Blaze King CALDERA Users Installation Operation & Maintenance Manual

Direct vented top or rear vent gas room heater

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THE CALDERA
U
SERS'
I
NSTALLATION
O
PERATION &
M
AINTENANCE
WARNING: If the information in this manual
is not followed exactly, fire or explosion may
result causing property damage, personal
injury or loss of life.
— Do not store or use gasoline or other
flammable
vapors and liquids in the vicinity of this or
any other appliance.
— WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance.
· Do not touch any electrical switch; do
not use any phone in your building.
· Immediately call your gas supplier from
a neighbor's phone. Follow the gas
supplier's instructions.
· If you cannot reach your gas supplier,
call the fire department.
— Installation and service must be
performed by a qualified installer, service
agency or the gas supplier.
INSTALLER: PLEASE LEAVE THIS MANUAL WITH
THE CUSTOMER
CUSTOMER: PLEASE KEEP MANUAL FOR FU-
TURE REFERENCE
Pour la version française de nos manuels S.V.P. vous référez à notre site web :
THE CALDERA
D
V
IRECT
ENTED TOP OR
V
G
Room Heater
ENT
AS
For use with natural gas or propane
This appliance may be installed in an
a fter ma rke t
manufactured (mobile) home, where not
prohibited by local codes.
This appliance is only for use with the type
of gas indicated on the rating plate. This
appliance is not convertible for use with
other gases, unless a certified kit is used.
Page 1
Rear
perm ane ntl y
l oc a ted,
www.blazeking.com
Version 1.09 SIT
Nov 2010

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  • Page 1 Page 1 THE CALDERA THE CALDERA Rear IRECT ENTED TOP OR Room Heater For use with natural gas or propane SERS’ NSTALLATION PERATION & AINTENANCE WARNING: If the information in this manual is not followed exactly, fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 2: Table Of Contents

    Page 2 THE CALDERA CONTENTS Page Introduction General Information Appliance Dimensions Installation Clearances 7 - 9 Installation Instructions - Appliance 10 - 12 Assembly Instructions - Log Set 13-14 Installation Instructions - Venting 15-23 Rigid Venting Parts List 24-26 Intermittent Pilot & Valve Information...
  • Page 3 Page 3 THE CALDERA Note: A copy of the certification label is provided here for your review. Due to constant up-grades it is possible that the information shown here may not coincide with the label as attached to the unit.
  • Page 4: Introduction

    Thank you for purchasing the Caldera Zero Clearance Fireplace Gas Heater. The Caldera is one of the most advanced direct vented zero clearance gas heaters on the market. It is designed using the latest technology and manufactured to the highest quality.
  • Page 5: General Information

    - ANSI Z21.88-2007 / CSA 2.33-2007 Vented Gas Fireplace Heaters, - CAN/CGA-2.17-M91 Gas-Fired Appliance fo Use at High Altitudes - CSA P.4.1-02 Testing Method for Measuring Annual Fireplace Efficiency Please contact Valley Comfort or Blaze King, if you have any questions regarding the certification of this appliance. INSTALLATION CODES This appliance must be installed by a qualified gas appliance installer.
  • Page 6: Appliance Dimensions

    Page 6 THE CALDERA APPLIANCE DIMENSIONS Figure 1...
  • Page 7: Installation Clearances

    Page 7 THE CALDERA INSTALLATION CLEARANCES Figure 2 A - Internal Ceiling Height min. 60" (1524 mm) B - Internal Framing min. 45" (1143 mm) C - Sidewall Clearance min. 6" (152 mm) D - Unexposed Back & Sides min. 2" (51 mm)
  • Page 8 Page 8 THE CALDERA INSTALLATION CLEARANCES Figure 3A Minimum framing dimensions Mantle Height Mantle Depth (A) Figure 3B Mantle Clearances to from Floor (B) Max. Combustibles 50" (1270 mm) 12" (300 mm) 49" (1245 mm) 11-5/16" (287 mm) 48" (1219 mm) 10-9/16"...
  • Page 9: Installation Clearances 7

