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
PSG-3000
PSG-4000
PSG-4500
PSG-5000
15 KW, 18 KW, 20 KW
15 KW, 18 KW, 20 KW, 25 KW
18 KW, 20 KW, 25 KW, 30 KW
18 KW, 20 KW, 25 KW, 30 KW
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!
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10. SELECTION CRITERIA (COMBINED WOOD/ELECTRIC FURNACE).......................... 28
11. TROUBLESHOOTING..................................................................................................... 29
12. DUCTS AND REGISTER MEASUREMENTS ................................................................. 30
LIMITED LIFETIME WARRANTY................................................................................. 31
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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.
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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.
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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 for
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 90o
elbows.
The owner must ensure a proper installation to allow a safe operation of the appliance.
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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 PSG 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.
OIL FLUE
PIPE
(OPTION)
WOOD
FLUE
PIPE
MAIN
COLLECTOR
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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
CAUSE RESTRICTION
2. A minimum rise of 1/4 inch per horizontal foot must be respected.
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
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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
Fresh air
Free air
intake
entry
Exterior
wall
N.B. The owner of the furnace is responsible for the room salubrity in case of negative pressure or temporary
negative pressure.
ELECTRICAL CONNECTION
The following instructions do not supersede the local code.
WOOD ONLY
Installed limit control on support provided on proper location of the appliance (two holes are predrilled on the edge of
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.
The switch located on the electric unit controls low speed operation, in either ON (continuous operation) or OFF
modes.
WARNING: USE FEEDING WIRES SUITABLE FOR 75OC
WOOD/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”. *
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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 SUITABLE FOR 75OC
* (With all reserves on the minimum combustion air to be increased depending on the type and quality of the
combustible).
ELECTRIC ELEMENT
The WOOD / ELECTRIC combined model is installed with two thermostats: one thermostat controls the electric
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 2o to 3o higher than the electric system
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
Red button
manual reset
Thermodisk L-170
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OUTSIDE VIEW OF THE ELECTRIC ELEMENT
THERMOSTAT
The thermostat must be installed on an inside wall in a location where it is not likely to be affected by the draft
coming from an air outlet. It must be installed at a minimum of 55 inches above the floor.
N.B. The combined wood / electric model must be installed with two thermostats at same level.
FAN CONTROL
The fan control setting varies depending on the type of heating installation. The setting “out of service” is preset at
110o F in factory. This setting should provide a proper operation for most installations. The temperature “in service” is
pre-set at 150o F.
It is preferable for a prolonged operation of the blower that the setting “out of service” be low enough. But a setting
“out of service” too low will cause a cold air circulation. To modify the setting, turn the button at the desired position on
the temperature scale.
The adjustment of all controls must be performed by a qualified technician. The controls setting and the blower
speed must conform to the recommendations of the “Warm Air Heating and Air Conditioning National Association”. To
obtain a continuous air circulation during summer, push the manual switch of the limit control from the “automatic”
position to the “manual or summer” position.
The switch located below the limit control or on the electric unit, controls the low speed either at the “on” position or
the “off” position. For a better efficiency we recommend to leave the high speed on automatic(wood side fan limit
control).
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4. OPERATING INSTRUCTIONS
Control system
On the wood furnaces only, the thermostat controls the air inlet damper. When the thermostat calls for heat, the
damper opens and the fire burns up. When the furnace gets hot enough, the combined limit control activates the
blower motor at the speed selected for wood heating.
The chain that links the air inlet damper to the motor must have a play of 1/8 inch. When there is no call for heat,
the air inlet damper must be completely closed and the chain must be affixed to the servo-motor at “8 o’clock”. *
* (With all reserve on the minimum air to be increased depending on the type and quality of the combustible).
LIGHTING:
1. Open the door
Note: In the case that there is a bed of coals in the bottom of the furnace, go to step b) Pre-heating.
2. Place one or two dry kindlings at the front of the furnace.
3. Place newspaper strips on top of the kindlings.
4. Cover the newspaper with more kindlings and small pieces of dry wood.
5. Add newspaper strips, then light the fire a low as possible and leave the door 1/2" (13 mm) opened. If you fail
lighting the fire, you might experience a back draft through the air inlets.
PREHEATING
1. Once the kindling is well ignited or the coals revived, put 2 or 3 fire logs in such a way that the flames can interlace
between the logs then close the door. It is important to respect these loading sequences so that the wood will burn
from the front to the back of the furnace.
2. Wait 15 to 20 minutes, then proceed with loading the furnace.
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HEATING
1. When loading the furnace, lower the kindled pieces of wood and place them at the center of the combustion
chamber before adding new logs.
