Page 1 THE CALDERA THE CALDERA DIRECT VENTED Room Heater For use with natural gas or propane USERS’ INSTALLATION OPERATION & MAINTENANCE 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.
Page 2 THE CALDERA CONTENTS Page Introduction 4 General Information 5 Appliance Dimensions 6 Installation Clearances 7-9 Installation Instructions - Appliance 10 - 12 Assembly Instructions - Log Set 13-14 Installation Instructions - Venting 15-22 Rigid Venting Parts List 23-25 Intermittent Pilot & Valve Information 26-27 Wiring Diagram 28 Lighting Instructions 29-30 Handheld Thermostat Remote Control - Operation instructions 31-35 Maintenance 36-37 Servicing 38-39 Fuel Convers
THE CALDERA Page 3 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 THE CALDERA 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. Some of the many features are: Electronic Valve Intermittent pilot & remote capability. Heater Classification It is classified as a heating appliance. Therefore, it can be operated continuously for zone heating.
Page 5 THE CALDERA GENERAL INFORMATION APPLIANCE CERTIFICATION This appliance is tested and certified to the following US and Canadian gas appliance standards. - 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.
Page 6 THE CALDERA APPLIANCE DIMENSIONS Figure 1
Page 7 THE CALDERA INSTALLATION CLEARANCES Figure 2 C D 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) Mantle - See Chart Vertical Vent - 1" (25 mm) to outside surface Can be installed on a combustible surface.
Page 8 THE CALDERA INSTALLATION CLEARANCES Figure 3A Minimum framing dimensions Figure 3B Mantle Clearances to Combustibles Mantle Height from Floor (B) Mantle Depth (A) Max.
THE CALDERA INSTALLATION CLEARANCES Figure 3C Minimum Framing Dimensions Figure 3D Minimum Framing Dimensions Page 9
Page 10 THE CALDERA INSTALLATION INSTRUCTIONS Figure 3C Cement Board Dimensions INSTALL VERTICAL HEAT SHIELD The heat shield which comes with the appliance, needs to be mounted vertically on top of the appliance. The three holes line up with the ones on top of the appliance, in front of the flue collar. Use three screws to mount the heat shield. IMPORTANT:When the heat shield is not installed, fire may result, causing property damage, personal injury or loss of life.
THE CALDERA Page 11 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. Provide adequate clearance around air openings of the appliance. Never obstruct front openings. Provide adequate clearances for proper operation and servicing of the appliance.
THE CALDERA Page 12 INSTALLATION INSTRUCTIONS Cont... VENT TERMINATION LOCATION 1. Establish a suitable vent termination location. (See ALLOWABLE TERMINATION LOCATIONS - page 42) 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. 3. Locate vent termination away from plants, bushes or any other object on or near the vent termination that will interfere or obstruct the air flow around it. 4.
Page 13 THE CALDERA ASSEMBLY INSTRUCTIONS GLASS DOOR REMOVAL Removing the Glass Door - Remove the top & bottom louvers. - Unhook the door latches found on the bottom of the firebox. - Carefully lift and remove the door. - Place the door at a safe location where it cannot be scratched or damaged. - If the glass door is damaged, it must be replaced with another glass door certified with this appliance only.
Page 14 THE CALDERA ASSEMBLY INSTRUCTIONS Cont... PLACEMENT OF LOGS AND TWIGS Step 1: Place rear log in notch on left side and on log pin on right side. Step 2: Place left and right twigs on log pins as shown. Step 3: Place left log on left front burner and rear log as shown. Step 4: Place center twig on rear log and front of burner as shown. Step 5: Place right log on rear log and front of burner as shown. WARNING : Do not place the logs in any other configuration than the one shown.
Page 15 THE CALDERA INSTALLATION INSTRUCTIONS Cont... VENTING 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" x 6-5/8" venting. Read the manufacturer’s installation instructions before installing the venting system.
THE CALDERA Page 16 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” (26 mm) sides and bottom, and 2” (51 mm) from top surfaces of horizontal vents. Always use a wall thimble when passing through combustible construction. 3.
