PSG MINI-CADDY User manual

45154
PSG
1700, Léon-Harmel
Québec (Québec)
G1N 4R9
Installation and Operating Instructions
for models MINI-CADDY wood furnaces and
wood/electric combination
FURNACE MODELS INCLUDED IN THIS MANUAL
MINI-CADDY WOOD AND WOOD/ELECTRIC COMBINATION
11.25 Kw
Read these instructions carefully before installing
and operating your furnace.
CONGRATULATIONS!
You have purchased one of the finest wood
or wood/electric 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

2
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................ 4
1. CHIMNEY AND DRAFT....................................................................................................................... 4
2. SAFETY RULES..................................................................................................................................... 4
GENERAL REQUIREMENTS.................................................................................................................. 4
ODOUR FROM THE PAINT..................................................................................................................... 5
ASH DISPOSAL ........................................................................................................................................ 5
CREOSOTE BUILD-UP AND REMOVAL.............................................................................................. 5
SMOKE DETECTOR................................................................................................................................. 6
DOOR GLASS ........................................................................................................................................... 6
GLASS SPECIFICATIONS....................................................................................................................... 6
ASH DRAWER.......................................................................................................................................... 7
ASH GRATE.............................................................................................................................................. 7
3. APPLIANCE INSTALLATION ............................................................................................................. 7
A- UNIT LOCATION ................................................................................................................................ 7
B- CLEARANCES TO COMBUSTIBLE MATERIALS .......................................................................... 8
C- PIPE CONNECTOR.............................................................................................................................. 9
D- DAMPER............................................................................................................................................. 10
E- COMBUSTION AIR............................................................................................................................ 10
PARALLEL INSTALLATION................................................................................................................ 11
F- ELECTRICAL CONNECTION........................................................................................................... 12
MINI-CADDY WOOD ONLY.................................................................................................................. 12
MINI-CADDY WOOD/ELECTRIC......................................................................................................... 12
G- ELECTRIC ELEMENT (MINI-CADDY WOOD /ELECTRIC)........................................................ 13
INSIDE VIEW OF THE ELECTRIC ELEMENT................................................................... 13
H- THERMOSTAT .................................................................................................................................. 14
I- FAN CONTROL................................................................................................................................... 14
4. OPERATING INSTRUCTIONS........................................................................................................... 15
CONTROL SYSTEM............................................................................................................................... 15
a) LIGHTING:...................................................................................................................................... 15
b) PREHEATING.................................................................................................................................. 15
HEATING ................................................................................................................................................ 16
EARLY SIGNS OF OVERFIRED FURNACE:....................................................................................... 16
WOOD AS HEATING FUEL................................................................................................................... 16
PROCEDURE TO OPEN THE LOADING DOOR ............................................................ 16
ALWAYS KEEP THE DOOR AND THE ASH DRAWER CLOSED............................... 16
CHIMNEY FIRES.................................................................................................................................... 17
5. MAINTENANCE.................................................................................................................................... 18
MAINTENANCE OF THE EXCHANGERS........................................................................................... 18
MINI-CADDY.................................................................................................................. 19
SECTION VIEW.............................................................................................................. 19
MAINTENANCE OF THE BLOWER MOTOR...................................................................................... 20
FILTERS .................................................................................................................................................. 20

3
DOOR GASKET MAINTENANCE ........................................................................................................ 20
6. REPLACEMENT PARTS..................................................................................................................... 21
DOOR GLASS ......................................................................................................................................... 22
GASKET .................................................................................................................................................. 22
7. WIRING DIAGRAM............................................................................................................................. 23
MINI CADDY WOOD ONLY................................................................................................................. 23
8. MINI-CADDY TECHNICAL DATA................................................................................................... 24
GENERAL TECHNICAL DATA ............................................................................................................ 24
TECHNICAL DATA –ELECTRIC MODE ............................................................................................ 24
9. DUCTS AND DAMPERS DIMENSIONS (EXAMPLES OF CALCULATION)............................ 25
10. MINI-CADDY BRICKS LAYOUT .................................................................................................... 26
Vermiculite baffle board........................................................................................................... 26
11. TROUBLE SHOOTING...................................................................................................................... 27
PSG LIMITED LIFETIME WARRANTY.............................................................................................. 28

