45446A
Printed in Canada 28-01-2016
PSG
250 de Copenhague
Saint-Augustin-de-Desmaures
Quebec, Canada
G3A 2H3
Installation and operating instructions
for the MAX CADDY wood furnace
(PF01101 model)
CERTIFIED ACCORDING TO CSA B415.1-10, CAN/CSA B366.1 M91,UL391 4
TH
EDITION 2006, CAN/CSA C22.2
NO.236-05, UL 1995 3
RD
EDITION 2003, CSA B140.4-04 AND UL 727 9
TH
EDITION 2006
FURNACE MODELS INCLUDED IN THIS MANUAL
MAX CADDY WOOD AND COMBINATION FURNACE
20 kW / 25 kW and UH-Max Caddy
Read these instructions 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’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 of information contained in any manual obtained from
unauthorized sources.
2
TABLE OF CONTENT
WOOD OR WOOD/ELECTRIC COMBINATION FURNACES .......................................................... 5
1. CHIMNEY AND DRAFT ....................................................................................................................... 5
2. SAFETY RULES ..................................................................................................................................... 5
2.1
GENERAL
REQUIREMENTS ...................................................................................................... 5
2.2
ODOUR
FROM
THE
PAINT ......................................................................................................... 6
2.3
ASH
DISPOSAL ............................................................................................................................ 6
2.4
CREOSOTE
BUILD-UP
AND
REMOVAL .................................................................................. 6
2.5
SMOKE
DETECTOR ..................................................................................................................... 6
2.6
DOOR
GLASS ............................................................................................................................... 6
2.7
GLASS
SPECIFICATIONS ........................................................................................................... 7
2.8
ASH
DRAWER .............................................................................................................................. 7
2.9
ASH
GRATE .................................................................................................................................. 7
3. APPLIANCE INSTALLATION ............................................................................................................. 8
3. APPLIANCE INSTALLATION ............................................................................................................. 8
3.1
COLD
AIR
RETURN
BOX
INSTALLATION .............................................................................. 9
3.2
COLD
AIR
DUCTING
SUPPORT
INSTALLATION ................................................................. 11
3.3
CONTROL
PCB
INSTALLATION
AND
CONNECTION ......................................................... 14
3.4
RTD
SUPPORT
BRACKET
INSTALLATION
AND
CONNECTION
(
RESISTANCE
TEMPERATURE DETECTOR
) ......................................................................................................................... 16
3.5
SERVOMOTOR
INSTALLATION
AND
CONNECTION ......................................................... 18
3.6
HANDLES
INSTALLATION ...................................................................................................... 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-electric or wood-oil furnace ................................................................. 27
3.13.3
Trio furnace (wood-oil-electric or wood-electric-oil ) ......................................................... 27
3.14
INSTALLATION
OF
A
DOMESTIC
WATER
PRE-HEATING
SYSTEM
(OPTIONAL) ........ 27
3.15
INSTALLATION
OF
AN
AIR
CONDITIONING
UNIT ............................................................. 28
3.16
OIL
BURNER
INSTALLATION
–
WOOD-OIL
MAX
CADDY
(OPTIONAL) ........................ 28
4. OPERATING INSTRUCTIONS ........................................................................................................... 29
4.1
CONTROL
SYSTEM ................................................................................................................... 29
4.2
FIRST
USE
–
GENERAL
INFORMATION ................................................................................ 29
4.3
FIRST
USE
-
SETTTINGS ........................................................................................................... 29
4.3.1
The use of the “BI-ENERGY” function .................................................................................... 30
4.4
FAN
CONTROL ........................................................................................................................... 30
3
4.5
MODES,
OPTIONS
AND
PROGRAMMING ............................................................................. 30
4.5.1
The speeds ................................................................................................................................. 30
4.5.2
System Balancing ...................................................................................................................... 31
4.5.3
HEAT Mode (automatic heating).............................................................................................. 31
4.5.4
COOL Mode (air conditioning) ................................................................................................ 31
4.5.5
CIRC (air circulation) .............................................................................................................. 32
4.5.6
MANU (manual heating) .......................................................................................................... 32
4.5.7
The Selections ........................................................................................................................... 32
4.6
