PSG CADDY MAX CADDY WOOD ADD-ON PF01102, Installation And Operating Instructions Manual

Page 1: ...ide years of comfort and safe operation Please keep this document Verified and tested for Canada by an accredited laboratory This manual is available for free download on the manufacturer s web site It is a copyrighted document Re sale is strictly prohibited The manufacturer may update this manual from time to time and cannot be responsible for problems injuries or damages arising out of the use o...

Page 2: ...ECTRICAL DIAGRAM FOR SERIAL ADD ON VIA MOTOR 22 15 INSTALLATION INSTRUCTIONS 24 15 1 LINK BOARD INSTALLATION AND CONNECTION 24 15 2 TOUCHSCREEN INSTALLATION AND CONNECTION 25 15 3 HOT AIR PLENUM TEMPERATURE PROBE INSTALLATION AND CONNECTION RTD 26 15 4 SERVOMOTOR INSTALLATION AND CONNECTION 27 15 5 UNIT LOCATION 28 15 6 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS AND FLOOR PROTECTION 28 15 7 MINIM...

Page 3: ...ENT PARTS 40 19 1 DOOR GLASS 41 19 2 GASKET 41 20 TROUBLESHOOTING 41 20 1 VALIDATING STATUS OF A COMPONENT 42 20 2 AIR DAMPER AND HOT WATER 42 20 3 TEMPERATURE PROBE RTD 42 20 4 MAIN ERROR CODES POSSIBLE CAUSES AND SOLUTIONS 42 20 5 UNIT OVERHEAT 43 20 6 NO HEAT 43 20 7 COMMUNICATION ERROR 44 20 8 SMOKE SMELL 44 20 9 THE LCD TOUCH SCREEN DOES NOT LIGHTUP 44 20 10 AUXILIARY OVERRIDE 44 21 EXPLODED ...

Page 4: ...e use of good seasoned cordwood The Max Caddy add on was tested and approved according to the CSA B415 1 10 Standard To optimize the efficiency of your add on here is some advice that you should follow when installing or operating your Max Caddy add on Respect the local codes when in doubt consult your local dealer Make sure your add on is installed according to the instructions on the certificati...

Page 5: ...d the presence of heat distribution systems have a significant impact in making heat circulation optimum 1 Values are as measured per CSA B415 1 10 except for the recommended heating area firebox volume maximum burn time and maximum input capacity Performances based on a fuel load prescribed by the standard at 10 lb ft and with moisture content between 18 and 28 2 Input value at 10lb ft fuel loadi...

Page 6: ...lly completed prior to being moved to a site for installation on a foundation and connection to service facilities and which conforms to the CAN CSA Z240 MH standard 4 SPECIFICATIONS Color Grey Thermostatic control Yes Door type Single glass with cast iron frame Glass type Ceramic glass Hot air plenum dimensions Depth or Height 32 1 8 in Hot air plenum dimension Width 25 3 8 in Ash pan dimensions ...

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Page 9: ...9 6 MAX CADDY ADD ON TECHNICAL DATA MODEL TEMP VAR STATIC PRESSURE OF MIN MAX INCH H2O MAX CADDY ADD ON SERIE 100 0 2 0 5 7 ADD ON DIMENSIONS TOP VIEW FRONT VIEW SIDE VIEW ...

Page 10: ...t 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 The adjustment should in no case be modified to increase combustion 9 SAFETY RULES WARNING THE INFORMATION GIVEN ON THE CERTIFICATION LABEL AFFIXED TO THE APPLIANCE ALWAYS OVERRIDES THE INFORMATION PUBLISHED IN ANY OTHER MEDIA OWNER S ...

Page 11: ...move ashes When ignited creosote produces an extremely hot fire inside the chimney In the first year of use inspect the chimney system at regular intervals to determine a cleaning cycle Depending on the type of wood used and its quality a semi annual cleaning may be required A yearly cleaning is mandatory If a significant layer of creosote has accumulated it must be removed immediately to eliminat...

Page 12: ...e ventilation system The drawer must be cleaned regularly Use a vacuum cleaner to remove any ashes around the drawer in order to avoid the dispersion of ashes in the ventilation system 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 a genuine replacement gasket 9 9 ...

