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Real Flame CALDOR Installation & Operating Manual

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C
C LDOR WOODHE TER
INST LL TION & OPER TING M NU L
VERSION 2

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  • Page 1 C LDOR WOODHE TER INST LL TION & OPER TING M NU L VERSION 2...
  • Page 2 FOREW RD THANK YOU FOR CHOOSING THIS WOOD INBUILT We want to congratulate you on your purchase and wish to help you get maximum satisfaction from your wood inbuilt. In the pages that follow, we will give you advice on wood heating as well as technical specifications regarding installation, operation and maintenance of the model you have chosen.

  • Page 3: Table Of Contents

    Regulations Covering Zero Clearance Wood Inbuilt Installation .....5 General Information.................6 Dimensions....................6 Standoff Installation ................10 Carrying the Zero Clearance Wood Inbuilt ..........10 Locating the Caldor ................10 Clearances to Heat-Sensitive Materials..........11 Hearth Extension Construction Configuration ........13 Floor Protection ..................14 Compliance of a Combustible Mantel and Mantel Shelf......15 Trim Installation ..................15...

  • Page 4: Installation

    INST LL TION Install the zero clearance wood inbuilt only as described in these instructions and using only components from the list below. Parts Required • BF16 zero clearance wood inbuilt; • Flue: - Flue lengths, - Elbows (where necessary), - Associated components as per these installation instructions.

  • Page 5: Regulations Covering Zero Clearance Wood Inbuilt Installation

    Regulations Covering Zero Clearance Wood Inbuilt Installation 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.

  • Page 6: General Information

    (Continued) INST LL TION General Information Model # SF00400 Colour Metallic black Combustible Hardwood Recommended heating area* < 93 m Test Standards (safety) AS/NZS 2918 Test Standard (emissions) AS/NZS 4012 & 4013 (exempt**) Flue Spigot Diameter 200 mm Flue system Triple skin flue system Ceramic glass thickness 4 mm...
  • Page 7 (Continued) INST LL TION (continued) Dimensions Combustion chamber Black straight narrow trim Black straight masonry trim...
  • Page 8 (Continued) INST LL TION (continued) Dimensions Glass surface Combustion chamber Door opening black straight narrow trim Door opening black straight masonry trim...
  • Page 9 (Continued) INST LL TION (continued) Dimensions Left side black straight narrow trim Left side black straight masonry trim Right side...

  • Page 10: Standoff Installation

    8 screws provided (B), as shown. Carrying the Zero Clearance Wood Inbuilt To facilitate transportation of the Caldor before its installation, we have designed handling grips (AC09200, sold separately). The moulded bricks are in a box you can carry separately. We suggest you install the bricks after the setting up of the zero clearance wood inbuilt.

  • Page 11: Clearances To Heat-Sensitive Materials

    (Continued) INST LL TION Location of the Certification Label Since 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 or web sites) it is important to refer to it to have a safe and compliant installation. In addition, you will find information about your zero clearance wood inbuilt (model, serial number, etc.).
  • Page 12 (Continued) INST LL TION (continued) Clearances to Heat-Sensitive Materials The roof of the enclosure must have a minimum of 400,000 mm² for example : 825 mm (X) • 500 mm (Y) = 412 500 mm ) 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 mm²...

  • Page 13: Hearth Extension Construction Configuration

    (Continued) INST LL TION Hearth Extension Construction Configuration The Caldor may be installed directly on the floor or on a raised combustible or non-combustible base. . Raised Base Installation More than 100 mm When installed with a more than 100...

  • Page 14: Floor Protection

    (Continued) INST LL TION (continued) Hearth Extension Construction Configuration B. Directly On the Floor In the case where the zero clearance wood inbuilt is installed directly on the floor, the joint between the hearth extension and the zero clearance wood inbuilt (E) must also be protected by a non- combustible material.

  • Page 15: Compliance Of A Combustible Mantel And Mantel Shelf

    (Continued) INST LL TION Compliance of a Combustible Mantel and Mantel Shelf The mantle shelf shall be a minimum of 500 mm above the appliance door opening and extend no further than 250 mm into the room. The mantle key shall be a minimum of 450 mm above the appliance door opening and no thicker than 40 mm.

  • Page 16: Moulded Refractory Brick Panels Installation

    (Continued) INST LL TION Moulded Refractory Brick Panels Installation a) Place the bottom refractory panels (A) and b) Place the lower back refractory panel (C). (B) at the bottom of the firebox and pull them Install it on the floor of the firebox, behind the toward the front of the unit to help positioning bottom refractory panels.

