Blaze King CALDERA Users Installation Operation & Maintenance Manual Download Page 41 | Manualshive

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THE CALDERA

Page 41

SERVICING

Cont...

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.
- Gently lift the assembly out and remove through the front.
- Replacing the assembly is the reverse of the above instructions.

* Check the tray sealing gasket. Replace if damaged.

GAS COMPONENTS ASSEMBLY

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Summary of Contents for CALDERA

Page 1: ...ion 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 suppli...

Page 2: ...Remote Control Operation instructions 32 36 Maintenance 37 39 Servicing 40 41 Fuel Conversion 42 43 Allowed Termination Location 44 Troubleshooting 45 46 Top Rear Vent Conversion 47 Fan Kit Installation 48 49 Replacement Parts 50 51 Warranty 52 Notes Service History 53 Wiring Diagram 29 Page Patents Pending MANUFACTURED IN USA BY Blaze King Industries 146 A Street Walla Walla WA 99362 Ph 1 509 522...

Page 3: ...s 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 In the event of a discrepancy between the labels the label on the unit is considered as the correct ...

Page 4: ...aintenance of the appliance will provide you with many years of enjoyment CAUTION Due to high temperatures the appliance should be located out of traffic and away from furniture and draperies Children and adults should be alerted to the hazards of high surface temperature and stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room ...

Page 5: ...CE CERTIFICATION INSTALLATION CODES This appliance must be installed by a qualified gas appliance installer The installation must conform with the local codes or in the absence of local codes with the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in the US or Installation Code CSA B149 1 in Canada Electrical connections and grounding must be in accordance with local codes if any if not follow...

Page 6: ...THE CALDERA Page 6 APPLIANCE DIMENSIONS Figure 1 ...

Page 7: ...al 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 Horizontal Vent 1 25 mm to outside bottom side surface 2 51 mm to outside top surface Can be installed on a combustible surface Figure 2 C D ...

Page 8: ... 1168 mm 9 3 16 233 mm 45 1143 mm 8 7 16 214 mm 44 1118 mm 7 3 4 197 mm 43 1092 mm 7 1 16 179 mm 42 1067 mm 6 5 16 160 mm 41 1041 mm 5 5 8 143 mm 40 1016 mm 4 15 16 125 mm 39 991 mm 4 3 16 106 mm 38 965 mm 3 1 2 89 mm 37 940 mm 2 13 16 71 mm 36 914 mm 2 1 16 52 mm 35 889 mm 1 3 8 35 mm 34 864 mm 11 16 17 mm Mantle Clearances to Combustibles Figure 3B Figure 3A Minimum framing dimensions ...

Page 9: ...THE CALDERA Page 9 Figure 3D Minimum Framing Dimensions Figure 3C Minimum Framing Dimensions INSTALLATION CLEARANCES ...

Page 10: ...mes 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 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 For top vent only ...

Page 11: ...g a solid fuel appliance LOCATING GAS FIREPLACE The venting system of this appliance must be installed in a location that is free of plumbing electrical wiring and heating or air conditioning ducts Select a location that is accessible for venting See the ALLOWABLE TERMINATION LOCATIONS page 45 in this manual ANCHORING UNIT After determining the location the appliance needs to be anchored to framin...

Page 12: ... 12 0 in w c 3 00 kPa for propane Maximum gas supply pressure should never exceed 14 0 in w c 3 48 kPa or 1 2 psi for both natural gas and propane BE SURE TO TIGHTEN THE PRESSURE TAP SET SCREW AFTER CHECKING THE PRESSURE Before connecting the appliance to the gas supply line double check that the appliance you have purchased is designed for the gas type you are using The gas type markings are loca...

Page 13: ...ler See Replacement Parts page 51 Replacing the Glass Door Check the condition of the glass and the gasket before installing door Carefully hook the door onto the tabs on the top of the firebox Connect the door latches at the bottom of the door and close latches Install the top bottom louvers If the glass has been damaged contact your dealer and replace the glass and gasket with a new glass and ga...

Page 14: ...he one shown Fire explosion or excessive carbon monoxide CO may result causing property damage personal injury or loss of life Step 1 Place rear log in notch on left side and on log pin on right side 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 ...

Page 15: ...elkirk Direct Temp Security Chimneys or Simpson Duravent 4 x 6 5 8 venting but for the snorkel only the American Metal can be used Read the manufacturer s installation instructions before installing the venting system Typical Installation for rear vented appliance 7 to 24 max horizontal vent pipe exiting wall behind the appliance and a 36 American Metal snorkel One 45o elbow is allowed for corner ...

Page 16: ...to 4 90o elbows or equivalent maximum Minimum 2 610mm straight length between bends The total vertical height up to 30 9 1 m maximum Use vent restrictor over 20 vertical height See page 18 The total horizontal run up to 16 4 9 m maximum Note 4 1 2m minimum of vertical height required if 16 horizontal Note Maximum vent lengths may be subject to local codes INSTALLATION INSTRUCTIONS Cont X Wall thic...

