PSG MAX CADDY PF01101, Installation And Operating Instructions Manual

Page 1: ...tructions carefully before installing and operating your furnace CONGRATULATIONS You have purchased one of the finest wood or combination furnaces available on the market We are confident that your furnace will provide years of comfort and safe operation Please keep this document READ THE MANUAL THOROUGHLY BEFORE OPERATING THE FURNACE This manual is available for free download on the manufacturer ...

Page 2: ...TALLATION 20 3 7 UNIT LOCATION 20 3 8 CLEARANCES TO COMBUSTIBLES AND FLOOR PROTECTOR 21 3 9 FLUE AND BAROMETRIC DRAFT CONTROL CONNECTION 23 3 9 1 Damper 24 3 10 FRESH AIR INTAKE ADAPTER INSTALLATION OPTIONAL 24 3 11 PARALLEL INSTALLATION 25 3 12 ELECTRICAL ELEMENT INSTALLATION WOOD ELECTRIC MAX CADDY OPTIONAL 26 3 13 THERMOSTAT INSTALLATION 27 3 13 1 Wood furnace only 27 3 13 2 Combination wood el...

Page 3: ...5 5 2 CHIMNEY MAINTENANCE 36 5 3 MAINTENANCE OF THE BLOWER MOTOR 36 5 4 FILTERS 36 5 5 DOOR GASKET MAINTENANCE 36 6 REPLACEMENT PARTS 37 6 1 DOOR GLASS 37 6 2 GASKET 37 7 GENERAL ELECTRIC DIAGRAM WITH BECKETT OIL BURNER 38 8 GENERAL ELECTRIC DIAGRAM WITH RIELLO OIL BURNER 39 9 ELECTRIC DIAGRAM WITH OPTIONAL ELECTRICAL ELEMENT 40 10 MAX CADDY TECHNICAL DATA 41 10 1 GENERAL TECHNICAL DATA 41 10 2 TE...

Page 4: ...TER YOU WARRANTY ONLINE To receive full warranty coverage you will need to show evidence of the date you purchased your furnace Keep your sales invoice We also recommend that you register your warranty online at http www psg distribution com warranty registration aspx Registering your warranty online will help us track rapidly the information we need on your furnace IMPORTANT NOTE THE INSTALLATION...

Page 5: ...ctric unit If an oil option may be installed in the future we also recommend a 7 inch chimney If the furnace is to be used as a wood only unit then a 6 inch chimney is recommended The unit is not to be connected to a chimney flue serving another appliance If the chimney draft exceeds 0 06 IN W C a barometric draft control should be installed on the smoke pipe Never install a manual damper The baro...

Page 6: ...o avoid chimney fires 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 eliminate the risk of chimney fire Remember that a small hot fire is preferable to a large smo...

Page 7: ...duced by the combustion of wood This drawer must not be left open during combustion as this may cause over firing and serious damages to the furnace The drawer must be emptied regularly 2 9 ASH GRATE You must replace the ash grate if it is damaged and a replacement may be obtained from your dealer It is important that the door and the ash drawer be kept closed while the appliance is in use Maintai...

Page 8: ...lower box electronic fan limit kit PA08565 CONTENT OF THE BOX 1 X BLOWER ASSEMBLY MANUAL KIT FOR MAX CADDY 27 X 10 X A TYPE METAL SCREW 2 X 20 X 1 ELEVATOR BOLT 1 X 100 OHM RTD 38 WIRE 1 X RTD SUPPORT 1 X 8 X METAL SCREW 1 X 3 8 1 SCREW CONNECTOR FOR BX WIRE 1 X RED PLASTIC SLEEVE FOR BX WIRE 2 X RED PLASTIC SLEEVE FOR BX WIRE ANTI SHORT SIZE 2 1 X SCREW CONNECTOR FOR BX WIRE WARNING THE INSTALLAT...

Page 9: ...9 3 1 COLD AIR RETURN BOX INSTALLATION Before installing the cold air return box you need to remove the back panel gasket and the back panel as shown below To do so remove the 8 screws ...

Page 10: ...emove the cold air ducting support from the cold air return box To do so remove the 12 screws as shown below Keep these screws You will need them to install the cold air ducting support in the new location ...