Page 17 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.
THE CALDERA Page 18 INSTALLATION INSTRUCTIONS Cont... VENT RESTRICTORS All 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. When your installation requires a vent restrictor you must remove the flue baffle and install the restrictor in the exhaust box as shown below.
Page 19 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. While you are assembling the pipe bear in mind the best visual appearance. Seams should be aligned and hidden as much as possible.
THE CALDERA Page 20 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. When planning your installation determine if ceiling joists, roof rafters or other framing will obstruct the vent system.
Page 21 THE CALDERA INSTALLATION INSTRUCTIONS Cont... Through Roof Framing Termination Above Roof Maintain 10” opening relative to the pitch of the roof. Consult local codes for minimum vent cap height above the roof, vent must be a minimum 2’ from any wall. 10” square Use a suitable round or square support through the roof. Ensure adequate heat shield protection is provided.
Page 22 THE CALDERA INSTALLATION INSTRUCTIONS Cont...
Page 23 THE CALDERA SIMPSON DURAVENT DIRECTVENT PRO GS SYSTEM PARTS SIMPSON DURAVENT GS/ SYSTEM PARTS LISTLIST Description Description Horizontal HorizontalTermination TerminationKitKit- In - InCanada—Mandatory Canada—Mandatorytotoadd adda awall wallthimble thimble. (46DVA-KHC.
Page 24 THE CALDERA SELKIRK PARTS LIST PART NUMBER DESCRIPTION 4DT- 6 4DT- 6B 4DT- 9 4DT- 9B 4DT-12 4DT-12B 4DT-18 4DT-18B 4DT-24 4DT-24B 4DT-36 4DT-36B 4DT-48 4DT-48B 4DT-AJ12 4DT-AJ12B 4DT-AJ14 4DT-AJ14B DIRECT-TEMP 6" PIPE LENGTH DIRECT-TEMP 6" PIPE LENGTH BLACK DIRECT-TEMP 9" PIPE LENGTH DIRECT-TEMP 9" PIPE LENGTH BLACK DIRECT-TEMP 12" PIPE LENGTH DIRECT-TEMP 12" PIPE LENGTH BLACK DIRECT-TEMP 18" PIPE LENGTH DIRECT-TEMP 18" PIPE LENGTH BLACK DIRECT-TEMP 24" PIPE LENGTH DIRECT-TEMP 24" PIPE LENGTH B
THE CALDERA Page 25 AMERICAN METAL PRODUCTS COMPONENTS LIST Description Part # 7” Pipe Length 4D7 12” Pipe Length 4D12 2’ Pipe Length 4D2 3’ Pipe Length 4D3 4’ Pipe Length 4D4 4” - 10” Adjustable Length 4D12A 45° Elbow 4D45L 90° Elbow 4D90L Vertical Termination 4DVC Horizontal Termination 4DHC 36” Snorkel 4D36S Wall Thimble 4DWT Wall Strap 4DWS Fire stop Support Plate 4DFSP Faceplate, Ceiling Support / Wall Thimble 4DFPB Roof Support 4DRSB Storm Collar 4DSC Standard Fla
Page 26 THE CALDERA INTERMITTENT PILOT & VALVE SIT 885 Proflame Valve Outlet pressure tap Stepper motor Pilot Connection (green) Main valve Connection (red) Ground connection Inlet pressure tap Pilot Flame adjustment
Page 27 THE CALDERA INTERMITTENT PILOT & VALVE (cont’d) Optional Wall thermostat (interrupt green wire)
Page 28 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.
Page 29 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. A. B. C. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. BEFORE LIGHTING smell all around the appliance area for gas.
Page 30 THE CALDERA OPERATION 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. NOTE : When operated for the first few times, the appliance will emit some odor and fumes.
THE CALDERA Page 31 HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions Fig.
