KAL-FIRE Fairo 60 User manual

Installation / User Manual
Product Fairo
Product group Balanced flue gas system
Models 60-70-75-100-105-
105 Tunnel-120-140-
140 Tunnel-160
Version 01-2011
Language English

Preface
Preface
Congratulations on purchasing your Kal-fire fireplace.
This manual describes the installation, daily use and maintenance of all
fireplaces from the Fairo series. Read this manual carefully before
installing and using the Fairo.
Please complete this proof of guarantee (appendix D) and keep it with
the invoice to verify the purchase date.
Always keep this manual close to your Fairo
An authorised installer will install the Fairo in compliance with the
nationally or locally applicable regulations. Check the fireplace for
transport damage on delivery. Report any transport damage to the
supplier immediately. The supplier cannot be held liable for any
consequential damage as a result of faulty installation.
If any problems occur or you have any questions about the operation of
your Fairo, 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 number, in order to give your dealer
technical support when needed. Now we will always be able to advise
your dealer professionally.
All rights reserved. Nothing from this manual may be copied, distributed or translated into
other languages, partly or wholly, without express 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 2011 Kal-fire B.V.
Belfeld, the Netherlands

Table of contents
Table of contents
1Introduction ......................................................................................1
2Safety ................................................................................................2
2.1 CE Quality mark.................................................................2
2.2 Safety instructions installer .................................................2
2.3 Safety instructions user ......................................................3
2.4 Safety precautions .............................................................3
3Technical specifications.....................................................................4
4Mounting and installation (by the installer only)...............................8
4.1 Checking the parts delivered ...............................................8
4.2 Placing the fireplace ...........................................................8
4.3 Placing the flue duct ...........................................................9
4.3.1 System calculation for concentric flue duct ................10
4.3.2 Wall duct C11 ........................................................11
4.3.3 Roof duct C31........................................................11
4.3.4 Roof duct existing flue duct C31S .............................11
4.3.5 Adjusting bypass plates for Fairo: ............................12
60, 70, 75, 100, 120, 140, 140 Tunnel, 160 ..............12
4.3.6 Adjusting restrictor plate for Fairo:...........................12
100, 120, 140, 140 Tunnel and 160..........................12
4.4 Connecting gas regulation unit...........................................14
4.5 Connecting the radiographic remote control.........................15
4.6 Placing/ finishing the surround...........................................16
4.7 Mounting the spacer .........................................................17
5Preparing for use.............................................................................19
5.1 Placing the decorative elements .........................................19
5.1.1 Fairo 60 ceramic logs..............................................20
5.1.2 Fairo 70 ceramic logs..............................................21
5.1.3 Fairo 75 ceramic logs..............................................22
5.1.4 Fairo 100 ceramic logs ............................................24
5.1.5 Fairo 105 and Fairo 105 Tunnel ceramic logs .............25
5.1.6 Fairo 120 ceramic logs ............................................26
5.1.7 Fairo 140 ceramic logs ............................................28
5.1.8 Fairo 140 Tunnel ceramic logs..................................30
Positioned log set Fairo 140 Tunnel –Step 4 ......................31
5.1.9 Fairo 160 ceramic logs ............................................32
5.2 The first test....................................................................34
6Operation ........................................................................................35
6.1 Using the remote control for the first time...........................35
6.2 Basic menu .....................................................................35
6.3 Operation ex-factory ........................................................36
6.4 Operation from Timer and Thermostat mode .......................37
6.5 Replacing batteries...........................................................41
7Maintenance ....................................................................................42

Table of contents
7.1 Yearly.............................................................................42
7.2 Before and during the burning season.................................42
7.2.1 Removing the glass (60-70-75-100-120-140-160) .....42
7.2.2 Replacing the glass (60-70-75-100-120-140-160)......44
7.2.3 Removing the glass from the Fairo 105 Tunnel and Fairo
105 Front ..............................................................45
7.2.4 Removing the glass (140 Tunnel) .............................46
7.2.5 Replacing the glass (140 Tunnel) .............................49
8Trouble shooting (for the installer only)..........................................51
APPENDIX A: EC declaration of compliance
APPENDIX B: Connection diagram
APPENDIX C: Dimension diagrams
APPENDIX D: Guarantee

