PSG CADDY ALTERNA II, Installation And Operating Instructions Manual

Page 1: ...LTERNA II PELLET AND 15 kW 20 kW COMBINATION FURNACE CONGRATULATIONS You have purchased one of the finest pellet or combination furnaces available on the market We are confident that your furnace will...

Page 2: ...g children should be supervised when they are in the same room as the furnace Contact your local building officials to obtain a permit and information on any installation restrictions or inspection re...

Page 3: ...11 5 1 1 HOPPER REMOVAL 12 5 1 2 BLOWER ASSEMBLY REMOVAL 13 5 2 UNIT LOCATION AND FIXATION TO THE FLOOR 15 5 3 HOPPER S LID OPENING 16 5 4 CLEARANCES TO COMBUSTIBLE MATERIALS 17 5 4 1 FLOOR PROTECTIO...

Page 4: ...HE COMBUSTION LEVEL HEAT OUTPUT 48 7 3 2 COMBUSTION SETTINGS AND PILOT SETTINGS DEPENDING ON FUEL QUALITY 48 7 3 3 SELECTING THE PILOT CYCLE 49 7 3 4 START STOP AND TIME DELAY PARAMETERS ADJUSTMENTS 5...

Page 5: ...THE AUGER MOTOR 74 11 4 AUGER REPLACEMENT 76 11 5 EXHAUST BLOWER REPLACEMENT 77 11 6 COMBUSTION BLOWER REPLACEMENT 78 11 7 DISTRIBUTION BLOWER REPLACEMENT 79 11 8 IGNITER REPLACEMENT 80 11 9 ACCESS TH...

Page 6: ...nline will help us track rapidly the information we need on your furnace 1 PELLET OR PELLET ELECTRIC COMBINATION FURNACES The Caddy Alterna II furnace was tested using the guidelines of the CSA B415 1...

Page 7: ...climate fuel type feed rate fuel level and other variables The recommended heated area for a given appliance is defined by the manufacturer as its capacity to maintain a minimum acceptable temperatur...

Page 8: ...he manufacturer as its capacity to maintain a minimum acceptable temperature considering that the space configuration and the presence of heat distribution systems have a significant impact on making...

Page 9: ...40 85 125 amps 3 120 240 4 x 5 kW PELLET 1 650 110 100 000 6 15 amps 14 120 N A 3 2 1 TECHNICAL DATA OTHER COMPONENTS Igniter lda00068 500 Watts 120 volts Fuses Midget 30 amps Time Delay Littelfuse 4...

Page 10: ...diately to eliminate the risk of chimney fire It is highly recommended to prepare an emergency procedure in case of a chimney fire It is recommended to clean the heat exchangers thoroughly at the end...

Page 11: ...be emptied regularly Once clean up is completed use an ash vac to carefully remove any ash around the drawer Failure to perform this important step may cause ashes to be dispersed through the ductwork...

Page 12: ...the vertical panel screws 4 2 Disconnect the hopper switch s connector by removing the right side panel to access the connector 3 After the bottom screws are removed and the vertical panel screws are...

Page 13: ...L The blower removal is done in three steps Step 1 Remove the covers Remove the blower box and the feed motor covers by removing the screws 11 Once all the screws are removed slide the covers assembly...

Page 14: ...tube must be put back on the right sensor side Unplug the four pellet feeding motors wires C Step 3 Unscrew the blower box Unscrew the screws located on each side of the blower box and the four screws...

Page 15: ...tall an outside air intake see Section 5 8 Combustion Air Once you have determined the location of the furnace and that clearances to combustible materials are respected it is highly recommended to se...

Page 16: ...epending on the different ducts installation chimney fresh air return fresh air inlet etc For that open the hopper s lid unscrew the three screws holding each of the hinges rotate the lid 180 and put...

Page 17: ...extending at least 2 on either side of the chimney connector The Alterna II furnace s air return plenum can be connected to a new or to an existing air return ductwork In both cases the minimum cleara...

