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PSG MINI-CADDY PF01301 Installation And Operating Instructions Manual

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Installation and operating
FURNACE MODELS INCLUDED IN THIS MANUAL:
ADD-ON
Read these instructions carefully before installing
Please keep this document!
Verified and tested for Canada
and the United States by :
Printed in Canada
instructions for the
MINI-CADDY FURNACE
PF01301
WOOD ONLY
and operating your furnace.
250, de Copenhague,
St-Augustin-de-Desmaures (Quebec)
CANADA G3A 2H3
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. 
PSG
COMBINATION:
WOOD/ÉLECTRIC
(11.25 Kw)
02-12-2011
45533A

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  • Page 1 250, de Copenhague, St-Augustin-de-Desmaures (Quebec) CANADA G3A 2H3 Installation and operating instructions for the MINI-CADDY FURNACE PF01301 FURNACE MODELS INCLUDED IN THIS MANUAL:    COMBINATION: ADD-ON WOOD ONLY WOOD/ÉLECTRIC (11.25 Kw) Read these instructions carefully before installing and operating your furnace. Please keep this document! This ...
  • Page 2 As one of the biggest most respected furnace wood manufacturer in North America, PSG prides in the quality and performance of all its products. This manual is intended to help you in getting the most satisfaction out of the use of this product.

  • Page 3: Table Of Contents

    Table of content INTRODUCTION ..................6 CHIMNEY AND DRAFT ................7 PART A - SAFETY RULES ................8 GENERAL REQUIREMENTS ..............8 ODOUR FROM THE PAINT ..............8 ASH DISPOSAL ..................8 CREOSOTE BUILD-UP AND REMOVAL ..........8 SMOKE DETECTOR ................9 DOOR GLASS ..................
  • Page 4 3.1.16 INSTALLATION WITH AN EXISTING OIL FURNACE ....28 3.1.17 WIRING DIAGRAM FOR CONNECTION OF THE MINI-CADDY ADD-ON WITH AN EXISTING OIL FURNACE....... 31 3.1.18 LOW VOLTAGE WIRING DIAGRAM FOR CONNECTION OF THE MINI-CADDY ADD-ON WITH AN EXISTING GAS OR ELECTRIC FURNACE.
  • Page 5 PART C – OPERATION ................49 LIGHTING ....................49 PREHEATING ..................49 HEATING ....................50 FIRST SIGNS OF AN OVERHEATING FURNACE ....... 50 WOOD AS A COMBUSTIBLE ............... 51 CHIMNEY FIRE ..................51 LOCAL FIRE DEPARTMENT..............52 PROLONGED POWER OUTAGE ............52 PART D - MAINTENANCE ................

  • Page 6: Introduction

    1.1 INTRODUCTION Take note that this furnace uses the same wood burning technology as a high efficiency EPA certified wood burning stove. This applies to the lighting, the ember bed, and the minimum combustion air intake which was calibrated to burn good seasoned cordwood.

  • Page 7: Chimney And Draft

    1.2 CHIMNEY AND DRAFT This furnace must be connected to a chimney certified for wood burning heating appliances; a 6” connector and chimney is mandatory. If the chimney draft exceeds -0.06’’ 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’’...

  • Page 8: Part A - Safety Rules

    2 PART A - SAFETY RULES 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 WASTES OR FLAMMABLE LIQUIDS SUCH AS GASOLINE, NAPHTHA, MOTOR OIL, OR OTHER UNSUITABLE MATTERS.

  • Page 9: Smoke Detector

    When ignited, creosote produces an extremely hot fire inside the chimney. To avoid this situation, it is important to do the rotation of wood away from heating appliances and lighting products. Inspect the chimney system at regular intervals to determine a cleaning cycle. A weekly cleaning might be required during mild temperature periods but a monthly cleaning should be sufficient during cold periods.

  • Page 10: Glass Characteristics

    The glass is made of 3/16” (5 mm) thick ceramic glass. 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.

  • Page 11: Flue And Barometric Draft Control Connection

    2.10 FLUE AND BAROMETRIC DRAFT CONTROL CONNECTION ATTENTION BEFORE CONNECTING THE STOVE PIPE, MAKE SURE YOU HAVE REMOVED THE SCRAPER FROM THE FLUE PIPE. 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 connectors (male and female).