1. Introduction
1
1Introduction
The built in gas fireplace you have purchased from the Fairo line
manufactured by Kal-fire, is guaranteed to provide a lifetime of heating
satisfaction.
The Fairo line has the following models:
Fairo 60
Fairo 70
Fairo 75
Fairo 100
Fairo 105
Fairo 105 Tunnel
Fairo 120
Fairo 140
Fairo 140 Tunnel
Fairo 160
Symbols used
Kal-fire uses a number of symbols in this manual. These symbols indicate
possible damage to the product and/or a life threatening situation, if the
procedures are not observed carefully.
Warning of danger.
Warning of hazardous electric voltage.
Fire hazard.
Explosion hazard.

2. Safety
2
2Safety
2.1 CE Quality mark
The appliance has been approved according to CE standard EN-613.
Each appliance that leaves the factory has been tested technically and
for functionality according to the Kal-fire quality standards.
2.2 Safety instructions installer
An authorised installer will connect the Fairo in compliance
with the nationally and/or locally applicable regulations.
Before installation the gas supplies must be installed
according to the prevailing regulations.
In the event of a malfunction you must never deactivate,
override or modify the safety features in the Fairo and gas
regulator. Check the Fairo for correct functioning
immediately after installation. The safety features set at the
factory must not be modified.
Take the necessary preventive measures by using non-
combustible material to prevent over heating of floor,
boards or walls close to the Fairo.
If you have intentionally or unintentionally activated the flame
failure device, causing the Fairo to go out, wait for 3 minutes
before re-lighting the Fairo.

2. Safety
3
2.3 Safety instructions user
The Fairo is only intended for use as an additional heat source
and must never be used as the main heat source.
Never use the Fairo as an open fireplace, not even to test it!
The guard does not offer full protection to young children
and old/or infirm people and the handicapped. We advise
you to use an extra fireguard.
Replace damaged or broken glass.
Do not use the Fairo if the glass is damaged, broken and/ or
if there is no door/with an open door.
Ensure that curtains and/or other combustible materials are at a
distance of at least 50cm from the Fairo.
If you have intentionally or unintentionally activated the flame
failure device, causing the Fairo to go out, wait for 3 minutes
before re-lighting the Fairo.
2.4 Safety precautions
If the Fairo does not detect a flame, the gas supply will be
blocked.
The flame detection feature uses electronic ionization
measurement.
If no flame is detected after three attempts, the device will
be locked-out for 24 hours. This means that the Fairo
cannot be lit for a period of 24 hours.
The Fairo has an overpressure valve to minimise the risk of
injury following an explosion.

