Kaden Ku5 User guide

Ducted Gas Heaters

Safety Information

Installation

Commissioning

Models

INSTALLER’S

MANUAL

Universal:

KU3 | KU4 | KU5

External

KE3 | KE4

2

Kaden Installer's Manual

Ducted Gas Heaters

Warnings and Important Information 4

Regulatory / Installation / Safety �� 4

1. General Guidelines 6

1�1 Inspection �� 6

1�2 Unpacking the Heater �� 6

1�3 Unloading or Lifting the Heater �� 6

1�4 Gas Inlet Connection �� 7

1�5 Electrical Power Supply �� 7

1�6 Installation of Duct Connection Pops �� 7

1�7 Heater Positioning �� 8

1�8 Installation of Internal Heaters �� 8

1�8�1 Installing in the Roof Space �� 8

1�8�2 Installing Beneath the Floor �� 8

1�9 Installation of Internal Heaters - Room, Enclosure or Plant Room �� 9

1�10 External Installations �� 9

2. KU Universal Model Guidelines 10

2�1 Heater Dimensions �� 10

2�2 Platform & Service Clearances �� 10

2�3 Internal Installation ��11

2�3�1 Splitting the Heater ��11

2.3.2 POP Conguration Installation ��11

2�3�3 Return & Supply Air POP Rotation Procedure �� 12

2�3�3�1 All KU3, KU4 & KU5 Models Return Air POP Rotation Procedure �� 12

2�3�3�2 KU315, KU320 & KU325 Supply Air POP Rotation Procedure �� 12

2�3�3�3 KU415, KU420, KU425, KU430, KU330 Supply Air POP Rotation Procedure �� 12

2�3�3�4 KU521 Supply Air POP Rotation Procedure �� 12

2�3�3�5 KU530 Supply Air POP Rotation Procedure �� 12

2�3�4 Internal Model Flueing Instructions �� 13

2�3�5 Kaden Remote Flue Terminal �� 13

2�4 External Installation �� 14

2�4�1 Supply Air Overheat Switch Position (KU530 & KU330 ONLY) �� 14

2�4�1�1 KU530 �� 14

2�4�1�2 KU330 �� 14

2�4�2 Modifying KU Model Duct Orientation �� 14

2�4�3 Installation of Flue Terminal �� 15

2�4�4 Flue Terminal Clearances �� 15

2�4�5 Area to Cut Out in Wall �� 15

2�4�6 Installation of Flashing �� 16

2�4�6�1 KU5 models �� 16

2�4�6�2 KU3 & KU4 models �� 16

2�4�7 Thermistor Installation KU4 & KU5 �� 17

3. KU4 & KU5 - Adaptive Zoning & Add-On AC 18

3�1 Wiring a Damper Motor to the Heater’s Control Module �� 18

TABLE OF CONTENTS

3

4. KE External Model Guidelines 19

4�1 Heater Dimensions �� 19

4�2 Service Clearances �� 19

4�3 Installation �� 20

4�3�1 Area to Cut Out in Wall �� 20

4�3�2 Installation of Flashing �� 20

4�3�3 Installation of Flue Terminal �� 21

4�3�4 Flue Terminal Clearances �� 21

5. Fan Speed KU3, KE3 & KE4 22

5�1 Fan Speed Setting For KU3, KE3 & KE4 Models �� 22

5�1�1 To Adjust The Fan Speed �� 22

6. Ducting Information 23

6�1 Minimum Recommended Return Air Grille Selection Chart �� 23

7. Outlet Guide 24

7�1 Outlet Register Chart �� 25

8. Wall Control Installation 26

8�1 Networker Installation KU5 �� 26

8�1�1 Wiring the Networker to a KU5 Heater �� 26

8�2 Programmable Wall Control Installation �� 27

8�2�1 Wiring the Programmable Wall Control to a KU4 Heater �� 27

8�2�2 Wiring the Programmable Wall Control to a KE4 Heater �� 28

8�2�3 Wiring Programmable Wall Control to KU3, KE3 & KE4 for ADD-ON Cooling �� 28

8�3 Manual Wall Control Installation �� 28

8�3�1 Wiring the Manual Wall Control to a KU3 Heater �� 28

8�3�2 Wiring the Manual Wall Control to a KE3 Heater �� 29

9. Commissioning KU4 & KU5 30

9�1 Heater Control Settings �� 30

9�2 Installer Parameters Control LCD Settings �� 31

9�3 KU4 & KU5 Commissioning Instructions �� 32

9�3�1 Initial Ignition and Gas Inlet Pressure Check �� 32

9�3�2 Heater Fan Speed and Temperature Settings �� 32

9�3�3 Final Checks �� 33

10. Commissioning KU3, KE3 & KE4 34

10�1 Commissioning Instructions �� 34

10�1�1 Start & Check Supply Pressure �� 34

10�1�2 Start & Check Burner Pressure �� 34

10�1�3 Setting the fan speed �� 35

10�1�4 Final Checks �� 35

11. Technical Specications 36

12. Technical Support 37

4

Kaden Installer's Manual

Ducted Gas Heaters

READ ALL INSTRUCTIONS BEFORE USING THE APPLIANCE.

