PSG MINI-CADDY PF01301 User manual

45533A
Printed in Canada 02-12-2011
PSG
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:

ADD-ON

WOOD ONLY

COMBINATION:
WOOD/ÉLECTRIC
(11.25 Kw)
Read these instructions carefully before installing
and operating your furnace.
Please keep this document!
Verified and tested for Canada
and the United States by :
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problems,injuries,ordamagesarisingoutoftheuseof
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2
THANK YOU FOR CHOOSING THIS PSG FURNACE
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.
In the following pages, you will be introduced to wood burning in general like
starting, building and maintaining a fire. You will also find detailed installation
instructions and recommendations on how to maintain your heating system in
order to get the best performance out of your wood furnace.
Congratulations for the judicious choice you made in buying a quality PSG
product.
Take the time to read this manual in its entirety before installing and
operating your new furnace. It is important that you follow these
installation instructions carefully. Failure to do so could result in a house
fire, bodily injuries or even death.
You may have to get a permit from the local authorities before installing
this furnace and the chimney it will be connected to. Contact you local
building inspector or fire department to know the particular requirements in
your area. We also recommend that you contact your household insurance
company to verify if the installation will have an incidence on your policy.
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
www.psg-distribution.com
Registering your warranty online will help us track rapidly the
information we need on your furnace.

3
Table of content
1.1 INTRODUCTION .....................................................................................6
1.2 CHIMNEY AND DRAFT...........................................................................7
2PART A - SAFETY RULES...........................................................................8
2.1 GENERAL REQUIREMENTS..................................................................8
2.2 ODOUR FROM THE PAINT....................................................................8
2.3 ASH DISPOSAL ......................................................................................8
2.4 CREOSOTE BUILD-UP AND REMOVAL................................................8
2.5 SMOKE DETECTOR...............................................................................9
2.6 DOOR GLASS.........................................................................................9
2.7 GLASS CHARACTERISTICS................................................................10
2.8 ASH DRAWER ......................................................................................10
2.9 ASH GRATE..........................................................................................10
2.10 FLUE AND BAROMETRIC DRAFT CONTROL CONNECTION.........11
2.11 DAMPER ...............................................................................................11
2.12 FRESH AIR INTAKE ..........................................................................12
3PART B - INSTALLATION..........................................................................14
3.1 WOOD ADD-ON....................................................................................16
3.1.1 INSTALLATION MINI-CADDY ADD-ON .........................................16
3.1.2 INTRODUCTION.............................................................................16
3.1.3 APPLIANCE INSTALLATION..........................................................16
3.1.4 UNIT LOCATION.............................................................................16
3.1.5 MATCHING THE TRANSFER DUCT BETWEEN THE TWO
HEAT GENERATORS.....................................................................17
3.1.6 BLOWER OF THE EXISTING FURNACE.......................................19
3.1.7 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
FOR MINI-CADDY ADD-ON...........................................................19
3.1.8 PIPE CONNECTOR AND DAMPER...............................................21
3.1.9 ELECTRICAL CONNECTIONS.......................................................22
3.1.10 FAN LIMIT CONTROL ....................................................................22
3.1.11 SERVOMOTOR ..............................................................................22
3.1.12 THERMOSTAT ...............................................................................23
3.1.13 SAFETY PRECAUTION..................................................................23
3.1.14 OPERATING INSTRUCTIONS.......................................................23
3.1.15 INSTALLATION OF MINI-CADDY ADD-ON ...................................24

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....................................................................32
3.1.19 MINI-CADDY ADD-ON TECHNICAL DATA....................................33
3.2 WOOD ONLY ........................................................................................35
3.2.1 MINI-CADDY WOOD ONLY INSTALLATION.................................35
3.2.2 UNIT LOCATION.............................................................................35
3.2.3 CLEARANCES TO COMBUSTIBLE MATERIAL ............................35
3.2.4 MINIMUM CLEARANCES REQUIRED FROM ANY
COMBUSTIBLE MATERIAL FOR THE MINI-CADDY FURNACE...35
3.2.5 ROUND HOT AIR PLENUM OPTION (PA07400)...........................37
3.2.6 CONNECTING PIPE.......................................................................37
3.2.7 PARALLEL INSTALLATION............................................................38
3.2.8 ELECTRICAL CONNECTION.........................................................39
3.2.9 THERMOSTAT ...............................................................................39
3.2.10 FAN LIMIT CONTROL.................................................................39
3.2.11 OPÉRATION INSTRUCTIONS .......................................................40
3.2.12 CONTROL SYSTEM....................................................................40
3.2.13 WIRING DIAGRAM......................................................................41
3.2.14 MINI-CADDY TECHNICAL DATA................................................42
3.2.15 GENERAL TECHNICAL DATA....................................................42
3.2.16 TECHNICAL DATA – ELECTRIC MODE.....................................42
3.3 WOOD/ELECTRIC COMBINATION ......................................................44
3.3.1 MINI-CADDY WOOD/ELECTRIC INSTALLATION .........................44
3.3.2 INTRODUCTION.............................................................................44
3.3.3 MINIMUM CLEARANCES REQUIRED TO ANY COMBUSTIBLE
MATERIAL......................................................................................45
3.3.4 ROUND HOT AIR PLENUM OPTION (PA07400)...........................45
3.3.5 ELECTRIC UNIT.............................................................................45
3.3.6 THERMOSTAT ...............................................................................47
3.3.7 WIRING DIAGRAM.........................................................................48