Page 13: ...13 INSTALLATION AND OPERATION INSTRUCTIONS MAX CADDY ADD ON SERIAL INSTALLATION FOR CANADA ONLY PF01102 ...

Page 14: ...d however the speed of the motor may be increased or decreased CAUTION THE BLOWER OF THE EXISTING FURNACE ITSELF SHALL NOT BE CHANGED WARNING THE ELECTRICAL CURRENT FLOWING THROUGH THE BLOWER MOTOR SHALL NOT EXCEED THE NAME PLATE RATING 12 APPLIANCE INSTALLATION If the exiting furnace must be modified the following standards must be respected Wood oil NFPA 31 Standard for the installation of oil b...

Page 15: ...n and cannot be directed downward Do not install connecting ducts in a way that would allow inversion of the air flow see example 1 and 3 The transfer duct between the existing furnace and the add on must be at least 540 square inches 0 35 m2 and deviations radius must be at least 6 152 mm See OPTION 1 and 2 Option 1 Option 2 Minimum duct size 540 square inches 0 35 m2 R Minimum radius 6 inches MA...

Page 16: ...16 Option 3 Option 4 ...

Page 17: ...17 EXAMPLE 1 EXAMPLE 2 WARNING DO NOT REMOVE RELOCATE OR BYPASS ANY OF THE SAFETY CONTROLS IN THE ORIGINAL FURNACE INSTALLATION Prohibited Prohibited Prohibited ...

Page 18: ... return temperature from that of the air exiting in the hot air plenum The result t will be needed for next step 3 Make the following verifications Existing oil electric or gas furnace Q ______q_____ 1 08 x T2 T1 Q Flow in cubic feet min q Heat flow in BTU h T1 Fresh air return temperature oF T2 Hot air outlet temperature oF 12 2 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS AND FLOOR PROTECTION N B...

Page 19: ...OR INSTALLATION See Section 14 5 SERVOMOTOR INSTALLATION AND CONNECTION THERMOSTAT INSTALLATION 12 7 OPERATING INSTRUCTIONS Operate the existing furnace periodically to ensure that it will operate satisfactorily when needed On the wood add on the thermostat controls the air inlet damper When the thermostat calls for heat the damper opens and the combustion is stirred up When the add on gets hot en...

Page 20: ...SBI 51035 relays to make the connection as in 3 relay diagrams It is possible to use only two relay White Rodger SPNC SPNO 90 380 for the two relay diagram The use of another brand or model of relay is not recommended since very limited technical support may be provided REQUIRES 3 RELAYS 51035 NOT INCLUDED ...

Page 21: ...21 REQUIRES 2 RELAY SPNO SPNC WHITE ROGERS P N 90 380 NOT INCLUDED AND 24V AVAILABLE ON EXISTING FURNACE ...

Page 22: ...22 14 ELECTRICAL DIAGRAM FOR SERIAL ADD ON VIA MOTOR REQUIRES 1 RELAY 51035 WITH 1 JUNCTION BOX NOT INCLUDED ...

Page 23: ...23 REQUIRES 2 RELAY SPNO SPNC WHITE ROGERS P N 90 380 WITH 1 JUNCTION BOX NOT INCLUDED AND 24V AVAILABLE ON EXISTING FURNACE ...

Page 24: ... preferred to facilitate the connection of auxiliary heating sources or for servicing The components to be installed are in the combustion chamber of the add on 1 Remove the link board housing cover 2 Remove the four screws on the add on located on the side of the desired installation 3 Align the holes of the board housing the holes on the side of the add on Use the screws removed in the previous ...

Page 25: ...link board with the touch screen using the telecommunication wire provided with the user manual Plug the telecommunication wire in connector labeled LCD and pull it out of the board housing through the top grommet Simply run the wire on the side of the add on using the plastic ties supplied with the user manual Replace the access panel of the link board Note that the touch screen is removable if a...