Page 17: ...op surfaces of horizontal vents Always use a wall thimble when passing through combustible construction 3 Observe all local code restrictions if any regarding the installation of this type of gas appliance 4 Observe the vent height and length restrictions given in this manual 5 Never slope horizontal vents downwards 6 Maintain at least an upward slope of 1 4 7 mm for every 1 ft 305 mm of horizonta...

Page 18: ... 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 Note for H V values for 45º venting see Chart IV elbows are not counted in H or V values vent chart starts from the top of the unit ...

Page 19: ... 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 The restrictor is fastened in with 2 screws represented by the dotted line in the figure below Once the vent restrictor has been installed the flue baffle must then be re in...

Page 20: ...pearance Seams should be aligned and hidden as much as possible Make sure you twist the mating section all the way to make a solid connection Note As this system is a sealed system a high temperature sealing compound must be used to seal the metal to metal joint Apply a bead of high temperature sealant to both the 4 exhaust and 6 5 8 intake section of the male pipe The female section of the pipe f...

Page 21: ...horizontal installations When planning your installation determine if ceiling joists roof rafters or other framing will obstruct the vent system You may have to use 45 elbows to navigate around any obstacles When passing through a flat ceiling install a Box Wall thimble Cut a 10 square hole and frame as shown in the diagram opposite Ensure all pipe sections are fully twist locked NOTE ALWAYS CHECK...

Page 22: ...tion is provided Termination Above Roof Consult local codes for minimum vent cap height above the roof vent must be a minimum 2 from any wall To prevent water seepage install the flashing with upper portion slid under the roofing material and the lower portion over the roofing material Note Do not fasten down until the final adjustments to the vent have been made INSTALLATION INSTRUCTIONS Cont ...

Page 23: ...DERA Page 23 INSTALLATION INSTRUCTIONS Cont Typical vent Installation High Wind Vertical Termination Cap Flashing Twist Lock Joints Wall Thimble or Fire Stop Alternate 45 pipe requiring strap support Figure 5 ...

Page 24: ...andatory to add a wall thimble 46DVA KHC 46DVA KHA 971 Vertical Termination Kit 978 6 Pipe Length Black 46DVA 06B 908B 6 Pipe Length Galvanized 46DVA 06 908 8 5 Black Extension 3 7 46DVA 08AB 8 5 Galvanized Extension 3 7 46DVA 08A 9 Pipe Length Black 46DVA 09B 907B 9 Pipe Length Galvanized 46DVA 09 907 12 Pipe Length Black 46DVA 12B 906B 12 Pipe Length Galvanized 46DVA 12 906 16 Black Extension 3 ...

Page 25: ... AJ12B DIRECT TEMP 12 ADJ PIPE LENGTH BLACK 1604084 4DT AJ14 DIRECT TEMP TELESCOPE ADJ LENGTH 1604084B 4DT AJ14B DIRECT TEMP TELESCOPE ADJ LEN BLACK 4 x 6 5 8 FITTINGS 1604215 4DT EL45 45 DEGREE ELBOW 1604215B 4DT EL45B 45 DEGREE ELBOW BLACK 1604230 4DT EL90S 90S DEGREE ELBOW 1604230B 4DT EL90SB 90S DEGREE ELBOW BLACK 4 x 6 5 8 ACCESSORIES 1604460B 4DT WTB WALL THIMBLE BLACK 1604500 4DT FS FIRESTO...

Page 26: ...pport Wall Thimble 4DFPB Roof Support 4DRSB Storm Collar 4DSC Standard Flashing 4DF Steep Pitch Flashing 4DF12 Attic Insulation Shield 4DAIS12 6 Pipe Length SV4L6 12 Pipe Length SV4L12 24 Pipe Length SV4L24 36 Pipe Length SV4L36 48 Pipe Length SV4L48 6 Adjustable Length SV4LA 12 Adjustable Length SV4LA12 45 Elbow SV4E45 90 Elbow SV4E90 Wall Band SV4BM Insulated Attic Shield SV4RSA Wall Shield SV4R...

Page 27: ...27 INTERMITTENT PILOT VALVE INTERMITTENT PILOT VALVE SIT 885 Proflame Valve Outlet pressure tap Inlet pressure tap Main valve Connection red Pilot Connection green Pilot Flame adjustment Stepper motor Ground connection ...

Page 28: ...THE CALDERA Page 28 INTERMITTENT PILOT VALVE cont d Optional Wall thermostat interrupt green wire ...

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

Page 30: ... DO IF YOU SMELL GAS 1 Read the safety information above on this label 2 Set the thermostat to the lowest setting 3 Turn off all electric power to the appliance 4 Do not attempt to light the pilot by hand 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to t ...

Page 31: ... 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 This is due to the evaporation of oils and solvents used in fabricating the appliance Close off the room to the rest of the house and open all windows Keep the room well ventilated LIGHTING INSTRUCT...

Page 32: ...THE CALDERA Page 32 HANDHELD THERMOSTAT REMOTE CONTROL operation instructions Fig 3 Receiver body ...

Page 33: ...THE CALDERA Page 33 HANDHELD THERMOSTAT REMOTE CONTROL operation instructions ...