5
4PART C – OPERATION..............................................................................49
4.1 LIGHTING..............................................................................................49
4.2 PREHEATING .......................................................................................49
4.3 HEATING...............................................................................................50
4.4 FIRST SIGNS OF AN OVERHEATING FURNACE...............................50
4.5 WOOD AS A COMBUSTIBLE ...............................................................51
4.6 CHIMNEY FIRE.....................................................................................51
4.7 LOCAL FIRE DEPARTMENT................................................................52
4.8 PROLONGED POWER OUTAGE .........................................................52
5PART D - MAINTENANCE..........................................................................53
5.1 HEAT EXCHANGERS CARE................................................................53
5.2 CHIMNEY MAINTENANCE...................................................................55
5.3 SMOKE PIPE INSPECTION..................................................................55
5.4 BLOWER MOTOR MAINTENANCE......................................................55
5.5 FILTERS................................................................................................55
5.6 DOOR GASKET RELACEMENT...........................................................56
6PART E – REMPLACEMENT PARTS ........................................................57
6.1 THE GLASS...........................................................................................57
6.2 THE DOOR GASKET ............................................................................57
6.3 MINI-CADDY BRICK LAYOUT..............................................................58
7PART F - DUCTS AND DAMPERS DIMENSIONS.....................................59
7.1 DUCTS AND DAMPERS DIMENSIONS
(EXAMPLES OF CALCULATION).........................................................59
8PART G - TROUBLESHOOTING................................................................60
9PART H - SPECIFICATIONS......................................................................61
10 APPENDIX A – ROUND HOT AIR PLENUM OPTION ...............................62
LIMITED LIFETIME WARRANTY ......................................................................63

6
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.
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).
This model line is certified as meeting the emissions limits in 40 C.F.R. part 60,
section 60.532 (B) per EPA methods 28 and 5G-3, February 1988.
To optimize the efficiency of your furnace, here is some advice that you should
follow when installing or operating your MINI-CADDY furnace:
Respect the local codes (when in doubt, consult your local dealer);
Verify the specifications on the certification plate concerning the clearances to
make sure that they correspond to the ones included in this instruction
manual.
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 the Warm Air Heating
and Air Conditioning National Association and should respect the static
pressure ranges in the warm air plenum of the furnace.
WARNING
THE 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).
Taux d’émissions : 6.0 g/h
Average efficiency: 84 % (LHV)

7
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’’ w.c. Please note that a draft
exceeding -0.06” w.c. will reduce the efficiency and could produce an
uncontrollable fire. On the other hand, the minimum draft required is 0.04”
w.c. in the evacuation pipe on the wood side, no matter what type of
furnace.

8
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.
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.
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.

9
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.
If a significant layer of creosote has accumulated, it must be removed
immediately to eliminate the risk of chimney fire. (It is recommended to clean
the heat exchangers thoroughly at the end of season in order to prevent
corrosion).
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 (See Section 4.6.)
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 wood stove glass cleaner. Clean
the glass ONLY when the unit has cooled down. Do not use abrasive cleanser.
Wood stove glass cleaners are available in most home centers and specialty
hearth retailers.
WARNING
AVOID KNOCKING OR SCRATCHING THE GLASS. IT COULD CRACK OR
BREAK.

10
2.7 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. 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.
WARNING
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.
2.9 ASH GRATE
You must replace the ash grate if it is damaged and a replacement may be
obtained from your dealer. The steel cover on the ash grate is meant to optimize
the temperature inside the combustion chamber and should only be removed to
empty the ashes.

