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White Rodgers G1N 4R9 manual

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  • Page 1

    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 K[...]

  • Page 2

    Table of contents INTRODUCTION ..................................................................................................................... 4 1. CHIMNEY AND DRAFT ...................................................................................................... 4 2. SAFETY RULES .........................................................[...]

  • Page 3

    3 10. SELECTION CRITERIA (COMBI NED WOOD/ELECTRIC FURNACE) .......................... 28 11. TROUBLESHOOTING ..................................................................................................... 29 12. DUCTS AND REGISTER MEASUREMENTS ................................................................. 30 LIMITED LIFETIME WARRANTY .....[...]

  • Page 4

    4 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 certi fication label and your inst ruction manual for minimum installation clearances. • Make sure that your furnace h as been installed in acco[...]

  • Page 5

    5 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 emanat e from the unit when you first light it. It is recommen ded to burn it at high rate and ventilate the building until the odour resorbs. ASH DISPOSAL Ashes mu st be placed in a metal container with a tight fi t[...]

  • Page 6

    SMOKE DETECTOR We highly recommend the use of a smoke detector. It mu st be installed at least 15 feet (4,57 m) from the appli ance in order to prevent undue triggering of the detector wh en reloading. ASH DRAWER Your appliance is equipped with an a sh drawer to collect ashes produced by the combustion of wood. This drawer must not be left open dur[...]

  • Page 7

    CLEARANCES TO COMB USTIBLE MATERIALS 7 N.B. This appliance must be installed in accordance with the instructions on the unit’s certification. MINIMUM CLEARA NCES TO COMBUSTIBLE MATERIAL S FOR PSG FURNACES 2” N.B. THE AIR RETURN CONDUITS SHOULD BE AT LEAS T EQUAL TO THE COLD AIR PLENUM DIMENSIONS. PIPE CONNECTOR AND DAMPER A 6” diameter chimne[...]

  • Page 8

    For a proper installation, follow the advi ces below: 1. All the joints of the evacuation pi pe must be secured, using three screws. Make sure that each screw goes through the inner walls of both connectors (m ale and female). See pictures below showing a male-female coupling. PROPER INSTALLATION UNPROPER INSTALLATION 8 2. A minimum rise of 1/4 inc[...]

  • Page 9

    NOTE: It is recommende d to install an outside air inlet of minimum 4” diameter in the room where the heating appliance is installed (see drawing bel ow). To do so, it is preferable to ch oose a wall which is not exp osed to extreme winds, according to the conditions surrounding your house. .B. The owner of the furnace is responsible for the room[...]

  • Page 10

    The switch located on the fan limit control a ctivate s the blower at high speed, in either automatic or manual The switch located on the electric unit controls low speed operation, in either O N (continuous operation) or OFF BLE FOR 75 C * (With all reserves on the minimu m combustion ai r to be increased dependi ng on the type and quality of the [...]

  • Page 11

    OUTSIDE VIEW OF THE ELECTRIC ELEMENT THERMOSTAT The thermostat must be installed on an inside wall in a l ocation where it is not likely to be affect ed by the draft coming from an air outlet. It must be installed at a minimum of 55 inches a bove the floor. N.B. The combined wood / electric model mu st be installed with two thermostats at sam e lev[...]

  • Page 12

    12 4. OPERATING INSTRUCTIONS Control system On the wood furnaces only, the thermostat cont rols the air inlet damper. When the thermo stat calls for heat, the damper opens and th e fire burns up. When th e furnace gets hot eno ugh, the combined limit control activates the blower motor at the speed selected for woo d heating. The chain that links th[...]

  • Page 13

    HEATING 1. When loadin g the furnace, lower the kindled pi eces of wood and place the m at the center of the combustion chamber before adding ne w logs. 2. Do not overload. Air must circulate fre ely in the upper part of the fu rnace in order to obtain an efficient operation of the appliance. Please note that a small hot fire will pr oduce much l e[...]

  • Page 14

    14 Whenever a high rate of smoke is noticed in the room, you must: 1. Open d oors and windows. 2. Make sure the furnace door is closed as well as the damper (if necessary, lower the the rmostat starting point or undo the chain of the damper and close m anually the barometric draft control ). 3. When the furnace has cooled down, inspect the chimney [...]

  • Page 15

    5. MAINTENANCE MAINTENANCE OF THE EXCHANGERS The evacuation pipe and the ex changers shoul d be inspected regularly during the burning season. Usi ng the scraper, clean the three ex changer pipes. INSTRUCTIONS o Wait until fire is completely out before cleaning. 1 o Remove the smoke pipe connecto r from the furnace. 2 o Inspect the furnace’s heat[...]