Page 26: ...ING SUITABLE FOR 75 C not included STEP 1 Remove the two screws already secured to the add on B on the side where you have chosen to install the link board Then secure the RTD support A using the two screws you previously removed STEP 2 Using a drill and a 9 32 bit drill a hole in the hot air plenum so that the RTD rod can pass into it STEP 3 and 4 Secure the RTD in place on the hot air plenum usi...

Page 27: ...er as shown above The chain must have a set of 1 8 When there is no call for heat the air inlet damper must be completely closed and the chain must be hooked to the servomotor at the 8 o clock position Then you must connect the servomotor and the link board Take the wires out of the servomotor and enter the wires in the wire cover through the grommet Pull them out through the grommet next to the l...

Page 28: ...H AIR INTAKE ADAPTER INSTALLATION OPTIONAL The add on must be positioned so that the connector is as short as possible Minimize the use of 90o elbows The owner must ensure a proper installation to allow a safe operation of the appliance 15 6 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS AND FLOOR PROTECTION N B This appliance must be installed in accordance with the instructions on the certification...

Page 29: ... 79 2 007 mm E 72 1 829 mm F 24 610 mm 1 HEAT SHIELD 15 8 MINIMUM CLEARANCES TO COMBUSTIBLES MATERIALS FOR HOT AIR PLENUM Plenums installed on the add on must be made of metal in accordance with CSA B365 The hot air duct can be passed through the side wall with a clearance of six 6 inches around thereof ...

Page 30: ...low FLOOR PROTECTION CANADA A 18 457 mm From door opening C 8 203 mm D 8 203 mm Note 1 Steel with a minimum thickness of 0 015 0 38 mm or ceramic tiles sealed together with grout No protection is required if the unit is installed on a non combustible floor ex concrete Note 1 The floor protection at the back of the add on is limited to the add on required clearance A if such clearance is smaller th...

Page 31: ... If the draft exceeds 0 06 IN W C a barometric control must installed Never install a manual damper Secure the exhaust pipe to the flue adapter with three screws For a proper installation follow the advice below All the exhaust pipe joints must be secured with three screws Make sure that each screw goes through the inner wall of both connectors male and female See pictures below showing a male fem...

Page 32: ...ded to install a fresh air supply A fresh air supply may be needed if Solid fuel units present anomalies such as irregular draft smoke return bad combustion and or reversed draft whether there is combustion or not Existing solid fuel units such as a stove or fireplace release odours heat badly cause smoke returns or reversed draft whether there is combustion or not The opening of a window even sli...

Page 33: ...room make sure it does not create a depression in the room where the add on is installed For more information regarding the installation of fresh air intake adapter refer to the option s manual 15 14 HOT AIR PLENUM The hot air plenum coming out of the add on is to have a minimum height of 24 610 mm These dimensions for all hot air add on are in accordance with the standards CSA B140 4 NOTE TO ENSU...

Page 34: ... 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 you want to provide power to the thermostat note that the connections may differ depending on the thermostat Some thermostats need Rc and C while others require Rh and C in this case verify the need for a jumper between Rc and Rh in t...

Page 35: ...onents and options Before you configure your system and learn how to operate it make sure that your wall thermostat is wired correctly to your add on that the temperature probe RTD is well installed in the hot air plenum and connected to the link board and that your air distribution system is complete The add on uses a touch screen the latest technology in control devices Options are controlled fr...

Page 36: ...the temperature unit and the alarm activation 17 6 SYSTEM BALANCING It is important to call upon a professional installer for the installation of the add on and the ducting system configuration Certain check ups must be performed and certain rules must be respected in order not to damage the blower of the existing furnace When all components are installed on the add on and the ducting system is co...

Page 37: ... add on 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 combustion chamber in order to obtain an efficient operation of the appliance secondary burn Please note that a small hot fire will produce much less residues than a large smouldering one IMPORTANT DURING THE HEA...

Page 38: ...RE In case of prolonged power failure over 10 minutes to reduce the risk of overheating it is recommended to heat moderately and to open the Add on filter compartment in order to facilitate air circulation by natural gravity around the firebox of the Max Caddy wood add on 17 14 CHIMNEY FIRES This might occur when the fire gets extremely hot Burning cardboard branches or small pieces of wood can ig...