  • Page 12: Fresh Air Intake

    2.12 FRESH AIR INTAKE When the furnace and the chimney are completely cold, it may be necessary to provide fresh air by opening a door or a window for a few minutes while lighting the fire. Take note that a house constructed or renovated in order to be airtight may lack the volume of fresh air necessary for the proper combustion of a solid-fuel heating appliance.
  • Page 13 INSULATED PIPE AIR SUPPLY AIR INLET EXTERIOR WALL N.B.: THE OWNER OF THE FURNACE IS RESPONSIBLE FOR THE ROOM’S AIR QUALITY IN CASE OF NEGATIVE PRESSURE OR TEMPORARY NEGATIVE PRESSURE.

  • Page 14: Part B - Installation

    3 PART B - INSTALLATION PART B of this manual contains installation instructions for the three types of Mini-Caddy furnace. You can consult only the section that applies to the furnace you have chosen.  WOOD ADD-ON ............15  WOOD ONLY ...............
  • Page 15 Installation Instructions  MINI-CADDY ADD-ON PF01301...

  • Page 16: Wood Add-On

     WOOD ADD-ON 3.1.1 INSTALLATION MINI-CADDY ADD-ON 3.1.2 INTRODUCTION The wood burning Mini-Caddy Add-on furnace is approved for in-line connection to an existing oil furnace with a firing rate of 0.8 G.P.H. (US) to 1.2 G.P.H. (US) or any gas or electric furnace with comparable heat output. The existing furnace must have a maximum heating capacity of 20,51 kW (75,000 BTU/h.) 3.1.3 APPLIANCE INSTALLATION Before installation, please read the instructions carefully and make sure...

  • Page 17: Matching The Transfer Duct Between The Two Heat Generators

    3.1.5 MATCHING THE TRANSFER DUCT BETWEEN THE TWO HEAT GENERATORS Install the plenum and heating ducts in line as in OPTION #1 and #2 of Section 3.1.15. Configurations shown in Examples 1, 2 and 3 of this same section are prohibited.
  • Page 18 3. Make the following verifications: a) Oil furnace: CFM = orifice size (SI)(liter/hour) x 39 023 x E 1.21 x t CFM = orifice size (Imperial)(gallon/hour) x 140 000 x E 1.1 x t E : Average heat generator efficiency (0.75) t: Temperature rise (ºC) b) Electric furnace:  ...

  • Page 19: Blower Of The Existing Furnace

    3.1.6 BLOWER OF THE EXISTING FURNACE The blower of the existing furnace shall produce an average air flow in the plenum in between 750 to 1,250 cfm when the external static pressure is adjusted to 0,2" of water column and in between 650 to 1100 cfm when adjusted to 0,5"...
  • Page 20 Figure 3.1.7 a The furnace may be installed on a combustible floor. Figure 3.1.7 b - Reduced clearances of insulated ductwork...

  • Page 21: Pipe Connector And Damper

    The insulation allowed for this kind of installation must have an R-value in between 3.5 and 6.5. The thickness of insulation needed will differ from an insulation material to another. WARNING YOUR INSULATION INSTALLED ON THE DUCTWORK SHOULD NEVER BE IN CONTACT WITH ANY COMBUSTIBLE MATERIAL.

  • Page 22: Electrical Connections

    OIL PIPE REDUCER 7" DIAMETER 3.1.9 ELECTRICAL CONNECTIONS The following instructions do not replace those of the local code. Installation and verification of this appliance must be done by a qualified service man. 3.1.10 FAN LIMIT CONTROL Install the fan limit control on the back of your furnace. 3.1.11 SERVOMOTOR If the ducts are connected in series as per OPTION #2 in Section 3.1.15 and the fan limit control of the existing furnace is located in the plenum, the divider must...

  • Page 23: Thermostat

    3.1.12 THERMOSTAT The thermostat must be installed on an inside wall in a location where it is not likely to be affected by the draft coming from an air outlet. It must be installed at a minimum of 55 inches above the floor. The two thermostats on a combined system must be installed at the same height.

