KAL-FIRE Heat Pure Series 65R Instruction Manual

Installation / User Manual
Product Heat Pure
Product group Wood burning fireplaces with lifting door
Application Open and closed
Models 65R, 65L, 66 3 , 90R, 90L, 90 3 , 80T,
105T
Version March 2016
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 series. 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  2016 Kal-fire B.V.
Belfeld, the Netherlands

Table of contents
Table of contents
1 Introduction 1
2 Safety 2
2.1 CE-marking ...................................................................... 2
2.2 afety instructions installer ................................................. 2
2.3 afety instructions user ...................................................... 3
2.4 afety precautions ............................................................. 4
3 Mounting and installation 10
3.1 Check before building in/mounting ..................................... 10
3.2 Check flue ...................................................................... 12
3.3 Placing the appliance ....................................................... 13
3.4 upply of combustion air .................................................. 16
3.5 upply of convection air ................................................... 18
3.6 Chimney/flue connection .................................................. 22
3.7 Mounting the damper ....................................................... 25
3.8 Adjusting the feet ............................................................ 26
3.9 Baffle plate ..................................................................... 29
3.10 Finish ............................................................................. 31
Preparing for use 3
4.1 Type of wood .................................................................. 34
4.2 toring the wood ............................................................. 35
4.3 Ventilation ...................................................................... 35
5 Lighting the Heat Pure 36
5.1 Lighting the Heat Pure for the first time .............................. 36
5.2 Opening the door ............................................................. 36
5.3 Air regulation .................................................................. 38
5.4 Using the Heat Pure with an open or closed door ................. 39
5.5 Igniting the Heat Pure ...................................................... 40
5.6 Optimal heat output ......................................................... 44
5.7 Operation the damper (optional) ....................................... 47
6 Maintenance 8
6.1 Keeping clean panes ........................................................ 48
6.2 Cleaning the pane ............................................................ 48
6.3 Cleaning the grate ........................................................... 50
6.4 Maintenance ................................................................... 53
7 Trouble shooting 5
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.
This installation and user manual is relevant for the following models in
the Heat Pure series:
•Heat Pure 65 corner right (65R)
•Heat Pure 65 corner left (65L)
•Heat Pure 66 3-sided (66 3 )
•Heat Pure 90 corner right (90R)
•Heat Pure 90 corner left (90L)
•Heat Pure 90 3-sided (90 3 )
•Heat Pure 80 tunnel (80T)
•Heat Pure 105 tunnel (105T)
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.

2. Safety
2
2Safety
2.1 CE-markin
The appliance has been approved according to the CE standard EN-
13229-A2.
Every appliance that leaves the factory has been tested for functionality
according to the Kal-fire quality standards.
National and local building and fire regulations apply to the
Heat Pure. Both local and national requirements must be
respected.
The relevant local authorities must be notified before
adding the external elements to the fireplace insert in
order to verify the quality of the installation.
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
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. 1: The distance between any built-in furniture and the
fireplace, should be at least 5 cm.
•Nr. 2: The distance between any wall-, floor- and /or ceiling
material should be at least 1 cm.
•Nr. 3+4: Make sure that curtains, furniture and/or other
combustible materials are at least 100 cm removed from the
Heat Pure. If a fireguard is used, this distance must be at
least 40 cm.
1
2
3
4

2. Safety
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 insulation
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.
Table 1: Prescribed insulation thickness to combustible materials
Heat
Pure
Type
Inspection Isorath 1000 Promasil
Mineral wool
(AGI Q 132)
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)
Rear panel (cm)
Side panel (cm)
Roof (cm)
Base (cm)
65R/L
5 5 9 * 2,6 2,7 5,3 * 2 2,1 4,1 * 5 5 9 *
90R/L
10 10 9 * 2,6 2,7 5,3 * 2 2,1 4,1 * 5 10 9 *
66 3s
10 10 9 * 2,6 2,7 5,3 * 2 2,1 4,1 * 10 10 9 *
90 3s
10 5 9 * 2,6 2,7 5,3 * 2 2,1 4,1 * 5 5 9 *
80T
10 - 9 * 2,6 - 5,3 * 2 - 4,1 * 5 - 9 *
105T
10 - 9 * 2,6 - 5,3 * 2 - 4,1 * 5 - 9 *

