KAL-FIRE 45 User manual

Installation/User Manual
Product Heat Pure
Product group Wood burning fireplaces with lifting door
Application Open and closed
Models 45, 60, 70, 7 , 85, 00, 05, 0, 20
Version April 20 5
Language English

Preface
Preface
Congratulations on purchasing your Kal-fire fireplace.
This manual describes the installation, daily use and maintenance of all
the fireplaces from the Heat Pure serie. Read this manual carefully before
installing and using the Heat Pure.
Please complete the proof of guarantee (appendix C) and keep it with the
invoice to verify the purchase date.
Always keep this manual close to your Heat Pure
An authorised installer will install the Heat Pure fireplace in compliance
with the national or local applicable regulations. Check the Heat Pure for
transport damage upon delivery. Report any transport damage to the
supplier immediately. The supplier cannot be held responsible for any
damage as a result of faulty installation.
In case any problems occur or if you have any questions concerning the
operation of your Heat Pure, please contact your dealer. Your dealer is
also the person to contact during the duration of the guarantee period.
Kal-fire has installed a telephone helpdesk, to support the technical
department of her dealers, to make sure your dealer will be able to
advise you in a professional way.
All rights reserved. Nothing from this manual may be copied, distributed or translated into
other languages, partly or wholly, without prior written permission from Kal-fire. Kal-fire
reserves the right to modify this manual without notice. Kal-fire can give no guarantee,
neither implicit nor explicit, for this manual. All risks are for the user.
Copyright  20 5 Kal-fire B.V.
Belfeld, the Netherlands

Table of contents
TABLE OF CONTENTS
1 ntroduction 1
2 Safety 2
2. CE-marking .............................................. 2
2.2 Safety instructions installer .............................................. 2
2.3 Safety instructions user .............................................. 3
2.4 Safety precautions .............................................. 4
3 Mounting and installation 9
3. Check before building in/mounting ....................................... 9
3.2 Check flue ............................................ 0
3.3 Placing the appliance ............................................
3.4 Supply of combustion air ............................................ 4
3.5 Supply of convection air ............................................ 6
3.6 Chimney/flue connection ............................................ 8
3.7 Mounting the damper ............................................ 22
3.8 Adjusting the feet ............................................ 22
3.9 Baffle plate ............................................ 25
4 Preparing for use 31
4. Type of wood ............................................ 3
4.2 Storing the wood ............................................ 32
4.3 Ventilation ............................................ 32
5 Lighting the Heat Pure 33
5. Lighting the Heat Pure for the first time .............................. 33
5.2 Opening the door ............................................ 34
5.3 Air regulation ............................................ 35
5.4 Using the Heat Pure with an open or closed door ................. 36
5.5 Igniting the Heat Pure ............................................ 37
5.6 Optimal heat output ............................................ 40
5.7 Operating the damper (optional) ....................................... 44
6 Maintenance 45
6. Keeping clean panes ............................................ 45
6.2 Cleaning the pane ............................................ 45
6.3 Cleaning the grate ............................................ 47
6.4 Maintenance ............................................ 48
7 Trouble shooting 49
APPENDIX A: EG-declaration of compliance
APPENDIX B: Dimension diagrams
APPENDIX C: Guarantee

1. Introduction
1
1Introduction
The wood burning, built in fireplace you have purchased from the Heat
Pure line manufactured by Kal-
fire, is guaranteed to provide a lifetime of
heating satisfaction.
The Heat Pure line has the following models:
•Heat Pure 45
•Heat Pure 60
•Heat Pure 70
•Heat Pure 7
•Heat Pure 85
•Heat Pure 00
•Heat Pure 05
•Heat Pure 0
•Heat Pure 20
Symbols used
In this manual Kal-
fire uses a number of symbols. These symbols
indicate possible damage to the product and/or a life
threatening
situation, if the procedures are not observed and followed carefully.
Warning of danger.
Warning of fire hazard through the presence of flammable
substances or a warning of high temperatures.
1. Introduction
The wood burning, built in fireplace you have purchased from the Heat
fire, is guaranteed to provide a lifetime of
fire uses a number of symbols. These symbols
threatening
situation, if the procedures are not observed and followed carefully.
Warning of fire hazard through the presence of flammable