  • Page 16

    16 FILTERS The furnace must not be operated wi thout the filters. In order to ope r ate a slow combustio n heating system efficiently and safely, you have to ensure a regular maintena nce. This means t hat the chimney, the joints and the flue must be in good condition. The air filters must b e replaced regularly. Use the same size and same type as [...]

  • Page 17

    7. ELECTRIC DIAGRAMS FOR UNITS BUILT FROM 2005 WOOD-ONLY FURNACES FAN LIMIT HONEYWELL L 6064(MOTOR (G-10) 4 SPEED AND (G-12) 2 SPEED) RED ON 150°F LIMIT 250°F OFF 110°F LIMIT LOAD FAN LINE HONEYWELL L6064 HIGH LINE LOW L2 120 V.A.C. L1 BLACK TR AN SFO JUNCTION BO X 24 V.A.C. 24 V.A.C. THERMOST AT SERVO-M OTOR RED BLACK WHITE BLACK BLACK 24 V.A.C[...]

  • Page 18

    WOOD/ELECTRIC FURNACES FAN LIMIT HONEYWELL L 6064(MOTOR (G-10) 4 SPEED AND (G-12) 2 SPEED) REVISION JU NE 16TH 200 5 POWER BLOCK LOW LINE HIGH S4 S3 CONNECTORS INDENTIFI C AT ION OF T HE SEQUENCER S6 S1 S2 S5 E BLOWER 15 KW @ 30KW RELAY POWER BLOCK B 4 SPEED MOTOR MED LO W LOW COMMON HIGH MED HIGH TERMI NAL BLACK 1 BLACK TRANSFO 120V 24V 20VA A C C[...]

  • Page 19

    PSG5000 WOOD-ONLY FURNACES FAN LIMIT HONEYWELL L6064 (MOTOR (G-12) 2 SPEED) THERMOSTAT SERVO-MOTOR REVISION JUNE 21ST 2005 WHITE - COMMON RED - HIGH SPEED 24 V.A.C. 24 V.A.C. TRANSFORMER 120 V.A.C. 24 V.A.C. BLACK WHITE - COMMON WHITE RED - HIGH SPEED JUNCTION BOX RED BLACK WHITE RED BLACK 2 SPEED MOTOR BLOWER 2 SPEED MOTOR 120 V.A.C . OR 240 V.A .[...]

  • Page 20

    PSG5000 WOOD/ELECTRIC FURNACES FAN LIMIT HONEYWELL L6064 (MOTOR (G-12) 2 SPEED) L-170 RE SE T C RELAY BREAKER A BC BLOWER 20 KW @ 30KW COMMAND BLOCK 3 2 4 1 RED - HIGH SPEED BLACK - LOW SPEED WHITE - COMMON POWER BLOCK RELAY BLACK E BLACK 1 TRANSFO 120V 24V 20VA POWER BLOCK COMMAND BLOCK COMMAND BLOCK 1 6 A B 6 HONEYWELL L6064 OFF 110°F LIMIT 25 0[...]

  • Page 21

    8. ELECTRIC DIAGRAMS FOR UNITS BUILT BEFORE 2005 WOOD ONLY FURNACES PSG 4000 & 4500 BELT-DRIVE G12 MOTOR FL 2 SPEED MOTOR NOIR WHITE RED HONEYWELL L4064 15 MARS 1990 RED BLANC JUNCTION BOX WHITE - COMMON RED - HIGH SPEED WHITE NOIR L2 BLACK - LOW SPEED BLOWER 120 V.A.C. L1 BLACK LIMIT 250 °F OFF 110°F ON 150°F F L WHITE RODGERS SWITCH OFF ON[...]

  • Page 22

    WOOD ONLY FURNACES PSG 5000 BELT-DRIVE G12 MOTOR 1 SPEED MOTOR 1 SPEED MOTOR F HONEYWELL L4064 L NOIR BLANC ROUGE ROUGE L NOIR F HONEYWELL L4064 BLACK RED BLAC K WHITE MARCH 15TH 1990 MOTOR 120/240 MOTOR 120/240 F L L1 120 V.A.C. OR 240 V.A.C. F LIMIT 250°F OFF 110°F ON 150° F L WHITE RODGERS WHITE BLACK RED SERVO-MOTOR 24 V.A.C. 24 V.A.C. THERM[...]