4
INTRODUCTION
To optimize the efficiency of your furnace, here are few advices you should follow when installing or operating
your Mini-Caddy furnace.
Respect the local codes (when in doubt, consult your local dealer).
Make sure your furnace is installed according to the instructions on the certification plate.
All controls adjustments must be performed by a qualified technician. The controls settings and the blower speed
must conform to the recommendations of the National Warm Air Heating and Air Conditioning Association and
respect the recommended static pressure ranges in the warm air bonnet of the furnace (see General Technical data
static pressure).
1. CHIMNEY AND DRAFT
This furnace must be connected to a chimney certified for wood burning heating appliances; a 6 inch inside
diameter chimney and connector is recommended for the Mini-Caddy.
Never install a manual damper.
If a barometric control must installed, it 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. could produce an
uncontrollable fire. On the other hand, the minimum draft required is -0.04 in. w.c. in the evacuation pipe(
MINI-CADDY WOOD OR MINI-CADDY WOOD/ELECTRIC).
2. SAFETY RULES
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 or motor oil.
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.
Average emissions rate: 6 g/hr
Average heating efficiency: 84%

5
ODOUR FROM THE PAINT
It is normal that a smoke odour emanate from the unit when you first light it. It is recommended to burn it at high
rate and ventilate the building until the odour resorbs.
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. If the ashes are meant to be buried in soil, you should wait until all cinders have
thoroughly cooled.
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 on the flue lining.
N.B.: To minimize the frequency of 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 content 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 the ashes.
When ignited, creosote produces an extremely hot fire inside the chimney.
To avoid chimney fires, it is important to do the turnover of wood. Inspect the chimney system at regular intervals
to determine a cleaning cycle. A weekly cleaning might be required during mild periods while a monthly cleaning
should be sufficient during colder periods. 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-up within the system. An emergency plan is necessary in case of a
chimney fire. It’s recommended to clean up the heat exchangers at the end of season in order to prevent corrosion.
W A R N I N G
-THE ASH DRAWER AND EXCHANGERS ACCESS PANEL GET VERY HOT.
-DO NOT MANIPULATE WITH BARE HANDS.

6
SMOKE DETECTOR
We highly recommend the use of a smoke detector. It should be installed at least 15 feet (4,57 m) from the
appliance in order to prevent undue triggering of the detector when reloading.
DOOR GLASS
To maintain a clean and safe installation, do not build your fire too close to the glass or allow the fire 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 going out, which would stain your glass.
An intense fire will help keeping the glass clean. However, in the event that your glass gets stained, which should
not occur, you will have to clean it using a wet cloth and an oven cleaner. The glass can be cleaned ONLY when
the unit has cooled down. Do not use abrasive cleanser. Wood stove glass cleaners are available on the market
and their efficiency makes no doubt.
WARNING: Avoid knocking or scratching the glass which could be damaged.
GLASS SPECIFICATIONS
The glass is made of Pyroceram type of glass, 3/16” – (5 mm) thick.
Do not operate your furnace with a broken glass, as this could seriously damage your appliance.
You can purchase your replacement glass from your dealer.

7
ASH DRAWER
Your appliance 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 cleaned regularly.
ASH GRATE
You must replace the ash grate if it is damaged and a replacement may be obtained from your dealer.
3. APPLIANCE INSTALLATION
A- 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 inlet (see details in: COMBUSTION AIR).
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.
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
replacement.

8
B- CLEARANCES TO COMBUSTIBLE MATERIALS
MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FOR MINI-CADDY FURNACE
45°
ELBOW
24"
24"
LEFT WALL
6"
HOT AIR PLENUM
18" 3"
CEILING
8" MIN.
1"
SEE
FIGURE
BELOW
72"
N.B. THE SIZE OF THE AIR RETURN CONDUITS SHOULD BE AT LEAST EQUAL TO THE SIZE OF
THE COLD AIR PLENUM OPENING.
In order to insure adequate static pressure, the quantity of air return should exceed the quantity
of hot air distribution by at least 5%.
Hot air plenum minimal height.
N.B. This appliance must be installed according to the instructions on the unit’s certification plate.

