RealFlame CALDOR Installation instructions

CALDOR WOODHEATER
INSTALLATION & OPERATING MANUAL
VERSION 2
C

2
FOREWARD
THANK YOU FOR HOOSING 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.
The instructions pertaining to the installation of your wood inbuilt comply with AS/NZS 4012/4013
and AS/NZS 2918 standards.
Please read this entire manual before you install and use your new wood inbuilt. Failure to follow
instructions may result in property damage, bodily injury, or even death . It is important that you
follow the installation guidelines exactly.
onsult your local city, borough or shire council about restrictions and installations requirements in
your area and the need to obtain a permit.
This heating unit is designed to serve as a supplementary heat source. We recommend that a
primary heat source also be available in the home. The manufacturer cannot be responsible for
costs associated with the use of another heating system.
KEEP HIS MANUAL FOR FU URE REFERENCE.
PLEASE NO E HA HE PIC URES SHOWN IN HIS MANUAL ARE GENERIC AND MAY
NO MA CH EXAC LY HE LOOK OF YOUR ZERO CLEARANCE WOOD INBUIL .

3
CONTENTS
INSTALLATION.......................................................................................................4
Safety Information ...................................................................................4
Regulations overing Zero learance Wood Inbuilt Installation .............5
General Information.................................................................................6
Dimensions..............................................................................................6
Standoff Installation...............................................................................10
arrying the Zero learance Wood Inbuilt ............................................10
Locating the aldor ...............................................................................10
learances to Heat-Sensitive Materials.................................................11
Hearth Extension onstruction onfiguration .......................................13
Floor Protection .....................................................................................14
ompliance of a ombustible Mantel and Mantel Shelf........................15
Trim Installation .....................................................................................15
Moulded Refractory Brick Panels Installation........................................16
Hot Air Gravity System ..........................................................................17
THE FLUE SYSTEM.............................................................................................24
General..................................................................................................24
Minimum Flue System Height................................................................24
Suitable Flue Systems...........................................................................25
The Relationship Between the Flue System and the House .................25
OPERATION AND MAINTENAN E .....................................................................25
Safety Information .................................................................................25
Fuel........................................................................................................27
Operating Your Zero learance Wood Inbuilt........................................27
Maintaining Your Wood Heating System ...............................................29
Flue and Flue Liner Maintenance..........................................................32
EXPLODED DIAGRAM AND PARTS LIST...........................................................33
Real Flame contact information ............................................................................36

4
INSTALLATION
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.
Required omponent (sold separately)
• Moulded bricks (SFA0080);
• Black straight narrow trim (SFA0085);
or
• Black straight masonry trim (SFA0087).
Options (sold separately)
• Air diffuser kit (SFA0086).
Safety Information
WARNING
• THE APPLIAN E AND FLUE-SYSTEM SHALL BE INSTALLED IN A ORDAN E
WITH AS/NZS 2918 AND THE APPROPRIATE REQUIREMENTS OF THE RELEVANT
BUILDING ODE OR ODES.
• APPLIAN ES INSTALLED IN A ORDAN E WITH THIS STANDARD SHALL
OMPLY WITH THE REQUIREMENTS OF AS/NS 4013 WHERE REQUIRED BY THE
REGULATORY AUTHORITY, I.E. THE APPLIAN E SHALL BE IDENTIFIABLE BY A
OMPLIAN E PLATE WITH THE MARKING 'TESTED TO AS/NZS 4013'.
• ANY MODIFI ATION OF THE APPLIAN E THAT HAS NOT BEEN APPROVED IN
WRITING BY THE TESTING AUTHORITY IS ONSIDERED AS BREA HING AS/NZS
4013.
CAUTION
• MIXING OF APPLIAN E OR FLUE SYSTEM OMPONENTS FROM DIFFERENT
SOUR ES OR MODIFYING THE DIMENSIONAL SPE IFI ATION OF
OMPONENTS MAY RESULT IN HAZARDOUS ONDITIONS. WHERE SU H
A TION IS ONSIDERED, THE MANUFA TURER SHOULD BE ONSULTED IN
THE FIRST INSTAN E.
• RA KED AND BROKEN OMPONENTS e.g. GLASS PANELS OR ERAMI TILES,
MAY RENDER THE INSTALLATION UNSAFE.
• A ARBON MONOXIDE ( O) DETE TOR/ALARM IS REQUIRED IN THE ROOM IN
WHI H THE ZERO LEARAN E WOOD INBUILT IS INSTALLED. THE O
DETE TOR WILL PROVIDE WARNING IF, FOR ANY REASON, THE APPLIAN E
FAILS TO FUN TION ORRE TLY.