Page 18: ...PROTECTION CANADA USA A 18 457 mm From door opening 16 406 mm From door opening B N A USA only 8 203 mm From door opening C 8 203 mm N A Canada only D 8 203 mm Note 1 N A Canada only E N A USA only N...

Page 19: ...nstalled as a standalone unit The ductwork and furnace should be adjusted in order to reach a static pressure of at least 0 20 IN WC but not more than 0 50 IN WC A back flow damper should be installed...

Page 20: ...wo furnaces and to ensure that hot air will flow into the house and will not return through the plenum of the other furnace Depending on your system configuration it is possible that more than one reg...

Page 21: ...the United States we recommend that you use a listed pellet vent that meets the UL 641 This unit can be vented in an existing chimney with the addition of a liner if the chimney is more than 4 in dia...

Page 22: ...THE VENT MANUFACTURER INSPECT AND CLEAN FLUES AND CHIMNEY REGULARLY 5 7 3 INSTALLATION CONFIGURATIONS A HORIZONTAL INSTALLATION THROUGH WALL Description A Wall Pass Thru B Tee C Wall Support D Vertic...

Page 23: ...all Furthermore there should always be at least one foot of vertical rise for each foot of horizontal run see Section 5 7 5 Horizontal and Vertical Vent Chart 6 To reduce the risk of smoke spillage ne...

Page 24: ...ed configuration zone on the chart because the venting system proposed does not have at least one foot of vertical rise for each foot of horizontal run Instead if the installation consisted of a horiz...

Page 25: ...indow or door that may be opened F 39 100 cm Clearance to corner or adjacent wall H 39 100 cm Not to be installed above a meter regulator assembly within 39 100 cm horizontally from the vertical centr...

Page 26: ...be located at least 12 30 cm away from a window or door The bottom of the exhaust terminal and air intake must be located at least 12 30 cm above the ground B VERTICAL INSTALLATION WITH NEW CHIMNEY SY...

Page 27: ...the vent manufacturer s instructions 1 Have the chimney inspected by a qualified chimney sweep or installer to determine its structural condition 2 You will need a pipe length equal to the chimney hei...

Page 28: ...mentioned above The house is equipped with a tight vapor barrier and adjusted windows and or is equipped with an interior air mechanical evacuation device There is excessive condensation on the window...

Page 29: ...order to avoid condensation the pipe should be insulated and its total length should be at least 10 feet 3 05 meters 5 9 AIR RETURN DUCTING SUPPORT INSTALLATION Your furnace must be equipped with the...

Page 30: ...n of the controls to the right or to the left of the furnace The most accessible side is preferable to facilitate the connection of auxiliary equipment or for servicing The components to be installed...

Page 31: ...on the side of the hopper Replace the screw to secure the housing Once installed the link board must be connected to the system with two telecom wires The wires can be found in the top compartment of...

Page 32: ...to their respective terminals Once the wires are outside the furnace run them along the back of the furnace and pass them through the bottom cable grommet of the link board housing Complete the instal...

Page 33: ...he Neutral N Ground F and Line L terminals Refer to the wiring diagram Section 14 for the other components connections Once done secure the wires with a BX connector not included and put the blower bo...

Page 34: ...the unit In order to secure the RTD support remove the two screws already secured to the furnace on the side where you have chosen to install the link board Then secure the RTD support using the two s...

Page 35: ...n the thermostat C W Y G and O If the thermostat is using a dry contact powered by batteries it is not necessary to connect the C common terminal to the thermostat Refer to the electrical diagram If y...

Page 36: ...he following instructions do not supersede the local code The electrical element must be connected to the power board see wiring diagram of your electrical element For security reasons the electrical...

Page 37: ...In order to complete the installation of an air conditioning unit the thermostat must be a heat cool type Furthermore the desired distribution blower speed in the air conditioning mode will have to b...

Page 38: ...iority of the operation of these two modes of heating you must go to Section 7 2 3 Prioritization heating sources For example if pellet heating is selected as priority 1 and a lack of pellets occur du...

