PSG MINI-CADDY PF01301, Installation And Operating Instructions Manual

Page 1: ...tions carefully before installing and operating your furnace Please keep this document Verified and tested for Canada and the United States by 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 arisin...

Page 2: ...y 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 part...

Page 3: ...12 3 PART 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 C...

Page 4: ...E 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 ELECT...

Page 5: ...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 6 PART E REMPLACEMENT PARTS 57 6 1 THE GLASS 57 6 2 THE DOOR GASKET 57 6 3 MINI CADDY BRICK LAYOUT 58 7 PART F DUCTS AND DAMPERS DIMENSIONS 59 7 1 DUCTS AND DAMPERS DIMENSIONS EXAMPLES OF CALCULATION 59 8 PART G TROUBLESHOOTING 60 9 PART H SPECIFICATIONS 61 1...

Page 6: ...ere 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 certifi...

Page 7: ...d 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 mat...

Page 8: ...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 pro...

Page 9: ...ire 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 se...

Page 10: ...ombustion 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 r...

Page 11: ...e 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 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 ...

Page 12: ...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 wher...

Page 13: ...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 ...

Page 14: ...T 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 ...

Page 15: ...15 MINI CADDY ADD ON Installation Instructions MINI CADDY ADD ON PF01301 ...

Page 16: ...ng 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 o...

Page 17: ...m 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 furn...

Page 18: ...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 ...

Page 19: ... 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 NAMEPLA...

Page 20: ...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 ...

Page 21: ...is not flush with the first horizontal section see Figure 3 1 7 c Otherwise the minimum height is 10 254 mm These dimensions for all hot air furnaces are in accordance with the standards CSA B140 4 UL 391 and UL 727 3 1 8 PIPE CONNECTOR AND DAMPER The Mini Caddy Add on furnace must be connected to a duct system and a chimney that are in good condition the use of separate chimneys is recommended If...

Page 22: ...our 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 be installed at least 5 127 mm above the fan limit casing This divider must be airtight All wiring and connections must be done according to the diagram The controls of the two furnaces must be interconnecte...

Page 23: ... 3 1 13 SAFETY PRECAUTION CAUTION THE OPERATION OF A GAS FURNACE MUST BE VERIFIED FOR ACCEPTABLE OPERATION BEFORE AND AFTER INSTALLATION OF THE MINI CADDY ADD ON APPLIANCE BY A GAS FITTER WHO IS RECOGNIZED BY THE REGULATORY AUTHORITY CAUTION DO NOT CONNECT TO ANY GAS FURNACE THAT HAS NOT BEEN CERTIFIED INITIALLY AS COMPLYING WITH CGA STANDARD CAN CGA 2 3 OR ITS PRECEDENTS 3 1 14 OPERATING INSTRUCT...

Page 24: ...24 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: ...25 MINI CADDY ADD ON Example 1 Example 2 ...

Page 26: ...mple 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: ... 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 Then remove the panel on the right side and secure it to the left side with the same screws Connect the duct Note Before connecting the ducts from the existing furnace to either side of the Mini Caddy Add on it is recommended to cut off the extra insulat...

Page 28: ...08522 not included with the furnace remove the cover on the fan limit control and the cover on the junction box Slide the fan limit control s probe in the opening 2 provided for that purpose next to the flue outlet on the back of the furnace Secure the fan limit control and junction box with screws not supplied in the holes intended for that purpose Once the wiring as per Appendix 1 is completed p...

Page 29: ...ur 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: ... Add on to the fan limit assembly s junction box C Note To perform the wiring see WIRING DIAGRAM FOR CONNECTION OF THE MINI CADDY ADD ON WITH AN EXISTING OIL FURNACE 3 1 17 Note For connection with an existing gas or electric furnace remove the fan limit control C from the assembly and use it for low voltage wiring as per diagram 3 1 18 Connection with a gas or electric furnace will require the us...

Page 31: ...31 MINI CADDY ADD ON 3 1 17 WIRING DIAGRAM FOR CONNECTION OF THE MINI CADDY ADD ON WITH AN EXISTING OIL FURNACE ...

Page 32: ...32 MINI CADDY ADD ON 3 1 18 LOW VOLTAGE WIRING DIAGRAM FOR CONNECTION OF THE MINI CADDY ADD ON WITH AN EXISTING GAS OR ELECTRIC FURNACE ...

Page 33: ... 8 740 mm B 23 3 4 603 mm C 45 5 8 1159 mm D 12 305 mm E 12 305 mm F 40 1 4 102 mm G 19 3 4 502 mm H 13 330 mm FLUE 6 152 mm WEIGHT 416 Lb 189 kg Reducer required GÉNÉRAL TECHNICAL DATA MODELE TEMP BTU HR STATIC PRESSURE VARIABLE WOOD MIN MAX F H20 MINI CADDY ADD ON 20 67 75 000 0 2 0 4 ...