Page 11: ...tallations have obstacles making the installation of the cold air ducting support difficult Configurations differ depending on the chosen location of the cold air ducting support You will find the different configurations in the following pages In order to realize the various configurations you must remove the three screws retaining the side plate where you wish to install the cold air ducting sup...

Page 12: ...12 Installation of the cold air ducting support at the RIGHT of the cold air return box Installation of the cold air ducting support at the LEFT of the cold air return box ...

Page 13: ...n of the cold air ducting support ON TOP of the cold air return box with filter exit towards the RIGHT Installation of the cold air ducting support ON TOP of the cold air return box with filter exit towards the LEFT ...

Page 14: ...r on the right side and keep these screws Remove the access panel of the control PCB Secure the control PCB where you removed the screws from the furnace Refer to the electric wiring diagram in section 7 for the electrical connections Do not screw the access panel back on the control PCB until all connections are made Control PCB installed on the RIGHT side of the furnace Control PCB installed on ...

Page 15: ...ontrol PCB and the blower Since the control PCB may be installed on either side of the furnace refer to the drawings below to run the wire properly Control PCB installed on the RIGHT side of the furnace Control PCB installed on the LEFT side of the furnace ...

Page 16: ...his RTD probe must be installed on the RTD support bracket The RTD support bracket may be installed on left side or on the right side of the furnace To install it all you need to do is to screw it in place in the two pre drilled holes as shown below RTD support bracket installed on the RIGHT side of the furnace RTD support bracket installed on the LEFT side of the furnace ...

Page 17: ...nnect the RTD probe to the control PCB To run the wire properly refer to the drawings below Refer to the electric wiring diagram in section 7 for the electrical connections RTD probe installed on the RIGHT side of the furnace RTD probe installed on the LEFT side of the furnace ...

Page 18: ... s manual The chain that links the air inlet damper to the motor must have a play of 1 8 and must be secured in place by the hook When there is no call for heat the air inlet damper must be completely closed and the chain must be hooked to the servo motor at the 8 o clock position see Detail A and B This way the air inlet damper should be about 3 4 open and the chain at the 10 o clock position whe...

Page 19: ...ectric wiring diagram in section 7 To run the wire properly refer to the drawings below Wire running to the control PCB installed on the LEFT side of the furnace Wire running to the control PCB installed on the RIGHT side of the furnace WARNING USE WIRING SUITABLE FOR 75O C not supplied ...

Page 20: ...N 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 intake The furnace 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 for a safe operation of the appliance ...

Page 21: ...HEAT SHIELD 24 LEFT WALL 24 IF UH MAX CADDY 72 1 24 HOT AIR PLENUM 8 MIN 6 STATIC PRESSURE CHECK POINT MIN 0 20 W C 18 45 ELBOW 18 CEILING 3 4 HEAT SHIELD 6 24 N B This appliance must be installed according to the instructions on the unit s certification label ...

Page 22: ...pening E N A USA only 8 203 mm F 8 203 mm N A Canada only G 8 203 mm N A Canada only I N A USA only Note 2 J 8 203 mm N A Canada only Steel with a minimum thickness of 0 015 0 38 mm or ceramic tiles sealed together with grout No protection is required if unit is installed on a non combustible floor ex concrete Note 2 Only required under the horizontal section of the connector Must exceed each side...

Page 23: ... reducer must be installed at the flue outlet of the furnace 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 1 All the exhaust pipe joints must be secured with three screws Make sure that each screw goes through the inner wall of both co...

Page 24: ...r 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 slightly in calm weather windless eliminates every problem mentioned above The house is equipped with a tight vapour barrier and adjusted windows and or is equipped ...

Page 25: ...pe of installation is only allowed in the United States Ideally the maximum BTU input of the existing oil gas or electric furnace should be equal or higher than the maximum BTU input of the wood furnace It is mandatory to respect minimum clearances between the ductwork and combustible material as if the wood furnace was installed as a standalone unit The ductwork and furnace should be adjusted in ...