Page 39: ...t be installed to ensure an auxiliary heat source for installation see Section 5 14 Electrical element connection For installation of air conditioning coil refer to Section 5 15 Installation of an air...

Page 40: ...II furnace the signal from the existing furnace s thermostat will override the Caddy Alterna II thermostat heat signal which will prevent both furnaces to run at the same time The wiring for an Add on...

Page 41: ...LD BE MAINTAINED AND OPERATED AT ALL TIMES IN ACCORDANCE WITH THESE INSTRUCTIONS NOT FOLLOWING THE INSTRUCTIONS OF THIS MANUAL MAY CAUSE SMOKE SPILLAGE AND OTHER POTENTIAL HAZARDS IT IS ALWAYS RECOMME...

Page 42: ...CALORIFIC VALUE APPROXIMATELY 8 500 BTU LB OTHER FUELS WITH A HIGH ASH CONTENT WILL REQUIRE A HIGHER LEVEL OF MAINTENANCE AND CLEANING THE FURNACE WILL NOT OPERATE USING NATURAL DRAFT OR WITHOUT A PO...

Page 43: ...our furnace You may want to have a few bags in the same room as your furnace for refueling but make sure to respect the minimum clearances to combustible materials and the space required for refilling...

Page 44: ...bution fan speeds Troubleshooting to detect problems with the appliance The power board is used to supply current to the different electrical components in particular Supply current to the different e...

Page 45: ...EM CONFIGURATION 7 2 1 SELECTING THE LANGUAGE AND TEMPERATURE SCALE F OR C To select preferred language and temperature scale go to the GENERAL menu You can choose between two languages English or Fre...

Page 46: ...urces when a heating demand from the wall thermostat is sent to the furnace If for example your pellet furnace is selected as first priority but runs empty on pellets the auxiliary heating source set...

Page 47: ...st be respected in order not to damage the blower When all components are installed on the furnace and the ducting system is connected to the various rooms of the house you must balance the ducting sy...

Page 48: ...ood pellets we strongly recommend the use of high quality pellets to obtain maximum performance out of your furnace see Section 6 2 1 Proper Fuel When using lower quality combustible a restrictive ven...

Page 49: ...on level is at the minimum setting You may also want to increase combustion fan speed to avoid unburned pellets to fall into the ash drawer at any combustion level Speed of exhaust fan You may want to...

Page 50: ...ch the fire in the burn pot is considered out If once your furnace has stopped and you still see a noticeable amount of embers you can decrease the temperature T _Stop Also if your furnace is located...

Page 51: ...MALL AMOUNT OF FUMES AS THE HIGH TEMPERATURE PAINT CURES OR BECOMES SEASONED TO THE METAL MAINTAINING SMALLER FIRES WILL MINIMIZE THIS AVOID PLACING ITEMS ON FURNACE TOP DURING THIS PERIOD TO AVOID DA...

Page 52: ...the temperature of the heat sensor on the exhaust drops The cooling cycle will take a few minutes before all other motors stops Once the furnace has stopped a warning message NO FUEL will be displayed...

Page 53: ...at the end of each heating season During the summer air is more humid with minimal natural flow in the furnace in these conditions remaining creosote and or soot in the exchanger will produce an acid...

Page 54: ...54 Then unscrew the two wing nuts to remove the access trap A located above the combustion chamber...

Page 55: ...moved Using the scraper clean the six exchanger pipes Using an ash vac will be the most efficient way to collect ashes that may have accumulated First vacuum the dust accumulated in front of the excha...

Page 56: ...nuts on each clean out traps and remove them To ensure a complete cleaning completely remove the separator of the exchanger A and clean the back pipe of the exchanger When done clean the bottom pipe O...

Page 57: ...ower impellers when you clean the inside of the evacuation box towards the blower Finish by putting back all clean out traps and closing the furnace s jacket access panels Should one of the clean out...

Page 58: ...of the combustion chamber 9 3 VENTING SYSTEM MAINTENANCE REGULARLY EXAMINE THE FLUE PIPES AND THE SEALING JOINTS TO ENSURE THAT THE SMOKE AND THE COMBUSTION GASES ARE NOT TRANSPORTED INTO THE AIR DUCT...