THE CALDERA Page 32 HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions
THE CALDERA Page 33 HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions
THE CALDERA Page 34 HANDHELD THERMOSTAT REMOTE CONTROL-operation instructions
Page 35 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. The switch is located behind the bottom louver, above the Receiver / Battery pack. Batteries under this cover Fig.
Page 36 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 Fig. 20 page 35) and turn burner switch OFF. Turning the electric supply off will not prevent unexpected ignition !! CLEANING THE APPLIANCE The exterior surfaces and glass may be cleaned with a soft, non-abrasive cloth and water or a suitable, mild, non-abrasive cleaner.
Page 37 THE CALDERA MAINTENANCE PLATING: 1. The plating requires little maintenance and needs only to be cleaned with a soft damp cloth. Do not use any abrasive cleaning materials. 2. Avoid fingerprints on gold. Wipe off fingerprints before firing. DOOR : Check the gasket to see that it is still forming a seal. Replace gasket if there is any sign of wear.
Page 38 THE CALDERA 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. WARNING: Servicing of this appliance must be conducted by a qualified service technician.
Page 39 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. - Disconnect the wires from the module-box - Remove the screws holding the gas component assembly to the appliance firebox bottom.
Page 40 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 not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life.
Page 41 THE CALDERA FUEL CONVERSION
THE CALDERA Page 42 ALLOWABLE TERMINATION LOCATIONS Figure 19 Canadian Installations1 US Installations2 ____________________________________________________________________________________________________ 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.
Page 43 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. The pilot will not stay lit. If the main burner does not come ON when the manual switch or remote control is turned ON. Pilot will not light.
Page 44 THE CALDERA TROUBLESHOOTING Cont... SYMPTOM ACTION The main burner shuts off when the appliance is warm. 1. This may be the normal operation of a wall thermostat installed to appliances. 2. Check for good pilot flames on the flame sensor (see fig.3 page 9). 3. Check for proper functioning of venting system (including termination for blockage). 4. Check wire connections. Expansion from heat affects a loose connection 5.
Page 45 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. To remove fan, for maintenance or replacement: 1) Remove the louvers and door. 2) Remove the logs, brick panels and burner. Note: Be careful when handling these items as they may break if dropped or handled roughly. 3) Remove fan guard (figure 24) and valve tray.
THE CALDERA FAN KIT INSTALLATION - continued Figure 24 Page 46
Page 47 THE CALDERA Replacement Parts list for Caldera No expl.
THE CALDERA Replacement Parts list for Caldera 1 Page 48
Page 49 THE CALDERA WARRANTY BLAZE KING GAS LIMITED WARRANTY Blaze King and its respective brands extends the following warranty for gas appliances purchased from an authorized Blaze King dealer and installed in the United States of America or Canada. Warranty starts with date of purchase by the original owner (End User) except as noted for replacement parts.
Page 50 THE CALDERA Blaze King Gas Limited 10 Year Warranty Blaze King is the manufacturer of the Blaze King line of heating products. At Blaze King, our commitment to the highest level of quality and customer service is the most important thing we do. Each Blaze King stove is built on a tradition of using only the finest materials and is backed by our limited lifetime warranty to the original purchaser.
THE CALDERA Page 51 If you are not satisfied with the service provided by the Blaze King dealer, write to Blaze King at the address listed on the last page of the Owner’s Manual. Include a copy of the original purchase invoice and a description of the problem. Exclusions and Limitations: 1. This Warranty does not cover tarnish, discoloration or wear on the plated surfaces. Painted finishes will change colour after initial firing and will continue to change through the lifetime of the stove.
THE CALDERA Page 52 19. Blaze King is free of liability for any damages caused by the fireplace or stove, as well as inconvenience expenses and materials. The Limited Warranty does not cover incidental or consequential damages. 20. The Limited Warranty does not cover any loss or damage incurred by the use or removal of any component or apparatus to or from the Blaze King fireplace or stove without the express written permission of Blaze King and bearing a Blaze King label of approval. 21.
Page 53 THE CALDERA NOTES SERVICE HISTORY DATE CORRECTIVE ACTION (INCLUDE REPLACEMENT PARTS)