Failure to carefully read and follow all instructions in this manual can result in equipment malfunction,

property damage, personal injury and/or death.

WARNINGS: WHEN IGNORED, CAN RESULT IN SERIOUS INJURY OR DEATH.

CAUTIONS: WHEN IGNORED, CAN RESULT IN MINOR INJURY OR PRODUCT DAMAGE.

SHALL / MUST/

IMPORTANT: INDICATES A MANDATORY REQUIREMENT OF THIS MANUAL.

SHOULD:

INDICATES A RECOMMENDED REQUIREMENT OF THIS MANUAL.

Any deviations from these instructions may void the warranty. As a result, the

customer and/or installer may be charged a fee for product non-warranty related call

outs. Also, note that failure to comply with these instructions may preclude servicing

of the unit.

DISCLAIMER:

This document is a guide only. Laws, regulations and industry standards can vary

between States and Territories. Accordingly, this guide MUST BE read in conjunction

with, and subject to, all laws, regulations and industry standards applicable in the

State or Territory in which the products are installed. You MUST ensure that the

installation of the products will comply with those laws, regulations and standards,

and that the products recommended to customers are t for the purpose for which

they are intended.

WARNING

REGULATORY / INSTALLATION / SAFETY

This appliance SHALL BE installed in accordance with:

Manufacturer’s Installation Instructions and the Kaden Sizing Guide.

Current AS/NZS 5601 (Gas Installation Standard) and Current AS/NZS 3000 (Electrical Codes) and

Local Gas / Electrical authority regulations.

Current AS 4254 Ductwork for air-handling systems in buildings, EPA guidelines and HB276-2004

“A Guide to Good Practice”

Local Regulations and Municipal Building Codes (BCA) including local OH&S requirements.

ALWAYS comply with the following precautions to avoid dangerous situations and to ensure optimum

performance.

This appliance MUST BE installed, maintained and removed by an Authorised Person.

DO NOT place any articles on or against this appliance

DO NOT use or store ammable materials near this appliance

DO NOT spray aerosols in the vicinity of this appliance while it is in operation

DO NOT modify this appliance

This appliance is NOT intended for use by persons (including children) with reduced physical,

sensory or mental capabilities, or lack of experience and knowledge, unless they have been given

supervision or instruction concerning use of the appliance by a person responsible for their safety

Children should be supervised to ensure that they DO NOT play with the appliance.

IMPORTANT

WARNINGS AND IMPORTANT INFORMATION

5

This Installer’s Manual is intended to be used as a guideline for the installation of Kaden Gas Fired Central

Heaters. It covers only the installation and commissioning of the heater and the allowable ueing congurations.

Although recommended return air grilles and allowable duct outlet quantities are specied, it does not cover the

actual ducting design required to suit the installation.

This Installer’s Manual is based on Australian codes – for all other applications, please refer to local codes and

regulations.

Kaden heaters must be installed and serviced by qualied personnel.

Models covered in this manual are as follows:

Kaden Universal Heaters Type of Wall Control (Thermostat) Supplied

KU5 Series KU521 Kaden Networker

KU530

KU4 Series

KU415

Kaden Programmable

KU420

KU425

KU430

KU3 Series

KU315

Kaden Manual

KU320

KU325

KU330

Kaden External Heaters Type of Wall Control (Thermostat) Supplied

KE4 Series

KE415

Kaden ProgrammableKE420

KE428

KE3 Series

KE315

Kaden ManualKE320

KE328

NOTE

All Kaden models are Natural Gas ONLY.

All Kaden models are non-condensing.

Universal models may be used in both internal & external applications.

For more details refer to “11. Technical Specications” on page 36.

Networker

KU5

Manual

KU3 & KE3

OFF HEAT

SYSTEM

Programmable

KU4 & KE4

FAN SYSTEM

OFFON AUTO COOL HEAT

SCOPE

6

Kaden Installer's Manual

Ducted Gas Heaters

Kaden heaters are designed to provide a central source of heat for a ducted central heating system.