2. Do not overload. Air must circulate freely in the upper part of the furnace in order to obtain an efficient operation of
the appliance. Please note that a small hot fire will produce much less residues than a large smouldering one.
IMPORTANT: DURING THE HEATING PROCESS, REMOVE THE ASHES AND WOOD THAT COULD
OBSTRUCT THE 1/4" (6.4 mm) HOLE LOCATED BELOW THE DOOR INSIDE THE FURNACE.
PROCEDURE TO OPEN THE LOADING DOOR
TO MINIMIZE THE RISK OF A BACK DRAUGHT OPEN THE DOOR 1”
AND WAIT ABOUT 10 SECONDS BEFORE OPENING COMPLETELY.
THE PURPOSE IS TO STABILIZE THE PRESSURE INSIDE THE FURNACE.
EARLY SIGNS OF OVERFIRED FURNACE
1. Roaring fire.
2. Chimney connector is glowing red.
3. Extreme heat coming from the furnace. If this occurs, DO NOT OPEN THE DOOR, shut-off the air inlet opening
completely, and wait until the glow has completely subsided.
ALWAYS KEEP THE DOOR AND THE ASH DRAWER CLOSED
(except for lighting and maintenance).
WOOD AS HEATING FUEL
We recommend that you burn dry wood only.
There are two important factors to be considered when choosing a type of wood: the moisture content and the wood
density. Hardwood, such as maple, oak and beech will provide better results because of the high density and minimal
tar produced during combustion. It is highly recommended to use wood that has been dried at least six months. Do
not use coal as heating fuel in this appliance.
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Whenever a high rate of smoke is noticed in the room, you must:
1. Open doors and windows.
2. Make sure the furnace door is closed as well as the damper (if necessary, lower the thermostat starting point or
undo the chain of the damper and close manually the barometric draft control).
3. When the furnace has cooled down, inspect the chimney to detect obstructions and consult a specialist to
determine the cause.
CARBON MONOXYDE IS A LETHAL GAS (ODOURLESS AND COLOURLESS), WHICH YOU MUST
BEWARE OF.
CHIMNEY FIRES
This might occur when the fire gets extremely hot. Burning cardboard, branches or pieces of wood can ignite the
creosote residue accumulated in the evacuation flue system. The usual signs are:
1. Rumbling
2. The flue gets extremely hot
3. Flames are coming out of the chimney
In case of a chimney fire, first call your local fire department and sprinkle the roof around
the chimney with water.
Make sure that the furnace door is closed as well as the damper (if necessary, lower the thermostat starting point or
release the chain from the damper and CLOSE the barometric draft control manually).
If the fire gets uncontrollable due to an improper use or because the draft is too strong, follow the same procedure
as in a chimney fire except that you will have to OPEN manually the barometric draft control.
LOCAL FIRE DEPARTMENT.
Phone number: ___________________________________
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5. MAINTENANCE
MAINTENANCE OF THE EXCHANGERS
The evacuation pipe and the exchangers should be inspected regularly during the burning season. Using the
scraper, clean the three exchanger pipes.
INSTRUCTIONS
1o Wait until fire is completely out before cleaning.
2o Remove the smoke pipe connector from the furnace.
3o Inspect the furnace’s heat exchangers (rectangular tubes) through the smoke outlet for creosote accumulation.
4o Using the supplied scraper, clean the heat exchangers and the combustion chamber and remove creosote residues.
5o Reassemble the smoke pipe connector.
CHIMNEY MAINTENANCE
One of the most efficient methods is to sweep the chimney, using a hard brush. Brush up and down. Soot and
creosote residue will come off the inside surface and fall at the bottom of the chimney where it can be removed easily.
The chimney must be checked regularly and if creosote has accumulated, it must be removed. Cleaning on a
monthly basis should be sufficient during the coldest months.
Smoke flue inspection
-
-
-
-
-
-
The smoke flue should be inspected regularly during the heating season.
If possible, the smoke flue should be dismantled and cleaned.
The flue should be inspected to detect any defect.
If no defect is noticed, put the flue back in place; otherwise, it must be replaced.
Use only wood as a combustible.
Seasoned hard wood logs 18” to 22” long are recommended as a combustible.
Regular maintenance is required for safe and efficient operation of a controlled-combustion heating system. Chimney,
gaskets and smoke pipes must remain in good working condition. Change the air filter regularly, with the same type
and same size.
MAINTENANCE OF THE BLOWER MOTOR
The two bearings of the motor must be lubricated once a year using non detergent SAE 20 oil.
DO NOT OVERLUBRICATE
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FILTERS
The furnace must not be operated without the filters. In order to operate a slow combustion heating system
efficiently and safely, you have to ensure a regular maintenance. This means that the chimney, the joints and the flue
must be in good condition. The air filters must be replaced regularly. Use the same size and same type as the original
filters.