2
2Safety
2.1 CE-markin
The appliance has been approved according to the CE standard EN
3229-A2.
Every appliance that leaves the factory has been tested for functionality
according to the Kal-fire quality standards.
The nation
al Building Regulations, Fire Regulations and the
municipal regulations apply to this product.
2.2 Safety instructions installer
•
An authorised installer will connect the Heat Pure in
compliance with the national and/or local applicable
regulations.
•
Check if the Heat Pure functions correctly immediately after
the installation.
•
Take the necessary preventive measures, by using non
combustible material, in order to prevent overheating of
floor, boards or walls close to the Heat Pure.
2. Safety
The appliance has been approved according to the CE standard EN
-
Every appliance that leaves the factory has been tested for functionality
al Building Regulations, Fire Regulations and the
An authorised installer will connect the Heat Pure in
compliance with the national and/or local applicable
Check if the Heat Pure functions correctly immediately after
Take the necessary preventive measures, by using non
-
combustible material, in order to prevent overheating of

3
2.3 Safety instructions user
•
The Heat Pure wood fire is only intended for use as an
additional heat source.
•
Careful! The exterior of the fireplace can become hot during
use.
•Nr. : The distance between any built-
in furniture and the
fireplace, should be at least 5 cm.
•Nr. 2: The distance between any wall-, floor
-
material should be at least cm.
•
Nr. 3+4: Make sure that curtains, furniture and/or other
combustible materials are at least 2
0 cm removed from the
Heat Pur
e. If a fireguard is used, this distance must be at
least 40 cm.
2. Safety
The Heat Pure wood fire is only intended for use as an
Careful! The exterior of the fireplace can become hot during
in furniture and the
-
and /or ceiling
Nr. 3+4: Make sure that curtains, furniture and/or other
0 cm removed from the
e. If a fireguard is used, this distance must be at

4
2.4 Safety precautions
•Insulation material must comply with the
national
applicable quality standards;
this material should,
amongst others, be resistant to high temperatures
(minimum 700 °C), in order to avoid strong odour
development during combustion.
•
Use ceramic fibre panels or hard panels made from mineral
wool to prevent loose particles of insulatio
n material
circulating in the convection system.
•
Prevent any insulation material covering the convection air
inlet. Attach the insulation material firmly, to prevent it from
slipping.
2. Safety
national
this material should,
amongst others, be resistant to high temperatures
(minimum 700 °C), in order to avoid strong odour
Use ceramic fibre panels or hard panels made from mineral
n material
Prevent any insulation material covering the convection air
inlet. Attach the insulation material firmly, to prevent it from

5
Table 1
: Prescribed insulation thickness to combustible materials
Heat
Pure
Type
nspection sorath 1000 Promasil
Rear panel (cm)
Side panel (cm)
Roof (cm)
Base (cm)
Rear panel (cm)
Side panel (cm)
Roof (cm)
Base (cm)
Rear panel (cm)
Side panel (cm)
Roof (cm)
Base (cm)
45 5 5 9 * 2,6 2,7 5,3
* 2,0
2,1 4,1
*
60 5 5 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
70 5 5 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
71 10 10 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
85 5 5 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
100 10 10 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
105 5 5 9 * 2,6 2,7 5,3
* 2 2,1 4,1
*
110 9,4 8,4 9,3 * 7,7 6,9 7,6
* 6,0
5,3 5,9
*
120 9,4 8,4 9,3 * 7,7 6,9 7,6
* 6,0
5,3 5,9
*
The floor, on which the Heat Pure is placed, must be
made from non-
combustible material, as hot ashes and
sparks may fall onto the floor.
2. Safety
: Prescribed insulation thickness to combustible materials
Mineral wool
(AG Q 132)
Rear panel (cm)
Side panel (cm)
Roof (cm)
Base (cm)
5 5 9 *
5 5 9 *
5 5 9 *
5 5 9 *
5 5 9 *
5 5 9 *
5 5 9 *
10 9 11 *
10 9 11 *
The floor, on which the Heat Pure is placed, must be
combustible material, as hot ashes and

