Real Flame CALDOR, Installation & Operating Manual

Page 1: ...CALDOR WOODHEATER INSTALLATION OPERATING MANUAL VERSION 2 C ...

Page 2: ...ur new wood inbuilt Failure to follow instructions may result in property damage bodily injury or even death It is important that you follow the installation guidelines exactly Consult your local city borough or shire council about restrictions and installations requirements in your area and the need to obtain a permit This heating unit is designed to serve as a supplementary heat source We recomm...

Page 3: ... 14 Compliance of a Combustible Mantel and Mantel Shelf 15 Trim Installation 15 Moulded Refractory Brick Panels Installation 16 Hot Air Gravity System 17 THE FLUE SYSTEM 24 General 24 Minimum Flue System Height 24 Suitable Flue Systems 25 The Relationship Between the Flue System and the House 25 OPERATION AND MAINTENANCE 25 Safety Information 25 Fuel 27 Operating Your Zero Clearance Wood Inbuilt 2...

Page 4: ...ARD SHALL COMPLY WITH THE REQUIREMENTS OF AS NS 4013 WHERE REQUIRED BY THE REGULATORY AUTHORITY I E THE APPLIANCE SHALL BE IDENTIFIABLE BY A COMPLIANCE PLATE WITH THE MARKING TESTED TO AS NZS 4013 ANY MODIFICATION OF THE APPLIANCE THAT HAS NOT BEEN APPROVED IN WRITING BY THE TESTING AUTHORITY IS CONSIDERED AS BREACHING AS NZS 4013 CAUTION MIXING OF APPLIANCE OR FLUE SYSTEM COMPONENTS FROM DIFFEREN...

Page 5: ...nnect this unit to a flue serving another appliance This zero clearance wood inbuilt has not been tested to be installed inside a masonry chimney When installed and operated as described in these instructions the Caldor zero clearance wood inbuilt is suitable for use in residential installations The Caldor zero clearance wood inbuilt is not intended for installation in a bedroom The zero clearance...

Page 6: ...lue system Ceramic glass thickness 4 mm Maximum Log Length 760 mm Firebox Volume 0 181 m3 Shipping Weight 347 kg Heating capacity may vary subject to location in home flue system draft flue system diameter locality heat loss factors climate fuels and other variables This unit is tested as a central system because it can be hooked up to hot air distribution ducts It is therefore exempt from emissio...

Page 7: ...INSTALLATION Continued Dimensions continued 7 Combustion chamber Black straight narrow trim Black straight masonry trim ...

Page 8: ...8 INSTALLATION Continued Dimensions continued Glass surface Door opening black straight narrow trim Door opening black straight masonry trim Combustion chamber ...

Page 9: ...9 INSTALLATION Continued Dimensions continued Left side black straight narrow trim Right side Left side black straight masonry trim ...

Page 10: ...e best location to install your zero clearance wood inbuilt is determined by considering the location of windows doors and the traffic flow in the room Figure some space in front of the unit for the hearth extension and the mantel and clearances to other combustible materials If possible choose a location where the vent will not interfere with any truss roof beams wall studs water pipes or electri...

Page 11: ...ance in the event you require replacement parts or technical assistance Clearances to Heat Sensitive Materials The clearances shown in this section have been determined by test according to procedures set out in safety standards AS NZS 2918 2001 When the zero clearance wood inbuilt is installed so that its surfaces are at or beyond the minimum clearances specified combustible surfaces will not ove...

Page 12: ... 500 mm Y 412 500 mm2 of venting to the ceiling cavity and a minimum of 50 mm clearance around the flue system and hot air ducts the 50 mm clearance can be included in the 400 000 mm of venting CAUTION BEFORE CLOSING THE WALLS MAKE SURE THAT THE FLUE DAMPER AND THE DOOR MECHANISM WORKS PROPERLY SEE SECTIONS Chimney Damper AND Access Door for Counterweight ...

Page 13: ...angle for the full width of the floor protection must be protected 50 mm horizontally and 50 mm vertically E by a piece of sheet metal not included Apart from these two corners the sheet metal does not have to cover the rest of the wall between the base of the wood inbuilt and the floor More than 100 mm In the case where F would be equal to 100 mm it is suggested that the sheet metal between the b...