DOOR GASKET MAINTENANCE
It is important to maintain the door gasket in good condition. After a while, the gasket might sag; a door adjustment
may be then required.
6. REPLACEMENT PARTS
Your PSG furnace is designed to burn clean and required little maintenance. It’s recommended conduct a visual
inspection at least once a month to uncover that any damage on the unit. Repairs must be done as soon as possible
with the original parts. You can find a complete list of replacement parts on our website at www.psg-distribution.com.
GASKET
We recommend to replace gasket that seal the door once a year, in order to maintain a good control of the combustion
for maximum efficiency and security. To replace your door gasket, remove the old gasket and glue. Clean the surface
thoroughly, apply glue sold for that particular use, and put the new gasket onto the door. Wait for at least 2 hours
before lighting your furnace.
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7. ELECTRIC DIAGRAMS FOR UNITS BUILT FROM 2005
WOOD-ONLY FURNACES
FAN LIMIT HONEYWELL L6064(MOTOR (G-10) 4 SPEED AND (G-12) 2 SPEED)
HONEYWELL
L6064
FAN
LINE
LIMIT
LOAD
ON 150°F
OFF 110°F
LIMIT 250°F
LOW HIGH LINE
THERMOSTAT
24 V.A.C.
SERVO-MOTOR
24 V.A.C.
JUNCTION BOX
BLUE
L1
BLACK
ON
1
2
3
BLOWER
120 V.A.C.
BLACK
WHITE
L2
OFF
4 SPEED
MOTOR
THERMINAL
BOARD
120 V.A.C.
HIGH
MED HIGH
MED LOW
LOW
TRANSFORMER
24 V.A.C.
MOVE THIS WIRE
TO CHANGE
MOTOR SPEED
REVISION JUNE 17TH 2005
COMMUN
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WOOD/ELECTRIC FURNACES
FAN LIMIT HONEYWELL L6064(MOTOR (G-10) 4 SPEED AND (G-12) 2 SPEED)
ELEMENTS
CONTACTOR
HONEYWELL
L6064
POWER
BLOCK
E
COIL
24V
25 KW OR 30 KW ONLY
40 A IND/50A RES
PER POLE
240V
FAN
LIMIT
600 V.A.C. MAX.
ON 150°F
L1
N
L2
OFF 110°F
COMMAND
BLOCK
TRANSFO
240V
4
BLACK
LIMIT 250°F
LINE
LOAD
24V
SEQUENCER
S3
BLACK/RED
RELAY
40VA
POWER
BLOCK
B
7
A
S1
S1
S4 S6
S6
LOW HIGH LINE
POWER
BLOCK
20 A
S2
S5
5 KW ELEM.
L -170 RESET
FAN
S5
S6
S1 S3
S2
5 KW ELEM.
5 KW ELEM.
1
2
3
6
S4
S6
B
A
C
S1
S1
S3
S6
S4
5 KW ELEM.
5 KW ELEM.
TRANSFO
120V
S6
S1
BLACK
BLACK
COMMAND
BLOCK
POWER
BLOCK
7
8
E
1
1
POWER
BLOCK
24V
COMMAND
BLOCK
RELAY
6
S1
S3
S6
S4
A
B
C
D
E
F
20VA
S1
S5 S6
BLOWER
4 SPEED
MOTOR
TERMINAL
2
1
8
7
HIGH
1
2
MED HIGH
MED LOW
LOW
RELAY
WOOD
THERMOSTAT
MOVE THIS WIRE
TO CHANGE MOTOR SPEED
3
4
5
6
3
4
COMMON
ELECTRIC
THERMOSTAT
COMMAND
BLOCK
15 KW @ 30KW
1
2
3
4
5
6
7
8
S3
S4
5
6
S2
S5
S6
SERVO
MOTOR
S1
CONNECTORS INDENTIFICATION OF THE SEQUENCER
REVISION JUNE 16TH 2005
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PSG5000 WOOD-ONLY FURNACES
FAN LIMIT HONEYWELL L6064(MOTOR (G-12) 2 SPEED)