3. Technical specifications
4
3Technical specifications
Fairo 60
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
7.1
6.2
0.75
18.8
87.1
I2E+
G20
20mbar
7.1
6.2
0.75
18.8
87.1
G25
25mbar
6.6
5.1
0.81
23.8
78.0
I2ELL
G25
20mbar
6.0
4.7
0.74
19.2
78.6
I2E
G20
20mbar
7.1
6.2
0.75
18.8
87.1
I2L
G25
25mbar
6.6
5.1
0.81
23.8
78.0
G110
8-10mbar
I3B/P
G30
50mbar
8.0
7.0
0.25
28.0
87.7
I3B/P
G30
30mbar
8.0
7.0
0.25
28.0
87.7
I3+
G30
28-30mbar
8.0
7.0
0.25
28.0
87.7
I3P
G31
50mbar
7.8
6.8
0.32
36.0
87.3
I3P
G31
37mbar
7.8
6.8
0.32
36.0
87.3
I3P
G31
30mbar
6.8
5.9
0.28
29.0
86.7
Fairo 70
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
6.8
5.8
0.70
18.8
85
I2E+
G20
20mbar
6.8
5.8
0.70
18.8
85
G25
25mbar
6.4
5.3
0.77
23.6
83
I2ELL
G25
20mbar
6.0
4.7
0.74
19.2
79
I2E
G20
20mbar
6.8
5.8
0.70
18.8
85
I2L
G25
25mbar
6.4
5.3
0.77
23.6
83
G110
8-10mbar
I3B/P
G30
50mbar
7.1
5.6
0.22
28
79
I3B/P
G30
30mbar
7.1
5.6
0.22
28
79
I3+
G30
28-30mbar
7.1
5.6
0.22
28
79
I3P
G31
50mbar
7.1
5.5
0.28
36
78
I3P
G31
37mbar
7.1
5.5
0.28
36
78
I3P
G31
30mbar
Fairo 75
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
7.7
6.7
0.81
19.2
86.0
I2E+
G20
20mbar
7.7
6.7
0.81
19.2
86.0
G25
25mbar
8.5
6.8
1.05
24.2
78.7
I2ELL
G25
20mbar
7.6
5.9
0.94
19.2
76.4
I2E
G20
20mbar
7.7
6.7
0.81
19.2
86.0
I2L
G25
25mbar
8.5
6.8
1.05
24.2
78.7
G110
8-10mbar
I3B/P
G30
50mbar
8.0
6.9
0.25
28.0
86.6
I3B/P
G30
30mbar
8.0
6.9
0.25
28.0
86.6
I3+
G30
28-30mbar
8.0
6.9
0.25
28.0
86.6
I3P
G31
50mbar
7.9
6.9
0.32
36.0
87.6
I3P
G31
37mbar
7.9
6.9
0.32
36.0
87.6
I3P
G31
30mbar
7.0
5.7
0.29
28.5
81.3

3. Technical specifications
5
Fairo 100
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
8.9
7.3
0.92
19
81
I2E+
G20
20mbar
8.9
7.3
0.92
19
81
G25
25mbar
8.9
7.2
1.1
23.1
81
I2ELL
G25
20mbar
7.6
5.9
0.93
19.2
77
I2E
G20
20mbar
8.9
7.3
0.92
19
81
I2L
G25
25mbar
8.9
7.2
1.1
23.1
81
G110
8-10mbar
I3B/P
G30
50mbar
8.9
6.8
0.27
28
77
I3B/P
G30
30mbar
8.9
6.8
0.27
28
77
I3+
G30
28-30mbar
I3P
G31
50mbar
8.8
6.7
0.35
36
76
I3P
G31
37mbar
8.8
6.7
0.35
36
76
I3P
G31
30mbar
Fairo 105 en Fairo 105 Tunnel
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
8.9
7.3
0.92
19
76
I2E+
G20
20mbar
8.9
7.3
0.92
19
76
G25
25mbar
8.9
7.2
1.1
23.1
76
I2ELL
G25
20mbar
7.6
5.9
0.93
19.2
77
I2E
G20
20mbar
8.9
7.3
0.92
19
81
I2L
G25
25mbar
8.9
7.2
1.1
23.1
81
G110
8-10mbar
I3B/P
G30
50mbar
8.9
6.8
0.27
28
77
I3B/P
G30
30mbar
8.9
6.8
0.27
28
77
I3+
G30
28-30mbar
I3P
G31
50mbar
8.8
6.7
0.35
36
76
I3P
G31
37mbar
8.8
6.7
0.35
36
76
I3P
G31
30mbar
Fairo 120
Input
kW
Output
kW
Consumption
m3/h
Burner pressure
mbar
Heat output
%
I2H
G20
20mbar
10.02
8.22
1.06
18,7
82
I2E+
G20
20mbar
10.02
8.22
1.06
18,7
82
G25
25mbar
I2ELL
G25
20mbar
I2E
G20
20mbar
10.02
8.22
1.06
18,7
82
I2L
G25
25mbar
9.64
7.91
1.18
23.8
82
G110
8-10mbar
I3B/P
G30
50mbar
I3B/P
G30
30mbar
8.01
7.02
0.25
28
88
I3+
G30
28-30mbar
8.01
7.02
0.25
28
88
I3P
G31
50mbar
I3P
G31
37mbar
10.44
8.55
0.42
36
82
I3P
G31
30mbar
9.38
7.48
0.38
29
80