2. Safety
6
2.4.1 Installation of the Heat Pure in combination with
combustible materials (e. . a wooden wall)
When installing the Heat Pure, make sure to respect the recommended
distance from any combustible building materials:
Combustible building materials behind the fire must also be shielded or
insulated by insulation material. The minimum thickness (A) of the
insulation material depends on the model and type of Heat Pure. Refer to
Table for the required minimum insulation thickness.
The distance from the back of the Heat Pure (or the side if the fire is built
into an alcove) to the insulation material must be a minimum of 0 cm.
Combustible material
insulation
combustible building material
A

7
Ensure that windows
are at a distance of minimum
the appliance.
Ensure that curtains, furniture and/or other combustible
materials are at a distance of minimum 50 cm from the
appliance.
* The floor the Heat Pure is placed on must
be made of non
combustible materials. The (combustible) floor in front of the
door opening must be protected (30 cm on both sides and 50
cm in front of the appliance).
2. Safety
are at a distance of minimum
00 cm from
Ensure that curtains, furniture and/or other combustible
materials are at a distance of minimum 50 cm from the
be made of non
-
combustible materials. The (combustible) floor in front of the
door opening must be protected (30 cm on both sides and 50

2. Safety
8
2.4.2 Prescribed materials
nsulation
Use mats, plates or strips made from silicate insulation materials (stone,
clinkers, ceramic fibres); construction class A according to DIN 4 02
Part , with an upper limit temperature of at least 700°C, tested
according to DIN 5227 and a nominal density of 80 kg/m.
These materials need to have a corresponding insulation material
registration number, according to AGI-Q 32. This number may not
include the combination “99”.
For as far as this insulation layer is not kept away from walls, claddings
or adjoining plates, attachments must be mounted at a mutual distance
of max. 33 cm.
Other insulation materials, consisting of, for example, covering concrete
or mineral base materials, must have a General Urban Development
Permit of the German Institute of Building Technology (DIBt). For further
details, see DIN 8895 resp. EN 3229/DIN 8 60.
Replacement insulation materials have various heat index values,
depending on the thickness of the insulation material. The required
thickness of the insulation material can be calculated from the graph
delivered by the manufacturer.
Some heat insulation materials can be used for preconstruction and heat
insulation, in order to considerably reduce the built-in depth. Cover heat
insulating materials made from stone and clinker fibre so they are not
subject to wear, otherwise loose particles may be blown by the airflow
into the mounting area. Other heat insulation plates may be supplied
wear proof from the factory.
Floors
The floor, on which the Heat Pure is placed, must have sufficient load
bearing capacity (for the weight of the Heat Pure, see table 4).

3. Mountin and installation
9
3Mountin and installation
Before installing the Heat Pure, ensure that the carrying capacity of the
floor is sufficient for the weight of the appliance and the planned
surround (see Table 5). If this is not the case, this should be first
addressed with the necessary steps (for example, the deviation of the
pressure points using a form-retaining, flame-proof plate).
3.1 Check before buildin in/mountin
. Check immediately upon arrival, if the products supplied are
complete and undamaged. Report any damaged or missing items to
the supplier immediately.
2. Remove the transport security (screws with yellow sticker on the
front of the convection casing).
3. Check the following parts for correct working:
- Lifting door up and down
- Forward tilting action of door for cleaning
- Air control
- Adjustment feet
- Any damper with control button (accessories)
- Any aeration valves (accessories)
4. Hand the installation/users manual personally to the user of the Heat
Pure.
5. Test the internal fresh air valve for correct working. This valve is
situated on the rear of the Heat Pure, behind the fresh air
connection. When the door is closed, the fresh air flows into the
combustion chamber via the air slide valve. When the door is
opened, the fresh air flows into the combustion chamber via the
convection casing and outlet openings.