LIGHTING ................................................................................................................................... 33
4.7
PREHEATING ............................................................................................................................. 33
4.8
HEATING..................................................................................................................................... 33
4.9
EARLY
SIGNS
OF
AN
OVERFIRED
FURNACE: .................................................................... 34
4.10
WOOD
AS
HEATING
FUEL ....................................................................................................... 34
4.11
PROLONGED
POWER
FAILURE .............................................................................................. 34
4.12
CHIMNEY
FIRES ........................................................................................................................ 34
5. MAINTENANCE .................................................................................................................................... 35
5.1
MAINTENANCE
OF
THE
EXCHANGERS ............................................................................... 35
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
TECHNICAL
DATA
–
ELECTRICAL
ELEMENT .................................................................... 41
11. MAX CADDY BRICKS LAYOUT ..................................................................................................... 42
12. TROUBLE SHOOTING ...................................................................................................................... 43
SECTION B ................................................................................................................................................. 44
WOOD/OIL COMBINATION FURNACE ............................................................................................. 44
GENERAL NOTES .................................................................................................................................... 46
1. DRAFT AND CHIMNEY ...................................................................................................................... 46
2. OIL TANK AND PIPING ...................................................................................................................... 46
2.1
BURNER
PUMP .......................................................................................................................... 46
3. APPLIANCE INSTALLATION ........................................................................................................... 47
3.1
LOCATING
THE
UNIT ............................................................................................................... 47
4
3.2
POSITIONING
THE
APPLIANCE .............................................................................................. 47
3.3
PIPE
CONNECTOR
AND
DAMPER .......................................................................................... 47
3.4
POSSIBLE
INSTALLATIONS .................................................................................................... 48
3.5
COMBUSTION
AIR .................................................................................................................... 49
3.6
ELECTRICAL
WIRING .............................................................................................................. 49
3.7
THERMOSTAT ........................................................................................................................... 49
3.8
FAN
CONTROL ........................................................................................................................... 49
3.9
COMBUSTION
SAFETY
CONTROL ........................................................................................ 49
3.10
COMBUSTION
ADJUSTMENT
AND
VERIFICATION ........................................................... 49
3.11
ELECTRODES
SETTING ........................................................................................................... 51
4- APPLIANCE START-UP ...................................................................................................................... 51
5- PROLONGED CLOSING ..................................................................................................................... 51
6- MAINTENANCE ................................................................................................................................... 51
7- ELECTRICAL DIAGRAMS ................................................................................................................ 52
8- TECHNICAL DATA ............................................................................................................................. 53
8.1
UH
–
MAX
CADDY ..................................................................................................................... 53
EXPLODED DIAGRAM AND PARTS LIST ......................................................................................... 54
WHY PURCHASE THROUGH AN AUTHORIZED PSG DEALER? ................................................ 58
PSG LIMITED LIFETIME WARRANTY (REGULAR) ...................................................................... 59
PSG LIMITED LIFETIME WARRANTY (PRIVILEGE) .................................................................... 60
REGISTER 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.caddyfurnaces.com/en/warranty/warranty-registration
Registering your warranty online will help us track rapidly the information we
need on your furnace.
IMPORTANT NOTE:
THE INSTALLATION OF THIS CENTRAL HEATING SYSTEM MUST BE PERFORMED BY A
QUALIFIED TECHNICIAN. PSG RESERVES ITSELF THE RIGHT TO VOID ITS WARRANTY
OR DENY TECHNICAL ADVICE IF THE FURNACE HAS NOT BEEN SOLD OR INSTALLED
BY A PROFESSIONAL.