Page 59: ...ducts We suggest using an ash vacuum Some regular vacuums and Shop Vac type leak ash into the room Your vacuum or Shop Vac should have a special filter or bag to eliminate this leakage 9 5 CLEANING TH...

Page 60: ...of blades Be careful not to damage the blades 9 7 CLEANING THE COMBUSTION BLOWER It is recommended to inspect the combustion blower according to maintenance schedule presented below see Section 9 12 R...

Page 61: ...sure a regular maintenance This means that the air filter must be replaced regularly use the same size and the same type as the original filter High efficiency 2 ply 3 ply or 4 ply filter is recommend...

Page 62: ...th your furnace your first reaction may be to call technical support This section will help you save time and money by enabling you to solve simple problems by yourself Most common problems are genera...

Page 63: ...MANIPULATE OR REPLACE ANY COMPONENTS THE FURNACE NEEDS TO BE DISCONNECTED FROM ITS POWER SOURCE To validate the status of a component go to PARAMETER TAB of the Main Status Page and then in the TROUBL...

Page 64: ...enu Page 2 and 3 will allow you to test every electrical component Note that you will be able to test only components when the furnace is OFF and that all the components are no more in function For ex...

Page 65: ...ufacturer s instructions A back draft occurred inside the flue This can occur on a very windy day or if your venting system does not have a proper termination The pressure sensor wire connections are...

Page 66: ...r s pellet contents completely to access the top of the rotary valve Once accessible make sure that no object other than wood pellets are found in the cavities of the rotary valve Thereafter before pu...

Page 67: ...low instructions for component check Test the igniter to see if it glows It should take no longer than two minutes If it does not glow red check the wiring and the G fuse see Section 11 9 Access the f...

Page 68: ...s defective or if the pot auger or rotary valve is jammed NOTE IF THE HOPPER GEAR MOTOR FAILED OR THE POT AUGER OR ROTARY VALVE IS JAMMED TO AVOID PELLET SPILLAGE EMPTY THE HOPPER OF ITS CONTENTS BEFO...

Page 69: ...no ash has filled the tube around the igniter Refer to the maintenance section Also make sure that the recommended fuel is used see Section 6 2 1 Proper Fuel The flue is not properly installed Make su...

Page 70: ...OMPLETELY as described in this manual See Section 9 Maintenance Verify the venting system and all other components mentioned above ONCE THE MAINTENANCE DONE AND THE VENTING SYSTEM CHECKED FOLLOW THESE...

Page 71: ...witch see Section 10 2 Testing Components Replace if necessary 10 3 8 POWER LOSS Power was interrupted while the furnace was functioning After the cool down cycle the furnace will restart using the la...

Page 72: ...produces a negative pressure in the room It draws air from the inside of the room through the furnace and then outdoors In the same manner other appliances can also create a larger negative pressure I...

Page 73: ...must be repaired without delay using genuine PSG replacement parts You can find a complete list of replacement parts in our website at www caddyfurnaces com 11 1 DOOR GLASS Inspect the glass regularly...

Page 74: ...from around the cover and remove it Disconnect the power supply wires B of the motor to change To remove the auger motor you must loosen the motor s screw axis A If the screw is not accessible go into...

Page 75: ...tor 1 The steps are the same disconnect the two power supply wires D align the motor shaft screw C using the furnace repair mode if required until the screw head is located in the Zone and unscrew the...

Page 76: ...Auger motor Then remove the furnace s jacket front panel open the combustion chamber door and remove the burn pot Unscrew the two screws on the access plate 1 in front of the pot receptacle Then unsc...

Page 77: ...n the auger tube making it more difficult to remove If this is the case turn the auger clockwise to release it 11 5 EXHAUST BLOWER REPLACEMENT To replace the exhaust blower remove the right panel of t...

Page 78: ...anel of the furnace s jacket Open the latch on the combustion blower support Take out the combustion blower motor by removing the support of its positioning holes at the bottom of the part Once the su...