11
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). See pictures below showing a male-female coupling.
PROPER INSTALLATION
IMPROPER INSTALLATION
2- A minimum rise of ¼” per horizontal foot must be respected.
2.11 DAMPER
The barometric damper must be adjusted so that the maximum draft measured at
the furnace outlet is limited to -0.06 in. w.c. However, the minimum draft to be
respected at all times is -0.04 in. w.c. in the evacuation pipe.
WARNING
DRAFT HIGHER THAN -0.06” W.C. MAY CAUSE AN UNCONTROLLABLE
FIRE.
CAUSES
RESTRICTION

12
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.
In such a case, when starting up the fire, do not operate appliances that
evacuate air outside the house, such as:
- Range hood
- Air exchanger
- Clothes dryer
- Bathroom fan
- Ventilated central vacuum system
ATTENTION
SUFFICIENT COMBUSTION AIR MUST BE AVAILABLE AT ALL TIMES;
LACK OF COMBUSTION AIR CONSTITUTES A DANGER.
NOTE:
It is recommended to install an outside air inlet with a diameter of at least 4
inches in the room where the heating appliance is installed (see drawing next
page). It is preferable to choose a wall which is not exposed to dominant winds,
depending on the conditions surrounding your house.

13
AIR SUPPLY
INSULATED PIPE
EXTERIOR WALL
AIR INLET
N.B.: THE OWNER OF THE FURNACE IS RESPONSIBLE FOR THE ROOM’S
AIR QUALITY IN CASE OF NEGATIVE PRESSURE OR TEMPORARY
NEGATIVE PRESSURE.

14
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 ...............................................................34
WOOD/ELECTRIC COMBINATION.............................43

15
MINI-CADDY ADD-ON
Installation Instructions

MINI-CADDY ADD-ON
PF01301

16
MINI-CADDY ADD-ON
3.1 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
you understand them:
The furnace must be installed in a state of the art manner. Installation must be
made in accordance with the CSA B.365 standard concerning the normalization
of solid fuel units. If modifications have to be made to the existing furnace, these
have to be conform respectively to CSA B.139 for oil furnaces, CSA C22.1 for
electric furnace and CAN/CSA B149.1 or CAN/CSA B149.2 for gas furnaces.
Inspect the furnace to make sure that nothing has been damaged in the shipping.
Pull out the wiring kit and the instructions manual from the firebox of the furnace
and the scraper from the flue pipe.
3.1.4 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.
Minimize the use of 90oelbows.
The owner must ensure a proper installation to allow a safe operation of
the appliance.

17
MINI-CADDY ADD-ON
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.
Install the plenum and heating ducts in line as in OPTION #1 de la Section
3.1.15. In series connection should be considered only if in line connection is not
possible.
If the ducts are installed in series (Section 3.1.15, OPTION #2) and the existing
furnace’s fan limit control is mounted on the plenum, the divider in the plenum
must be installed at least 5” (127 mm) above the fan limit control casing. This
divider must be air tight.
Do not install connecting ducts in a way that would allow inversion of the air flow.
Do not use elbows with a radius less than 6 inches (153 mm).
The transfer duct between the existing furnace and the add-on must be at least 260
square inches (0.16 m2) and deviations radius must be at least 6” (153 mm). (See
OPTION #1 and #2 in Section 3.1.15).
WARNING
DO NOT CONNECT TO A DOWN FLOW FURNACE.
WARNING
DO NOT REMOVE, RELOCATE OR BYPASS ANY OF THE SAFETY
CONTROLS IN THE ORIGINAL FURNACE INSTALLATION.
You must determine the air flow through the existing furnace before installing the
Mini-Caddy add-on:
1. Run the furnace to which the Mini-Caddy add-on is connected until it reaches
its maximum temperature.
2. With a thermometer, measure the temperature of the cold air entering the
furnace and that of the air exiting the furnace in the hot air plenum.
Note: There can be a large lag in the readings of many commercially available
thermometers. Give them adequate time to stabilize when taking temperatures.
The temperature rise is obtained by subtracting the cold air return temperature
from that of the air exiting in the hot air plenum. The result (t) will be needed for
next step.

18
MINI-CADDY ADD-ON
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:
  
1.21  

Re = Electrical energy input rate, kW
t= Temperature rise (ºC)
c) Gas furnace:
    
1.21  
Rg = Gas input rate, kW
Eg = Efficiency of a typical atmospheric gas furnace (0.7)
4. After the installation of the add-on, the original numbers must be restored in
order to maintain a constant air flow through the furnace.

19
MINI-CADDY ADD-ON
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" of water column.
Some adjustment on the motor and blower of the existing furnace may be
necessary. In this case, the following rules apply:
On a belt-driven system, blower pulleys and motor pulleys may be changed to
do the adjustment.
On a direct-drive system, the motor shall not be changed; 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 NAMEPLATE RATING.
3.1.7 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FOR MINI-
CADDY ADD-ON
N.B.: THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE WITH THE
INSTRUCTIONS ON THE CERTIFICATION PLATE APPLIED ON THE UNIT.

20
MINI-CADDY ADD-ON
Figure 3.1.7 a
The furnace may be installed on a combustible floor.
Figure 3.1.7 b - Reduced clearances of insulated ductwork