Page 26: ...r inlet damper closes down if opened the blower starts and the electric elements are successively activated per block of 5 kW When the call for electric heating is satisfied the wood system will take over if the starting point of the wood system thermostat is superior to that of the electric system Therefore under normal wood electric combination use you should set the wood system thermostat 2o to...

Page 27: ...se at the temperature programmed on the second thermostat option If the thermostats use a dry contact hook up the main thermostat wood to the WOOD MECH port on the PC board and the option s thermostat to the USER MECH port If the thermostats send a 24 volt signal to the appliance hook up the main thermostat wood to the WOOD 24V port on the PC board and the option s thermostat to the USER 24V port ...

Page 28: ...st be in a COOL mode and the desired distribution blower speed must be programmed see MODES section for complete instructions It must be noted that upon thermostatic demand for cooling the distribution blower will start immediately The capacity and characteristics of the air conditioning unit that has been tested with the MAX Caddy are stated below The use of another brand with similar capacity an...

Page 29: ... distribution blower s speed in order to maintain the BEP inside the hot air plenum 4 2 FIRST USE GENERAL INFORMATION Once the installation is complete and prior to using the furnace the electronic control of the furnace must be set to enable all applicable functions depending on the options chosen To do this it is important to know the options that are installed on your furnace Table 1 shows the ...

Page 30: ...t the MODES section of this manual Under the manual mode the MAX Caddy operates as a conventional furnace That is the distribution blower starts at the speed programmed in the PC board one single speed based on only one temperature point read by the RTD probe inside the hot air plenum The adjustment of all controls must be performed by a qualified technician In order to obtain a continuous air cir...

Page 31: ... the blower speed gradually returns to the speed required to maintain the BEP Programming Make sure that your wall thermostat is well connected to the PC board Make sure that the right port has been selected based on the type of thermostat e g 24VAC or Millivolt In the MODE menu select HEAT by pushing the SELECT button Then using the arrows buttons choose from the different selections KIP TEMP or ...

Page 32: ...blower will automatically select the maximal speed and the front air damper will close in order to slow down combustion When the temperature returns to a safe level the blower will return to the speed selected by the user Programming Make sure that your wall thermostat is well connected to the PC board Make sure that the right port has been selected based on the type of thermostat e g 24VAC or Mil...

Page 33: ...he BEP inside the hot air plenum 4 6 LIGHTING 1 Open the furnace door Note If there is already a bed of coals in the firebox go to 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 d...

Page 34: ... PROLONGED POWER FAILURE YOU CAN USE YOUR FURNACE THE DAMPER REMAINS IN CLOSED POSITION AND THE FURNACE FUNCTIONS AT THE MINIMUM BURN RATE IT IS VERY IMPORTANT YOU ENSURE THE HOLES DIAMETER LOCATED UNDER THE LOADING DOOR INSIDE THE FURNACE S COMBUSTION CHAMBER ARE FREE TO ENSURE A GOOD PERFORMANCE CARBON MONOXYDE IS A LETHAL GAS ODOURLESS AND COLOURLESS WHICH YOU MUST BEWARE OF 4 12 CHIMNEY FIRES ...

Page 35: ...ATE THE CORROSION PROCESS AND WILL PERFORATE THE STEEL PREMATURELY WHICH IN RETURN WOULD NOT BE COVERED UNDER THIS WARRANTY Before cleaning the three exchanger pipes move the upper vermiculite 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 combustion chamber ...

Page 36: ...using a vacuum cleaner is necessary in order not to affect performance and cause overheating of the latter 5 4 FILTERS The furnace must not be operated without filters In order to efficiently and safely operate a slow combustion heating system you have to ensure a regular maintenance This means that the chimney the joints and the flue must be kept in good condition and the air filters must be repl...

Page 37: ...PSG authorized dealer To replace the glass remove the screws that hold the glass retainers in place Removed these retainers and replace the defective glass the glass gasket should be replace at the same time To put back in place reverse the procedure Do not use abrasive cleanser Special cleansers for wood fireplaces glass are available in any good hardware store or specialty hearth retailer Clean ...

Page 38: ...38 7 GENERAL ELECTRIC DIAGRAM WITH BECKETT OIL BURNER ...