9
C- PIPE CONNECTOR
The Mini-Caddy must be connected to a 6” chimney. If draft exceed –0.06 w.c., you must install a barometric
control. The barometric control must be adjusted so that the maximum draft measured at the furnace outlet is
limited to -0.06 in. w.c. Please note that a draft higher than -0.06 W.C. could result in an uncontrollable fire. On the
other hand, the minimum draft to be respected is -0.04 in. w.c. in the evacuation pipe.
For a proper installation, follow the advices below:
1. All the evacuation pipe joints must be secured with three screws.
Make sure that each screw goes through the inner walls of both connectors (male and female). See
pictures below showing a male-female coupling.
2. A minimum rise of 1/4 inch per horizontal foot must be respected.
PROPER INSTALLATION IMPROPER INSTALLATION
CAUSES RESTRICTION

10
D- DAMPER
The barometric control must be adjusted so that the maximum draft measured at the furnace outlet is limited to -
0.06 in. w.c. Please note that a draft higher than -0.06 in. H2O could result in an uncontrollable fire. On the other
hand, the minimum draft to be respected is -0.04 in. w.c. in the evacuation pipe.
E- COMBUSTION AIR
When the furnace and the chimney are completely cold, it might 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 is liable to lack fresh air necessary for the
proper combustion of a flame producing 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
NOTE:
It is recommended to install an outside air inlet of minimum 4” diameter in the room where the heating appliance is
installed (see drawing below). It is preferable to choose a wall that is not exposed to dominant winds, depending on
the conditions surrounding your house.
N.B. The owner of the furnace is responsible for the room salubrity in case of negative pressure or
temporary negative pressure.
Insulated conduit full length
Fresh air
intake
Exterior
w
all
Free air
entr
y

11
PARALLEL INSTALLATION
The installation of this furnace with another furnace using the same ductwork is not allowed in Canada. This type
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 order to reach a static pressure of at least 0.20
IN.WC, but not more than 0.50 IN.WC. A back-flow damper should be installed in the plenum. The back-flow damper
assures that when either unit is operated by itself, the hot air will flow into the home, and not back through the other
furnace. Depending on your installation (see figures examples below), a back-flow damper may be required in each
plenum.

12
F- ELECTRICAL CONNECTION
MINI-CADDY WOOD ONLY
To install the Mini-Caddy in wood only configuration, the use of the PSG “fan limit kit for wood only furnaces” option
(PA00500) is required and it has to be ordered separately.
The combined limit control is part of that wiring kit and it must be mounted near the flue outlet, where holes are set
for the control’s sensor and mounting screws. Once in place, the limit control will not be vertical and this is normal.
Plastic bushings are installed on the edge of the blower compartment that let you run the metal jacket cable (14-3) to
the junction box inside the blower compartment where the blower connections will be done.
The 24 volts control circuit will be fed from the transformer mounted to the fan limit junction box and the main power
input (115 volts) will also connect into that box.
Make connections as instructed in the diagram included in this manual
Warning: Use wiring suitable for 75°C or more
MINI-CADDY WOOD/ELECTRIC
The use of the “fan limit kit for wood only furnaces (PA00500)” option is not required for installation of the Mini-
Caddy in wood/electric configuration as the 11.25kw electric unit option includes all the electrical components
required for that type of installation.
The combined limit control must be mounted near the flue outlet as in the wood only installation; the metal jacket
cable (14/4) that is attached to it will run to the electric unit inside the furnace through the plastic bushings on the
edge of the blower compartment and the knock-outs in the dividing panel and the side of the electric unit. Connect
as showed in the wiring diagram included with the electric unit.
Another piece of metal jacket cable (14/3) is included with the electric unit and it will run inside the furnace, through
the knock-out in the dividing panel, and connect the blower to the power block in the electric unit (as showed in the
diagram).
The 24 volts control circuit will also be fed from the electric unit and will be connected to the command block
(numbered 1 to 8) as in the diagram.
The main power supply (6/3) will enter the electric unit through the knock-out on the left front panel and connect to
the supply terminal (L1, N, L2) as in the diagram.
Warning: Use wiring suitable for 75°C or more.
The electric unit has two separate internal protections against overheating: one is a L-200 automatic reset
thermodisc and the other one is a L-250 manual reset thermodisc.
In the first generation units, the L-200 does not exist and a second combined limit control is included with the units; it
must be mounted on the left side of the furnace, right of the electric unit where there is a knock-out for the limit’s
sensor, and the metal jacket cable (14/2) must be connected in the unit as showed in the diagram that comes with
that unit.