  • Page 23

    WOOD/ELECTRIC FURNACES PSG 4000 & 4500 BELT-DRIVE G12 MOTOR L F WHITE BLACK RED HONEYWELL L4064 2 SPEED MOTOR POWER BLOCK POWER BLOCK RELAY 8 7 POWER BLOCK 4 COMMAND BLOCK COMMAND BLOCK POWER BLOCK POWER BLOCK COMMAND BLOCK COMMAND BLOCK BLACK BLACK 1 E 6 1 TRANSFO 120V 24V 20VA 6 RELAY 5 KW ELEM. 5 KW ELEM. 5 KW ELEM. 5 KW ELEM. 5 KW ELEM. REL[...]

  • Page 24

    WOOD/ELECTRIC FURNACES PSG 5000 40KW @ 60KW BELT-DRIVE G12 MOTOR L BLACK FROM TRANSFO RED F HONEYWELL L4064 WHITE BLACK FROM TRANSFO WHITE F L RED HONEYWELL L4064 10 9 7 8 6 5 1 2 4 3 RELAY 4 COIL 24V 40 A IND/50A RES PER POLE 600 V.A.C. MAX. CONTACTOR COMMAND BLOCK WHITE RODGERS F BLACK L RED BLACK WHITE ON 150°F OFF 110°F LIMIT 250°F 2 1 POWER[...]

  • Page 25

    WOOD ONLY FUR NACES PSG 2000-3000-4000 DIRECT-DRIVE G10 MOTOR 2 3 1 L F RED BLACK TRANSFO RED BLACK BLACK FROM TRANSFO BLACK RED HONEYWELL L4064 TERMINAL BOARD 4 SPEED MOTOR RELAY RED 3 1 5 2 4 BLACK WHITE COMMUN LOW MED LOW MED HIGH HIGH F L WHITE RODGERS OFF 110°F ON 150°F 120 V.A.C. L2 L1 BLACK LIMIT 250°F BLOWE R JUNCTION BOX ON OFF SERVO-MO[...]

  • Page 26

    WOOD/ELECTRIC FURN ACES PSG 2000-3000-4000 DIRECT-DRIVE G10 MOTOR WOOD THERMOSTAT MOVE THI S WIRE TO CHANGE MOTOR SPEED MED LOW 15 KW @ 30KW COMMAND BLOCK COMMUN LOW 1 2 4 36 5 2 4 3 5 6 78 3 45 6 ELECTRIC THERMOSTAT SERVO MOTOR TRANSFO 240V 24V 40VA E LIMIT 250°F OFF 110°F ON 150°F 4 SPEED MOTOR RELAY POWER BLOCK BLA CK BLACK BLOWER E 1 B RED C[...]

  • Page 27

    27 9. TECHNICAL SPECIFICATIONS 2000 3000 4000 4500 5000 A 45 ¼" 47" 50" 52 ½" 54 ½" B 23 ½" 25 ½" 29 ½" 33 ½" 54" C 45 ½" 47 ¼" 48" 48" 56 ¾" D 15 ⅞ " 15 ⅞ " 19" 19" 19 ¾" E 26 ⅜ " 28" 28" 30" 31 ½" F 22 ½&[...]

  • Page 28

    28 10. SELECTION CRITERIA (COMBINED WOOD/ELECTRIC FURNACE) RESIDENTIAL AREA House including: basement , first floor and second floor (half) Floor area * New house Existing house 1100 square feet or less PSG 2000 – 15 PSG 2000 – 18 or 20 1100 to 1450 square feet PSG 3000 – 18 PSG 3000 – 20 or 25 1400 to 2000 square feet PSG 4000 – 20 PSG 4[...]

  • Page 29

    29 11. TROUBLESHOOTING PROBLEM CAUSES SOLUTIONS 1. Sudden drop in heating performance follows adequate heating from first loadings. Ash accumulation at lower intake blocks combustion air intake and causes deposits in heat excha nger and flue pipes. Clear air intake of any ash accumulation. Clean heat exchanger a nd flue pipes. 2. Insufficient heat [...]

  • Page 30

    30 12. DUCTS AND REGISTER MEASUREMENTS (sample calculations) SIMPLIFIED METHOD DISTRIBUTION SYSTEM Ducts size (heat) 4 inch outlet reduce by 1” 5 inch outlet reduce by 2” Always by 8” thick 6 inch outlet reduce by 3” N.B.: The main duct must be reduced every 2 outlets. Ducts specifications (heat) Dimensions Length Elbow Average equivalence [...]

  • Page 31

    1700, rue Léon-Harmel, Québec (Québec) G1N 4R9 tel. : (418) 527-3060 fax : (418) 527-4311 e-mail : tech@sbi-international.com web sit e : www.psg-distribution.com LIMITED LIFETIME WARRANTY The PSG warranty extends only to the orig inal consumer purc haser and is not transferable. This warranty cov ers brand new products only, which have not been[...]