Kaden KEX Series, Installer Manual

Page 1: ...Ducted Gas Heaters Safety Information Installation Commissioning Models INSTALLER S MANUAL Universal KUN3 KUN4 KUN5 External KEX3 KEX4 ...

Page 2: ...3 2 POP Configuration Installation 12 2 3 3 Return Supply Air POP Rotation Procedure 13 2 3 4 Internal Model Flueing Instructions 14 2 3 5 Kaden Remote Flue Terminal 14 2 4 External Installation 15 2 4 1 Supply Air Overheat Switch Position KUN530 KUN330 ONLY 15 2 4 2 Modifying KUN Model Duct Orientation 15 2 4 3 Installation of Flue Terminal 16 2 4 4 Area to Cut Out in Wall 16 2 4 5 Installation o...

Page 3: ...ssioning KUN4 KUN5 32 9 1 Heater Control Settings 32 9 2 Installer Parameters Via Networker 33 9 2 1 Networker Installer Parameter KUN4 KUN5 33 9 2 2 Adjust Networker Parameters 34 9 3 KUN4 KUN5 Commissioning Instructions 34 9 3 1 Initial Ignition and Gas Inlet Pressure Check 34 9 3 2 Heater Fan Speed and Temperature Settings 35 9 3 3 Final Checks 36 9 4 Fault Code Identification on Heater PCB 36 ...

Page 4: ... in accordance with Manufacturer s Installation Instructions and the Kaden Sizing Guide Current AS NZS 5601 Gas Installation Standard AS NZS 5141 Residential Climate Control Systems AS NZS 3000 Electrical Codes and Local Gas Electrical authority regulations Current AS 4254 Ductwork for air handling systems in buildings EPA guidelines and HB276 2004 A Guide to Good Practice Local Regulations and Mu...

Page 5: ...mance of any 3rd party device is entirely the responsibility of the device s supplier or installer Any 3rd party device technical installation operation performance or other enquiries need to be referred to the device s supplier or installer Any adverse effects of 3rd party devices on the operation performance or reliability of this appliance is not covered by the manufacturer s product warranty ...

Page 6: ...gulations Kaden heaters must be installed and serviced by qualified personnel Models covered in this manual are as follows Kaden Universal Heaters Type of Wall Control Thermostat Supplied KUN5 Series KUN521 Kaden Networker KUN530 KUN4 Series KUN415 Kaden Networker KUN420 KUN425 KUN430 KUN3 Series KUN315 Kaden Manual KUN320 KUN325 KUN330 Kaden External Heaters Type of Wall Control Thermostat Suppli...

Page 7: ...m design that will result in efficient installation and provide a higher level of comfort and economical operation For the hourly input and the gas type to be used see the appliance data label located inside the service compartment or 11 Technical Specifications on page 40 1 1 INSPECTION This appliance has been inspected and tested at the time of manufacture packaged and released for transportatio...

Page 8: ...hed socket outlet adjacent to the heater in a convenient location so it can be turned OFF quickly and easily NOTE A qualified electrician must install the 220 to 240 volt wiring according to local regulations IMPORTANT Switch OFF the power and unplug the heater before touching any wiring If any electrical wiring is damaged it must be replaced by the manufacturer its service agents or an electrical...

Page 9: ...l side and fan motor access panel side s for the entire length of the heater The air gap created between the base of the heater and the platform by the heater s legs shall be maintained Permanent artificial lighting shall be provided at the heater with the switch located at the roof access opening 1 8 2 Installing Beneath the Floor There shall be a minimum clearance of 200mm between any part of th...

Page 10: ...600 Gas appliance in a plant room Directly to outside 150 Via an adjacent room 300 Table 2 NOTE DIRECTLY TO OUTSIDE is either through an outside wall into a cavity vented to outside into an underfloor space or roof space vented to outside Installation of a gas appliance in a room or enclosure for properties approved for construction AFTER 31st March 2014 1 Determine if the unit s MJ hr rating for ...