Page 14: ... into frame materials if mounting the unit above floor level Note that the floor under of the zero clearance wood inbuilt should match or exceed the height of the floor protection A minimum of 1492 mm deep x 1590 mm wide x 18 mm thick floor protector Bellis Board must be used under and in front of the appliance base when installing the appliance The floor protector should extend 685 mm in front of...

Page 15: ... INSTALLATION Continued Compliance of a Combustible Mantel and Mantel Shelf In order to complete the zero clearance wood inbuilt installation you must install either the black straight narrow trim SFA0085 or the black straight masonry trim SFA0087 Installation instructions can be found in the trim kit Trim Installation NOTICE THE FACING OF THE TRIM SHOULD NEVER COME IN CONTACT WITH MASONRY PRODUCT...

Page 16: ... Install it on the floor of the firebox behind the bottom refractory panels c Place the left and right lower refractory panels D and E Set them on the floor of the firebox as shown d Lay the upper back refractory panel F on top of the middle back refractory panel e Place the upper left and right refractory panels G and H onto the notches of the middle left and right refractory panels f Secure the ...

Page 17: ...Adapters can be found in the firebox of the wood inbuilt When installing the kit all four air diffuser must be used Hot Air Gravity System Ducts for air intake must be 150 mm in diameter flexible or rigid insulated or not with a zero clearance to heat sensitive materials They should also be as short as possible For an optimal air circulation install the air intake diffusers on both sides of the wo...

Page 18: ...inbuilt using pliers Install the adapter by aligning the adapter notch with the wood inbuilt fresh air inlet notch and turn until the flange is fully inserted The adapter is well in place when its flange is completely inserted and the adapter can rotate freely d Install the air diffuser adapter on the diffuser inner plate a To install the air intake diffusers locate the holes 2 on each side of the...

Page 19: ...h air diffuser and using a flat screwdriver bend the four tabs to secure the diffusers in place inside the wall f Bend the inside tabs on both air diffuser h Reach inside the air diffuser and grab the inner plate with the duct already installed on it Hook it on the air diffuser plate e Secure the other end of the duct to the air intake diffuser inner plate using a second adjustable clamp ...

Page 20: ...Diffusers Ducts Ducts for the hot air diffusers must be 200 mm in diameter flexible or rigid rigid is highly recommended insulated or not with a 25 mm clearance to heat sensitive materials Total length of duct must not exceed 4 meters Hot air diffusers must have a 152 mm clearance to heat sensitive materials Hot air diffuser s framing should be 318 mm X 295 mm ...

Page 21: ...21 Refer to the image below for ducting heat to other rooms on the same floor INSTALLATION Continued B Hot Air Diffusers Ducts Refer to the image below for ducting heat to an upper floor ...

Page 22: ...d bottom plate with a screwdriver Pass a thread in the plate and remove the plate with pliers Pull on the thread and put the plate away b Remove the insulation and the bottom plate d Install both adapter which can be found in the wood inbuilt firebox a Remove the top knockouts with a pair of pliers ...

Page 23: ...user inner plate using an adjustable clamp if necessary e Install the ducts on the adapter h Cut two holes at the chosen location following the dimensions mentioned above Install both air diffuser and using a flat screwdriver bend the four tabs to secure the diffusers in place inside the wall g Bend the inside tabs on both air diffuser ...

Page 24: ...zero clearance wood inbuilt will not function safely and efficiently as intended if it is not connected to a suitable flue system The heat in the flue gases that pass from the zero clearance wood inbuilt into the flue system is not waste heat This heat is what the flue system uses to make the draft that draws in combustion air keeps smoke inside the zero clearance wood inbuilt and safely vents exh...

Page 25: ...d to a 200 mm diameter flue The Relationship Between the Flue System and the House Because the flue system is the engine that drives the wood heating system it must have the right characteristics The signs of bad system design are cold backdrafting when there is no fire in the zero clearance wood inbuilt slow kindling of new fires and smoke roll out when the door is opened for loading WARNING ANY ...