5
INSTALLATION ( ontinued)
NOTICE
• 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).
• onnect this wood inbuilt only to a triple skin flue system as per AS/NZS 2918,
APPENDIX B, or any flue system tested to and past the requirements of AS/NZS 2918,
APPENDIX F, for use with solid fuel.
• If required, a supply of combustion air shall be provided to the room.
• Do not connect to, or use in conjunction with any existing air distribution ductwork
unless specifically approved with the appliance.
• Do not connect this unit to a flue serving another appliance.
• This zero clearance wood inbuilt has not been tested to be installed inside a masonry
chimney.
When installed and operated as described in these instructions, the aldor zero clearance wood
inbuilt is suitable for use in residential installations. The aldor zero clearance wood inbuilt is not
intended for installation in a bedroom.
The zero clearance wood inbuilt is not approved for use with a so-called “positive flue connection”
to the clay tile of a masonry flue system.
Regu ations Covering Zero C earance Wood Inbui t Insta ation
CAUTION
• THIS ALDOR ZERO LEARAN E WOOD INBUILT SHOULD BE INSTALLED ONLY
BY A LI ENSED A REDITED INSTALLER. FAILURE TO USE AN AUTHORIZED
INSTALLER MAY VOID YOUR HOME & ONTENTS INSURAN E POLI IES.
PLEASE REFER TO YOUR RETAILER TO LO ATE AN INSTALLER.

6
INSTALLATION ( ontinued)
Model # SF00400
olour Metallic black
ombustible Hardwood
Recommended heating area* < 93 m2
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
eramic glass thickness 4 mm
Maximum Log Length 760 mm
Firebox Volume 0,181 m3
Shipping Weight 347 kg
* Heating capacity may vary subject to location in home, flue system draft, flue system diameter,
locality, heat loss factors, climate, fuels and other variables.
** This unit is tested as a central system because it can be hooked-up to hot air distribution ducts.
It is therefore exempt from emissions testing.
Genera Information
Dimensions
Top view

INSTALLATION ( ontinued)
Dimensions (continued)
7
ombustion chamber
Black straight narrow trim Black straight masonry trim

8
INSTALLATION ( ontinued)
Dimensions (continued)
Glass surface
Door opening black straight narrow trim Door opening black straight masonry trim
ombustion chamber

9
INSTALLATION ( ontinued)
Dimensions (continued)
Left side black straight narrow trim
Right side
Left side black straight masonry trim

10
INSTALLATION ( ontinued)
Standoff Insta ation
Before installing the zero clearance wood inbuilt, two standoffs must be secured to the top of the
appliance. These parts are required to maintain proper clearances to heat sensitive materials. You
will find the standoffs in the firebox and the screws in the owner’s manual kit. Align the holes of the
spacers (A) with the pre-drilled holes on top of the zero clearance wood inbuilt and secure them
with 8 screws provided (B), as shown.
Carrying the Zero C earance Wood Inbui t
To facilitate transportation of the aldor before its installation, we have designed handling grips
(A 09200, 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. To install the
bricks, see section Moulded Refractory Brick Panels Installation.
Locating the Ca dor
The best location to install your zero clearance wood inbuilt is determined by considering the
location of windows, doors and the traffic flow in the room. Figure some space in front of the unit
for the hearth extension and the mantel and clearances to other combustible materials. If possible,
choose a location where the vent will not interfere with any truss, roof beams, wall studs, water
pipes or electrical wiring. It may be easier to relocate the appliance than to rework the building
structure. Also choose a location that allows installing the least number of offsets in the flue.
Usually, no additional floor support is needed for the zero clearance wood inbuilt. The adequacy of
the floor can be checked by first estimating the weight of the zero clearance wood inbuilt. Weights
are given in the section General Information. Next, measure the area occupied by the zero
clearance wood inbuilt. Note the floor construction and consult your local building code to
determine if additional support is needed.
HE ZERO CLEARANCE WOOD INBUIL MUS BE INS ALLED ON A LEVEL AND
S RAIGH (NO UNEVEN) SURFACE.