Kaden heaters should not be installed downstream from an air washer, an evaporative cooler or refrigerative

cooling system. Nor are they designed to be installed on a marine craft, houseboat, or any similar environment.

Kaden heaters must be installed in accordance with these instructions and related regulations, codes, standards,

and authorities. These include but may not be limited to:

• Kaden Sizing Guide

• AS/NZS 5601 - Gas installations

• AS 4254 - Ductwork for air-handling systems in buildings

• Local Building Regulations

• HB 276 - A Guide to Good Practice

• Environment Authorities

• Local Gas and Electricity Authority Codes

• Building Code of Australia (BCA)

IMPORTANT

The installer assumes the responsibility for equipment installed in violation of any code, regulations

and these installation instructions.

It is recommended the Kaden Sizing Guide be followed in estimating heating requirements and

for system design that will result in efcient installation and provide a higher level of comfort and

economical operation.

For the hourly input and the gas type to be used, see the appliance data label located inside the

service compartment or the "11. Technical Specications" on page 36.

1.1 INSPECTION

This appliance has been inspected and tested at the time of manufacture, packaged and released for transportation

without known damage. Upon receipt, inspect the exterior for evidence of rough handling in shipment.

Ensure that the appliance is labelled correctly for the gas to which it is intended to be connected. Immediately

report to supplier any discrepancies or damage.

1.2 UNPACKING THE HEATER

Heaters are supplied with a box cover. To unpack:

• Cut and remove any nylon straps.

• Lift the box off and dispose of thoughtfully.

• Remove the packaging and dispose of thoughtfully.

NOTE

Always remove and dispose of the plastic lm before mounting the heater onto a base box (if

tted).

1.3 UNLOADING OR LIFTING THE HEATER

When unloading or lifting the heater, ensure lifting equipment is in good operating condition and capable of lifting

the total load.

Ensure there is a clear area to place the heater down, which is within reach of the lifting equipment.

NOTE

If tting the heater to elevated heights such as a roof, use suitable lifting equipment.

1. GENERAL GUIDELINES

7

1.4 GAS INLET CONNECTION

• All piping must be in accordance with AS/NZS 5601 and any local gas regulations.

• The connection point for all Kaden model heaters is a female G3/4 compression tting to AS 3688. For KE

models this is located at the base of the heaters outer cabinet, and for KU models the gas feed tube is supplied

loose in the control compartment and MUST BE tted to suit the installation.

• A gas cock shall be tted in the gas line adjacent to the heater and in a convenient location so it can be turned

OFF quickly and easily.

• The gas supply shall in no way interfere with any servicing of the heater.

NOTE

The gas supply must be installed by a licensed gas tter. The gas pipe and gas meter should be

sized so the heater can maintain its required incoming gas pressure at maximum consumption

with all other gas appliances operating at their maximum capacity at the same time as the heater.

1.5 ELECTRICAL POWER SUPPLY

The heater is pre-wired with a 3-pin plug and lead, and shall be plugged into a standard 10 Amp 220 to 240 volt

xed switched socket outlet adjacent to the heater, in a convenient location so it can be turned OFF quickly and

easily.

NOTE

A qualied electrician must install the 220 to 240 volt wiring according to local regulations.

IMPORTANT

Switch OFF the power and unplug the heater before touching any wiring. If any electrical wiring is

damaged, it must be replaced by the manufacturer, its service agents or an electrically qualied

technician, in order to avoid a hazard.

The electricity supply must be 220 to 240 V at 50 Hz, and from an authorised power supplier. Generators should

never be used, as their output may be incompatible with, or prone to damage the heater’s electronic components.

1.6 INSTALLATION OF DUCT CONNECTION POPS

On Kaden KU Series heaters, the pops need to be fastened to the heater cabinet as follows:

• Insert pops into the hole in the POP plate, ensuring the POP ange is placed over the prescribed wall of the

cabinet, refer to the “POP Installation Matrix” below.

• Spread POP ange to t tightly into the hole in the cabinet (the notch side overlapping the other).

• Secure pops with the rivets supplied.

POP Installation Matrix

Series Return Air Supply Air

Number of walls Installation POP Number of walls Installation POP

KU3 1 No Option 2 Inner Wall

KU4 2 Inner Wall 2 Inner Wall

KU5 2 Inner Wall 2 Inner Wall

Table 1

NOTE

The POP is tted to a POP plate for some models and a panel for others.