3. Mountin and installation
10
3.2 Check flue
In order to guarantee correct functioning, we advise you to test/ignite
the Heat Pure at the earliest possible opportunity (before it has been
completely built-in) (see Chapter 5 Lighting the fireplace). Why?
•This will allow you to decide if an external damper is necessary.
•The enamel can also cure before the surround is finished. Allowing the
enamel to cure will also cause less nuisance for the end user.
•This gives you the chance to find out in an early stage, whether or not
the fireplace-flue combination is working correctly.
Checklist (to be executed) when using the fireplace
. Check the flue for proper functioning; minimum required draught
(suction) is 2 Pa.
2. Test the air slide valve for proper functioning; this will work after
the fire has burnt for 50 minutes: (see chapter 3.3. )
- extreme right position = maximum supply of combustion air
- extreme left position = air supply closed; the flames will slowly
extinguish.
If the flames do not react, or do not react enough, to the change in
the air slide position, it may be worthwhile considering installing an
external damper on the Heat Pure.
3. After a while close all windows and doors and ensure that all
appliances that remove air from the home, such as cooker hoods,
fans etc. are switched off. Check if the appliance can be used with
an opened door (no smoke trickles back into the room). (see
chapter 3.3)
4. Use a little smoke to check for correct supply and exhaust of
convection air.

3. Mountin and installation
11
3.3 Placin the appliance
The appliance may not
be placed in the following situations:
•in
stairwells, with the exception of buildings with no more
than two dwellings;
•in entrance halls with public access;
•
in rooms where flammable or explosive substances or
mixtures are processed, stored or manufactured;
•in rooms or dwellings where air is extrac
ted by air
conditioning or with air heating using fans, with the
exception of the following cases where a risk free
functioning of the Heat Pure is safeguarded:
-
-
-
the installation only circulates air in the room;
the installation has
reliable safety precautions, so that
over pressure is automatically created in the room where
the Heat Pure is installed;
the combustion air flow of the Heat Pure and the volume
flows of ventilating installations in the room and the
rooms connected by
ventilation ducts, create an under
pressure that remains below 0.04 mbar. ATTENTION:
situation must also be safeguarded if easily accessible
control equipment used for the ventilating installation is
moved or removed.
3. Mountin and installation
be placed in the following situations:
stairwells, with the exception of buildings with no more
in rooms where flammable or explosive substances or
mixtures are processed, stored or manufactured;
ted by air
-
conditioning or with air heating using fans, with the
exception of the following cases where a risk free
the installation only circulates air in the room;
reliable safety precautions, so that
over pressure is automatically created in the room where
the combustion air flow of the Heat Pure and the volume
flows of ventilating installations in the room and the
ventilation ducts, create an under
pressure that remains below 0.04 mbar. ATTENTION:
This
situation must also be safeguarded if easily accessible
control equipment used for the ventilating installation is

3. Mountin and installation
12
3.3.1 Workin combustion air
If used with a closed door, the Heat Pure
takes the combustion air directly from
the connection at the rear (A) or base
(A’) of the Heat Pure. This combustion
air is guided into the combustion
chamber via de air control (B) and the
primary thermostat (C), where it is used
as primary or secondary combustion air.
Primary combustion air (P)
The thermostat regulates this air flow
automatically. When the Heat Pure is
cold the thermostat ensures that air
enters the combustion chamber via the
lower spoiler. As the Heat Pure warms
up, the air flow will gradually decrease.
After approximately 50 minutes, the
Heat Pure is so warm, that this air flow
stops altogether.
The primary air control is 00%
automatic and cannot be influenced by
yourself.
Secondary combustion air (S)
The air flow is regulated manually via
the operating feature to the right of the
appliance.
Via risers to the left and right of the
combustion chamber, this air is warmed
up and guided to the combustion
chamber via the upper spoiler.
The secondary air flow is used to
regulate the flames and to keep the
glass door clean. This air flow may
therefore never be completely closed off.