HONEYWELL
L6064
HONEYWELL
L6064
ON 150°F
OFF 110°F
LIMIT 250°F
FAN
LIMIT
FAN
LIMIT
LINE
LOAD
LINE
LOAD
LOW HIGH LINE
LOW HIGH LINE
THERMOSTAT
24 V.A.C.
SERVO-MOTOR
24 V.A.C.
RED
BLACK
JUNCTION BOX
FAN
FAN
1
2
3
1
2
3
L1 - BLACK
120 V.A.C. OR 240 V.A.C.
L2 - WHITE
BLOWER
RED - HIGH SPEED
120 V.A.C.
BLACK - LOW SPEED
2 SPEED
MOTOR
TRANSFORMER
WHITE - COMMON
24 V.A.C.
REVISION
JUNE 21ST 2005
RED - HIGH SPEED
2 SPEED
MOTOR
BLACK - LOW SPEED
WHITE - COMMON
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PSG5000 WOOD/ELECTRIC FURNACES
FAN LIMIT HONEYWELL L6064(MOTOR (G-12) 2 SPEED)
HONEYWELL
L6064
HONEYWELL
L6064
ON 150°F
ON 150°F
CONTACTOR
CONTACTOR
OFF 110°F
ELEMENTS
OFF 110°F
LIMIT 250°F
FAN
LIMIT
FAN
LIMIT
LIMIT 250°F
ELEMENTS
COIL
24V
COIL
24V
25KW OR 30 KW ONLY
25KW OR 30 KW ONLY
SERVO
MOTOR
40
A
IND/50A RES
40
A
IND/50A RES
PER POLE
PER POLE
E
POWER
BLOCK
POWER
BLOCK
600 V.A.C. MAX.
600 V.A.C. MAX.
LINE
LOAD
E
LINE
LOAD
240V
COMMAND
BLOCK
COMMAND
BLOCK
TRANSFO
240V
TRANSFO
240V
4
4
LOW HIGH LINE
LOW HIGH LINE
240V
N
L1
N
L2
24V
1
2
24V
SEQUENCER
S3
SEQUENCER
WOOD
THERMOSTAT
RELAY
RELAY
L1
L2
40VA
POWER
BLOCK
40VA
POWER
BLOCK
7
B
7
A
B
S6
S3
S6
S1
S1
S1
S4
S4
S5
S5
POWER
BLOCK
POWER A
20 A
BLOCK
20 A
L-170 RESET
S2
S2
S3
S5
S5
5
KW ELEM.
5
KW ELEM.
S1
S1
S1
S1
S1
S1
S1
S6
S6
S6
S6
S6
S6
B
A
C
B
A
C
FAN
FAN
6
L -170 RESET
6
S3
5
5
KW ELEM.
KW ELEM.
S1
S1
S1
S1
S1
S1
5
5
KW ELEM.
KW ELEM.
1
2
3
1
2
3
S4
S4
S4
S4
S2
S3
S2
S3
S6
S6
S6
S6
5
KW ELEM.
KW ELEM.
5
KW ELEM.
KW ELEM.
7
8
7
8
S6
A
B
C
D
E
F
A
B
C
D
E
F
S6
S4
S3
S3
5
S4
5
POWER
BLOCK
POWER
BLOCK
TRANSFO
120V
TRANSFO
120V
S5 S6
S5 S6
BLACK
BLACK
COMMAND
BLOCK
BLACK
COMMAND
BLOCK
POWER
BLOCK
POWER
BLOCK
E
1
1
6
E
1
1
6
24V
24V
COMMAND
BLOCK
BLACK
COMMAND
BLOCK
RELAY
RELAY
20VA
20VA
2
3
1
8
7
2
3
1
8
7
BLOWER
BLOWER
RED - HIGH SPEED
WHITE - COMMON
BLACK - LOW SPEED
RED - HIGH SPEED
WHITE - COMMON
BLACK - LOW SPEED
RELAY
#1
RELAY
2
3
1
8
7
6
4
5
6
4
5
6
RELAY
#2
COMMAND
BLOCK
20 KW @ 30KW
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
4
5
S3
S4
20 KW @ 30KW
COMMAND
BLOCK
S2
S5
S6
S1
3
4
3
4
ELECTRIC
THERMOSTAT
9
10
ELECTRIC
THERMOSTAT
CONNECTORS INDENTIFICATION OF THE SEQUENCER
20
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8. ELECTRIC DIAGRAMS FOR UNITS BUILT BEFORE 2005