3. Technical specifications
6
Fairo 140
Input
kW
Output
kW
Verbruik
m3/h
Branderdruk
mbar
Rendement
%
I2H
G20
20mbar
13.8
9.9
1.46
19.3
72
I2E+
G20
20mbar
13.8
9.9
1.46
19.3
72
G25
25mbar
13.1
9.0
1.61
23.7
70
I2ELL
G25
20mbar
I2E
G20
20mbar
13.8
9.9
1.46
19.3
72
I2L
G25
25mbar
13.1
9.0
1.61
23.7
70
G110
8-10mbar
I3B/P
G30
50mbar
12.1
8.1
0.38
28
67
I3B/P
G30
30mbar
12.1
8.1
0.38
28
67
I3+
G30
28-30mbar
12.1
8.1
0.38
28
67
I3P
G31
50mbar
15.9
12.2
0.65
35.8
77
I3P
G31
37mbar
15.9
12.2
0.65
35.8
77
I3P
G31
30mbar
Fairo 140 Tunnel
Input
kW
Output
kW
Verbruik
m3/h
Branderdruk
mbar
Rendement
%
I2H
G20
20mbar
15.1
12.3
1.58
19.0
82
I2E+
G20
20mbar
15.1
12.3
1.58
19.0
82
G25
25mbar
15.4
12.3
1.86
23.8
81
I2ELL
G25
20mbar
I2E
G20
20mbar
15.1
12.3
1.58
19.0
82
I2L
G25
25mbar
15.4
12.3
1.86
23.8
81
G110
8-10mbar
I3B/P
G30
50mbar
I3B/P
G30
30mbar
I3+
G30
28-30mbar
13.7
10.9
0.45
29.4
80
I3P
G31
50mbar
I3P
G31
37mbar
I3P
G31
30mbar
Fairo 160
Input
kW
Output
kW
Verbruik
m3/h
Branderdruk
mbar
Rendement
%
I2H
G20
20mbar
14.4
11.3
1.51
18.5
79
I2E+
G20
20mbar
14.4
11.3
1.51
18.5
79
G25
25mbar
15.2
12.2
1.86
22.6
80
I2ELL
G25
20mbar
I2E
G20
20mbar
14.4
11.3
1.51
18.5
79
I2L
G25
25mbar
15.2
12.2
1.86
22.6
80
G110
8-10mbar
I3B/P
G30
50mbar
16.5
12.9
0.51
28
78
I3B/P
G30
30mbar
16.5
12.9
0.51
28
78
I3+
G30
28-30mbar
I3P
G31
50mbar
16.0
12.3
0.66
35.6
76
I3P
G31
37mbar
16.0
12.3
0.66
35.6
76
I3P
G31
30mbar
14.7
10.8
0.60
29
74

3. Technical specifications
7
Country overview
AT
BE
CH
CZ
DE
DK
ES
FI
FR
HU
I2H
G20
20mbar
√
√
√
√
√
√
√
I2E+
G20
20mbar
√
√
G25
25mbar
√
√
I2ELL
G25
20mbar
√
I2E
G20
20mbar
√
I2L
G25
25mbar
G110
8-10mbar
√
√
√
I3B/P
G30
50mbar
√
√
√
√
I3B/P
G30
30mbar
√
√
√
√
√
√
I3+
G30
28-30mbar
√
√
√
√
√
I3P
G31
50mbar
√
√
√
√
√
√
I3P
G31
37mbar
√
√
√
√
√
I3P
G31
30mbar
√
√
Country overview (continued)
GB
GR
IE
IT
LU
NL
NO
PT
PL
I2H
G20
20mbar
√
√
√
√
√
√
I2E+
G20
20mbar
G25
25mbar
I2ELL
G25
20mbar
√
√
I2E
G20
20mbar
√
√
I2L
G25
25mbar
√
G110
8-10mbar
√
I3B/P
G30
50mbar
I3B/P
G30
30mbar
√
√
√
√
I3+
G30
28-30mbar
√
√
√
√
√
I3P
G31
50mbar
√
√
√
I3P
G31
37mbar
√
√
√
√
√
√
I3P
G31
30mbar
√
√

