White Rodgers G1N 4R9 User Manual

Stove Builder International Inc.

1700, Léon-Harmel

Québec(Québec)

G1N 4R9

Installation and Operating

Instructions for Wood and

Combined Wood-electric Furnaces

THIS MANUAL CONCERNS THE FOLLOWING FURNACES

WOOD COMBINED ELECTRIC

PSG-2000 15 KW, 18 KW, 20 KW PSG-3000 15 KW, 18 KW, 20 KW, 25 KW PSG-4000 18 KW, 20 KW, 25 KW, 30 KW PSG-4500 18 KW, 20 KW, 25 KW, 30 KW PSG-5000 40 KW, 50 KW, 60 KW

All the instructions must be read carefully

before installing and operating furnace.

CONGRATULATIONS!

You have just purchased one of the best wood or combined

wood-electric furnace on the market.

We are convinced that your furnace will provide you

with many years of comfort, safely.

Keep these instructions!

Table of contents

INTRODUCTION ..................................................................................................................... 4

1. CHIMNEY AND DRAFT...................................................................................................... 4

2. SAFETY RULES................................................................................................................. 4

.............................................................................................................................................4 GENERAL REQUIREMENTS

................................................................................................................................................5 ODOUR FROM THE PAINT

......................................................................................................................................................................5 ASH DISPOSAL

.........................................................................................................................5 CREOSOTE BUILD-UP AND REMOVAL

.............................................................................................................................................................6 SMOKE DETECTOR

.......................................................................................................................................................................6 ASH DRAWER

...........................................................................................................................................................................6 ASH GRATE

3. APPLIANCE INSTALLATION............................................................................................. 6

..................................................................................................................................................................6 UNIT LOCATION

.........................................................................................................7 CLEARANCES TO COMBUSTIBLE MATERIALS

...................................................................................................................................7 PIPE CONNECTOR AND DAMPER

.................................................................................................................................................................................8 DAMPER

...............................................................................................................................................................8 COMBUSTION AIR

............................................................................................................................................9 ELECTRICAL CONNECTION

.......................................................................................................................................................10 ELECTRIC ELEMENT

....................................................................................................................................................................11 THERMOSTAT

...................................................................................................................................................................11 FAN CONTROL

4. OPERATING INSTRUCTIONS.......................................................................................... 12

.......................................................................................................................................................................12 Control system

..............................................................................................................................................................................13 HEATING

..................................................................................................................13 EARLY SIGNS OF OVERFIRED FURNACE

..............................................................................................................................................13 WOOD AS HEATING FUEL

................................................................................................................................................................14 CHIMNEY FIRES

5. MAINTENANCE ................................................................................................................ 15

.....................................................................................................................15 MAINTENANCE OF THE EXCHANGERS

...............................................................................................................15 MAINTENANCE OF THE BLOWER MOTOR

................................................................................................................................................................................16 FILTERS

....................................................................................................................................16 DOOR GASKET MAINTENANCE

6. REPLACEMENT PARTS................................................................................................... 16

................................................................................................................................................................................16 GASKET

7. ELECTRIC DIAGRAMS FOR UNITS BUILT FROM 2005 ................................................ 17

................................................................................................................................................17 WOOD-ONLY FURNACES

.......................................................................................................................................18 WOOD/ELECTRIC FURNACES

................................................................................................................................19 PSG5000 WOOD-ONLY FURNACES

.......................................................................................................................20 PSG5000 WOOD/ELECTRIC FURNACES

8. ELECTRIC DIAGRAMS FOR UNITS BUILT BEFORE 2005............................................ 21

..................................................................................................................21 WOOD ONLY FURNACES PSG 4000 & 4500

...............................................................................................................................22 WOOD ONLY FURNACES PSG 5 000

........................................................................................................23 WOOD/ELECTRIC FURNACES PSG 4000 & 4500

.........................................................................................24 WOOD/ELECTRIC FURNACES PSG 5000 40KW @ 60KW

............................................................................................................25 WOOD ONLY FURNACES PSG 2000-3000-4000

...................................................................................................26 WOOD/ELECTRIC FURNACES PSG 2000-3000-4000

9. TECHNICAL SPECIFICATIONS ....................................................................................... 27

10. SELECTION CRITERIA (COMBINED WOOD/ELECTRIC FURNACE).......................... 28

11. TROUBLESHOOTING..................................................................................................... 29

12. DUCTS AND REGISTER MEASUREMENTS ................................................................. 30

LIMITED LIFETIME WARRANTY................................................................................. 31

INTRODUCTION

To get maximum performance from your PSG furnace, keep in mind the following:

• Comply with local codes (if in doubt, contact your local heating specialist).

• Refer to the furnace’s certification label and your instruction manual for minimum installation clearances.

• Make sure that your furnace has been installed in accordance with the required standards specified on the

furnace’s identification label.

1. CHIMNEY AND DRAFT

This furnace must be connected to a chimney approved for wood-burning appliances; the chimney connector for a PSG 2000 must have 6" diameter; 7” for PSG3000 and PSG4000, for all other models, use an 8" diameter chimney connector.