Page 39: ...39 8 GENERAL ELECTRIC DIAGRAM WITH RIELLO OIL BURNER ...

Page 40: ...40 9 ELECTRIC DIAGRAM WITH OPTIONAL ELECTRICAL ELEMENT MAX CADDY WOOD ELECTRIC COMBINATION FURNACE ...

Page 41: ...RE FILTER FAN MOTOR SPEED CFM O F WOOD MIN MAX 1 IN W C MAX CADDY G 10 1 2HP 4 1780 100 180 000 0 2 0 5 16 x 20 X 1 10 2 TECHNICAL DATA ELECTRICAL ELEMENT MODEL OUTPUT CFM TEMP VAR O F BTU HR AMPS TOTAL BREAKER REQUIRED FEEDER GAUGE VOLTAGE SINGLE PHASE ELEMENTS QTY 20 kW 1800 75 68 240 85 125 amps 3 120 240 4 x 5 kW 25 kW 1800 85 85 325 100 150 amps 2 120 240 5 x 5 kW WOOD 1800 100 180 000 5 15 a...

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Page 43: ...re the thermostat is located Relocate the thermostat Adjust the chain that links the damper to the servo motor Rebalance the ventilation system in order to increase the air flow in the room where the thermostat is located Fan start up is too slow Fan ON setting too high Return air is too cold temperature lower than 65 degrees RTD not well located in the warm air plenum Lower the temperature starti...

Page 44: ...Y OF THIS HEATING UNIT DO NOT ATTEMPT TO LIGHT THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE APPLIANCE IS FULL OF VAPOR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT DO NOT BURN WASTE OR PAPER IN THE APPLIANCE DO NOT LEAVE PAPER OR ANY COMBUSTIBLE MATERIAL AROUND THE APPLIANCE WARNING INSTALL THE NOZZLE ADJUST THE ELECTRODES ADJUST PRESSION NOTE IF A PROBLEM RESULTS FROM IMPROPER INSTALLATION N...

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Page 46: ...s in the evacuation pipe of the wood burning side is 0 04 IN W C Also make sure to install the blocked vent shut off system PA00600 in case of vent blocking 2 OIL TANK AND PIPING The maximum capacity of the tank must not exceed 200 imperial gallons and the tank must be located at least 6 inches from the burner a 24 inche distance is however recommended for maintenance Local codes will govern the s...

Page 47: ...directions Give each U shape track an equal support so that the weight is evenly distributed 3 3 PIPE CONNECTOR AND DAMPER The pipe connecting the furnace to the chimney must be as short as possible If a deviation is required the use of 45o elbows is highly recommended for a better evacuation of the smoke in the chimney of the wood burning furnace The barometric damper provided with the appliance ...

Page 48: ...AFT 0 02 W C VERIFICATION HOLE FOR OIL COMBUSTION CEILING Ø7 18 REDUCER 7 TO 6 MINIMUM DRAFT IN WOOD FLUE PIPE 0 04 W C FURNACE TYPE CHIMNEY PIPE DIAMETER MAX CADDY 7 REQUIRE A FLUE PIPE REDUCER WALL T CONNECTOR MINIMUM DRAUGHT IN WOOD FLUE PIPE 0 04 W C BAROMETRIC DAMPER 5 DRAFT 0 02 W C REDUCER 7 À 6 18 Ø7 ELBOW 45 ...

Page 49: ...re purge function and a new more durable drive motor PRE PURGE When there is a call for heat the burner s fan will run for 15 seconds before the actual ignition takes place to vent the combustion chamber and generate a proper draft This will result in a smoother ignition of the oil burner SAFE OPERATION If the flame goes out while the burner is running the CAD cell will detect it the control will ...

Page 50: ...UTES D OVER THE FIRE DRAFT 0 01 TO 0 02 IN W C THE DRAFT OVER THE FIRE MUST BE MEASURED IN THE OPENING OF VISION TUBE S PULSATION TRAP E SMOKE TEST BETWEEN 0 AND 1 ON THE SHELL BACHARACH SCALE TRACES F DRAFT IN THE CHIMNEY 0 02 IN W C G PERCENTAGE OF EXCESS AIR 20 TO 40 12 CO2 5 O2 H AVERAGE EFFICIENCY OF 83 TO 87 BASED ON THE TYPE OF BURNER AND ITS INPUT I TIGHTEN ALL THE LOCKING SCREWS AFTER COM...