Page 34: ...THE CALDERA Page 34 HANDHELD THERMOSTAT REMOTE CONTROL operation instructions ...

Page 35: ...THE CALDERA Page 35 HANDHELD THERMOSTAT REMOTE CONTROL operation instructions ...

Page 36: ...ght 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 Continuous Pilot ON OFF Batteries under this cover ...

Page 37: ...ave a qualified service technician Completely inspect the appliance and the venting system Clean and remove any lint accumulations or debris in the firebox on the burners on the pilot at the primary air opening on the convection air blower and in any combustion and convection air passage ways Check the safety shut off system of the gas valve WARNING All parts removed or disturbed must be properly ...

Page 38: ...to operate abnormally Poor flame pattern shutting down etc this could be an indication of ice build up 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 The composition of the deposit varies widely from various locations and also from time to time...

Page 39: ...r is in OFF position Turning the electric supply off will not prevent unexpected ignition 1 Turn off electric supply 2 Open the right door arched shroud or take off shroud rectangular shroud 3 Using a screw driver remove the cover plate rectangular shroud only 4 Remove old bulb by pulling straight out to insert new bulb push straight in Avoid touching glass with bare hands hold bulb with clean clo...

Page 40: ...r rocker switch caution make sure unit is not hot as burns may result Sliding the shutter lever right increases aeration while sliding the lever to the left decreases aeration Tighten screw Remove the glass door logs and firebox liner panels Remove the burner Remove the screws holding the aeration box to the firebox floor and lift it out Use a 1 2 wrench to unscrew the orifice Change the orifice D...

Page 41: ...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 Gently lift the assembly out and remove through the front Replacing the assembly is the reverse of the above instructions Check the tray sealing gasket Replace if damaged GAS COM...

Page 42: ... the next steps Replace burner orifices Replace stepper motor see next page Convert pilot fuel see instructions below How to convert Pilot fuel Use a 7 16 wrench to loosen the pilot hood Push the little tab in and the little tab with hole should pop out The hole stamp tab LP out is used for Propane The stamped tab NA out is for Natural Gas Re tighten the pilot hood Fill out the fuel conversion lab...

Page 43: ...THE CALDERA Page 43 FUEL CONVERSION ...

Page 44: ... side of centerline 3 91cm within a height 15 4 5m extended above meter regulator assembly above the meter regulator assembly ____________________________________________________________________________________________________ I Clearance to service regulator vent outlet 3 91cm ____________________________________________________________________________________________________ J Clearance to no me...

Page 45: ...re properly connected to the DFC board See page 27 for terminal loca tions 3 If using the remote control check the condition of the batteries 4 Check if there is gas supply to the appliance Pilot will not light 1 When lighting the appliance for the first time after installation or after servicing there is air in the gas line It takes a while for all the air to purge out of the pilot before gas can...

Page 46: ... that section in the instruction manual 3 Check for proper venting and blockage of the vent termination 4 Check manifold pressure and clock input rating for over firing Sharp blue flames with flames lifting off the burner at the ends 1 Too much primary air Reduce primary air by closing the primary air shutter During cold temperatures some flame lifting may occur during start up See page 34 for adj...

Page 47: ...the air intake assembly 3 4 Remove the exhaust assembly 4 5 Rotate the exhaust 4 and air intake 3 assem blies into the rear vent position and re install 6 Rotate the heat shield cover plate 2 and re install 7 Insert the round blanket cutout into hole on top 8 Rotate the flue collar plate 1 and re install 1 2 3 4 1 2 3 4 Figure 21 Figure 20 Note When converting from rear to top vent make sure heat ...

Page 48: ...vers 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 4 Disconnect wires be sure to label wires prior to disconnecting to ensure they are replaced in the correct location 5 Remove the four screws Figure 22 and take fan out 6 Installation is the reverse order of th...

Page 49: ...THE CALDERA Page 49 FAN KIT INSTALLATION continued Figure 24 ...

Page 50: ...GAS 6 500 8 500ft 1 EA 01 0254C DOOR GASKET part FTI 1071 114 long 1 EA 02 0244 GLASS CERAMIC 33 1 8 x 22 15 16 1 EA 03 M Z7405B BURNER TRAY 1 EA 04 Z7454 BRICK PANEL SET 1 EA 05 0712A PSE PILOT PSE C7 520 1 EA 06 M SIT0584302 CONTROL MODULE 1 EA 07 M SIT0885001 SIT VALVE MODEL PROFLAME 885 1 EA 08 M SIT0584521 RECEIVER BATTERY PACK 1 EA 09 0719D FAN 1 EA 10 0136 RHEOSTAT FAN SPEED CONTROL 1 EA M ...

Page 51: ...THE CALDERA Page 51 Replacement Parts list for Caldera 1 ...

Page 52: ...the purchaser has complied with all the terms and conditions of this warranty and if the purchaser has notified Blaze King of the defect prior to the expiration of any warranted items the following procedure will occur 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...

Page 53: ...THE CALDERA Page 53 NOTES SERVICE HISTORY DATE CORRECTIVE ACTION INCLUDE REPLACEMENT PARTS ...

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