WOOD ONLY FURNACES PSG 4000 & 4500
BELT-DRIVE G12 MOTOR
HONEYWELL
L4064
WHITE RODGERS
ON 150°F
F
L
OFF 110°F
L
F
RED
WHITE
LIMIT 250°F
THERMOSTAT
24 V.A.C.
SERVO-MOTOR
24 V.A.C.
JUNCTION BOX
L1
ON
120 V.A.C.
L2
OFF
BLOWER
120 V.A.C.
RED - HIGH SPEED
TRANSFORMER
2 SPEED
MOTOR
24 V.A.C.
WHITE - COMMON
15 MARS 1990
BLACK - LOW SPEED
21
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WOOD ONLY FURNACES PSG 5000
BELT-DRIVE G12 MOTOR
HONEYWELL
L4064
HONEYWELL
L4064
WHITE RODGERS
ON 150°F
F
L
F
L
OFF 110°F
L
F
L
F
ROUGE
ROUGE
BLANC
LIMIT 250°F
THERMOSTAT
24 V.A.C.
SERVO-MOTOR
24 V.A.C.
RED
BLACK
JUNCTION BOX
L1
120 V.A.C. OR 240 V.A.C.
L2
BLOWER
MOTOR
120/240
120 V.A.C.
BLACK
WHITE
1 SPEED
MOTOR
TRANSFORMER
24 V.A.C.
240 V.A.C.
TRANSFORMER
FOR 240 VOLT ONLY
MARCH 15TH 1990
24 V.A.C.
MOTOR
120/240
1 SPEED
MOTOR
BLACK
WHITE
IMPORTANT: A BREAKER IS MANDATORY FOR 240 VOLT
VERIFY CONNECTIONS OF THE MOTOR 3/4 H.P.
IF CONNECTED ONTO THE RIGHT CIRCUIT(120/240)
22
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WOOD/ELECTRIC FURNACES PSG 4000 & 4500
BELT-DRIVE G12 MOTOR
WHITE RODGERS
HONEYWELL
L4064
CONTACTOR
ON 150°F
F
L
L
F
RED
WHITE
OFF 110°F
LIMIT 250°F
COIL
24V
40 A IND/50A RES
PER PÔLE
600 V.A.C. MAX.
ELEMENTS
COMMAND
LOW SPEED
SWITCH
BLACK
TRANSFO
240V
4
BLOCK
POWER
BLOCK
24V
E
SEQUENCER
RELAY
40VA
POWER
BLOCK
110 VOLT
MOTOR 3/4 H.P.
FOR 240 V
B
7
A
POWER
BLOCK
240V
N
5 KW ELEM.
L1
L2
A
B
C
D
L- 160
F- 110
5 KW ELEM.
5 KW ELEM.
20 A
6
5 KW ELEM.
5 KW ELEM.
7
8
1
2
WOOD
THERMOSTAT
A
B
C
D
E
F
POWER
BLOCK
TRANSFO
120V
BLACK
BLACK
COMMAND
BLOCK
POWER
BLOCK
E
1
6
24V
COMMAND
BLOCK
RELAY
1
20VA
3
4
ELECTRIC
THERMOSTAT
2
3
1
8
7
6
BLOWER
HIGH SPEED - RED
COMMON - WHITE
LOW SPEED - BLACK
RELAY
2 SPEED
MOTOR
5
6
SERVO
MOTOR
4
5
1
2
3
4
5
6
7
8
15 KW @ 30KW
COMMAND
BLOCK
23
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WOOD/ELECTRIC FURNACES PSG 5000 40KW @ 60KW
BELT-DRIVE G12 MOTOR
HONEYWELL
L4064
HONEYWELL
L4064
WHITE RODGERS
WHITE RODGERS
CONTACTOR
CONTACTOR
F
L
F
L
ON 150°F
ON 150°F
BLACK FROM
TRANSFO
BLACK FROM
TRANSFO
RED
RED
L
F
L
F
OFF 110°F
LIMIT 250°F
COIL
24V
OFF 110°F
LIMIT 250°F
COIL
24V
SERVO
MOTOR
BLACK
BLACK
40
A
IND/50A RES
40
A
IND/50A RES
PER POLE
PER PÔLE
600 V.A.C. MAX.
600 V.A.C. MAX.
BLOC
COMMANDE
COMMAND
BLOCK
ELEMENTS
POWER
ELEMENTS
TRANSFO
240V
4
TRANSFO
240V
4
POWER
BLOCK
24V
1
2
24V
E
E
SEQUENCER
SEQUENCER
BLOCK
WOOD
THERMOSTAT
RELAY
RELAY
40VA
POWER
BLOCK
40VA
POWER
BLOCK
110 VOLT LINE
3/4 H.P. MOTOR
240
110 VOLT LINE
3/4 H.P. MOTOR
B
B
7
7
POWER
BLOCK
POWER
BLOCK
B
C
A
B
C
A
V
240
V
A
A
240V
240V
5
KW ELEM.
5
KW ELEM.
L1
N
L2
L1
N
L2
L- 160
F- 110
L -160
F -110
5
5
KW ELEM.
KW ELEM.
5
5
KW ELEM.
KW ELEM.
20 A
20 A
6
6
IMPORTANT:
IMPORTANT:
5
KW ELEM.
KW ELEM.
5
KW ELEM.
KW ELEM.