Page 51: ...REFER TO THE BURNER MANUAL 4 APPLIANCE START UP The start up must be performed by a qualified technician Make sure the installation is completed and the oil tank has been filled up The oil line must also have been purged 5 PROLONGED CLOSING A Cut off the electric circuit B Close the oil shut off valve NOTE THE SHUT OFF VALVE MUST BE CLOSED WHEN THE APPLIANCE IS OUT OF SERVICE FOR A PROLONGED PERIO...

Page 52: ... of this manual NOTES ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________...

Page 53: ...US H 2 46 L H F0 100 PSI 690 kPa 0 7 85 UH MAX CADDY BECKETT AFG 120 000 0 65 700 W DELAVAN 0 86 GAL US H 3 26 L H F0 175 PSI 1205 kPa 1 6 83 UH MAX CADDY RIELLO 40 F3 91 000 0 50 700 W DELAVAN 0 60 GAL US H 2 27 L H 150 PSI 1035 kPa 1 2 5 87 UH MAX CADDY RIELLO 40 F3 120 000 0 65 700 W DELAVAN 0 84 GAL US H 3 18 L H 165 PSI 1135 kPa 1 2 5 85 For any additional information consult the rating plate...

Page 54: ...54 EXPLODED DIAGRAM AND PARTS LIST ...

Page 55: ...T SET SCREW 1 4 20 X 1 1 4 1 3 30100 BLACK HEX NUT 1 4 20 1 4 30474 DOOR HANDLE SWIVEL 1 5 30482 3 8 24 ZINC NUT 1 6 30415 HANDLE SPACER 1 7 PL51294 DOOR HANDLE 1 8 30429 3 8 NICKEL COIL HANDLE 2 9 SE56287 REPLACEMENT GLASS WITH GASKET 10 7 8 X 15 1 8 1 10 AC06400 BLACK SELF ADHESIVE GLASS GASKET 6 1 11 PL56285 GLASS RETAINER 2 12 OA11400 SILICONE GASKET KIT 3 4 8 FEET 2 13 PL51351 GLASS RETAINER ...

Page 56: ...6 LEVELING BOLT 1 4 20 x 1 2 40 PL56329 BLOWER BOX REMOVABLE COVER 2 41 30406 BLACK SNAP ON BUSHING 1 3 4 X 7 8 X 1 1 42 30108 MECHANICAL SCREW M4 X 4MM PAN PHILLIPS ZINC 2 43 28062 BLACK DRAWER HANDLE 3 25 32 1 44 SE56336 FILTER DRAWER 1 45 21231 CARDBOARD AIR FILTER 20 X 16 X 1 1 46 SE56317 BLOWER ACCESS DOOR ASSEMBLY 1 47 SE30433 HANDLE AND LATCH FOR ACCESS PANELS 1 48 SE56301 RIGHT PANEL WITH ...

Page 57: ...3 PL36039 6 X 7 X 1 1 4 REFRACTORY BRICK 2 74 21343 4 X 8 X 1 1 4 REFRACTORY BRICK WITH HOLE 3 75 PL56286 BRICK RETAINER 3 76 30526 5 32 x 2 COTTER PIN 4 77 PL56293 FRONT SECONDARY AIR TUBE 1 78 PL56294 FRONT MIDDLE SECONDARY AIR TUBE 1 79 PL56277 MIDDLE REAR SECONDARY AIR TUBE 1 80 PL56278 REAR SECONDARY AIR TUBE 1 81 21220 C CAST BAFFLE 19 3 4 X 11 3 8 X 1 1 4 2 82 PL56344 PLENUM HEAT SHIELD 2 8...

Page 58: ...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 furnace delivers its full potential This is why PSG offers an additional warranty that covers the cost of labor if your furnace has been purchased through an authorized PSG dealer If you want to enjoy the best service on the market and substantial...

Page 59: ...fter 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 purchase price of the product A on...

Page 60: ...t 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 of any warranted but defective pa...