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Kaden Installer's Manual

Ducted Gas Heaters

1.7 HEATER POSITIONING

Install the heater in a position that allows adequate and safe access for service as per guidelines in this manual

and applicable standards. The cost of any equipment and additional labour involved in accessing such heater

installations will not be accepted for warranty purposes.

NOTE

All service clearance measurements must be adhered to, otherwise this will impede the

serviceability of the heater.

1.8 INSTALLATION OF INTERNAL HEATERS

All Kaden Universal models are primarily designed to be installed in the roof or beneath the oor. This must be

done in accordance with the following guidelines and AS/NZS 5601.

1.8.1 Installing in the Roof Space

• The area under the heater shall be capable of supporting the additional load, without causing deformation of

any part of the building structure.

• The appliance shall be accessible by means of xed access, a normal ladder or steps.

• A passage of 600mm wide shall be provided between the roof access opening and the heater.

• This passage shall have a suitable walkway of at least 19mm thick particle board or equivalent.

• A permanent level platform shall be provided beneath the heater and this platform area shall extend 750mm

out from the controls access panel side and fan motor access panel side/s for the entire length of the heater.

• The air gap created between the base of the heater and the platform by the heater’s legs shall be maintained.

• Permanent articial lighting shall be provided at the heater, with the switch located at the roof access opening.

1.8.2 Installing Beneath the Floor

• There shall be a minimum clearance of 200mm between any part of the appliance and the lowest part of the oor

structure. In addition to this, refer to “Service Clearances” for the specic Kaden KU model.

• The heater shall be located within 2m of the access opening, or there is to be a minimum clearance of 1.2m

between the lowest part of the oor structure and ground level, maintained from the access opening to the

heater.

• All under oor installations shall be on a level concrete base (50mm thick), and provision made to drain any

condensate, seepage or ground water away from the heater.

• Permanent articial lighting shall be provided at the heater with the switch located at the access opening.

• Lateral (horizontal) ues may be installed in accordance with AS/NZS 5601, ensuring that the lateral ue section

has a minimum rise of a 20mm per metre of lateral run.

• The ue shall be terminated outside the building in accordance with AS/NZS 5601. For KU heaters, termination

can be performed using a Remote Flue Terminal. Refer to Internal Model Flueing instructions for the specic

Kaden KU model.

9

1.9 INSTALLATION OF INTERNAL HEATERS - ROOM, ENCLOSURE OR PLANT ROOM

In a room, enclosure, residential garage or a plant room with natural ventilation conditions.

Installation of a gas appliance in a room or enclosure for properties approved for construction PRIOR TO

31st March 2014.

1. Determine if the unit(s) MJ/hr rating for each cubic metre of the room or enclosure, is greater than 3 MJ/hr per m³.

e.g. Unit rating (Ur) = 120MJ/hr

Room volume (Rv) = 1m x 1m x 2.4m = 2.4m³

Ur/Rv = 120/2.4 = 50 MJ/hr per m³ > 3 MJ/hr per m³

Additional ventilation required in the room or enclosure.

2. Two permanent openings are required, each equivalent in area to the determined value “A”. The lower vent

shall be located close to the oor or at burner level. The upper vent shall be located at or above the top of the

unit. The two openings may be combined as long as the above conditions are met.

Determine free ventilation area using A = T x F.

Where A = The minimum free ventilation area, mm2

T = The total gas consumption of all gas appliances, MJ/hr, i.e. KU521 = 90MJ/hr

F = The factor detailed in the below table

Gas appliance location Source of Ventilation Factor F

Gas appliance in a room or enclosure Directly to outside 300

Via an adjacent room 600

Gas appliance in a plant room Directly to outside 150

Via an adjacent room 300

Table 2

NOTE

DIRECTLY TO OUTSIDE is either through an outside wall, into a cavity vented to outside, into

an underoor space or roof space vented to outside.

Installation of a gas appliance in a room or enclosure for properties approved for construction AFTER

31st March 2014.

1. Determine if the unit(s) MJ/hr rating for each cubic metre of the room, enclosure, residential garage or plant

room is greater than 0.4 MJ/hr per m³.

e.g. Unit rating (Ur) = 120MJ/hr

Room volume (Rv) = 1m x 1m x 2.4m = 2.4m³

Ur/Rv = 120/2.4 = 50 MJ/hr per m³ > 0.4 MJ/hr per m³

Additional ventilation required in the room, enclosure,residential garage or plant room.

Refer to AS5601 for natural ventilation requirements.

NOTE

For all other applications, e.g. Mechanical Ventilation, refer AS/NZS 5601.