  • Page 24: Installation Of Mini-Caddy Add-On

    3.1.15 INSTALLATION OF MINI-CADDY ADD-ON *Minimum duct size 260 square inches * r = Minimum radius 6 inches...
  • Page 25 Example 1 Example 2...
  • Page 26 Example 3 To install the connecting duct from the existing furnace to the left or right side of your Mini-Caddy Add-on, unscrew the small access panel on the left side and secure it to the rear of the furnace with the same screws.
  • Page 27 To install the connecting duct from the existing furnace to the left side of your Mini-Caddy Add-on, unscrew the big access panel on the left side (you may discard the panel). Connect the duct. To install the connecting duct from the existing furnace to the right side of your Mini-Caddy Add-on, unscrew the big access panel on the left side (see previous drawing) (you may discard the panel).

  • Page 28: Installation With An Existing Oil Furnace

    3.1.16 INSTALLATION WITH AN EXISTING OIL FURNACE Note: the fan limit control PA08522 (1) is not provided with the furnace and has to be purchased separately. To install the fan limit control assembly (1) (PA08522 not included with the furnace), remove the cover on the fan limit control and the cover on the junction box.
  • Page 29  Run a cable (F) from your house electrical entrance to the fan limit control’s junction box. Note: It is recommended to connect the Mini-Caddy Add-on on the same circuit as the existing furnace.  Pull the red and black wires (E) out of junction box through the wire grommet.
  • Page 30  Run an 18-2 cable from the thermostat (A) of the Add-on to the fan limit assembly’s junction box (C).  Run an 18-2 cable from the thermostat (A) of the existing oil furnace to the fan limit assembly’s junction box (C). ...

  • Page 31: Wiring Diagram For Connection Of The Mini-Caddy Add-On With An Existing Oil Furnace

    3.1.17 WIRING DIAGRAM FOR CONNECTION OF THE MINI-CADDY ADD-ON WITH AN EXISTING OIL FURNACE.

  • Page 32: Low Voltage Wiring Diagram For Connection Of The Mini-Caddy Add-On With An Existing Gas Or Electric Furnace

    3.1.18 LOW VOLTAGE WIRING DIAGRAM FOR CONNECTION OF THE MINI- CADDY ADD-ON WITH AN EXISTING GAS OR ELECTRIC FURNACE.

  • Page 33: Mini-Caddy Add-On Technical Data

    3.1.19 MINI-CADDY ADD-ON TECHNICAL DATA MINI-CADDY ADD-ON 29 1/8" (740 mm) 23 3/4" (603 mm) 45 5/8" (1159 mm) 12" (305 mm) 12" (305 mm) 40 1/4" (102 mm) 19 3/4” (502 mm) 13” (330 mm) FLUE * 6" (152 mm) 416 Lb (189 kg) WEIGHT * Reducer required...
  • Page 34 Installation instructions for  MINI-CADDY WOOD ONLY PF01301...

  • Page 35: Wood Only

     WOOD ONLY 3.2.1 MINI-CADDY WOOD ONLY INSTALLATION 3.2.2 UNIT LOCATION The furnace must be installed where outside air supply will be sufficient for proper combustion. In airtight houses, it might be necessary to install an outside air inlet (see Section 2.12.) The furnace must be positioned so that the connector is as short as possible.
  • Page 36 N.B.: THE VOLUME OF COLD AIR RETURN SHOULD BE AT LEAST EQUAL TO THE VOLUME OF THE HOT AIR DISTRIBUTION. Figure 3.2.4 b N.B.: THE SIZE OF THE AIR RETURN CONDUITS SHOULD BE AT LEAST EQUAL TO THE SIZE OF THE COLD AIR PLENUM OPENING. To ensure adequate static pressure, the amount of cold air return should exceed the amount of hot air distribution of at least 5%.

  • Page 37: Round Hot Air Plenum Option (Pa07400)

    3.2.5 ROUND HOT AIR PLENUM OPTION (PA07400) See APPENDIX A. 3.2.6 CONNECTING PIPE The flue outlet on the Mini-Caddy furnace is 6 inch inside diameter. In case of excessive draft, a barometric draft control must be installed. The barometric drafty control must be set so that the draft measured at the furnace outlet does not exceed -.06 in.