IT IS MANDATORY TO CHANGE THE
TRANSFORMER 120-24 FOR 240-24
IF YOU USED 3/4 H.P. MOTOR ON 240
IT IS MANDATORY TO CHANGE THE
TRANSFORMER 120-24 FOR 240-24
IF YOU USED 3/4 H.P. MOTOR ON 240
A
A
V
V
7
8
7
8
A
B
C
D
E
F
A
B
C
D
E
F
5
5
POWER
BLOCK
POWER
BLOCK
TRANSFO
120V
TRANSFO
BLACK
BLACK
COMMAND
BLOCK
BLACK
BLACK
120V
COMMAND
BLOCK
POWER
BLOCK
POWER
BLOCK
E
1
1
6
E
1
1
6
24V
24V
COMMAND
BLOCK
COMMAND
BLOCK
RELAY
RELAY
20VA
20VA
2
3
1
8
7
6
2
3
1
8
7
6
BLOWER
BLOWER
RELAY
RELAY
WHITE
BLACK
WHITE
BLACK
2
3
1
8
7
6
4
5
4
5
RELAY
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
4
5
20 KW @ 30KW
20 KW @ 30KW
COMMAND
BLOCK
COMMAND
BLOCK
3
4
3
4
ELECTRIC
THERMOSTAT
9
10
ELECTRIC
THERMOSTAT
4
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WOOD ONLY FURNACES PSG 2000-3000-4000
DIRECT-DRIVE G10 MOTOR
HONEYWELL
L4064
WHITE RODGERS
F
L
BLACK FROM
TRANSFO
ON 150°F
RED
L
F
OFF 110°F
LIMIT 250°F
THERMOSTAT
24 V.A.C.
SERVO-MOTOR
24 V.A.C.
RELAY
JUNCTION BOX
RED
L1
2
5
1
4
3
ON
1
2
BLOWER
120 V.A.C.
L2
BLACK
3
OFF
4 SPEED
MOTOR
TERMINAL
BOARD
120 V.A.C.
HIGH
MED HIGH
MED LOW
LOW
TRANSFORMER
24 V.A.C.
REVISION MAY 20TH 1994
COMMUN
25
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WOOD/ELECTRIC FURNACES PSG 2000-3000-4000
DIRECT-DRIVE G10 MOTOR
HONEYWELL
L4064
WHITE RODGERS
F
L
ON 150°F
BLACK TO
TRANSFOMER
RED
L
F
OFF 110°F
LIMIT 250°F
CONTACTOR
BLACK
COIL
24V
40 A IND/50A RES
PER POLE
600 V.A.C. MAX.
ELEMENTS
POWER
COMMAND
BLOCK
TRANSFO
240V
4
24V
B
C
A
E
BLOCK
SEQUENCER
RELAY
7
40VA
POWER
BLOCK
B
POWERA
240V
BLOCK
ELEM. 5 KW
L1
N
L2
FAN
L -170 RESET
ELEM. 5 KW
ELEM. 5 KW
20 A
6
5
FAN
RELAY
ELEM. 5 KW
ELEM. 5 KW
TRANSFO
120V
BLACK
COMMAND
BLOCK
POWER
BLOCK
7
8
E
1
1
6
POWER
BLOCK
24V
BLACK
COMMAND
BLOCK
RELAY
A
B
C
D
E
F
20VA
BLOWER
FAN RELAY
POWER
BLOCK
POWER
BLOCK
2
5
3
4
D
B
4 SPEED
MOTOR
TERMINAL
BOARD
1
2
3
1
8
7
6
E
A
HIGH
MED HIGH
MED LOW
LOW
POWER
BLOCK
POWER
BLOCK
RELAY
MOVE THIS WIRE
TO CHANGE MOTOR SPEED
1
2
WOOD
THERMOSTAT
4
5
COMMUN
3
4
ELECTRIC
THERMOSTAT
1
2
3
4
5
6
7
8
15 KW @ 30KW
COMMAND
BLOCK
5
6
SERVO
MOTOR
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9. TECHNICAL SPECIFICATIONS
2000 3000 4000 4500 5000
45 ¼"
47"
50"
52 ½" 54 ½"
A
B
C
D
E
F
23 ½" 25 ½" 29 ½" 33 ½"
54"
45 ½" 47 ¼"
48"
19"
28"
48"
19"
30"
56 ¾"
19 ¾"
31 ½"
15 ⅞" 15 ⅞"
26 ⅜"
28"
22 ½" 24 ½" 28 ½" 32 ½" 51 ⅛"
40 ½" 41 ¼"
42"
42"
49 ½"
G
PIPES
WEIGHT
7"
445
8"
540
8"
600
8"
8"
660
1200
GENERAL TECHNICAL DATA
MODEL
BELT DRIVE
DIRECT DRIVE
FAN
MOTOR SPEED
FAN
MOTOR SPEED OUTPUT TEMP BTU/
STATIC
PRESSURE
( "WATER)
FILTER
(2)
*
(C.F.M.)