1.10 EXTERNAL INSTALLATIONS

Kaden KE3 & KE4 External, KU3, KU4 & KU5 Universal models can be installed outside of the house. For an

installation under a house oor, a KU3, KU4 or KU5 Universal model should be chosen.

All heaters that are installed externally on the ground should be installed on a level concrete base or pad, and there

must be provision made to drain away any surface water from the heater.

If the heater is to be installed in an elevated position or on a roof, the installation must comply with AS/NZS 5601.

It must be secured to prevent movement and it must have adequate provision for service access.

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Kaden Installer's Manual

Ducted Gas Heaters

2.1 HEATER DIMENSIONS

Ø SaØ Ra

H DIG

F

EB

JC

A

K

Model A B C D E F G H I J K ØSa ØRa

KU521 657 1046 430 15 104 510 238 187 621 575 477 300 300

KU530 707 1096 550 15 240 560 280 280 536 540 528 350 350

KU415 625 845 397 15 95 495 197 197 446 445 471 300 300

KU420 625 845 397 15 95 495 197 197 446 446 471 300 300

KU425 625 845 397 15 95 495 197 197 446 447 471 350 350

KU430 644 923 549 15 246 515 237 201 483 447 491 350 350

KU315 627 844 408 15 95 496 230 197 414 445 471 300 300

KU320 627 844 408 15 95 496 230 197 414 445 471 300 300

KU325 627 844 408 15 95 496 230 197 414 445 471 350 350

KU330 645 941 552 15 240 516 236 235 468 470 491 350 350

All dimension in mm

Diagram 1

2.2 PLATFORM & SERVICE CLEARANCES

BB

AA

CC

Platform

& Service

Area

i

ii

DD

EE

Minimum Service

Clearance

Internal External

Method 1 Method 2

A = Front 750mm 750mm 500mm

B = End 750mm N/A 300mm

C = End N/A N/A 300mm

D = Top 250mm 800mm 1000mm

E = From Platform &

Service Area

D + The height of the heater

(Heater height = Diagram 1 dimension A)

Diagram 2

i. There are two methods of installing the KU series internally, in ceilings and under the oor.

Method 1 is for when the minimum clearance (B) at the Fan cabinet end is available.

Method 2 is for when the minimum clearance (B) at the Fan cabinet end is not available.

ii. This minimum clearance height (E) must be maintained across the entire Platform and Service Area.

IMPORTANT

For all internal installations, permanent articial lighting shall be provided at the heater, with the

switch located at the access opening.

2. KU UNIVERSAL MODEL GUIDELINES

11

2.3 INTERNAL INSTALLATION

2.3.1 Splitting the Heater

The KU model heaters can be split for ease of installation. To split the heater, follow these simple instructions.

1. Remove the heater’s roof after removing the roof screws.

2. Disconnect the gas valve, overheat/pressure switch loom, igniter and ame sensor from the control board.

3. Disconnect the ue pipe.

4. Remove the screws fastening the fan cabinet tabs to the heat exchanger cabinet. These are located at the

top of the heat exchanger cabinet on the heater’s split line.

5. Pivot the fan cabinet upwards high enough to dislodge the lower locking tabs xed to the fan cabinet near

the base.

6. The heater is now split in two.

7. Protect the exposed looms and tabs from damage while the heater is split in two.

8. Once ready, reassemble in reverse order.

IMPORTANT

Ensure when reassembling the heater that everything is put back and connected correctly.

2.3.2 POP Conguration Installation

POP conguration can be changed to suit the installation site, for the preferred and alternative duct connection

options refer to Diagram 3.

Heat exchanger

cabinet

Fan cabinet

Plan View

Supply Air Side Return Air Side

Diagram 3

NOTE

In "Diagram 3" the grey arrows denote the preferred option and is the factory delivered

conguration. The white arrows denote the available alternative options.

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Kaden Installer's Manual

Ducted Gas Heaters

2.3.3 Return & Supply Air POP Rotation Procedure

For KU model heaters the return air POP can ONLY be changed from the front side to back side. The supply air

POP can be changed from front to back or end of heater (refer to Diagram 3 page 11).