Page 34: ...34 MINI CADDY WOOD ONLY Installation instructions for MINI CADDY WOOD ONLY PF01301 ...

Page 35: ...Section 2 12 The furnace must be positioned so that the connector is as short as possible Minimize the use of 90o elbows The owner must ensure a proper installation to allow a safe operation of the appliance 3 2 3 CLEARANCES TO COMBUSTIBLE MATERIAL N B THIS APPLIANCE MUST BE INSTALLED IN ACCORDANCE TO THE INSTRUCTIONS MENTIONED ON THE FURNACE S CERTIFICATION PLATE 3 2 4 MINIMUM CLEARANCES REQUIRED...

Page 36: ...e the amount of cold air return should exceed the amount of hot air distribution of at least 5 Figure 3 2 4 c Hot air plenum minimal height The hot air plenum coming out of the furnace is to have a minimum height of 24 610 mm if the top of the first vertical section is not flush with the first horizontal section see Figure 3 2 4 c Otherwise the minimum height is 10 254 mm These dimensions for all ...

Page 37: ...f 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 W C Draft above 06 in W C could result in an uncontrollable fire and furnace overheat However draft should not drop below 04 in W C in the smoke pipe ATTENTION DO NOT INSTALL A MANUAL DAMPER ON THIS FURNACE ...

Page 38: ...ual or superior to that of the wood furnace Duct clearances must be respected as if the wood furnace was installed a by itself Necessary adjustments must be made to the distribution ducts so as to maintain static pressure between 0 20 and 0 05 in W C A back flow damper must be installed in order to make sure that the hot air circulates to the house and does not flow back through the plenum of the ...

Page 39: ...ge control circuit will be fed from the transformer attached to the junction box of the fan limit assembly and the 120 volts circuit from the house electrical entrance will also be connected to that junction box as per the wiring diagram 31 2 13 ATTENTION USE WIRES SUITABLE FOR 75 C OR MORE 3 2 9 THERMOSTAT The thermostat must be installed on an inside wall in a location where it is less likely to...

Page 40: ...erature before the blower starts in order to operate efficiently 3 2 11 OPÉRATION INSTRUCTIONS 3 2 12 CONTROL SYSTEM On wood only furnaces when the thermostat calls for heat the air inlet damper opens and the fire stirs up when the temperature inside the furnace is sufficient the fan limit control will turn the blower on at the speed selected for wood heating and this one will stay on until the te...

Page 41: ...41 MINI CADDY WOOD ONLY 3 2 13 WIRING DIAGRAM ...

Page 42: ... E 12 305 mm 3 2 15 GENERAL TECHNICAL DATA MODEL DIRECT DRIVE DEBIT TEMP VAR BTU H STATIC PRESSURE FILTER VENT MOT VIT CFM O F BOIS MIN MAX 2 H2O MINI CADDY DCT 916 800 5 HP 4 1100 67 73900 0 2 0 4 15 x 20 x 1 3 2 16 TECHNICAL DATA ELECTRIC MODE MODEL DÉBIT CFM TEMP VAR OF BTU H TOTAL AMPERAGE BREAKER ALIMENT CALIBRE VOLTAGE 1 PHASE OF ÉLÉMENTS 11 25 KW 1100 67 38400 45 60 6 120 240 4 x 3 75 KW BO...

Page 43: ...43 MINI CADDY WOOD ELECTRIC Installation instructions for MINI CADDY WOOD ELECTRIC PF01301 ...

Page 44: ...s cable through the knock outs in the rear panel of the furnace and the electric unit The low voltage control circuit web e hooked up to the command block numbered 1 to 8 as shown in the wiring diagram The feeder cable 6 3 will enter the electric unit using a suitable cable connector through the left front panel of the unit and will be connected to the terminal block L1 N L2 of the unit ATTENTION ...

Page 45: ...tion the wood thermostat should be set slightly higher 3 C or 5 F than the electric thermostat to allow the wood furnace to stabilize the temperature before the electric thermostat calls The bigger the increment the more wood will contribute to the global heating needs This furnace s blower uses a four speed motor one speed LOW is controlled by the manual switch for summer operation Three heating ...

Page 46: ...46 MINI CADDY WOOD ELECTRIC INSIDE VIEW OF THE ELECTRIC UNIT OUTSIDE VIEW OF THE ELECTRIC UNIT L 250 Thermodisc manual reset Red button manual reset ...

Page 47: ...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: ...48 MINI CADDY WOOD ELECTRIC 3 3 7 WIRING DIAGRAM ...

Page 49: ... the paper at 2 or 3 different spots as low as possible and leave the door opened about inch until the fire is burning well If lighting fails some smoke could spill out of the furnace through the air inlets 4 2 PREHEATING 1 Once the kindling are burning well or the ember bed stirred up lay 2 or 3 pieces of seasoned cordwood down in a way that the flame can circulate around the logs split wood igni...