3. Mountin and installation
13
If used with an open door, the air need
of the Heat Pure changes. The opening
at the front will cause large volumes of
air to be sucked into the appliance. This
air will be taken from the room the
appliance is installed in.
With an opened door, the built-in valve
ensures that the passage to the
combustion chamber is closed (see
figure). The connected air is re-routed to
the convection casing, where the air is
warmed before it flows into the room.
This air then becomes available in the
room where the appliance is installed so
it can be used in the combustion
process.
Detail ‘‘valve closed‘‘
Detail ’’valve open’’

3. Mountin and installation
14
3.4 Supply of combustion air
The appliance must have enough outside air to ensure problem
free ignition. If lower values are established based on the
calculated volume
of combustion air, building in the appliance is
for the risk of the installer.
The Heat Pure has a built-
in air supply valve; in normal situations no
extra air valve is required. In situations where the side gable is subjected
to frequent high winds or where there are large indoor/outdoor pressure
differences, it is advisable to mount an extra air valve.
In that case the valve must be clearly marked to indicate the open and
closed position. Inform the users about the function and working of the
valve(s).
Some air valve manufacturers use plastic sleeves. Mount these
outside the he
at radiation range of the Heat Pure.
Ensure that the fresh air actually is outside air. For example, if
the combustion air originates from a cellar, this cellar must
have sufficient air vents to ensure that any extracted air is
replaced by fresh, outside air.
Ensure that the gratings are placed so,
that they cannot become
blocked.
3.4.1 Fresh air connection base or rear
The standard for the Heat Pure, is that
the fresh air connection is situated on
the rear. This connection can be
relocated to the base.
Method
. Demount the connecting collar at
the rear of the Heat Pure.
2. Demount the closing plate at the
base of the Heat Pure. Mount the
closing plate in the former position
of the connecting collar.
3. Mount the connecting collar on the
base of the Heat Pure in the former
position of the closing plate.
3. Mountin and installation
The appliance must have enough outside air to ensure problem
free ignition. If lower values are established based on the
of combustion air, building in the appliance is
in air supply valve; in normal situations no
extra air valve is required. In situations where the side gable is subjected
to frequent high winds or where there are large indoor/outdoor pressure
In that case the valve must be clearly marked to indicate the open and
closed position. Inform the users about the function and working of the
Some air valve manufacturers use plastic sleeves. Mount these
at radiation range of the Heat Pure.
Ensure that the fresh air actually is outside air. For example, if
the combustion air originates from a cellar, this cellar must
have sufficient air vents to ensure that any extracted air is
that they cannot become

3. Mountin and installation
15
3.4.2 Fresh air connection without connectin collar
If there is not enough space for the
connection collar, you can demount this
and the air connection using a built
construction. In this case, the Heat
Pure is positioned on or against an
opening for fresh air. Use a ceramic
cord to seal off the transition between
the Heat Pure and the constructed
opening. (Available as an option)
Examples:
•The Heat Pure is positioned against
an opening to a cellar.
•The Heat Pure is positioned against
an outside wall, which has an
opening to the outside air.
Kal-fire connection kit (optional)
•a ceramic cord to fill gaps of max. 2 cm.
•
metal strips to attach the cord to the Heat Pure.
Ceramic cord