2.3.3.1 All KU3, KU4 & KU5 Models Return Air POP Rotation Procedure

1. Remove screws securing the lid and remove the lid.

2. Remove the screws securing the POP panel, blanking panel, and remove panels.

3. Swap panels to opposite sides and fasten with the same screws.

4. Secure lid with original screws.

2.3.3.2 KU315, KU320 & KU325 Supply Air POP Rotation Procedure

1. Remove the screws securing the outer POP plate and remove outer POP plate.

2. Remove the screws securing the nominated outer POP blanking plate and remove outer POP blanking plate.

3. Remove the screws securing the inner POP blanking plate and remove inner POP blanking plate.

4. Relocate and secure inner POP blanking plate in new location.

5. Relocate and secure outer POP plate and outer POP blanking plate in their new locations.

6. The pressure switch and mounting bracket will need to be swapped to the POP panel that is being exchanged.

2.3.3.3 KU415, KU420, KU425, KU430, KU330 Supply Air POP Rotation Procedure

1. Remove screws securing the lid and remove the lid.

2. Remove the screws securing the POP panel, blanking panel, and remove panels.

3. Remove gas feed tube plate and secure to alternate panel.

4. Swap panels to nominated sides and fasten with the same screws.

5. Secure lid with original screws.

6. For the KU330 ONLY the pressure switch and mounting bracket will need to be swapped to the POP panel

that is being exchanged.

2.3.3.4 KU521 Supply Air POP Rotation Procedure

1. Remove the screws securing the outer POP plate and remove outer POP plate.

2. Remove the insulation that is beneath the outer POP plate.

3. Remove the screws securing the nominated outer POP blanking plate and remove outer POP blanking plate.

4. Remove the screws securing the inner POP blanking plate and remove inner POP blanking plate.

5. Relocate and secure inner POP blanking plate in new location.

6. Insert the outer POP insulation in new location.

7. Relocate and secure outer POP plate and outer POP blanking plate in their new locations.

2.3.3.5 KU530 Supply Air POP Rotation Procedure

1. Remove screws securing the lid and remove the lid.

2. Remove the screws securing the POP panel, blanking panel, and remove panels.

3. Remove POP and blanking panel insulation.

4. Remove POP blanking panel and fasten in new location.

5. Insert POP and blanking insulation into their new locations.

6. Swap panels to nominated sides and fasten with the same screws.

7. Secure lid with original screws.

13

2.3.4 Internal Model Flueing Instructions

General

• All ues must be installed in accordance with AS/NZS 5601.

• Horizontal ues must have a minimum rise of 20mm per 1m run.

• Horizontal ues terminating on a wall must be at least 300mm above ground level.

• An external ue terminal clearance to an opening in a building shall be no less than 1000mm in the vertical

direction and 300mm in the horizontal direction.

• Systems with both vertical and horizontal ue runs should be treated as all horizontal.

• 1 x 45º bend is equivalent to 0.5 x 90º bend (i.e. 2 x 45º bends = 1 x 90º bend).

• Provide adequate support to ue sections (e.g. saddles / strapping).

100mm non-corrosive metal ue.

• Requires a 100mm round single or twin wall non-corrosive metal ue, suitably terminated.

• All ues must have a bolted ue sleeve connection to allow for repairs and/or removal of the appliance.

• Twin Wall ue - maximum ue length of 6m.

• Single Wall ue - maximum ue length of 2m.

• Up to 4 x 90º elbows are permitted with the same length requirements specied above.

2.3.5 Kaden Remote Flue Terminal

In specic installations, for example under the oor, it is recommended that a remote terminal be used to terminate

the ue on the outside wall of the building.

Please refer to instructions supplied with a Remote Flue Terminal (KADEN PART NO. 1621343).

Diagram 4 depicts a typical KU series heater underoor conguration.

Ground level

Wall

Remote flue terminal

House floor

Level concrete base

Control cabel access

Gas Inlet

Flue outlet

Minimum 20mm rise per 1m run

Power lead

300mm

Minimum

A= Maximum flue length

For single skin flue A = 2m

For twin skin flue A = 6m

Diagram 4

14

Kaden Installer's Manual

Ducted Gas Heaters

2.4 EXTERNAL INSTALLATION

2.4.1 Supply Air Overheat Switch Position (KU530 & KU330 ONLY)

For external installations of the KU530 (refer to Diagram 5) and KU330 (refer to Diagram 6) heaters the supply air

overheat switch position must be changed from end discharge to side discharge modify as follows:

2.4.1.1 KU530

1. Disconnect the quick connect terminals (Orange / White) for the overheat switch loom connected from the

end discharge overheat switch behind the burners.

2. Reconnect the quick connect terminals (Orange / White) to the side discharge overheat switch. These

terminals can be identied by the label "SIDE DISCHARGE O/H SWITCH".

Flue Terminal

Connection

KU530

End Discaharge O/H Switch

quick connect terminals

(factory default connection)

Side Discharge O/H Switch

quick connect terminals

12

O/H Switch Loom

Diagram 5

2.4.1.2 KU330

1. Disconnect the quick connect terminals (Orange / White) for the overheat switch loom connected to the end

discharge overheat switch behind the burners.