Page 11: ...70 491 350 350 All dimension in mm Diagram 1 2 2 PLATFORM SERVICE CLEARANCES B B A A C C Platform Service Area i ii D D E E Minimum Service Clearance Internal External Method 1 Method 2 A Front 750mm 750mm 500mm B End 750mm N A 300mm C End N A N A 300mm D Top 250mm 800mm 1000mm E From Platform Service Area D The height of the heater Heater height Diagram 1 dimension A Diagram 2 i There are two met...

Page 12: ...an cabinet upwards high enough to dislodge the lower locking tabs fixed to the fan cabinet near the base 6 The heater is now split in two 7 Protect the exposed looms and tabs from damage while the heater is split in two 8 Once ready reassemble in reverse order IMPORTANT Ensure when reassembling the heater that everything is put back and connected correctly 2 3 2 POP Configuration Installation POP ...

Page 13: ...ews securing the lid and remove the lid 2 Remove the screws securing the POP panel blanking panel and remove panels 3 Remove gas feed tube plate and secure to alternate panel 4 Swap panels to nominated sides and fasten with the same screws 5 Secure lid with original screws 6 For the KUN330 ONLY the pressure switch and mounting bracket will need to be swapped to the POP panel that is being exchange...

Page 14: ...ingle or twin wall non corrosive metal flue suitably terminated All flues must have a bolted flue sleeve connection to allow for repairs and or removal of the appliance Twin Wall flue maximum flue length of 6m Single Wall flue maximum flue length of 2m Up to 4 x 90º elbows are permitted with the same length requirements specified above 2 3 5 Kaden Remote Flue Terminal In specific installations for...

Page 15: ...itch Loom Diagram 5 2 4 1 2 KUN330 1 Disconnect the quick connect terminals Orange White for the overheat switch loom connected to the end discharge overheat switch behind the burners 2 The KUN330 is fitted with both left and right side discharge O H Switches reconnect the quick connect terminals Orange White to the O H Switch on the same side the air is supplied from These terminals can be identi...

Page 16: ...r other projections From the ground above a balcony or other surface To a return wall or external corner Measured horizontally from an opening window door non mechanical air inlet or any other opening into the building except sub floor ventilation or 1500mm in direction of discharge 500mm From an electricity meter or fuse box prohibited area extends to ground level 1000mm Measured vertically from ...

Page 17: ... in place silicone along the upstanding face of top flashing Step 4 Push the heater up against the wall and secure side flashing to the wall NOTE It is important to allow for sufficient slack in the ducting connected to the heater s pops to allow the heater to be moved out from the wall if required for servicing 2 4 6 KUN3 KUN4 models NOTE For installation of flashing refer to the instructions pro...

Page 18: ...n the heater and the first BTO fitting or evaporator coil Drill a 20mm diameter hole through the top of the inlet end of the first BTO fitting refer to Diagram 9 or through the top of the evaporator coils discharge POP Carefully insert the thermistor assembly probe end first into this hole and secure using the self drilling screw provided Seal any remaining openings with duct tape Ensure that the ...

Page 19: ...AMPER MOTOR 24 VAC ZONE DAMPER MOTOR 24 VAC ZONE DAMPER MOTOR Diagram 10 3 1 WIRING A DAMPER MOTOR TO THE HEATER S CONTROL MODULE a 24 Vac Power Open Power Close Damper Motor ZONE B ZONE A N C 0V N O N C 0V N O Close Common Open Damper Motor 24VAC Power Open Power Close RJ12 Connectors b 24 Vac Power Open Spring Return Damper Motor ZONE B ZONE A N C 0V N O N C 0V N O Active Neutral Damper Motor 24...

Page 20: ... heater PCB The RJ12 socket in Diagram 12 contains six terminal wires the left two are connected to Normally Open N O on the 3 way terminal block the middle two are connected to 0V and the right two are connected to Normally Open N C Check the installation manual accompanying the damper motor to determine if the RJ12 socket on the heater PCB is suitable 3 1 3 RJ12 socket detail on heater PCB Diagr...

Page 21: ...5 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300 KEX420 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300 XA 350 350 KEX428 894 1030 579 387 41 238 135 557 1280 415 951 Std 350 350 XA 400 400 All dimension in mm Diagram 13 4 2 SERVICE CLEARANCES B B A A C C Service Area i D D E E Minimum Service Clearance A Front 500mm B End 300mm C End 300mm D Top 1000mm E From Service Area D The h...