Page 79: ...IBUTION BLOWER REPLACEMENT To replace the furnace s distribution blower first remove two side panels of the blower housing one on the back and the other on the side Unplug the fan connector A from the...

Page 80: ...posite side of the air return support 11 8 IGNITER REPLACEMENT Remove the furnace s jacket front panel and open the combustion chamber door Unscrew the two screws that hold in place the igniter and th...

Page 81: ...e disconnected lift the igniter to take it out of the combustion chamber Align the igniter connector in the igniter support hole to ease its removal 11 9 ACCESS THE FUSES To access the fuses remove th...

Page 82: ...FUSE FONCTION AMPS A BOARD MAIN FUSE 7 5A B CONVECTION BLOWER 5A C COMBUSTION BLOWER 3A D EXHAUST BLOWER 3A E UPPER AUGER MOTOR 1 3A F BOTTOM AUGER MOTOR 2 3A G IGNITER 5A FUSE FONCTION AMPS H POWER B...

Page 83: ...83 12 EXPLODED VIEWS AND REPLACEMENT PARTS...

Page 84: ...84 SECTION A SECTION B...

Page 85: ...85 SECTION C SECTION D...

Page 86: ...86 SECTION E SECTION F...

Page 87: ...87 SECTION G SECTION H...

Page 88: ...88 SECTION I SECTION J...

Page 89: ...89 SECTION K SECTION L...

Page 90: ...90 SECTION M SECTION N...

Page 91: ...91 SECTION O...

Page 92: ...92 HARNESS SECTION...

Page 93: ...93...

Page 94: ...94 TELECOMMUNICATION WIRES SECTION...

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Page 98: ...ANDLE BLACK 2 12 SE68561 HEAT EXCHANGER CLEANING TRAP ASSEMBLY 1 13 AC06900 BLACK 1 2 ROUND X 9 GASKET KIT WITH ADHESIVE 1 14 30484 WING NUT 1 4 20 2 15 SE24008 02 ALTERNA CAST IRON DOOR WITH HANDLE 1...

Page 99: ...INUM 1 PLI 15 1 59 21400 COMBUSTION FAN GASKET 2 60 SE44147 AXIAL BLOWER ASSEMBLY 115V 9W 92 X 92 X 38 1 61 30777 PLASTIC BACKDRAFT DAMPER ASSEMBLY 1 62 SE44144 EXHAUST BLOWER ASSEMBLY 1 63 30220 FLAN...

Page 100: ...96 99999 BUILD TO ORDER 1 97 PL68533 ROTARY VALVE CASE 1 98 44182 TRIAC BOARD 1 99 60368 TRANSFORMER 120 V 24 V 40 VA 1 100 60224 ELECTRICAL ELEMENT WIRE 2 101 44137 FUSE 1A 250V 1 4 DIA X 1 1 4 LONG...

Page 101: ...101 13 GENERAL ELECTRIC DIAGRAM...

Page 102: ...102 14 WIRING DIAGRAM WITH OPTIONAL ELECTRICAL ELEMENT PA08570 PA08580 CADDY ALTERNA II PELLET ELECTRIC COMBINATION FURNACE...

Page 103: ...e to find on the market options having higher or lower electrical consumption than those shown in the table below In the event that the combined electrical consumption of the installed options are hig...

Page 104: ...104 15 3 HOT WATER OPTION 15 4 24V ADDITIONAL EQUIPMENT 15 5 AIR CONDITIONING DAMPER...

Page 105: ...105 15 6 HUMIDIFIER 15 7 HEAT PUMP...

Page 106: ...to standards Given the importance of the installation PSG recommends that it be carried out by a professional certified in the Building Code so that the furnace delivers its full potential This is wh...

Page 107: ...igation of the defect The manufacturer may at its discretion fully discharge all obligations with respect to this warranty by refunding the wholesale price of any warranted but defective parts The man...

Page 108: ...ur costs covered by this warranty are limited according to the table below The manufacturer at its discretion may decide to repair or replace any part or unit after inspection and investigation of the...