Max Caddy problem...HELP!!!

[Jason762]

I had a new Max caddy (wood/oil) furnace installed in my house over the summer. Since I began to use it last week, I have had an odor of smoke in the house and today my CO alarm activated. I had around 75ppm of CO throughout my house. After I ventilated the house, I held the CO meted directly up to the air vents in the house and had about 20ppm of CO blowing out. When I use the oil backup there is no odor and no CO. What could be the problem and who do I turn to for repairs????? The unit is vented with 7" SS liner into the existing 9"x12" masonry flue. There are four flues side by side that terminate above the roof, could a downdraft from one of the other flues be drawing the smoke back down into the house? Could it be a draft issue and I should reline the masonry chimney with 7" flex pipe? Could there be a problem in the wood fire chamber that is allowing smoke to get into the air ducts? Thank you and please give me some advice if you can.

 

[stee6043]

I don't know about the downdraft issue you mentioned but one thing I would check is for leaks. With a fire going (preferable early in a fire, just after you start it) make it dark in the room where your woodburner sits. With a small/bright flashlight go over every door seal, every joint in the flue and every joint in the body paneling. You should be able to see smoke escaping. If you can smell smoke, you should be able to see it with this method.

CO is no joke though. Good thing you have the detector. Make sure you're safe while troubleshooting this thing.

 

[laynes69]

Do you have a manometer, and is your chimney lined with a 7" liner or 9x12" liner? You should have your draft verified. When did you notice the CO, did you have a strong fire or just coals in the firebox?

 

[Jason762]

I have a manometer on the 5" oil burner vent not on the 7" wood burner vent. The 7" wood burner vent goes into the 9"x12" masonry flue. I started the fire again tonight and do not smell or see any smoke and I went over the stove and indoor vent pipe with a bright flashlight in the dark as was suggested and saw no smoke. I did however notice a small area of black creosote looking liquid right where the 7" pipe comes out of the back of the stove and a little more at the 45 degree elbow right behind that.
The CO was noticed during a smoldering fire with mainly coals but the odor had been persistent throughout the week. I went outside and saw that the smoke was exiting the termination of the flue very quickly as it is a windy night as well. Hopefully I get a rep from the store I bought it from out here soon. Thanks for the help so far. Any more thoughts...

 

[Jason762]

Here's some pics of the creosote and the vent pipe

 

[laynes69]

You will get poor performance (little draft) from a chimney that size. You need a 7" liner inside that chimney. With the coal bed and the current chimney size, you more than likely had zero draft which caused your CO problem. The liquid you have in the chimney is condensation. Your furnace will not have flue temps high enough to support draft in a chimney that size. How is your wood? I have a Caddy and experienced the same issues your having until the chimney was lined. Judging from the creosote and your glass, you either have wet wood or your not burning hot enough. Personally, I wouldn't use it until it's lined. I don't understand why a company would install a high efficiency furnace in a chimney that large, when the manual specifies a 7" chimney.

 

[Jason762]

The wood is pretty dry, it's been split and stacked for over 6 months, hardwood only. It lights up and burns quickly. I think the problem really intensifies when none of the zones is calling for heat and the damper closes which causes a lot more smoke. I'll order up a 7" liner asap. Thanks for the help laynes69.

 

[laynes69]

6 months won't be long enough for some wood, unless it's split on the smaller size, a year is better. Oak takes a couple of years.

This time of year, small hot fires will be your friend. Burn hot and let burn out or build smaller shorter fires.

 

[brenndatomu]

I second laynes last post. Your wood is WAY wet. Get some ECO brix or the like, or some old pallets to cut up and add to your wood, it will help the fire burn cleaner/hotter. If your wood is Oak it may even take up to three years to dry depending on how/where you stack it. Is your chimney exterior to the house? If so consider insulating that liner, it will make for even better draft and a cleaner flue.

 

[Need4speed0to60]

Hey Jason I was just wondering if your issue was resolved. I just got a max caddy last year and now I'm having an odor issue in the house as well. It's not a typical wood smoke smell. More like a melting plastic type odor. I let the fire go out before getting too hot because of this.