11
INSTALLATION ( ontinued)
Location of the Certification Labe
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.). You can find the
certification label inside the wood inbuilt, on the right side when facing it.
We recommend that you note the wood inbuilt’s serial number on this manual, since it will be
needed to precisely identify the version of the appliance in the event you require replacement parts
or technical assistance.
C earances to Heat-Sensitive Materia s
The clearances shown in this section have been determined by test according to procedures set
out in safety standards AS/NZS 2918:2001. When the zero clearance wood inbuilt is installed so
that its surfaces are at or beyond the minimum clearances specified, combustible surfaces will not
overheat under normal and even abnormal operating conditions.
WARNING
• NO PART OF THE ZERO LEARAN E WOOD INBUILT MAY BE LO ATED LOSER
TO OMBUSTIBLES THAN THE MINIMUM LEARAN E FIGURES GIVEN.
The appliance must be built into an enclosure with the front wall made from a minimum 9 mm non-
combustible material (Bellis board or similar), the side and rear walls, which can be made from
combustible material, shall be a minimum of 70 mm from the side and rear of the appliance outer
case.

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INSTALLATION ( ontinued)
C earances to Heat-Sensitive Materia s (continued)
The roof of the enclosure must have a minimum of 400,000 mm² for example : 825 mm (X) • 500
mm (Y) = 412 500 mm2) 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 of venting).
CAUTION
BEFORE LOSING THE WALLS, MAKE SURE THAT THE FLUE DAMPER AND THE
DOOR ME HANISM WORKS PROPERLY. SEE SE TIONS himney Damper AND
Access Door for ounterweight.

The aldor may be installed directly on the floor or on a raised combustible or non-combustible
base.
13
INSTALLATION ( ontinued)
Hearth Extension Construction Configuration
A. Raised Base Insta ation
When installed with a more than 100
mm raised base, the upper and
lower angle, for the full width of the
floor protection, must be protected
50 mm horizontally and 50 mm
vertically (E) by a piece of sheet
metal (not included). Apart from
these two corners, the sheet metal
does not have to cover the rest of
the wall between the base of the
wood inbuilt and the floor.
More than 100 mm
In the case where (F) would be
equal to 100 mm, it is suggested
that the sheet metal between the
base of the zero clearance wood
inbuilt and floor be in one piece.
100 mm

14
INSTALLATION ( ontinued)
Hearth Extension Construction Configuration (continued)
B. Direct y On the F oor
F oor Protection
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. For example, a piece of sheet metal (not included).
We also advise using
adhesive glue to secure the
hearth where possible
instead of metal nails, to
minimize thermal conduction
into frame materials, if
mounting the unit above
floor level.
Note that the floor under of
the zero clearance wood
inbuilt should match or
exceed the height of the
floor protection.
A minimum of 1492 mm deep x
1590 mm wide x 18 mm thick floor
protector (Bellis Board) must be
used under and in front of the
appliance base when installing the
appliance.
The floor protector should extend
685 mm in front of the appliance
door and be placed centrally in the
1590 mm width. The thermal
conductivity of the floor protector is
0.1m².K/W minimum for 9 mm thick
sheets.
REFER O AS 2918 – 1990
CLAUSES 2.2, 3.3.1, 3.3.2 AS
HERE ARE VARIA IONS O HE
CONS RUC ION OF HEAR HS.
NOTICE
DO NOT LEAVE ARPET UNDER THE FLOOR PROTE TION.