Use the supplied barometric draft control. Never use a manual chimney damper.

The barometric control must be adjusted so that the maximum draft measured at the furnace outlet does not exceed

-0.06 in. w.c. Please note that a draft exceeding -0.06 in. w.c. could produce an uncontrollable fire. On the other

hand, the minimum draft required is -0.04 in. w.c. in the evacuation pipe on the wood side, no matter what type of furnace (PSG Wood, PSG Wood/Electric and PSG Wood/Oil).

• Never light your furnace using chemicals or other liquid fuels. Never installed automatic feeder on that unit.

• Never store wood near the furnace. Respect the required minimum clearances between combustibles and

your furnace.

• Keep your furnace, chimney and smoke pipe connector clean and in good working order at all times. We recommend that you establish clear procedures for wood storage, system maintenance and operation of your furnace. Check creosote accumulation daily until you can determine by experience how often to clean. Weekly cleanings may be necessary in mild weather, while a monthly cleaning may be all that is required during the colder months of the year.

• Keep loading and ash drawer doors shut during operation and make sure their gaskets are in good condition. To replace defective gaskets, see your dealer.

• A plentiful supply of air and a vigorous fire will reduce creosote accumulation.

All controls adjustments must be performed by a qualified technician. The controls settings and the blower speed must conform to the recommendations of the National Warm Air Heating and Air Conditioning Association and respect the recommended static pressure ranges in the warm air bonnet of the furnace (see General Technical data static pressure).

2. SAFETY RULES

GENERAL REQUIREMENTS

 Make sure the chimney outlet and the pipes are clean and in good condition.  Do not use chemical products or liquids to light the fire.  Do not burn wood coated with paint, glue or chemical products.  Do not burn wastes or flammable liquids such as gasoline, naphtha or motor oil.  Do not install an automatic feeder on this furnace.  Do not store wood in the vicinity of the furnace. Respect the required clearances between combustible materials

and the source of heat.

W A R N I N G

-THE ASH DRAWER GET VERY HOT.

-DO NOT MANIPULATE WITH BARE HANDS.

ODOUR FROM THE PAINT

It is normal that a smoke odor emanate from the unit when you first light it. It is recommended to burn it at high rate

and ventilate the building until the odour resorbs.

ASH DISPOSAL

Ashes must be placed in a metal container with a tight fitting lid. The container should be placed outside, well away from combustible materials. If the ashes are meant to be buried in soil, you should wait until all cinders have thoroughly cooled.

CREOSOTE BUILD-UP AND REMOVAL

When wood is burned slowly, it produces tar and other organic vapours which, when combined with moisture, form creosote. The creosote vapours condensate in a relatively cool chimney flue. As a result, creosote residue accumulates in the flue lining. N.B.: To minimize the frequency of the chimney cleaning, buy your firewood at least one year before using it. Store it in a dry place in order to obtain the minimum moisture rate and optimize the efficiency. Do not store wood or combustible materials within the installation minimum clearances or the space required to reload the appliance and remove the ashes.

When ignited, creosote produces an extremely hot fire inside the chimney.

To avoid this situation, it is important to do the turnover of wood. Inspect the chimney system at regular intervals to determine a cleaning cycle. A weekly cleaning might be required during mild temperature periods but a monthly

cleaning should be sufficient during cold periods. If a significant layer of creosote has accumulated, it should be removed immediately to eliminate the risk of a chimney fire. Remember that a small hot fire is preferable to a

large smouldering one to prevent creosote build-up within the system. An emergency plan is necessary in case of a chimney fire. It’s recommended to clean up the heat exchangers at the end of season in order to prevent corrosion build-up.

SMOKE DETECTOR

We highly recommend the use of a smoke detector. It must be installed at least 15 feet (4,57 m) from the appliance in order to prevent undue triggering of the detector when reloading.

ASH DRAWER

Your appliance is equipped with an ash drawer to collect ashes produced by the combustion of wood. This drawer must not be left open during combustion as this will cause over firing and serious damage to the furnace.

The drawer must be cleaned regularly.

It is important that the door and the ash drawer be kept closed while the appliance is in use. Maintain all gaskets in good condition: in case of deterioration, contact your dealer fo replacement.

ASH GRATE

You must replace the ash grate if it is damaged and a replacement may be obtained from your dealer.

3. APPLIANCE INSTALLATION

UNIT LOCATION

The furnace must be installed where outside air supply is sufficient for proper combustion. In airtight houses, it might be necessary to install an outside air inlet (see details in: «3- INSTALLATION» D- COMBUSTION AIR).

The furnace must be positioned so that the connector is as short as possible in order to minimize the use of 90 elbows.

The owner must ensure a proper installation to allow a safe operation of the appliance.

CLEARANCES TO COMBUSTIBLE MATERIALS

N.B. This appliance must be installed in accordance with the instructions on the unit’s certification.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FOR P SG FURNACES

2”

24” both sides for

PSG5000

N.B. THE AIR RETURN CONDUITS SHOULD BE AT LEAST EQUAL TO THE COLD AIR

PLENUM DIMENSIONS.