Page 50: ...ATED BELOW THE DOOR INSIDE THE COMBUSTION CHAMBER FREE OF ASH OPENING PROCEDURE FOR THE LOADING DOOR TO MINIMISE THE RISK OF SMOKE SPILLAGE CRACK THE DOOR OPEN ABOUT AN INCH AND WAIT ABOUT 10 SECONDS BEFORE OPENING IT WIDE TO ALLOW STABILISATION OF THE PRESSURE INSIDE THE FURNACE 4 4 FIRST SIGNS OF AN OVERHEATING FURNACE 1 The fire rumbles 2 The smoke pipe turns red 3 Extreme heat emanates from th...

Page 51: ...doors 2 Make sure the furnace door and the air inlet are closed if need be lower the thermostat setting or unhook the air intake damper connecting rod and manually CLOSE the barometric draft damper 3 Once the furnace has cooled down check for possible obstructions in the exchangers the smoke pipe and the chimney or call a specialist to determine the cause of the spillage and the way to prevent it ...

Page 52: ...sed by wrongful operation or excessive chimney draft follow the same procedure as in a chimney fire but you must then OPEN the barometric draft damper manually if one is installed 4 7 LOCAL FIRE DEPARTMENT Telephone ___________________________________ 4 8 PROLONGED POWER OUTAGE To reduce the risk of overheating during a prolonged power outage more than 10 minutes it is recommended to Make certain ...

Page 53: ... sooth deposits in the exchangers to form an acid that could accelerate the corrosion process and induce premature decay of the steel Corrosion damages are not covered under warranty Smoke pipe and exchangers must be inspected regularly during the heating season Access to the exchangers is easy and does not require tools just remove the decorative facing by just lifting it remove the wing nut that...

Page 54: ...ed 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 Verify that the baffle is free of deposits and do not forget to push it back to its original position Finally close the exchangers access panel Cut view of the Mini Caddy interior ...

Page 55: ... pipe must be examined carefully to detect any defect or damage The pipe can be reassembled if no defect is detected and defective pipe must be replaced immediately Burn wood only in this furnace As a combustible well seasoned hardwood in 18 logs works best 5 4 BLOWER MOTOR MAINTENANCE After 3 seasons of operation lubricate the motor annually with a few drops of 5W30 oil DO NOT OVERLUBRICATE 5 5 F...

Page 56: ...k and the door must then be adjusted as described below If the door still leaks after the maximum adjustment replace the gasket Door adjustment procedure 1 Remove the blockage pin by turning and pulling it out with pliers 2 Turn the handle counter clockwise to increase the pressure between the door gasket and the stove body 3 Reinstall the blockage pin by hammering it in carefully ...

Page 57: ...aterial To replace the glass remove the screws that hold the glass retainers to the door frame and remove the retainers Replace the damaged glass by the new one and reinstall the retainers The genuine glass sold by your dealer will have a new gasket installed on it make sure you install a new gasket if you do not use the PSG replacement part Never clean the glass with a product that could scratch ...

Page 58: ... MINI CADDY BRICK LAYOUT BRICK LAYOUT QTY 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: ...tlet 2 x 12 damper or 4 x 10 For a 6 warm air outlet 2 x 14 damper or 4 x 12 WARM AIR SYSTEM INSTALLATION HOUSE DIMENSIONS Example 28 x 40 bungalow 1 120 sq ft 28 x 40 x 8 8 960 sq ft x 1 8 Ch air hr 16 128 Btu Exposed walls 40 40 28 28 136 x 8 1 088 sq ft x 22 23 936 Btu Number of windows 12 of 3 x 4 144 x 60 8 640 Btu Number of doors 2 x 3 x 7 42 x 100 4 200 Btu 52 904 Btu Non insulated basement...

Page 60: ...e chain that links the damper to the servo motor Rebalance the ventilation system in order to increase the air flow in the room where the thermostat is located Fan start up is too slow Fan ON setting too high Return air is too cold temperatures lower than 65 degrees Limit control not well located on the furnace Lower the temperature starting point Usually the limit control is set at 150 degrees we...

Page 61: ...Cast iron with ceramic glass Dimensions of the hot air plenum 12 x 12 or 12 round with PSG optional distribution box Dimensions of the cold air plenum 22 3 8 W x 13 5 8 L or adaptor with 8 round 5 outlets supplied with the PSG optional distribution box Dimensions of ash drawer 11 3 4 L x 12 D x 2 5 8 H Number of filters 1 Dimensions of the filters 15 L x 20 P x 1 H Blower Wood or wood electric opt...

Page 62: ...62 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: ... costs covered by this warranty are limited according to the table below The manufacturer at its discretion may decide to repair or replace any part or unit after inspection and investigation of the defect The manufacturer may at its discretion fully discharge all obligations with respect to this warranty by refunding the wholesale price of any warranted but defective parts The manufacturer shall ...