Page 22: ... NOTE Refer to the Base Box for required wall cut out dimensions Diagram 15 4 3 2 Installation of Flashing Flashing MUST BE fitted to ensure the ductwork is adequately weather protected Step 1 Fit side flashing using existing screws on cabinet sides Step 2 Slide top flashing under flashing rail on base box Silcone Step 3 Sit top flashing on top of side flashing edges Once in place silicone along t...

Page 23: ...es Clearance Description 75mm From the wall against which the heater is mounted From a drain or soil pipe 300mm From a flue terminal cowl or combustion air intake Below eaves balconies or other projections From the ground above a balcony or other surface To a return wall or external corner Measured horizontally from an opening window door non mechanical air inlet or any other opening into the buil...

Page 24: ...xed switched socket outlet adjacent to the heater Access the controls and change as required COMMON LOW MED HIGH SPEED Fan speed high Factory Default Connections Fan speed medium LOW MED HIGH COMMON SPEED Fan speed low LOW MED HIGH COMMON SPEED Diagram 17 For High fan speed do not adjust For Medium fan speed move terminal from HIGH to MED For Low fan speed move terminal from HIGH to LOW Turn the p...

Page 25: ...atory under building codes to install insulated fire rated duct If a filter is fitted to the return air grille it should be easily accessible for regular cleaning Table 5 gives the minimum recommended return air grille sizes for each model heater to handle the maximum rated airflow 6 1 MINIMUM RECOMMENDED RETURN AIR GRILLE SELECTION CHART Model Without Filter With Filter Grille Size m Example of S...

Page 26: ...ystem does not have zone dampers installed or where there are zone dampers but these zones are not operated from a Networker wall control e g wall switches C The minimum number of outlets that should be fully open for floor ceiling systems where the system has zone dampers installed and these zones are being operated from a Networker wall control using the heater s on board zone relays or a zone m...

Page 27: ...895 13 8 N A External Heaters KEX4 KEX415 300mm 498 N A 4 N A KEX420 300mm 581 N A 5 N A KEX420XA 350mm 622 N A 5 N A KEX428 350mm 896 N A 8 N A KEX428XA 400mm 1012 N A 8 N A KEX3 KEX315 300mm 498 N A 4 N A KEX320 300mm 581 N A 5 N A KEX320XA 350mm 622 N A 5 N A KEX328 350mm 896 N A 8 N A KEX328XA 400mm 1012 N A 8 N A Model and base box duct size Table 6 NOTE Airflow figures are based on a total s...

Page 28: ... or warm pipes and duct running in the wall behind it Avoid cold spots Keep it as far away as possible from draughts caused by doorways stairwells windows or return air inlets Avoid dead spots Keep it away from areas of less than normal air circulation e g behind doors in alcoves or corners Interference from other electrical connections Ensure the Wall Control and wiring are kept away from other e...

Page 29: ... wire cable Networkers can be wired directly to KUN4 and KUN5 heaters as follows Run a twin wire cable i e figure 8 cable 0 75mm2 from the heater to the Networker Remove the backing plate from the Kaden Networker by unclipping it at the sides Draw the wires from the wall cavity and feed them through the opening in the backing plate Connect the cable to the terminal connections on the backing plate...

Page 30: ... the controller Feed the cable through the grommet located at the end of the heater Connect the other end of the cable to the terminals marked R and W in the heater s electronic control module Refer to Diagram 19 KUN3 Terminal Block R W Manual Wall Control Earth Optional Grommet for control cable access Backing Plate Thermostat Face Round Knockout Diagram 19 8 2 2 Wiring the Manual Wall Control to...

Page 31: ...access panel Connect the other end of the cable to the terminals marked R and W in the heater s electronic control module refer to Diagram 20 R W KEX3 Terminal Block Grommet for control cable access Earth Optional Manual Wall Control Backing Plate Thermostat Face Round Knockout Diagram 20 ...