  • Page 38: Parallel Installation

    3.2.7 PARALLEL INSTALLATION Parallel installation with another furnace that shares the same ducts system is not permitted in Canada. That type of installation is permitted in the USA only. In parallel installation, the maximum heat input of the existing gas, oil or electric furnace should be equal or superior to that of the wood furnace.

  • Page 39: Electrical Connection

    3.2.8 ELECTRICAL CONNECTION The following instructions do not replace those of the local code. Installation and verification of this appliance must be done by a qualified technician. Installation of the Mini-Caddy wood only furnace requires the use of the ``fan limit assembly for wood only`` option (PA00500) which must be purchased separately.

  • Page 40: Opération Instructions

    control which controls the low speed either at the “on” position or the “off” position. It is not recommended to let the blower run on continuous mode when heating with wood since the wood furnace must reach a certain temperature before the blower starts in order to operate efficiently.

  • Page 41: Wiring Diagram

    3.2.13 WIRING DIAGRAM...

  • Page 42: Mini-Caddy Technical Data

    3.2.14 MINI-CADDY TECHNICAL DATA MINI-CADDY MINI-CADDY 44 1/4” (112 cm) 12” (305 mm) 23 3/4” (60 cm) 40 1/4” (102 cm) 45 5/8” (116 cm) 6” (15 mm) FLUE 13 3/8” x 22” (34 X 56 mm) 462 Lb (210 kg) WEIGHT 12”...
  • Page 43 Installation instructions for  MINI-CADDY WOOD/ELECTRIC PF01301...

  • Page 44: Wood/Electric Combination

     WOOD/ELECTRIC COMBINATION 3.3.1 MINI-CADDY WOOD/ELECTRIC INSTALLATION 3.3.2 INTRODUCTION The fan limit assembly for wood only (PA00500) is not required for this installation. The 11.25 kW electric unit option includes everything you need for wood/electric installation. The fan limit control must be installed next to the flue outlet as in the wood only installation and only one cable (14-4) cable is attached to it;...

  • Page 45: Minimum Clearances Required To Any Combustible Material

    3.3.3 MINIMUM CLEARANCES REQUIRED TO ANY COMBUSTIBLE MATERIAL. See Section 3.2.4. 3.3.4 ROUND HOT AIR PLENUM OPTION (PA07400) See Appendix A. 3.3.5 ELECTRIC UNIT The wood/electric combination model uses two wall thermostats; one controls the electric heat and the other one the wood heat. In this configuration, the electric heat has priority over the wood so whenever there is a call for heat from the electric thermostat, the air intake damper closes, the blower kicks on and the electric elements turn on in sequence 3.75 kW at the time.
  • Page 46 Red button manual reset L-250 Thermodisc manual reset INSIDE VIEW OF THE ELECTRIC UNIT OUTSIDE VIEW OF THE ELECTRIC UNIT...

  • Page 47: Thermostat

    3.3.6 THERMOSTAT The thermostat must be installed on an inside wall in a location where it is less likely to be affected by the draft coming from an air outlet. It must be installed at a minimum of 55 inches above the floor N.B.: THE WOOD/ELECTRIC USES TWO THERMOSTATS INSTALLED AT THE SAME HEIGHT FROM THE FLOOR.

  • Page 48: Wiring Diagram

    3.3.7 WIRING DIAGRAM...

  • Page 49: Part C - Operation

    4 PART C – OPERATION 4.1 LIGHTING WARNING NEVER USE CHEMICALS OR FLAMMABLE LIQUIDS TO LIGHT THE FIRE 1. Open the door. Note: if there already is a bed of embers in the combustion chamber, proceed directly to the PREHEATING step. 2.

  • Page 50: Heating

    4.3 HEATING 1. Poke the fire and spread the embers evenly at the center of the combustion chamber before adding more wood. 2. Avoid overfilling the combustion chamber; air must be allowed to circulate freely through the upper portion of the chamber for the stove to perform best. Also remember that a small hot fire burns cleaner than a big smoldering one.

  • Page 51: Wood As A Combustible

    4.5 WOOD AS A COMBUSTIBLE WARNING NEVER BURN GARBAGE, GASOLINE, NAPHTA, MOTOR OIL OR ANY SIMILAR FLAMMABLE PRODUCTS IN THIS FURNACE. We recommend that you only burn well seasoned cordwood in your furnace. Two important factors should be considered when buying cordwood; water content and density of the wood.