4. Mounting and installation
8
4Mounting and installation (by the installer only)
4.1 Checking the parts delivered
Check that you have received the following parts:
Appliance
Installation and user instructions
Ceramic logs / Chips / Kal-Glow (glowing effect) / White stones
(depending on your order)
Adjustment feet
Mounting bracket with mounting material
Aerosol can
Suction cup
4.2 Placing the fireplace
1. Screw the adjustment feet in
the Fairo and place the Fairo in
the required position. The
Fairo must rest on the
adjustment feet.
Setting range: 4 cm

4. Mounting and installation
9
2. The Fairo must not be positioned against a
wall that is warmer than 85 C. We advise
you to insulate the wall using, for example,
3 cm calcium silicate plate (0.07W/m.K) and
a small gap between the Fairo and the
insulation.
To prevent overheating, do not
insulate the Fairo entirely.
3. Use the brackets supplied to
mount the Fairo stably to the
wall.
4.3 Placing the flue duct
The Fairo must only be connected using the Kal-fire concentric
flue gas material. If this instruction is not obeyed, no safeguard
can be given for the system. During the CE inspection the
appliances are certified with this duct; different resistance values
apply to each type of duct.
The flue duct must be connected air-tight to the Fairo. If there is
any play between the Fairo and the flue duct, close this gap with
sealing material (fibreglass cord).

4. Mounting and installation
10
4.3.1 System calculation for concentric flue duct
Use the following rules of thumb to calculate the flue duct. The
calculations apply to the wall and roof ducts. If you use calculations
different to those shown below, Kal-fire can give no safeguard or
guarantee for the Fairo.
Flue/ chimney calculation
Value per
metre
Max.
Value
1st vertical metre
9
9
2nd and next vertical metre
1
11
Horizontal metre
-1
-7
Vertical elbow 90° (A)
-2
-6
Vertical elbow 45°
-1
Horizontal elbow 90° (B)
-4
-8
Horizontal elbow 45°
-2
Result
0 / positive
If you use too many elbows and mount the duct in a rather horizontal
position, too much resistance will be created in the flue. The combustion
air will have difficulty reaching the Fairo, which will considerably change
the effect of the flames.
Always start with 1 metre of vertical pipe section!
Maximum permitted total system length
Maximum permitted horizontal system length
12m
7m
The longer the duct, the longer it will take before you get
attractive flames.
Calculation example
Flue/chimney calculation
Example:
number of
elements
used (X)
Value per m:
a number, no
quantity
(Y)
Total
value
example
(X * Y)
Max.
permit-
ted
value
1st vertical metre
1
9
9
9
2nd and next vertical metre
1
11
Horizontal metre
-1
-7
Vertical elbow 90° (A)
-2
-6
Vertical elbow 45°
-1
Horizontal elbow 90° (B)
-4
-8
Horizontal elbow 45°
-2
Result*
*The sum of all values must be zero or positive, otherwise the Fairo will not function
according to EN613.
B
A
A

4. Mounting and installation
11
4.3.2 Wall duct C11
For distances to adjoining walls, coverings and windows, please
refer to the national legislation.
4.3.3 Roof duct C31
When placing the roof duct ensure no air turbulence can occur in
the mounting area. For this reason, always leave enough space
between the wall/roof and the roof duct.
4.3.4 Roof duct existing flue duct C31S
With an existing flue duct, you can use two connectors.
At the top use the ventilation plate with a draught
increasing hood. Connect a flue liner or flexible flue liner to
this, fitted through the existing duct.
Check the flue duct for any leaks which may cause under
pressure. In turn this will prevent the closed system from
functioning properly.
With a very old flue, use two flexible pipes. The inner pipe
must be centred in the middle, to prevent blockages.
At the entrance to the flue duct, mount the cover plate.
Ensure this is well sealed.
For distances to adjoining walls, coverings and windows, please
refer to the national legislation.