2. The KU330 is tted with both left and right side discharge O/H Switches, reconnect the quick connect

terminals (Orange / White) to the O/H Switch on the same side the air is supplied from. These terminals can

be identied by labels on the sheet metal plate above the burner "LEFT SIDE DISCHARGE O/H SWITCH"

or "RIGHT SIDE DISCHARGE O/H SWITCH".

Flue Terminal

Connection

KU330

Left Side Discharge O/H

Switch quick connect terminals

1

2

LR

End Discaharge O/H Switch

quick connect terminals (factory

default connection)

O/H Switch Loom

Right Side Discharge O/H

Switch quick connect terminals

Diagram 6

2.4.2 Modifying KU Model Duct Orientation

The duct orientation of KU series heaters can be reversed if the installation requires it. For more information refer

to "2.3.3 Return & Supply Air POP Rotation Procedure" on page 12.

15

2.4.3 Installation of Flue Terminal

The ue terminal for KU series heaters is not supplied, and

MUST BE ordered separately when a KU series heaters is to

be installed externally (KADEN PART NO. 1621303). The ue

outlet socket is located on the fan cabinet end of the heater.

• Remove labels and packaging from the ue terminal, then

insert into the ue outlet socket.

Ground

level

Wall

Level

concrete

base

Flashing

Open area of flue terminal

IMPORTANT

The ue terminal MUST BE orientated correctly,

rotate the ue terminal to ensure that the ue

gases are expelled away from the dwelling (refer

to Diagram 7).

The ue terminal MUST always be installed

before starting the heater.

Diagram 7

2.4.4 Flue Terminal Clearances

Heaters should be positioned so that the following minimum clearances exist when measured from the ue edges.

Clearance Description

75mm From the wall against which the heater is mounted.

From a drain or soil pipe.

300mm

From a flue terminal, cowl or combustion air intake.

Below eaves, balconies or other projections.

From the ground, above a balcony or other surface.

To a return wall or external corner.

Measured horizontally, from an opening window, door, non-mechanical air inlet or any other opening into the

building (except sub floor ventilation) or 1500mm in direction of discharge.

500mm From an electricity meter or fuse box (prohibited area extends to ground level).

1000mm

Measured vertically, from an opening window, door, non-mechanical air inlet or any other opening into the

building (except sub floor ventilation).

From a gas meter.

From a mechanical air inlet, including a spa blower, measured both vertically and horizontally.

A flue terminal of this type shall not be located under a roofed area, unless the roofed area is fully open on at

least two sides, and a free flow of air at the appliance is achieved.

Table 3

2.4.5 Area to Cut Out in Wall

When installing the heater at ground level, create two holes to suit the pops all the way to ground level (refer to

Diagram 8), or one rectangular hole to cover the distance of both pops ensuring there is no impediment to the

structural integrity of the dwelling.

Ground level

Level concrete base

Wall cut-out areas

Diagram 8

NOTE

Refer to "2.1 Heater Dimensions" on page 10 to obtain the required dimensions.

16

Kaden Installer's Manual

Ducted Gas Heaters

2.4.6 Installation of Flashing

2.4.6.1 KU5 models

Flashing MUST BE tted to ensure the ductwork is adequately weather protected.

Step 1. Fit side ashing using existing screws on

cabinet sides.

Step 2. Fit ashing rail using the existing screws

from the cabinet.

Silcone

Step 3. Slide top ashing with fold under ashing

rail. Once in place silicone along the

upstanding face of top ashing.

Step 4. Push the heater up against the wall and

secure side ashing to the wall.

NOTE

It is important to allow for sufcient slack in the ducting connected to the heater’s pops, to allow

the heater to be moved out from the wall if required for servicing.

2.4.6.2 KU3 & KU4 models

NOTE

For installation of ashing refer to the instructions provided with the ashing kit.

KU315, KU320, KU325, KU415, KU420 & KU425 use Kaden Part No. 1621299

KU330 & KU430 use Kaden Part No. 1621300

17

2.4.7 Thermistor Installation KU4 & KU5

All KU4 and KU5 heaters are supplied with a remote thermistor assembly. The thermistor must be installed in the

supply air duct, between 1m to 3m away from the heater, but NEVER beyond the rst Branch Take Off (BTO) tting.

NOTE

Where an Add-On air conditioning indoor evaporator coil is installed, the thermistor MUST BE

located in the discharge air POP of the indoor cooling coil.