Page 26: ... closed If door is left partially open gas and flame may be drawn out of the opening creating risks from both fire and smoke Never leave the zero clearance wood inbuilt unattended when in use This zero clearance wood inbuilt has been tested for use with open door in conjunction with screen door always closed The screen door may be opened only during lighting procedures or reloading Always close th...

Page 27: ...s with any chemical additives Manufactured logs made of 100 compressed sawdust can be burned but use caution in the number of these logs burned at one time Start with one manufactured log and see how the wood inbuilt reacts Opening the Glass Door For transportation purposes you will find the removable handle A that allows you to open the glass door of the zero clearance wood inbuilt inside the com...

Page 28: ...es of cordwood spaced 25 mm to 51 mm apart and allowing air to get under the fuel Criss crossing or arranging the fuel so that air can get underneath will help the fire to get started easily Maintaining the Fire Once the wood has been consumed or partially consumed and you have obtained a good bed of embers you can reload the unit In order to do so proceed by opening the glass door or the screen d...

Page 29: ...e glass after a week or so of use This is normal and can be easily removed when the zero clearance wood inbuilt is cool by wiping with a damp cloth or paper towel and then drying Never try to clean the glass when the zero clearance wood inbuilt is hot Do not use abrasives to clean your zero clearance wood inbuilt s door glass Cleaning and Painting the Zero Clearance Wood Inbuilt Do not attempt to ...

Page 30: ... as needed 6 Without changing the performed adjustment move up about 6 the screen door 7 Tighten the 2 bolts Access Door for Counterweight It is possible to access the zero clearance wood inbuilt counterweight by opening access doors on each side of the zero clearance wood inbuilt NOTE Do not lubricate pulleys Glass door 1 Move the screen door completely to the top 2 Move down the glass door to th...

Page 31: ...REFRACTORY PANEL WARNING TEMPERED GLASS OR ORDINARY GLASS WILL NOT WITHSTAND THE HIGH TEMPERATURES OF THE CALDOR DO NOT ABUSE THE GLASS DOOR BY SLAMMING IT AGAINST THE WOOD INBUILT DO NOT OPERATE THE WOOD INBUILT WITH A CRACKED OR BROKEN GLASS WHEN YOU REMOVE THE GLASS FROM ITS FRAME DUE TO ITS WEIGHT THE DOOR WILL SEEK TO GO UPWARDS QUICKLY 1 Open the glass door A by lifting the lock located E on...

Page 32: ...e cleaned and inspected at least once each year Cleaning the Flue System Flue system cleaning can be a difficult and dangerous job If you don t have experience cleaning flue systems you might want to hire a professional flue system sweep to clean and inspect the system for the first time After having seen the cleaning process you can decide if it is a job you would like to take on The most common ...

Page 33: ...33 EXPLODED DIAGRAM AND PARTS LIST ...

Page 34: ...QUADREX STEEL C1022 ZINC 6 24 PL63951 CLEARANCE SPACER 4 25 PL63581 TOP SPACER 2 26 SE66647 ANCHOR PLATE OR COUPLER 8 2 27 PL63576 SMOKE FUNNEL INSULATION BOTTOM SUPPORT 1 28 21373 FRONT BOTTOM SMOKE FUNNEL INSULATION 1 29 21372 FRONT CORNER SMOKE FUNNEL INSULATION 2 30 PL63575 SMOKE FUNNEL INSULATION MIDDLE SUPPORT 1 31 21371 SIDE SMOKE FUNNEL INSULATION 2 32 21374 FRONT TOP SMOKE FUNNEL INSULATI...

Page 35: ...4 SIDE AND REAR REFRACTORY PANEL INSULATION 9 48 PL63952 LEFT DOUBLE BOTTOM 1 49 PL63953 RIGHT DOUBLE BOTTOM 1 50 21304 FLOOR REFRACTORY INSULATION 1 51 VA7070 PAINTED CAST IRON ANDIRON 1 52 SFA0086 AIR DIFFUSER KIT 1 53 SE63978 REAR GRILL CONNECTOR 2 54 SE63976 8 TROMPE L OEIL GRILL 2 55 PL63979 FRONT PANEL 2 56 PL63985 6 SHORT ADAPTATOR 2 57 PL63983 ATTACHMENT PLATE 2 58 SE63980 6 TROMPE L OEIL ...

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