4. Mounting and installation
12
4.3.5 Adjusting bypass plates for Fairo:
60, 70, 75, 100, 120, 140, 140 Tunnel, 160
With a roof duct or strong draught in the flue duct, the bypass plate at
the rear of the burner cover should be removed. This will create higher
flames.
With Bypass plate
Without Bypass plate
4.3.6 Adjusting restrictor plate for Fairo:
100, 120, 140, 140 Tunnel and 160
Position restrictor plate
Result of chimney calculation
Plates removed
0 to 7
Plates pushed inwards
8 to 10
Plates pushed outwards
11 to 14
Without Bypass plate (see page 11)
15 to 20
Plates removed:
Plates pushed inwards:

4. Mounting and installation
13
Plates pushed outwards:

4. Mounting and installation
14
4.4 Connecting gas regulation unit
On delivery the gas regulation unit is on the
left side of the Fairo. The technical box with
the gas regulator should be placed, seen from
the left side of the Fairo, within a range of
1.5m (4m with flexible gas pipe), behind the
supplied hatch.
Method
1. Disconnect technical box with the gas
regulator and place it, preferably, in
one of the side walls of the surround.
Always connect an approved, operable
gas tap; space has been reserved for
the gas tap in the technical box with
the gas regulator. Remove the receiver
in order to easily turn the gas tap in
the gas regulator. The connection is
1/2" female thread.
2. Place the technical box with the gas
regulator, seen from the left side of
the Fairo, within a range of 1.5m. In
order to work within a range of 4m,
the Fairo will be delivered with 4m
flexible gas pipe. With the 1.5 metre
version, 4m of cabling is always
delivered; this must not be shortened.

4. Mounting and installation
15
Ferriferous materials can block the remote control signal. Take this
into account during installation. The signal strength is also weaker
if there is an intermediate wall. Check by pressing keys and on
the remote control simultaneously. If both figures exceed -80 (e.g.
-60), then Kal-fire guarantees good functioning.
The technical box must not become warmer than 60 C, otherwise
the Fairo will go into safety mode.
Conversion to a different category of gas is only permitted by the
producer or the installer in cooperation with the producer.
3. Before connecting the gas, check the entire installation for leaks.
4. Check the pre-pressure using a gas pressure meter and ensure that
all soiling is removed from the pipes; this is to prevent blockages and
obstructions. The pre-pressure must correspond with the pressure
stated on the CE-identification plate. If the pipes used are too small,
the pre-pressure may drop during use. The difference may not be
more than 2mbar.
4.5 Connecting the radiographic remote control
The Fairo has a radiographic remote control. Place a 230V earthed
socket, a phase and a zero.
The Fairo is phase sensitive. Please take this into account. If you
start the Fairo and an F08 malfunction occurs, turn the plug. This is
not possible in every country. In the female plug it is possible to
reverse the polarity of the phase wire and the zero wire.

4. Mounting and installation
16
4.6 Placing/ finishing the surround
Test the Fairo, if possible, before completely finishing the surround
(section 5.2).
The coefficient of expansion of the Fairo and the surround differ. For this
reason, to prevent cracks appearing in the plasterwork or any other
damage, ensure the Fairo and the surround do not touch. The material
used for the surround must be heat resistant and fireproof. There must
be no combustible materials in the vicinity of the Fairo. Material,
plasterwork and wallpaper used to decorate the wall (especially above
the appliance) must be heat resistant.
A heat protection plate is mounted at
the front of the Fairo to ensure the
surround is cooled properly. Ensure
that air is exhausted into the same
pressure area. The opening used to
extract the air must have a surface
area of 2*150*100mm (150 cm²).
Discoloration of walls, ceilings and gratings
Once the Fairo is ignited, burnt dust particles can cause the walls,
ceilings and gratings to discolour. This is a natural process, which
Kal-fire cannot be held liable for. This is why we advise you to
follow the guidelines set by the fire-place gilde, in order to limit
the discoloration to a minimum.