These installation practices promote more accurate supply air temperature control and optimise heater performance.

• Ensure that there is at least 1 metre of appropriately sized ducting installed between the heater and the rst BTO

tting (or evaporator coil).

• Drill a 20mm diameter hole through the top of the inlet end of the rst BTO tting (refer to Diagram 9) or through

the top of the evaporator coils discharge POP.

• Carefully insert the thermistor assembly (probe end rst) into this hole and secure using the self drilling screw

provided. Seal any remaining openings with duct tape.

• Ensure that the thermistor lead is secured to timbers or duct outer casing (refer to Diagram 9) to prevent

damage.

Where the rst BTO tting is installed more than 3m away from the heater, an additional duct joiner (installer

supplied) will be required so that the thermistor assembly can be tted correctly. Install the joiner between 1m

to 3m away from the heater ensuring that the thermistor can reach this joint. Then follow the steps above as per

normal practice.

Thermistor

Diagram 9

18

Kaden Installer's Manual

Ducted Gas Heaters

KU4 & KU5 heaters can be congured for adaptive zoning and / or Add-On Refrigerative Air Conditioning.

There are three 24 Vac relays on the heater’s control module, which can be congured for control of up to three

zone motors, refer to Diagram 10 below.

Control Board

Grommet for

control cable

access

KU5/4

24 Vac Zone damper motor

(Power open/spring return example)

24 Vac Zone damper motor

(Power open/close example)

24 Vac Zone damper motor

(Power open/spring return example)

Diagram 10

3.1 WIRING A DAMPER MOTOR TO THE HEATER’S CONTROL MODULE

a. 24 Vac Power Open / Power Close Damper Motor

ZONE B

ZONE A

ZONE/ADD-ON

N/O

O V

N/C

N/O

O V

N/C

N/O

O V

Close

Common

Open

24 Vac

Power Open /

Power Close

Damper Motor

b. 24 Vac Power Open / Spring Return Damper Motor

ZONE B

ZONE A

ZONE/ADD-ON

N/O

O V

N/C

N/O

O V

N/C

N/O

O V

Active

Neutral

24 Vac

Power Open /

Spring Return

Damper Motor

c. 240 Vac Power Open / Power Close Damper Motor

ZONE B

ZONE A

ZONE/ADD-ON

N/O

O V

N/C

N/O

O V

N/C

N/O

O V

Close

Common

Open

24 Vac

Power Open /

Power Close

Damper Motor

240 Vac Power Supply

Active

Neutral

24 Vac Relay

Diagram 11

3. KU4 & KU5 - ADAPTIVE ZONING & ADD-ON AC

19

4.1 HEATER DIMENSIONS

A

B

J

KH

D

E

F

C

G

Ø RaØ Sa

Model A B C D E F G H I J K Base

Box ØSa ØRa

KE315 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300

KE320 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300

XA 350 350

KE328 894 1030 579 387 41 238 135 557 1280 415 951 Std 350 350

XA 400 400

KE415 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300

KE420 775 850 420 341 41 156 135 391 1145 370 771 Std 300 300

XA 350 350

KE428 894 1030 579 387 41 238 135 557 1280 415 951 Std 350 350

XA 400 400

All dimension in mm

Diagram 12

4.2 SERVICE CLEARANCES

BB

AA

CC

Service

Area

i

DD

EE

Minimum Service Clearance

A = Front 500mm

B = End 300mm

C = End 300mm

D = Top 1000mm

E = From Service Area D + The height of the heater ((Heater

height = Diagram 1 dimension I)

Diagram 13

i. This minimum clearance height (E) must be maintained across the entire Service Area.

4. KE EXTERNAL MODEL GUIDELINES

20

Kaden Installer's Manual

Ducted Gas Heaters

4.3 INSTALLATION

4.3.1 Area to Cut Out in Wall

When installing the heater at ground level,

create one rectangular hole to suit the total

POP width and height, all the way to ground

level, (refer to Diagram 14)

Ground level

Level concrete base

Base Box

Wall cut-out areas

NOTE

Refer to the Base Box for required

wall cut out dimensions.

Diagram 14

4.3.2 Installation of Flashing

Flashing MUST BE tted to ensure the ductwork is adequately weather protected.

Step 1. Fit side ashing using existing screws on

cabinet sides.

Step 2. Slide top ashing under ashing rail on

base box

Silcone

Step 3. Sit top ashing on top of side ashing

edges. Once in place silicone along the

upstanding face of top ashing.

Step 4. Push the heater up against the wall and

secure side ashing to the wall.

Kaden KU5 User guide

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