the water flow rate through the heat exchanger. Adjust the exit water temperature to range from 150 to 190 F.  Note: these high temperatures are not recommended for bathing applications.

The Model 30 Exhaust Heat Exchanger is a single wall design and to meet US code requirements for heating potable (drinking) water a double walled heat exchanger is required.


  • Water flow temperature regulator. 

  • Access tap for measuring exhaust backpressure.

  • Galvanic isolation (water side).

  • Heat exchangers for space heating.  

  • Over pressure relief value.


5-year warranty for salt water and marine applications.  10-years warranty for fresh water.  Warranty void due to corrosion as a result of electrolysis.  Warranty also does not cover the build up of scale.  

Application notes:

12-hp engine load (7 kW) produces 30,000 Btu/hr of hot water at a flow rate of 10 gpm.  Engine exhaust gas temperature is under 140 F leaving the heat exchanger with water leaving the heat exchanger at 120 F.  Water increases in temperature 6 degrees on each pass through the heat exchanger.  

Some simple calculations:

To produce 5,000 watts of electricity your generator produces over 5,882 watts in heat.  It makes no sense to buy a generator and hook it up to an electric water heater or central heating system.  This is a clear waste of fuel resource.  


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Revised: March 21, 2005 .