13
G- ELECTRIC ELEMENT (MINI-CADDY WOOD / ELECTRIC)
The WOOD / ELECTRIC combined model is installed with two thermostats: one thermostat controls the electric
heating, the other one controls the wood heating. With this system, the electric heating has priority over the wood
heating. When the thermostat activates the electric heating, the air inlet closes down (if opened), the blower starts
and the electric elements are successively activated per block of 3.75 kW.
When the call for electric heating is satisfied, the wood system will take over if the starting point of the wood
system is superior to that of the electric system so, in normal bi-energy use, you should set the wood thermostat 2oC
to 3oC higher than the electric system thermostat; the bigger the gap, the more the wood heating will contribute to
the overall heating needs.
Take note that this furnace is equipped with a four speed blower motor. Aside from low speed, you may select
medium-low, medium-high or high speed.
If the temperature in the electric unit exceeds 200°F, the L-200 thermodisc will disengage the elements until has
cooled down and automatically turn them back on if the thermostat is still calling for heat. Should the temperature
keep on increasing and reach 250°F, the L-250 thermodisc will disengage the elements and it will have to be
reactivated manually by pushing the reset button. Find and fix the cause of overheating before reactivating the unit.
INSIDE VIEW OF THE ELECTRIC ELEMENT
Thermodisc
L250 manual reset
manual reset
button

14
H- 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.
N.B. Both thermostats on the combined wood / electric model must be installed at same height.
I- FAN CONTROL
The fan control setting varies depending on the type of installation. The setting “out of service” is preset at 110oF
at the factory. This setting should provide a proper operation for most installations. The temperature “in service” is
factory set at 150oF.
It is preferable for a prolonged operation of the blower that the setting “out of service” be low enough. But a
setting “out of service” too low will cause undesirable cold air circulation. To modify the setting, move the tab to the
desired position on the temperature dial of the fan limit control.
The adjustment of all controls must be performed by a qualified technician. The controls setting and the blower
speed must conform to the recommendations of the “Warm Air Heating and Air Conditioning National Association”.
The summer switch located on the electric unit controls the low speed either at the “on” or the “off” position. For a
quieter operation, it is recommended to use low speed for continuous operation of the blower (summer) and to leave
the high speed on automatic (wood side fan limit control) during the heating season.
OUTSIDE VIEW OF THE ELECTRIC ELEMENT

15
4. OPERATING INSTRUCTIONS
CONTROL SYSTEM
On the wood only furnaces, the thermostat controls the air inlet damper. When the thermostat calls for heat, the
damper opens and the fire stirs up. When the furnace gets hot enough, the combined limit control activates the
blower motor at the speed selected for heating.
a) LIGHTING:
1. Open the door
Note: If there already a bed of coals in the firebox, go to step b) 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 door 1/2" (13 mm) opened. If you fail
lighting the fire, you might experience a back draft through the air inlets.
b) PREHEATING
1. Once the kindling is well ignited or the coals revived, put 2 or 3 fire logs in such a way that the flames can
interlace between the logs then close the door. It is important to respect these loading sequences so that the
wood will burn from the front to the back of the furnace.
2. Wait 15 to 20 minutes, then proceed with loading the furnace.