VAR.
HR
(WOOD)
(O F)
H2O
2000
3000
4000
4000
4500
5000
N/A
N/A
N/A
G-12
G-12
G-12
G-10
G-10
G-10
N/A
N/A
N/A
1/3
1/3
1/3
4
4
4
950
68
78
128
93
121
125
70000
0,2
0,4
0,6
0,6
0,8
0,8
1,45
11 x 20
12 x 24
12 x 24
12 x 24
12 x 24
20 x 24
1300
1300
1800
1800
3600
110000 0,2
180000 0,2
180000 0,2
235000 0,2
350000 0,2
3/4
3/4
3/4
2
2
2
TECHNICAL DATA – ELECTRIC MODE
MODEL OUTPUT TEMP. VAR. BTU/HR AMPERES BREAKER FEEDER
VOLTAGE
ELEMENTS
QTY
3 – 5 KW
(C.F.M.)
950
(O F)
50
36
26
60
44
32
67
49
35
83
61
44
73
53
TOTAL
75
REQUIRED GAUGE SINGLE PHASE
15 KW
18 KW
20 KW
25 KW
51195
61434
68260
85325
102390
100
100
115
140
170
4
4
3
2
1
120/240
120/240
120/240
120/240
1300
1800
950
1300
1800
950
1300
1800
950
1300
1800
1300
1800
87
95
2 – 5 KW, 2 – 4 KW
4 – 5 KW
115
5 – 5 KW
30 KW
WOOD
140
15
120/240
120
6 – 5 KW
27
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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
1100 to 1450 square feet
1400 to 2000 square feet
2000 to 3000 square feet
PSG 2000 – 15
PSG 3000 – 18
PSG 4000 – 20
PSG 4500 – 25
PSG 2000 – 18 or 20
PSG 3000 – 20 or 25
PSG 4000 – 25 or 30
PSG 4500 – 30
COMMERCIAL AREA
Building including:
Walls 14 to 16 feet high
Garage doors, no basement
Floor area
2500 to 3800 square feet
PSG 4500 Wood
4000 to 10000 square feet
* Consider main floor only.
PSG 5000 – 40 or 60
28
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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 exchanger
and flue pipes.
Clear air intake of any ash
accumulation.
Clean heat exchanger and flue pipes.
2. Insufficient heat from first loadings, Wrong setting of draft regulator
Set draft regulator (reduce opening).
Reduce distance between furnace
low draft
(opening too large).
Restriction in chimney flue (excessive and chimney and eliminate 90o
length of chimney connector, right-
angled elbows).
elbows.
Maximum length: 10 feet.
Tight-angle elbows: maximum 3.
3. Poor heating in the rooms while
hot air plenum and furnace are hot.
Inadequate duct installation.
Insufficient static pressure.
Reposition ducts.
Unbalanced system (too many hot air
outlets for too few cold air intakes).
4. Furnace burns too much wood.
The thermostats controlling the air
combustion damper is located too
close to cold air and demands heat
continuously.
Wrong setting of air intake register.
Poor building insulation.
Relocate thermostat.
Adjust chain between damper motor
and combustion air damper.
Balance the ventilation system as to
increase the flow air in room where
thermostat is located.
Ash drawer left open.
Furnace too small for heating needs.
Unbalanced ventilation system,
insufficient heat near thermostat.
5. Fan starts too late.
Fan starting temperature is too high.
Cold air return is too cold.
Inappropriate location of fan limit
control in hot air plenum.
Lower starting temperature (the fan
limit control is normally set at 150 oF);
under certain conditions, this limit
should be reduced.
Reduce the cold air intake.
Relocate fan limit control within the
hot air plenum.
6. Creosote accumulation, very
average performance.
Damp wood.
Insufficient draft.
Clogged chimney.
Use dry wood.
Adjust draft regulator.
Clean chimney, chimney connector
and furnace heat exchangers.
7. Hot air plenum remains barely
Damp wood.
Use dry wood.
warm while furnace in full operation.
Too much cold air return in relation to Redistribute ventilation system.
hot air ducts.
Unbalanced ventilation system.
IMPORTANT NOTE
WE STRONGLY RECOMMEND CONSULTING A HEATING SYSTEM SPECIALIST
FOR THE INSTALLATION OF A CENTRAL HEATING VENTILATION SYSTEM.
N.B.: STOVE BUILDER INTERNATIONAL INC. IS NOT LIABLE FOR ANY FAULTY INSTALLATION WHICH RENDERS THIS
UNIT INOPERATIVE
29
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12. DUCTS AND REGISTER MEASUREMENTS
(sample calculations)
SIMPLIFIED METHOD
WARM AIR SYSTEM INSTALLATION
DISTRIBUTION SYSTEM
HOUSE DIMENSIONS
Example: 28 x 40 bungalow: 1,120 sq. ft.