  • Page 52: Local Fire Department

    In the event of a chimney fire, first call your local fire department and water the roof in the vicinity of the chimney. Make sure that the furnace door and the air intake damper are closed (if need be, lower the thermostat setting or unhook the air intake damper connecting rod). CLOSE the barometric draft damper manually if one is installed.

  • Page 53: Part D - Maintenance

    5 PART D - MAINTENANCE 5.1 HEAT EXCHANGERS CARE Heat exchangers must be cleaned thoroughly at the end of every heating season. During summer, the air in basements is damper and with minimal air circulation within the furnace, it can mix with creosote and/or sooth deposits in the exchangers to form an acid that could accelerate the corrosion process and induce premature decay of the steel.
  • Page 54 Before cleaning the three exchanger pipes (3), pull the baffle forward as on the drawing below. Using the scraper (1) clean all three pipes. The dirt in the lateral pipes can be pushed forward and it will fall directly into the combustion chamber while the dirt in the central pipe will have to be retrieved either from the front access panel or the rear by removing the smoke pipe.

  • Page 55: Chimney Maintenance

    5.2 CHIMNEY MAINTENANCE The most efficient way to sweep a chimney is to run a hard chimney sweeping brush. Brush from the top down so sooth and creosote deposits will detach from the chimney liner and fall down to the bottom of the chimney where it can be easily removed.

  • Page 56: Door Gasket Relacement

    5.6 DOOR GASKET RELACEMENT It is important to keep the door gasket in good condition. The door is adjusted at the factory to seal the door tight. After a while, the gasket could sink and the door must then be adjusted as described below. If the door still leaks after the maximum adjustment, replace the gasket.

  • Page 57: Part E - Remplacement Parts

    It is good to visually check the furnace once a month for damaged or defective parts. Any required repair should be made without delay using genuine PSG parts. An exploded view and complete parts list is available for you on the PSG web site at www.psg-distribution.com.

  • Page 58: Mini-Caddy Brick Layout

    6.3 MINI-CADDY BRICK LAYOUT #  QTY  BRICK LAYOUT  1  BRICK 1 1/16" x 6 3/4" x 1 1/4" (HD)  2  2  BRICK 2 1/8" x 9" x 1 1/4" (HD)  4  3  C‐CAST  BAFFLE BOARD  1  4  ASH GRATE  1  5  BRICK 4" x 8" (HD)  8  6  BRICK 4" x 9" (HD)  9  7  BRICK 4 1/2" x 9" (HD)  5 ...

  • Page 59: Part F - Ducts And Dampers Dimensions

    7 PART F - DUCTS AND DAMPERS DIMENSIONS 7.1 DUCTS AND DAMPERS DIMENSIONS (EXAMPLES OF CALCULATION) SIMPLIFIED METHOD WARM AIR SYSTEM INSTALLATION DISTRIBUTION SYSTEM HOUSE DIMENSIONS Example: 28 x 40 bungalow = 1,120 sq. ft. Ducts size (heat) 4 inch outlet reduce by 1”...

  • Page 60: Part G - Troubleshooting

    8 PART G - TROUBLESHOOTING PROBLEM CAUSES SOLUTIONS Heating inefficient during the first Improper adjustment of the Adjust the damper, minimize the combustions. Lack of draft. barometric damper (opened too smoke pipe length and use 45 wide). Chimney flue restriction elbows.

  • Page 61: Part H - Specifications

    13 1/2”L x 9 5/8”H Type of door Cast iron with ceramic glass 12" x 12" or 12" round with PSG optional distribution Dimensions of the hot air plenum 22 3/8"W x 13 5/8"L or adaptor with 8 round 5"...

  • Page 62: Appendix A - Round Hot Air Plenum Option

    10 APPENDIX A – ROUND HOT AIR PLENUM OPTION It is possible to install the round hot air plenum option (PA07400) on your furnace. This option may be ordered from our PSG dealer.

  • Page 63: Limited Lifetime Warranty

    Firebrick * Pictures required Shall your unit or a components be defective, contact immediately your PSG dealer. Prior to your call make sure you have the following information necessary to your warranty claim treatment:  ...

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