2. Safety
5
2.4.1 Installation of the Heat Pure 65 corner in combination with
combustible materials (e. . a wooden wall)
When installing the Heat Pure pay attention to the distance to
combustible building materials:
Image: cross-section of a corner Heat Pure 65 corner
Combustible materials must be shielded by insulation material with a
minimum thickness of 5 cm. The distance from the back of the Heat Pure
to the combustible material must be a minimum of 10 cm.
* The floor the Heat Pure 65 corner is placed on must be made
of non-combustible materials. The (combustible) floor in front
of the door opening must be protected to a distance of at least
50 cm in front of the appliance (side/sides with a glass door).
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
6
2.4.2 Installation of the Heat Pure 90 corner in combination with
combustible materials (e. . a wooden wall)
When installing the Heat Pure 90 corner pay attention to the distance to
combustible building materials:
Image: cross-section of a corner Heat Pure 90 corner
Combustible materials must be shielded by insulation material with a
minimum thickness of 10 cm.
* The floor the Heat Pure 90 corner is placed on must be made
of non-combustible materials. The (combustible) floor in front
of the door opening must be protected to a distance of at least
50 cm in front of the appliance (side/sides with a glass door).

2. Safety
7
2.4.3 Installation of the Heat Pure 66 3-sided and Heat Pure 90 3-
sided in combination with combustible materials (e. . a
wooden wall)
When installing the Heat Pure 66 3-sided and Heat Pure 90 3-sided pay
attention to the distance to combustible building materials:
Image: cross-section of a 3-sided Heat Pure
Combustible materials must be shielded by insulation material with a
minimum thickness of 10 cm. The distance from the back of the Heat
Pure to the combustible material must be a minimum of 10 cm.
* The floor the Heat Pure 3-sided is placed on must be made
of non-combustible materials. The (combustible) floor in front
of the door opening must be protected to a distance of at least
50 cm in front of the appliance (side/sides with a glass door).

2. Safety
8
2.4.4 Installation of the Heat Pure 80 tunnel and Heat Pure 105
tunnel in combination with combustible materials (e. . a
wooden wall)
When installing the Heat Pure 80 tunnel and Heat Pure 105 tunnel pay
attention to the distance to combustible building materials:
Image: cross-section of a Heat Pure tunnel
Combustible materials must be shielded by insulation material with a
minimum thickness of 10 cm. The distance from the back of the Heat
Pure to the combustible material must be a minimum of 30 cm.
* The floor the Heat Pure tunnel is placed on must be made of
non-combustible materials. The (combustible) floor in front of
the door opening must be protected to a distance of at least 50
cm in front of the appliance (side/sides with a glass door).

2. Safety
9
2.4.5 Prescribed materials
Insulation
Use mats, plates or strips made from silicate insulation materials (stone,
clinkers, ceramic fibres); construction class A1 according to DIN 4102
Part 1, with an upper limit temperature of at least 700°C, tested
according to DIN 52271 and a nominal density of 80 kg/m.
These materials need to have a corresponding insulation material
registration number, according to AGI-Q 132. 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 18895 resp. EN 13229/DIN 18160.
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.
ome 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
10
3Mountin and installation
Before installing the appliance, check if the load bearing capacity of the
floor is sufficient to bear the weight of the appliance and the intended
surround (see table 5) for a long period of time. If this is not the case,
please take the necessary precautions (e.g. distributing the pressure
points by using a dimensionally stable, fire resistant sheet)
3.1 Check before buildin in/mountin
3.1.1 Heat Pure 65 corner, 66 3-sided, 90 corner and 90 3-sided
1. 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 (Two screws in the convection duct with
yellow sticker on the rear of the convection casing).
3. Check the following parts for correct working:
- Lifting door up and down
- Opening and closing the design doors
- 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
Heat Pure 3
-
sided
Heat Pure corner

3. Mountin and installation
11
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.
3.1.2 Heat Pure 80 tunnel and Heat Pure 105 tunnel
1. 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/user 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
12
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
1. Check the flue for proper functioning; minimum required draught
(suction) is 12 Pa.
2. Test the air slide valve for proper functioning; this will work after the
fire has burnt for 50 minutes: (see chapter 3.3.1)
- 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
13
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 extracted 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:
This situation must also be safeguarded if easily
accessible control equipment used for the ventilating
installation is moved or removed.
a supply of fresh air is ensured by the air intake system,
allowing the smoke extraction system to function (e.g.
by means of an open window or a fresh air supply
system).

3. Mountin and installation
14
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 100%
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
a liance.
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
15
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 closed”

3. Mountin and installation
16
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).
ome air valve manufacturers use plastic sleeves. Mount
these outside the heat 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. Mountin and installation
17
3.4.1 Fresh air connection base or rear (corner, 3-sided and
tunnel)
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
1. 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.