  • Page 17: Hot Air Gravity System

    (Continued) INST LL TION (continued) Moulded Refractory Brick Panels Installation g) Install the andirons and secure them with anchor bolts. ir Gravity System A hot air gravity system can be installed by fitting the air diffuser kit SFA0086, sold separately. This kit includes four air diffusers.
  • Page 18 (Continued) INST LL TION ir Intake Diffusers Ducts - ssembly and Installation a) To install the air intake diffusers, locate the b) Remove the knockout on both side of the holes (2) on each side of the wood inbuilt. wood 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.
  • Page 19 (Continued) INST LL TION ir Intake Diffusers Ducts - ssembly and Installation e) Secure the other end of the duct to the air f) Bend the inside tabs on both air diffuser. intake diffuser inner plate using a second adjustable clamp. g) Cut a hole on each side of the wood inbuilt h) Reach inside the air diffuser and grab the enclosure following the dimensions...
  • Page 20 (Continued) INST LL TION ir Intake Diffusers Ducts - ssembly and Installation i) Install the decorative plate by pressing on both sides of the plate. B. Hot ir 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.
  • Page 21 (Continued) INST LL TION B. Hot ir Diffusers Ducts Refer to the image below for ducting heat to other rooms on the same floor. Refer to the image below for ducting heat to an upper floor.
  • Page 22 (Continued) INST LL TION B. Hot ir Diffusers Ducts - ssembly and Installation a) Remove the top knockouts with a pair of b) Remove the insulation and the bottom pliers. plate. c) Pull on the second bottom plate with a d) Install both adapter, which can be found in screwdriver.
  • Page 23 (Continued) INST LL TION B. Hot ir Diffusers Ducts - ssembly and Installation e) Install the ducts on the adapter. f) Secure the other end of the duct to the air intake diffuser inner plate, using an adjustable clamp, if necessary. g) Bend the inside tabs on both air diffuser.

  • Page 24: The Flue System

    (Continued) INST LL TION B. Hot ir Diffusers Ducts - ssembly and Installation i) Reach inside the air diffuser and grab the j) Install the decorative plate by pressing on inside plate with the pipe already installed on both sides of the plate. it.

  • Page 25: Suitable Flue Systems

    (Continued) THE FLUE SYSTEM Minimum Flue System Height The top of the flue system should be tall enough to be above the air turbulence caused when wind blows against the house and its roof. The flue exit shall be located outside the building in which the appliance is installed so that: a) The flue shall extend not less than 4.6 m above the top of the floor protector;...
  • Page 26 (Continued) OPER TION ND M INTEN NCE Safety Information C UTION • USING A ZERO CLEARANCE WOOD INBUILT WITH CRACKED OR BROKEN COMPONENTS, SUCH AS GLASS OR FIREBRICKS OR BAFFLES MAY PRODUCE AN UNSAFE CONDITION AND MAY DAMAGE THE ZERO CLEARANCE WOOD INBUILT.

  • Page 27: Fuel

    (Continued) OPER TION ND M INTEN NCE Fuel What is Good Firewood? Good firewood has been cut to the correct length for the wood fire, split to a range of sizes and stacked in the open until its moisture content is reduced to 11 to 16 per cent. Tree Species The tree species the firewood is produced from is less important than its moisture content.
  • Page 28 (Continued) OPER TION ND M INTEN NCE Your First Fires As the paint cures, some of the chemicals vaporize. The vapours are not poisonous, but they do smell bad. Fresh paint fumes can also cause false alarms in smoke detectors. So, when you first light your zero clearance wood inbuilt, be prepared by opening doors and/or windows to ventilate the house.

  • Page 29: Maintaining Your Wood Heating System

    (Continued) OPER TION ND M INTEN NCE Chimney Damper When in use, the fireplace chimney damper must be set in the fully open position (Position +).The chimney damper should be in the closed position (Position -) when there has not been any wood or embers in the fireplace for a few hours.
  • Page 30 (Continued) OPER TION ND M INTEN NCE Door djustment Screen door 1. Lift the screen and the glass door completely to the top. 2. Unscrew one of the two bolts which are located in the lower right corner of the screen door.
  • Page 31 Replacing the Glass The glass used in the Caldor is ceramic glass 4 mm thick having dimensions of: 315 mm x 1036 mm and tested to reach temperatures up to 1400 ºF. If the glass breaks, it must be replaced with one having the same specification.

  • Page 32: Flue And Flue Liner Maintenance

    (Continued) OPER TION ND M INTEN NCE Flue and Flue Liner Maintenance Why Flue System Cleaning is Necessary Wood smoke can condense inside the flue and flue system, forming a combustible deposit called creosote. If creosote is allowed to build up in the flue system, it can ignite when a hot fire is burned in the wood inbuilt and a very hot fire can progress to the top of the flue system.

  • Page 33: Exploded Diagram And Parts List

    EXPLODED DI GR M ND P RTS LIST...
  • Page 34 (Continued) EXPLODED DI GR M ND P RTS LIST IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement parts for your zero clearance wood inbuilt, please provide the model number and the serial number. We reserve the right to change parts due to technology upgrade or availability.
  • Page 35 8" TROMPE L'OEIL GRILL PL63979 FRONT PANEL PL63985 6" SHORT ADAPTATOR PL63983 ATTACHMENT PLATE SE63980 6" TROMPE L'OEIL GRILL PL63984 FRONT PANEL AC05963 METALLIC BLACK STOVE PAINT - 85 g (3oz) AEROSOL SE45913 REAL FLAME BF16 FIREPLACE INSTRUCTIONS MANUAL KIT...

  • Page 36: Real Flame Contact Information

    GLEN DIMPLEX AUSTRALIA PTY LTD ABN 69 118 275 460 Head Office/Factory/Showroom 1340 Ferntree Gully Rd. Scoresby Vic 3179 Ph: (03) 8706 2000 Fax: (03) 8706 2001 E-mail: info@realflame.com.au Richmond - VIC Showroom 300 Swan St. Richmond Vic 3121 Ph: (03) 9428 4443 Fax: (03) 9428 4445 Dandenong - VIC Showroom 3/328 South Gippsland Highway, Dandenong South Vic 3164...

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