    Page 9 THE CALDERA INSTALLATION CLEARANCES Figure 3C Minimum Framing Dimensions Figure 3D Minimum Framing Dimensions...
  • Page 10: Installation Instructions - Appliance

    Page 10 THE CALDERA INSTALLATION INSTRUCTIONS Figure 3C Cement Board Dimensions INSTALL VERTICAL HEAT SHIELD (Top Vent Only) The heat shield which comes with the appliance, needs to be mounted vertically on top of the appli- ance. The three holes line up with the ones on top of the appliance, in front of the flue collar.
  • Page 11 Page 11 THE CALDERA INSTALLATION INSTRUCTIONS Cont... PRECAUTIONS  This appliance must be installed by a qualified gas installer and the installation conform to applicable installation codes.  This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate ventilation air.
  • Page 12 Page 12 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENT TERMINATION LOCATION 1. Establish a suitable vent termination location. (See ALLOWABLE TERMINATION LOCATIONS - page 45) 2. In heavy snowfall areas make sure vent termination is located where it can not be blocked by snowfall or snow from snow removal equipment.
  • Page 13: Assembly Instructions

    - If the glass door is damaged, it must be replaced with another glass door certified with this appliance only. - Replacement glass doors are available through your Blaze King dealer (See Replacement Parts page 51) Replacing the Glass Door - Check the condition of the glass and the gasket before installing door.
  • Page 14 Page 14 THE CALDERA ASSEMBLY INSTRUCTIONS Cont... PLACEMENT OF LOGS AND TWIGS Step 1: Place rear log in notch on left Step 2: Place left and right twigs on log pins side and on log pin on right side. as shown.
  • Page 15 Page 15 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENTING - Rear Vent This appliance will not function without being connected to a proper venting system. This appliance uses 4" x 6-5/8" rigid vent, when used with Simpson Duravent adapter 0923AR (included with appliance). This unit can be used with Selkirk (Direct-Temp), Security Chimneys or Simpson Duravent 4"...
  • Page 16 Page 16 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENTING - Top Vent This appliance will not function without being connected to a proper venting system. This appliance uses 4" x 6-5/8" rigid vent, when used with Simpson Duravent adapter 0923AR (included with appliance). This unit can be used with Selkirk (Direct-Temp), Security Chimneys or Simpson Duravent 4"...
  • Page 17 Page 17 THE CALDERA INSTALLATION INSTRUCTIONS Cont... For best venting performance, here are some general venting rules: 1. Use only vent systems and components certified for use with this appliance 2. Maintain a minimum of 1” (26 mm) clearance to combustibles from the outside surfaces of vertical vents and minimum of 1”...
  • Page 18: Installation Instructions - Venting