Page 39: ... require tools just remove the decorative facing by just lifting it remove the wing nut that keeps the hinged access panel closed See pictures below Before cleaning the three exchanger pipes move the upper c cast baffle board of the combustion chamber forward see drawing on next page Using the scraper clean the three exchanger pipes The accumulated dirt in the lateral exchangers will fall into the...

Page 40: ...that the smoke and the combustion gases are not transported into the air ducting system 18 4 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 then be required If the door adjustment is not sufficient replace the door gasket with a genuine one 18 5 DOOR ADJUSTMENT PROCEDURE 1 Unscrew completely the locking...

Page 41: ...UBLESHOOTING When you have issues with your add on 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 generally caused by the following five factors 1 Wrong operation or lack of maintenance 2 Bad installation 3 Poor quality combustible 4 Component failure 5 Factory defect ...

Page 42: ...re in the plenum and displays it on the main page in the upper right corner If the probe fails the error message PLENUM OVERTEMP will appear See section 20 4 MAIN ERROR CODES POSSIBLE CAUSES AND SOLUTIONS for more information 20 4 MAIN ERROR CODES POSSIBLE CAUSES AND SOLUTIONS This section contains main error codes possible causes and many suggestions to guide you in resolving them To go back to t...

Page 43: ... probe is either disconnected or defective Check the probe connection see Section 15 3 HOT AIR PLENUM TEMPERATURE PROBE INSTALLATION AND CONNECTION RTD or replace if necessary 20 6 NO HEAT This message appears When the wood add on failed to raise the temperature in the plenum enough to start the blower of the existing furnace Make sure there is a fire in the add on ...

Page 44: ...gaskets are in good condition and replace them with original parts if necessary Make sure the door is well adjusted Negative pressure A faint wood burning odor during ignition or shut down is normal Although if this increases beyond what is considered normal or if you notice an unusual soot build up on walls or furniture check your venting system carefully for leaks and make sure all gaskets are i...

Page 45: ...45 21 EXPLODED VIEW AND PART LIST ...

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Page 50: ... SE56407 RIGHT AIR JACKET PANEL WITH ISULATION 1 20 SE56414 RIGHT PANEL WITH INSULATION WATER LOOP OPTION 1 21 30153 METAL SCREW 8 X 1 2 PAN SQUARE TEK BLACK SELF DRILLING 2 22 SE44096 100 OHM RTD PROBE 38 WIRE WITH CONNECTOR 1 23 PL56343 RTD SUPPORT BRACKET 1 24 30416 WING NUT 3 8 16 1 25 30205 ZINC WASHER ID 13 32 X OD 13 16 4 26 30055 HINGE PIN RETAINING RING 5 16 ID X 0 512 OD 2 27 30168 HINGE...

Page 51: ...8 1 61 PL36232 4 X 8 3 4 X 1 1 4 X 1 2 X 3 1 4 REFRACTORY BRICK 1 62 PL36233 3 1 2 X 6 X 1 1 4 REFRACTORY BRICK 2 63 60363 8 COMMUNICATION WIRE 4 CONDUCTOR 1 64 SE56777 MAX CADDY TOUCH SCREEN BOARD LCD WITH HOUSING 1 65 PL48251 PC BOARD HOUSING COVER 1 66 30412 BLACK UNIVERSAL SNAP IN BUSHING 1 67 PL48250 PC BOARD HOUSING 1 68 30408 ELECTRONIC BOARD CLIP 9 69 SE56823 POWER BOARD HOUSING ASSEMBLY 1...

Page 52: ... to standards Given the importance of the installation PSG recommends that it is carried out by a professional certified in the Building Code so that the add on delivers its full potential This is why PSG offers an additional warranty that covers the cost of labor if your add on has been purchased through an authorized PSG dealer If you want to enjoy the best service on the market and substantial ...

Page 53: ...epair or replace any part or unit after inspection and investigation 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 manufacturer shall in no event be responsible for any special indirect consequential damages of any nature which are in excess of the original...

Page 54: ... wholesale price of the replacement part All parts and labour 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 defect The manufacturer may at its discretion fully discharge all obligations with respect to this warranty by refunding the wholesale price...