WARNING
:
THE INSTALLATION OF THIS APPLIANCE REQUIRES THE ADITION OF A
BLOWER ASSEMBLY WITH ELECTRONIC FAN LIMIT (#PA08565)
Emissions: 5.9 g/h or 0.316 g/MJ
Average efficiency: 85 % (LHV) / 77% (HHV)
5
SECTION A:
WOOD OR WOOD/ELECTRIC COMBINATION FURNACES
Take note that this furnace operates like an EPA wood burning stove. This applies to the lighting, the ember bed,
and the minimum combustion air intake which was determined based on the use of good seasoned cordwood.
The Max Caddy furnace was tested and approved according to the CSA B415.1-10 Standard.
To optimize the efficiency of your furnace, here is some advice that you should follow when installing or operating
your Max Caddy.
• Respect the local codes (when in doubt, consult your local dealer);
• Make sure your furnace is installed according to the instructions on the certification label;
• All controls and adjustments must be performed by a qualified technician. The blower speed must conform
to the recommendations of local codes and should respect the static pressure ranges in the warm air
plenum of the furnace.
We recommend that our wood burning hearth products be installed and serviced by professionals who are certified
in the United States by NFI (National Fireplace Institute
®
) or in Canada by WETT (Wood Energy Technical Training)
or in Quebec by APC (Association des Professionnels du Chauffage).
1. CHIMNEY AND DRAFT
This furnace must be connected to a chimney certified for use with wood burning heating appliances. A 7-inch
chimney and connector are recommended for the Max Caddy if it is used as a wood-oil unit or a wood-oil-electric
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 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. will reduce the efficiency and 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 (WOOD, WOOD / ELECTRIC OR WOOD / OIL).
The adjustment should in no case be modified to increase combustion.
2. SAFETY RULES
WARNING:
• T
HE INFORMATION GIVEN ON THE CERTIFICATION LABEL AFFIXED TO THE APPLIANCE ALWAYS
OVERRIDES THE INFORMATION PUBLISHED
,
IN ANY OTHER MEDIA
(
OWNER
’
S MANUAL
,
CATALOGUES
,
FLYERS
,
MAGAZINES AND
/
OR WEB SITES
).
2.1 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, MOTOR OIL, OR
OTHER UNSUITABLE MATTERS.
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.
6
WARNING
THE ASH DRAWER AND EXCHANGERS ACCESS PANEL GET VERY HOT. DO NOT
MANIPULATE WITH BARE HANDS.
2.2 ODOUR FROM THE PAINT
It is normal that smoke and odours emanate from the unit when you first light it. It is recommended to burn it at high
rate and ventilate the building until the odours disappear. The smoke is not toxic.
2.3 ASH DISPOSAL
Ashes must be placed in a metal container with a tight fitting lid. The container should be stored outdoors, well away
from combustible materials. This container should not receive any other type of waste. If the ashes are meant to be
buried in soil, wait until all embers have thoroughly cooled before burying.
2.4 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 residues
accumulate inside the flue lining and the exchangers.
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 ashes.
When ignited, creosote produces an extremely hot fire inside the chimney.
In the first year of use, in order to 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 smouldering one to prevent creosote build-ups within the
system. Prepare an emergency procedure in case of a chimney fire.
It is recommended to clean the heat exchangers thoroughly at the end of season in order to prevent
corrosion.
2.5 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.
2.6 DOOR GLASS
To maintain a clean and safe installation, do not build your fire too close to the glass or allow logs to lean on the
glass.
Do not operate your furnace at too low a setting. Keep the air inlet opened long enough during the fire start-up to
prevent the fire from smouldering, which could stain the glass.
An intense fire will help keep the glass clean. However, in the event that your glass gets stained, which should not
occur under normal operating conditions, you will have to clean it using a wet cloth and a fireplace glass cleaner.