    Page 18 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENTING CHART Example 1 V Value = 3A (12') + 1C (3') = 15' H Value = 2B (4') =4' V Value = Total length of all vertical sections in feet. H Value = Total length of all horizontal sections in feet.
  • Page 19 Page 19 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENT RESTRICTORS FOR TOP VENT INSTALLATIONS All top vent installations above 20' (6.1 m) require the use of 60% restrictor. The restrictor is installed in the exhaust of the appliance. Vent Restrictors Due to the extra flow produced by certain venting configurations vent restrictors must be placed in the vent to maintain performance.
  • Page 20 Page 20 THE CALDERA INSTALLATION INSTRUCTIONS Cont... WARNING: A minimum clearance of 1” to combustibles must be maintained on vertical pipe runs and 2” for horizontal pipe runs (sides and bottom 1”) The rigid vent systems use twist lock connections. The adaptor attached to the unit connects to the approved venting system.
  • Page 21 Page 21 THE CALDERA INSTALLATION INSTRUCTIONS Cont... Vertical Installations Always maintain the 1” clearance around the vent pipe (vertical), when passing through ceilings, walls, roofs, enclosures, attic rafters or any combustible surfaces. DO NOT PACK AIR SPACES WITH INSULATION. Refer to the vent chart for maximum allowable vertical and horizontal installations.
  • Page 22 Page 22 THE CALDERA INSTALLATION INSTRUCTIONS Cont... Through Roof Framing Termination Above Roof Maintain 10” opening relative to the pitch of Consult local codes for minimum vent cap the roof. height above the roof, vent must be a minimum 2’ from any wall.
  • Page 23 Page 23 THE CALDERA INSTALLATION INSTRUCTIONS Cont... Typical vent Installation High Wind Vertical Termination Cap Flashing Alternate 45° pipe requiring strap support Figure 5 Twist Lock Joints Wall Thimble or Fire-Stop...
  • Page 24 Page 24 THE CALDERA SIMPSON DURAVENT DIRECTVENT PRO / GS SYSTEM PARTS LIST SIMPSON DURAVENT GS SYSTEM PARTS LIST Description Part # Old Part # Description Part # Horizontal Termination Kit - In Canada—Mandatory to add a wall thimble 46DVA-KHA Horizontal Termination Kit - In Canada—Mandatory to add a wall thimble.
  • Page 25 Page 25 THE CALDERA SELKIRK PARTS LIST PART NUMBER DESCRIPTION 4" x 6 " LENGTHS 1604006 4DT- 6 DIRECT-TEMP 6" PIPE LENGTH 1604006B 4DT- 6B DIRECT-TEMP 6" PIPE LENGTH BLACK 1604009 4DT- 9 DIRECT-TEMP 9" PIPE LENGTH 1604009B 4DT- 9B DIRECT-TEMP 9"...
  • Page 26 Page 26 THE CALDERA AMERICAN METAL PRODUCTS COMPONENTS LIST Description Part # 7” Pipe Length 12” Pipe Length 4D12 2’ Pipe Length 3’ Pipe Length 4’ Pipe Length 4” - 10” Adjustable Length 4D12A 45° Elbow 4D45L 90° Elbow 4D90L...
  • Page 27: Intermittent Pilot & Valve Information

    Page 27 THE CALDERA INTERMITTENT PILOT & VALVE INTERMITTENT PILOT & VALVE SIT 885 Proflame Valve Outlet pressure tap Stepper motor Pilot Connection (green) Inlet pressure tap Pilot Flame adjustment Main valve Connection (red) Ground connection...
  • Page 28 Page 28 THE CALDERA INTERMITTENT PILOT & VALVE (cont’d) Optional Wall thermostat (interrupt green wire)
  • Page 29: Wiring Diagram

    Page 29 THE CALDERA WIRING DIAGRAM Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Figure 16...
  • Page 30: Lighting Instructions

    Page 30 THE CALDERA LIGHTING INSTRUCTIONS - Intermittent Pilot FOR YOUR SAFETY, READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
  • Page 31: Lighting Instructions

    Page 31 THE CALDERA OPERATION INSTRUCTIONS LIGHTING INSTRUCTIONS FOR YOUR SAFETY, READ BEFORE LIGHTING INITIAL OPERATION - Check that the appliance is properly vented and connected to the gas supply. - Check the logs and twigs are properly placed. - Check all external parts, such as grills, door and control cover are properly attached and fastened.
  • Page 32: Handheld Thermostat Remote Control-Operation Instructions

    Page 32 THE CALDERA HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions Fig. 3: Receiver body...
  • Page 33 Page 33 THE CALDERA HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions...
  • Page 34 Page 34 THE CALDERA HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions...
  • Page 35 Page 35 THE CALDERA HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions...
  • Page 36: Handheld Thermostat Remote Control - Operation Instructions

    Page 36 THE CALDERA HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions Continuous Pilot ON/OFF Continuous pilot The pilot on this unit will light automatically when turning the unit on. If a standing pilot is preferred (especially in cold weather) , the pilot can be run continuously by switching the continuous pilot switch to the ON position.
  • Page 37: Maintenance

    Page 37 THE CALDERA MAINTENANCE CAUTION :Do not conduct maintenance on the appliance while it is operating or while it is still hot. Make sure Remote switch on the Module is in OFF position (See figure 9 page 29) and turn burner switch OFF.
  • Page 38 In the event the glass breaks, contact your dealer or BLAZE KING to arrange for your glass to be replaced / repaired (see page 12). IMPORTANT - GLASS CLEANING - WHITE MINERAL DEPOSITS One of the byproducts of the combustion process in a gas appliance, is a mineral which can show up as a white film on the ceramic glass of the viewing door.
  • Page 39: Maintenance