Page 32: ...ng any wiring All these steps must be carried out by a qualified trades person If the heater cannot be adjusted to operate in accordance with these instructions then contact 1300 4KADEN 1300 452 336 For technical support please call 9 1 HEATER CONTROL SETTINGS The NG 3 controller requires a Networker to access and modify installation parameters KUN4 5 Control Board NG 3 Controller Defaults Clear D...

Page 33: ...N The fan RPM setting in circulation mode That is fan operation between heating or cooling cycles when the set room temperature has been achieved 6 H01 ID06 65 SUPPLY AIR THERMISTOR SET POINT TEMPERATURE The temperature that the heater gas valve modulates to maintain This setting can be adjusted from 45 C to 70 C default setting varies between different models and should be set to provide a comfor...

Page 34: ... 9 3 KUN4 KUN5 COMMISSIONING INSTRUCTIONS With a correctly designed and installed ducted system generally the balancing damper in an outlet should be initially set as follows Living areas 100 open Bedrooms 50 open Bathrooms ensuite Laundry 25 open 9 3 1 Initial Ignition and Gas Inlet Pressure Check Disconnect the power supply from the system at the power point Connect a networker to enable access ...

Page 35: ...r level For new system installations not changeovers you should not need to adjust the thermistor set temperature This setting should only be adjusted if the system is NOT achieving the following temperature rise ceiling outlets 25º to 30º C and floor outlets 35º to 40º C This temperature rise is measured from the closest outlet to the heater minus the return air intake temperature i e with a retu...

Page 36: ... Owners Manual Ensure the required gas inlet pressure is supplied at all times during the heater s operation this should be with all other gas appliances operating at the same time and at their full capacity Go back to the wall control and press the ON OFF button to turn the heater off Ensure that the burners and fan turn off then turn off the gas supply at the supply tap and remove the manometer ...

Page 37: ...Fault 36 3 6 Bad Supply Air Thermistor Location 40 4 0 Return Air Overheat 41 4 1 Supply Air Overheat 48 4 8 Pressure Lost 60 6 0 Motor Open Circuit 69 6 9 Fuse Blown 24Vac 2A 50 5 0 Ignition Lockout 51 5 1 Rollout No Gas 54 5 4 Rollout Lockout 56 5 6 Pressure Switch Stuck Open 57 5 7 Pressure Switch Stuck Closed 58 5 8 Pressure Switch Fail Table 8 To reset the appliance and clear a lockout fault ...

Page 38: ...the unit OFF at the wall control isolate the gas and the 240 Volt power supply adjacent to the unit 12 Remove and replace test point with the grub screw IMPORTANT If the unit does not ignite on the first attempt it may be a result of all air not being purged from the gas supply line The heater will attempt to ignite up to five times before locking out after which it will require a power reset If t...

Page 39: ... all other gas appliances in operation 2 The burner pressure is as indicated on the appliance data label 3 The temperature of the warm air at any outlet is not more than 45º C above the return air temperature 4 The fan continues to run while the burners are operating Once Confirmed Turn the heater OFF at the wall control Ensure that the burners and fan turn OFF then turn OFF the gas supply at the ...

Page 40: ... KUN315 70 15 300 0 19 0 28 475 453 430 407 48 250 3 0 4 10 KUN320 90 19 300 0 22 0 32 540 525 505 485 49 315 3 0 4 10 KUN325 107 23 350 0 24 0 35 650 625 595 565 49 315 3 8 4 10 KUN330 133 30 350 0 35 0 51 970 948 920 895 68 600 6 0 6 5 15 KEX415 62 15 5 300 0 19 0 28 498 480 461 443 57 250 1 8 4 N A KEX420 Std 82 20 300 0 22 0 32 581 561 541 521 58 315 2 5 4 N A XA 82 20 350 0 24 0 35 622 598 57...

Page 41: ...41 12 TECHNICAL SUPPORT For technical support please call 1300 4KADEN 1300 452 336 NOTE Product warranty registration forms can be found online at www metalflex com au kaden or in the owner s manual ...

Page 42: ...42 Kaden Installer s Manual Ducted Gas Heaters NOTES ...

Page 43: ...43 NOTES ...

Page 44: ...B063650 Issue D January 2020 ...