16
HEATING
1. When loading the furnace, lower the kindled pieces of wood and place them at the center of the combustion
chamber before adding new logs.
2. Do not overload. Air must circulate freely in the upper part of the combustion chamber in order to obtain an
efficient operation of the appliance. Please note that a small hot fire will produce much less residues than a large
smouldering one.
IMPORTANT: WHEN RELOADING, PUSH AWAY THE ASHES AND COALS THAT COULD
OBSTRUCT THE HOLES LOCATED BELOW THE DOOR INSIDE THE FURNACE.
EARLY SIGNS OF OVERFIRED FURNACE:
1. Roaring fire.
2. Chimney connector is glowing red.
3. Extreme heat coming from the furnace. If this occurs, DO NOT OPEN THE DOOR, shut-off the air inlet opening
completely, and wait until the glow has completely subsided.
WOOD AS HEATING FUEL
We recommend that you burn seasoned hard wood only.
There are two important factors to be considered when choosing a type of wood: the moisture content and the
wood density. Hardwood, such as maple, oak and beech will provide better results because of the high density and
minimal tar produced during combustion. It is highly recommended to use wood that has been dried at least six
months. Do not use coal as heating fuel in this appliance.
PROCEDURE TO OPEN THE LOADING DOOR
TO MINIMIZE THE RISK OF SMOKE SPILLAGE, CRACK THE DOOR OPEN 1”
AND WAIT ABOUT 10 SECONDS BEFORE OPENING COMPLETELY.
THE PURPOSE IS TO STABILIZE THE PRESSURE INSIDE THE FURNACE.
ALWAYS KEEP THE DOOR AND THE ASH DRAWER CLOSED
(except for lighting and maintenance).

17
Whenever a substantial amount of smoke is noticed in the room, you must:
1. Open doors and windows.
2. Make sure the furnace door is closed as well as the damper (if necessary, lower the thermostat starting point or
unhook the damper chain, and close the barometric draft control manually).
3. When the furnace has cooled down, inspect the chimney to detect obstructions and consult a specialist to
determine the cause of the smoke spillage.
CARBON MONOXYDE IS A LETHAL GAS (ODOURLESS AND COLOURLESS), WHICH YOU MUST
BEWARE OF.
CHIMNEY FIRES
This might occur when the fire gets extremely hot. Burning cardboard, branches or small pieces of wood can
ignite the creosote residue accumulated in the evacuation system. The usual signs are:
1. Rumbling
2. The flue gets extremely hot
3. Flames shooting out of the chimney
In case of a chimney fire, call your local fire department immediately and sprinkle the
roof around the chimney with water.
Make sure that the furnace door is closed as well as the damper (if necessary, lower the thermostat starting point
or release the chain from the damper and CLOSE the barometric draft control manually).
If the fire gets uncontrollable due to an improper use or because the draft is too strong, follow the same procedure
as in a chimney fire except that you will have to OPEN the barometric draft control manually.
LOCAL FIRE DEPARTMENT.
Phone number: ___________________________________

18
5. MAINTENANCE
MAINTENANCE OF THE EXCHANGERS
The evacuation pipe and the exchangers should be inspected regularly during the burning season. Easy access
is provided (without the use of tools): unscrew the wing nut on the exchangers access door.
See pictures below.
Before cleaning the three exchanger pipes, move the upper plate 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, if pushed to the rear; the dirt in the central exchanger will have to
be removed from the front or the back of the furnace. Then, ensure that the upper plate is free of ashes. Do not
forget to push the upper plate backward to it’s original position. Finally, close the exchanger access door.

19
REAR BRICK
SCRAPER
FLUE
OUTLET
DIRT
BAFFLE BOARD
MOVED FOWARD
FOR CLEANING
PURPOSE ONLY
MINI-CADDY
SECTION VIEW

20
CHIMNEY MAINTENANCE
The most efficient method to sweep the chimney is using a hard brush. Brush downwards so soot and creosote
residues will come off the inner surface and fall at the bottom of the chimney where they can be removed easily.
The chimney must be checked regularly and if creosote has accumulated, it must be removed without delay.
Cleaning on a monthly basis should be sufficient during the coldest months.
Smoke flue inspection
- The flue pipe should be inspected regularly during the heating season.
- If possible, the flue pipe should be disassembled and cleaned.
- The flue should be inspected for possible damage.
- If it is in good condition, put the flue pipe back in place; otherwise, it must be replaced.
- Use only wood as a combustible.
- Seasoned hard wood logs 18” long are recommended as combustible.
MAINTENANCE OF THE BLOWER MOTOR
After 3 years of use, the two motor bearings must be lubricated once a year using 10 drops of 5W30 oil.
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 replaced regularly; use the same size and same type as
the original filters.
Filters dimensions
15” x 20” x 1” filters (Mini-Caddy) #21044
DOOR GASKET MAINTENANCE
It is important to maintain the door gasket in good condition. With time, the gasket might sag and if a door
adjustment is not sufficient to insure tightness, replace the gasket.
DO NOT OVERLUBRICATE