    Page 39 THE CALDERA MAINTENANCE REPLACING HALOGEN LIGHT BULB (OPTIONAL SHROUDS ONLY) The light is situated at the inside of the shroud. Replace with the light bulb specified in the replacement parts list on page 49. To replace the light bulb follow these instructions: Ensure the stove is completely cooled before you change the bulb.
  • Page 40: Servicing

    SERVICING SERVICING UNDER WARRANTY Before servicing, read the terms and conditions of the Blaze King warranty at the back of this manual. Contact the Blaze King authorized dealer which you purchased the appliance from and provide him with details of the problem and the installation information which the installer filled out at the back of the manual.
  • Page 41: Servicing

    Page 41 THE CALDERA SERVICING Cont... GAS COMPONENTS ASSEMBLY The gas component assembly can be taken out of the appliance for easier servicing. Replacing Gas Component Assembly - Disconnect electricity to the appliance. - Shut off the gas supply to the appliance and disconnect the gas line at the valve - Remove the glass door, logs and burner.
  • Page 42: Fuel Conversion

    Page 42 THE CALDERA FUEL CONVERSION “WARNING” This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is...
  • Page 43: Fuel Conversion

    Page 43 THE CALDERA FUEL CONVERSION...
  • Page 44: Allowable Termination Locations

    Page 44 THE CALDERA ALLOWABLE TERMINATION LOCATIONS Figure 19 Canadian Installations US Installations ____________________________________________________________________________________________________ A= Clearance above grade, veranda *min. 12”(30 mm) *min. 12”(30 mm) porch, deck or balcony ____________________________________________________________________________________________________ B= Clearance to window or door *min. 12”(30 mm) *min. 12”(30 mm)
  • Page 45: Troubleshooting

    Page 45 THE CALDERA TROUBLESHOOTING Please check to make sure the instructions are followed exactly before attempting trouble shooting of the appliance. WARNING: Troubleshooting and servicing of gas and electrical devices of the appliance should only be conducted by a qualified service technician.
  • Page 46: Troubleshooting

    Page 46 THE CALDERA TROUBLESHOOTING Cont... SYMPTOM ACTION The main burner shuts off 1. This may be the normal operation of a wall thermostat installed to when the appliance is warm. appliances. 2. Check for good pilot flames on the flame sensor (see fig.3 page 9).
  • Page 47: Top/Rear Vent Conversion

    Page 47 THE CALDERA TOP/REAR VENT CONVERSION Figure 20 Note : When converting from rear to top vent , make sure heat shield (#5) is installed (see page 9) The appliance is easily converted from top vent to rear vent.
  • Page 48 Page 48 THE CALDERA FAN KIT REMOVAL & INSTALLATION Before removing the fan be sure to let unit cool to room temperature, disconnect electrical power to the unit, shut off gas to the unit and disconnect the gas line to the appliance.
  • Page 49: Fan Kit Installation

    Page 49 THE CALDERA FAN KIT INSTALLATION - continued Figure 24...
  • Page 50: Replacement Parts

    Page 50 THE CALDERA Replacement Parts list for Caldera Part Description QTY Unit expl. view OM7405 OWNERS MANUAL, CALDERA DVT/DVR Z0758A CONVERSION KIT-NATURAL GAS TO PROPANE 0-4,500ft Z0758B CONVERSION KIT-NATURAL GAS TO PROPANE 4,500-6,500ft Z0758C CONVERSION KIT-NATURAL GAS TO PROPANE 6,500-8,500ft...
  • Page 51: Replacement Parts

    Page 51 THE CALDERA Replacement Parts list for Caldera...
  • Page 52: Warranty

    Blaze King will inspect the product to determine that there is indeed a defect and that the defect is covered by warranty. Blaze King will either repair or replace the product at its' discretion. Under no condition whatsoever does Blaze King provide or imply warranty coverage for venting components used in the installation of our products.
  • Page 53 Page 53 THE CALDERA NOTES SERVICE HISTORY DATE CORRECTIVE ACTION (INCLUDE REPLACEMENT PARTS)

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