Ducts size (heat)
4 inch outlet reduce by 1”
28 x 40 x 8: 8,960 cu. ft. x 1.8 Ch. air/hr:
16,128 Btu
5 inch outlet reduce by 2” Always by 8” thick
6 inch outlet reduce by 3”
Exposed walls:
N.B.: The main duct must be reduced every 2
outlets.
40 + 40 + 28 + 28: 136 x 8: 1,088 cu. ft. x 22: 23,936 Btu
Number of windows:
12 of 3 x 4: 144 x 60:
Number of doors:
2 x 3 x 7: 42 x 100:
8,640 Btu
Ducts specifications (heat)
Dimensions Length Elbow
Average equivalence
Max 4,000 Btu
4,200 Btu
4”
5”
6”
10’
10’
10’
1 x 90o
1 x 90o
1 x 90o
52,904 Btu
Max 6,000 Btu
Non-insulated basement: 25%
Insulated basement: 15%
Max 7,000 Btu
7,906 Btu
or 54 Btu per sq. ft.
60,840 Btu
FOR ELECTRIC ELEMENTS 80%:48,672 Btu or 14,28 kW
TO BE ADDED:House 1 1/2 floor = 25%
DAMPER
House 2 floors
= 40%
For a 4” warm air outlet: 2” x 10” damper
For a 5” warm air outlet: 2” x 12” damper or 4” x 10”
For a 6” warm air outlet: 2” x 14” damper or 4” x 12”
BEDROOM (for example: 12 x 12)
12 x 12 x 8: 1,152 cu. ft. x 1.8 Ch. air/hr:
Exposed walls:
2,074 Btu
4,224 Btu
12 + 12 x 8: 192 x 22:
Windows:
3 x 4 x 60
720 Btu
7,018 Btu
30
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1700, rue Léon-Harmel, Québec (Québec) G1N 4R9
tel. : (418) 527-3060 fax : (418) 527-4311
LIMITED LIFETIME WARRANTY
The PSG warranty extends only to the original consumer purchaser and is not transferable. This warranty covers brand new
products only, which have not been altered, modified nor repaired since shipment from factory. Proof of purchase (dated bill of
sale), model name and serial number must be supplied when making any warranty claim to your PSG dealer
This warranty applies to normal use only. Damages caused by misuse, abuse, improper installation, lack of maintenance, over firing,
negligence or accident during transportation are not covered by this warranty.
This warranty does not cover any scratch or discoloration caused by over firing, abrasives or chemical cleaners. Any defect or
damage caused by the use of unauthorized parts or others than original parts void this warranty.
An authorized qualified technician must perform the installation in accordance with the Instructions supplied with this product and
all local and national building codes. Any service call related to an improper installation is not covered by this warranty.
Returned products are to be shipped prepaid to PSG for investigation. If a product is found to be defective, PSG will repair or replace
such defect and reasonable transportation fees will be refund. Repair work covered by the warranty, executed at the purchaser
domicile by an authorized qualified technician requires the prior approval of PSG. Labour cost and repair work to the account of PSG
are based on predetermined rate schedule and must not exceed the wholesale price of the replacement part.
PSG at its discretion may decide to repair or replace any part or unit after inspection and investigation of the defect. PSG may, at its
discretion, fully discharge all obligations with respect to this warranty by refunding the wholesale price of any warranted but
defective parts
PSG shall in no event be responsible for any special, indirect, consequential damages of any nature, which are in excess of the
original purchase price of the product.
WARRANTY APPLICATION
DESCRIPTION
LABOUR
5 years
n/a
Combustion chamber (weldings only)
Perforation caused by rust
Stainless steel baffle
1 year
1 year
n/a
Carbon steel baffle
Handle assembly
Ash drawer
1 year
1 year
n/a
Cast iron parts
Ceramic glass (thermal breakage only)
Paint, refractory bricks, gasket, blower, thermal switch (thermodisc) and
rheostat
1 year
n/a
n/a
Plating
Shall your unit or a components be defective, contact immediately your PSG dealer. Prior to your call make sure you have the
following information necessary to your warranty claim treatment:
•
•
You name, address and telephone number;
Bill of sale, dealer’s name;
•
•
Serial number and model name as indicated on the
nameplate fixed to the back of your unit;
Nature of the defect and any relevant information.
Before shipping your unit or defective component to our plant, you must obtain from your PSG dealer an
Authorization Number. Any merchandise shipped to our plant without authorization will be refused
automatically and returned to sender.
31
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