Clean the glass ONLY when the unit has cooled down. Do not use abrasive cleanser. Fireplace glass cleaners are
available in most home centers and specialty hearth retailers.
WARNING: Avoid knocking or scratching the glass. I could crack or break.
7
2.7 GLASS SPECIFICATIONS
The glass is made of 3/16" (5mm) thick Pyroceram.
Do not operate your wood furnace with a broken glass, as this could seriously damage your furnace.
You can purchase a replacement glass from your PSG dealer.
2.8 ASH DRAWER
Your furnace 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 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.
Maintain all gaskets in good condition; in case of deterioration, contact your dealer for a genuine
replacement gasket.
8
3. APPLIANCE INSTALLATION
The installation instructions of this section apply to the wood-only Max Caddy, the wood-electric Max Caddy, the
wood-oil Max caddy, and the wood-oil-electric trio Max Caddy.
CAUTION: The following instructions do not supersede the local code.
Detailed content of the blower assembly with electronic fan limit (#PA08565):
CONTENT OF THE BOX
1 X BLOWER ASSEMBLY MANUAL KIT FOR MAX CADDY
27 X #10 X ½" ‘’A’’ TYPE METAL SCREW
2 X ¼-20 X 1" ELEVATOR BOLT
1 X 100 OHM RTD - 38" WIRE
1 X RTD SUPPORT
1 X #8 X ½" 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 ¾" SCREW CONNECTOR FOR BX WIRE
WARNING
:
THE INSTALLATION OF THIS APPLIANCE REQUIRES THE ADITION OF A
BLOWER ASSEMBLY WITH ELECTRONIC FAN LIMIT
(#PA08565)
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.
10
Remove 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.
11
Then, secure the cold air return box to the furnace. To do so, use the 8 screws as shown below. Then, level the cold
air return box by screwing or unscrewing the elevator bolts.
3.2 COLD AIR DUCTING SUPPORT INSTALLATION
On the cold air return box, you will find two side plates and the cold air return box door. The cold air ducting support
can be configured in several ways. You have the flexibility to choose the desired configuration depending of your
installation. Indeed, some installations 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 support. Keep the screws which retained the side plate to install the side plate at
the new desired location. The side plate and the cold air ducting support must be secured using nine screws each
(kept from the previous step). Remaining screws are provided with the cold air return box.
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
13
Installation 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
14
3.3 CONTROL PCB INSTALLATION AND CONNECTION
The control PCB may be installed on either side of the furnace. Remove the 4 screws secured on the side of the
furnace where you wish to install the control PCB, either on the left or 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 the LEFT side of the furnace
15
Now, it is time to make the connection between the control 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
16
3.4 RTD SUPPORT BRACKET INSTALLATION AND CONNECTION
(resistance temperature detector)
Your Max Caddy furnace is equipped with a RTD probe (resistance temperature detector). This 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
17
Once the RTD probe is installed on the RTD support bracket, you need to connect 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
18
3.5 SERVOMOTOR INSTALLATION AND CONNECTION
Your Max Caddy furnace is equipped with a servomotor. You need to secure it in place in the two pre-drilled holes
using two screws as shown below.
Once installed, you need to install the chain that links the air inlet damper to the servomotor as shown below. For
more information regarding this installation, refer to the furnace owner’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 when there is a call for heat (see Detail C and D). Refer to the electric wiring diagram in
section 7 for the electrical connections.
WARNING: USE WIRING SUITABLE FOR 75
O
C (not supplied)
19
Then, you need to connect the servomotor to the control PCB. To do so, refer to the electric 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 75
O
C (not supplied)
20
3.6 HANDLES INSTALLATION
The following step consists of installing the handles on the handle rods of the ash drawer and the door as shown
below.
3.7 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 intake.
The furnace must be positioned so that the connector is as short as possible; minimize the use of 90
o
elbows.
The owner must ensure a proper installation to allow for a safe operation of the appliance.
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