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.
The mantle upright shall be no closer than 225 mm from the side of the appliance door and extend
no thicker than 70 mm.
15
INSTALLATION ( ontinued)
Comp iance of a Combustib e Mante and Mante She f
In order to complete the zero clearance wood inbuilt installation, you must install either the black
straight narrow trim (SFA0085) or the black straight masonry trim (SFA0087). Installation
instructions can be found in the trim kit.
Trim Insta ation
NOTICE
THE FA ING OF THE TRIM SHOULD NEVER OME IN ONTA T WITH MASONRY
PRODU TS SU H AS MORTAR, A ID OR ANY OTHER PRODU TS ONTAINING
ABRASIVES. DAMAGES AND DIS OLOURATION AUSED BY THESE PRODU TS
WILL NOT BE OVERED BY THE WARRANTY.

16
INSTALLATION ( ontinued)
Mou ded Refractory Brick Pane s Insta ation
a) Place the bottom refractory panels (A) and
(B) at the bottom of the firebox and pull them
toward the front of the unit to help positioning
the sides and back refractory panels.
b) Place the lower back refractory panel ( ).
Install it on the floor of the firebox, behind the
bottom refractory panels.
c) Place the left and right lower refractory
panels (D) and (E). Set them on the floor of
the firebox, as shown.
d) Lay the upper back refractory panel (F) on
top of the middle back refractory panel.
e) Place the upper left and right refractory
panels (G) and (H) onto the notches of the
middle left and right refractory panels.
f) Secure the upper refractory panels
retainers using the screws provided with the
owner's manual kit.

g) Install the andirons and secure them with
anchor bolts.
17
INSTALLATION ( ontinued)
A hot air gravity system can be installed by fitting the air diffuser kit SFA0086, sold separately.
This kit includes four air diffusers. The two small air diffusers must be installed as air intakes at
the bottom of the wood inbuilt. The two larger air diffusers must be installed as hot air diffusers, at
the top of the wood inbuilt. Ducts are not included and must be purchased separately. Adapters
can be found in the firebox of the wood inbuilt. When installing the kit, all four air diffuser
must be used.
Hot Air Gravity System
Ducts for air intake must be 150 mm in diameter, flexible or rigid, insulated or not, with a zero
clearance to heat sensitive materials. They should also be as short as possible.
For an optimal air circulation, install the air intake diffusers on both sides of the wood inbuilt
enclosure. Diffuser’s framing should be 241 mm X 219 mm. The air intake diffusers should be
located less than 152 mm higher than the centre of the air intake of the wood inbuilt.
A. Air Intake Diffusers Ducts
Mou ded Refractory Brick Pane s Insta ation (continued)

18
INSTALLATION ( ontinued)
A. Air Intake Diffusers Ducts - Assemb y and Insta ation
c) Install one end of the duct to the wood
inbuilt adapter using an adjustable clamp.
b) Remove the knockout on both side of the
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. The adapter is well in
place when its flange is completely inserted,
and the adapter can rotate freely.
d) Install the air diffuser adapter on the
diffuser inner plate.
a) To install the air intake diffusers, locate the
holes (2) on each side of the wood inbuilt.

19
INSTALLATION ( ontinued)
A. Air Intake Diffusers Ducts - Assemb y and Insta ation
g) ut a hole on each side of the wood inbuilt
enclosure following the dimensions
mentioned above. Install both air diffuser and,
using a flat screwdriver, bend the four tabs to
secure the diffusers in place inside the wall.
f) Bend the inside tabs on both air diffuser.
h) Reach inside the air diffuser and grab the
inner plate with the duct already installed on
it. Hook it on the air diffuser plate.
e) Secure the other end of the duct to the air
intake diffuser inner plate using a second
adjustable clamp.

20
INSTALLATION ( ontinued)
A. Air Intake Diffusers Ducts - Assemb y and Insta ation
i) Install the decorative plate by pressing on
both sides of the plate.
B. Hot Air 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. Total length
of duct must not exceed 4 meters. Hot air diffusers must have a 152 mm clearance to heat
sensitive materials. Hot air diffuser’s framing should be 318 mm X 295 mm.