3. Mountin and installation
16
3.5 Supply of convection air
The Heat Pure is surrounded by a
convection casing, that warms up the
room in a constantly pleasant and
efficient manner.
For this system to operate to its
maximum effect, a convection set is
required.
This optional convection set consists
of:
Heat Pure 45 and 60
•4 flexible aluminium hoses Ø 50 mm .25 m: 2 hoses of 2.5 m which
must be divided in half, in order to get a total of 4 hoses.
•8 clamping strips.
•4 gratings: outer dimensions 20 x 20 cm, recess dimension 6.5 x
6.5 cm, with connection collar Ø 50 mm.
•Mantel iron; this must be sawn to the correct size.
•Roll of felt to create an expansion joint between the metal of the
mantel iron and the surround.
This convection set is ordered separately to the Heat Pure. Instead of a
grating, openings (for example recessed plinths) can be used. Do not
reduce the convection openings.
Place all of the gratings / openings, both upper and lower, to facilitate
the natural circulation. The gratings / openings should be situated in the
same pressure area (the same room) as the Heat Pure.
Heat Pure 70, 71, 85, 100, 105, 110 and 120
•8 flexible aluminium hoses Ø 50 mm 4x .25 m long and 4x 0.62 m.
2 hoses of 2.5 m which must be divided in half, in order to get a total
of 4 hoses and hose of 2.5 m which must be divided into 4.
•6 clamping strips.
•4 gratings: outer dimensions 35 x 20 cm, recess dimension 33 x 6.5
cm, with 2 connection collars Ø 50 mm each.
•Mantel iron; this must be sawn to the correct size.

3. Mountin and installation
17
•Roll of felt to create an expansion
joint between the metal of the
mantel iron and the surround.
Method when using gratings
Ensure that, at the base, there is sufficient supply for the cold convection
air from the room (see table below).
At the top connect the gratings to the outlet opening
s of the warm
convection air (see table below).
Table 2: Through put openings for convection air
Heat Pure 45, 60
Heat Pure 70, 71, 85,
110, 120
nlet
convection air
2x Ø 50 mm
4x Ø 50 mm
355 cm
2
705 cm
Outlet
convection air
2x Ø 50 mm
4x Ø 50 mm
355 cm
2
705 cm
Attention! When mounting the gratings, ensure they are placed in such a
position, that they cannot become blocked.
Method when using openings
If you do not want to use gratings, openings at the top
surround (chimneybreast) are also sufficient. For through put openings,
see Table 2. These openings serve the same function as the gratings and
supply and extract the convection air. We advise you, to place tubes or
hoses on the outlet open
ings. This makes the convection system (just a
little) more powerful and the heat is guided more easily to the openings.
If you do not use the recommended convection set, this may
damage the Heat Pure by overheating. The result may be soiled
walls and ceilings in the room. There is always a risk of
discolouration to walls and ceilings, but this risk can be
considerably reduc
ed, by correctly ventilating the room.
Mount the gratings at a distance of at least 30 cm from the
ceiling or wall. Ensure there are no flammable materials closer
than 30 cm next to and 50 cm above the gratings.
3. Mountin and installation
joint between the metal of the
Ensure that, at the base, there is sufficient supply for the cold convection
s of the warm
Heat Pure 70, 71, 85,
100, 105,
110, 120
4x Ø 50 mm
705 cm
2
4x Ø 50 mm
705 cm
2
Attention! When mounting the gratings, ensure they are placed in such a
and base of the
surround (chimneybreast) are also sufficient. For through put openings,
see Table 2. These openings serve the same function as the gratings and
supply and extract the convection air. We advise you, to place tubes or
ings. This makes the convection system (just a
little) more powerful and the heat is guided more easily to the openings.
If you do not use the recommended convection set, this may
damage the Heat Pure by overheating. The result may be soiled
walls and ceilings in the room. There is always a risk of
discolouration to walls and ceilings, but this risk can be
ed, by correctly ventilating the room.
Mount the gratings at a distance of at least 30 cm from the
ceiling or wall. Ensure there are no flammable materials closer
than 30 cm next to and 50 cm above the gratings.