KAL-FIRE Fairo 90 Instruction Manual

Installation / User Manual
Product Fairo 90 Tunnel 3-sided
Fairo 90 open sided L/R
Fairo 90 3-sided front
Product group Balanced flue gas system
Model 90
Version 0 -2013
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.
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  2013 Kal-fire B.V.
Belfeld, the Netherlands

Table of contents
Table of contents
1 Introduction .............................................................................1
2 Safety .....................................................................................2
2.1 CE Quality mark .................................................................2
2.2 Safety instructions installer .................................................2
2.3 Safety instructions user ......................................................3
2.4 Safety precautions .............................................................3
3 Technical specifications .............................................................4
4 Mounting and installation (by the installer only)............................7
4.1 Checking the parts delivered ...............................................7
4.2 Placing the fireplace ...........................................................7
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 restrictor plate for Fairo 90 Tunnel 3-sided .. 12
4.3.6 Adjusting restrictor plate for Fairo 90 3-sided Front .... 13
4.4 Connecting gas regulation unit ........................................... 14
4.5 Connecting the radiographic remote control......................... 15
4.6 Placing/ finishing the surround ........................................... 16
5 Preparing for use .................................................................... 17
5.1 Placing the decorative elements ......................................... 17
5.1.1 Fairo 90 Tunnel 3-sided ceramic logs ........................ 1
5.1.2 Fairo 90 3-sided Front ceramic logs .......................... 21
6 Operation .............................................................................. 25
6.1 Using the remote control for the first time ........................... 25
6.2 Basic menu ..................................................................... 25
6.3 Operation ex-factory ........................................................ 26
6.4 Operation from Timer and Thermostat mode ....................... 27
6.5 Replacing batteries ........................................................... 31
7 Maintenance .......................................................................... 32
7.1 Yearly ............................................................................. 32
7.2 Before and during the burning season ................................. 32
7.2.1 Removing the glass Fairo Tunnel 3-sided ................... 32
7.2.2 Replacing the glass Fairo Tunnel 3-sided ................... 34
7.2.3 Removing the glass Fairo 90 open sided L/R .............. 36
7.2.4 Replacing the glass Fairo 90 open sided L/R .............. 3
7.2.5 Removing the glass Fairo 90 3-sided Front ................ 40
7.2.6 Replacing the glass Fairo 90 3-sided Front................. 41
Trouble shooting (for the installer only) ..................................... 42

Table of contents
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.
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
2. 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.
After installation the glass is considered to be an active zone. Be
aware that temperatures here can become very high!
...............................................................................................
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.

. Technical specifications
4
Technical specifications
Fairo 90 Tunnel 3-sided and Fairo 90 Open-sided
Gas
cat.
Gas
type
Connect.
pressure
Input
kW
Output
kW
with 1m, 90⁰
and wall duct
Consumption
m3/h
Burner
pressure
mbar
Heat
output
class
I2H G20 20mbar 9.5 .1 1.01 1 .9 1
I2E+ G20 20mbar 9.5 .1 1.01 1 .9 1
I2E G20 20mbar 9.5 .1 1.01 1 .9 1
I2L G25 25mbar 9.4 .01 1.15 23.6 1
I3B/P G30 30mbar 7.2 5.91 0.22 27.9 1
I3B/P G30 50mbar
I3+ G30 25-30mbar 7.2 5.91 0.22 27.9 1
I3+ G31 37 mbar 7.2 5.95 0.29 35. 1
I3P G31 30mbar 6.4 5.30 0.26 2 .9 1
I3P G31 37mbar 7.2 5.95 0.29 35. 1
I3P G31 50mbar
Fairo 90 3-sided front
Gas
cat.
Gas
type
Connect.
pressure
Input
kW
Output
kW
with 1m, 90⁰
and wall duct
Consumption
m3/h
Burner
pressure
mbar
Heat
output
class
I2H G20 20mbar .6 6.7 0.91 19.1 2
I2E+ G20 20mbar .6 6.7 0.91 19.1 2
I2E G20 20mbar .6 6.7 0.91 19.1 2
I2L G25 25mbar .0 6.2 0.9 23.6 2
I2ELL G25 20mbar 7,2 5.4 0. 9 19.1 2
I3B/P G30 30mbar 6.4 4. 0.20 16 2
I3B/P G30 50mbar 6.4 4. 0.20 16 2
I3+ G30 25-30mbar 6.4 4. 0.20 16 2
I3+ G31 37 mbar - - - - -
I3P G31 30mbar - - - - -
I3P G31 37mbar - - - - -
I3P G31 50mbar - - - - -