PIPE CONNECTOR AND DAMPER

Before proceeding to connection, remove all accessories such as: scraper, shovel and poker in the evacuation pipe of the furnace.

A 6” diameter chimney listed for use with wood burning heating appliances is recommended for the PSG2000, 7” for PSG3000-4000 and 8” for the others models. Install the barometric control provided with the furnace. Never install a manual damper.

WOOD FLUE PIPE

OIL FLUE PIPE (OPTION)

MAIN COLLECTOR

For a proper installation, follow the advices below:

1. All the joints of the evacuation pipe must be secured, using three screws.

Make sure that each screw goes through the inner walls of both connectors (male and female). See pictures below showing a male-female coupling.

PROPER INSTALLATION UNPROPER INSTALLATION

2. A minimum rise of 1/4 inch per horizontal foot must be respected.

CAUSE RESTRICTION

DAMPER

The barometric control must be adjusted so that the maximum draft measured at the furnace outlet is limited to -0.06

in. w.c. Please note that a draft higher than -0.06 in. H2O could result in an uncontrollable fire. On the other hand,

the minimum draft to be respected is -0.04 in. w.c. in the evacuation pipe on the solid fuel side, no matter what type of furnace.

COMBUSTION AIR

In the event that the furnace and the chimney are completely cold, it might be necessary before lighting, to provide fresh air by opening a door or a window for a few minutes.

Take note that a house constructed or renovated in order to be airtight is liable to lack fresh air which is necessary for a proper combustion and a proper operation of heating units.

In such a case, when starting up the fire, do not operate appliances which evacuate air outside the house such as:

- Range hood

- Air exchanger

- Cloths dryer

- Bathroom fan

- Ventilated central vacuum system

NOTE:

It is recommended to install an outside air inlet of minimum 4” diameter in the room where the heating appliance is installed (see drawing below). To do so, it is preferable to choose a wall which is not exposed to extreme winds, according to the conditions surrounding your house.

Insulated conduit full lenght

Free air entr

Exterior

.B. The owner of the furnace is responsible for the room salubrity in case of negative pressure or temporary

negative pressure.

LECTRICAL CONNECTION

The following instructions do not supersede the local cod

OOD ONLY

Installed limit control on support roper location of the appliance (two holes are predrilled on the edge of

provided on p the furnace), and connected to the electrical box along with the transformer. Install the servo-motor on the front facade above the door, on the right side (use pre-drilled holes). The chain that links the air inlet latch to the motor must have a play of 1/8 in. When there is no call for heat, the air inlet latch must be completely shut and the chain must be affixed

to the servo-motor at “8 o’clock”.

The switch located on the fan limit control activates high speed operation, in either automatic or manual (continuous

operation) modes.

e switch located on the electric unit controls low speed operation, in either ON (continuous operation) or OFF

Th modes.

ARNING: USE FEEDING WIRES SUITABLE FOR 75OC

all

Fresh air intake

OOD/ELECTRIC

The limit control is a manual reset thermostatic captor and is located directly inside the electric element (see

WIRING DIAGRAMS). The electric elements must be installed as shown on the diagram. Install the combined limit

control on the support provided, at the determined location. The connections must conform to the diagram.

Install the servo-motor on the front façade above the door, on the right side (use pre-drilled holes). The chain that

links the air inlet latch to the motor must have a play of 1/8 in. When there is no call for heat, the air inlet latch must be completely shut and the chain must be affixed to the servo-motor at “8 o’clock”.

The switch located on the fan limit control activates the blower at high speed, in either automatic or manual (continuous operation) modes.

The switch located on the electric unit controls low speed operation, in either ON (continuous operation) or OFF

modes (PSG 3000 or PSG 4000 models only).

WARNING: USE FEEDING WIRES SUITA

* (With all reserves on the minimum combustion air to be increased depending on the type and quality of the

combustible).

BLE FOR 75 C

LECTRIC ELEMENT

The WOOD / ELECTRIC combin heating, the other one controls the wood heating. With this system, the electric heating has priority over the wood heating. When the thermostat activates the electric heating, the air inlet closes down (if opened), the blower starts and the electric elements are successively activated per block of 5 kW. The system might be equipped with an exterior thermostat which will allow the last block of elements (5 kW) to start up only when the outside temperature is cold enough. This will reduce the power of the systems by 5 kW during mild temperature for more comfort.

When the call for electric heating is completed, the wood system will take over if the starting point of the wood system is superior to the electric system.

So, in normal bi-energy use, you must set the wood system thermostat 2 thermostat.

Take note that this furnace is equipped with a four speed motor. Aside from low speed, three choices are available: medium-low, medium-high or high.

If the temperature of the element exceeds the limit allowed, the thermodisk will disengage the element. For reactivation, press the red button “manual reset” of the thermodisk L-170 and find out why the temperature limit has been exceeded (static pressure too high, fan breakage, dirty filter, etc.)

INSIDE VIEW OF THE ELECTRIC ELEMENT

ed model is installed with two thermostats: one thermostat controls the electric

to 3o higher than the electric system

Red button manual rese

Thermodisk L-170

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