. Technical specifications
5
ountry 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 -10mbar
I3B/P G30 50mbar
I3B/P G30 30mbar √ √ √ √ √ √
I3+ G30 2 -30mbar
√ √ √ √ √
I3P G31 50mbar
I3P G31 37mbar √ √ √ √ √
I3P G31 30mbar √ √
ountry 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 -10mbar √
I3B/P G30 50mbar
I3B/P G30 30mbar √ √ √ √
I3+ G30 2 -30mbar √ √ √ √ √
I3P G31 50mbar
I3P G31 37mbar √ √ √ √ √ √
I3P G31 30mbar √ √

. Technical specifications
6
Electric connection data
•230V
•50Hz
•12 mA
•3W maximum

4. Mounting and installation
7
4Mounting and installation (by the installer only)
Before installation check if the gas pressure and gas category correspond
with the connection data on the type identification plate.
Provide a 230V wall socket with earthed plug.
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 (optional)
• 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 or on
the optional suspension bracket.
Setting range: 4 cm
2. The Fairo must not be positioned
against a wall that is warmer than
5°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.

4. Mounting and installation
8
Mount the suspension plate
using left and right fixing points.
Mount the bracket to the wall.
Hook the fireplace onto the
bracket.
Screw the bracket to the fireplace.
Start mounting the surround.
Hook the cover (optional) onto
the surround using the
mounting bracket.
Place and screw the cover onto the
brackets.
3. Mounting (optional) brackets and support for stable mounting of the
Fairo 90 3-sided Tunnel/90 Corner on a wall. This is not available for
the Fairo 90 3-sided Front.
1 2
3 4
5 6

4. Mounting and installation
9
If a platform has to be mounted
to the fireplace, supports can be
placed around the appliance
around. Then slide the platform
over the edges of the brackets.
Attention!
Max. platform weight: ±70kg.
4. 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).
The Fairo 90 series should be connected using Kal-fire air concentric flue
gas outlet systems with a diameter of Ø100/150mm.

4. Mounting and installation
10
4. .1 System calculation for concentric flue duct
Important: use Kal-fire concentric flue duct materials with the correct
diameter. 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
Diameter 150/100
Value per
metre
Max.
permitted
Value
1
st
vertical metre
9
9
2
nd
and next vertical metre
1
11
Horizontal metre
-
1
-
3
Vertical elbow 90° (A)
-
2
-
6
V
ertical 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
3m
The longer the duct, the longer it will take before you get
attractive flames.
alculation example
Flue/chimney calculation
Diameter 150/100
Example:
number of
elements
used (X)
Value per m:
a number, no
quantity
(Y)
Total
value
example
(X * Y)
Max.
permit-
ted
value
1
st
vertical metre 1 9 9 9
2
nd
and next vertical metre 1 11
Horizontal metre -1 -3
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. .2 Wall duct C11
For distances to adjoining walls, coverings and windows, please
refer to the national legislation.
4. . Roof duct C 1
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. .4 Roof duct existing flue duct C 1S
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. .5 Adjusting restrictor plate for Fairo 90 Tunnel -sided
Position restrictor plate Result of chimney calculation
Plates pushed inwards (position 1) 0 to 10
Plates pushed outwards (position 2) 11 to 14
Plates pushed inwards (position 1):
Plates pushed outwards (position 2):

4. Mounting and installation
1
4. .6 Adjusting restrictor plate for Fairo 90 -sided Front
Position restrictor plate Result of chimney calculation
Plates pushed inwards ( position1) 0 to 10
Plates pushed outwards (position 2) 11 to 14
Plates pushed inwards (position 1):
Plates pushed outwards (position 2):

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 extension set), 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 (e.g.
approved by national authorities),
operationable gas tap; space has been
reserved for the gas tap in the
technical box with the gas regulator.
Remove the receiver to turn the gas
tap more easily.
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. The
Fairo will be delivered with 4m flexible
gas pipe so you can work within a
range of 4m. 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 - 0 (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 F0 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.
The Fairo 90 Tunnel 3-
sided expands a
minimum of 5m
horizontally/vertically. To
prevent cracks appearing
in the plasterwork or any
other damage, ensure
the Fairo and the surround do not touch (10 mm gap). 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.
Ensure that de-aeration of the
convection and aeration take place
in the same area of pressure. This
should have a surface of at least
2*150*100mm (150 cm²).
The Fairo 90 3-sided Front
features a convection casing as
standard. This must be connected
using the convection tubes (2*
150mm) and grids or outlets.
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. Please follow the advice given by
suppliers of fireplaces to restrict discolouration to a minimum.