Kinder Concept Series User manual

Concept
DECORATIVE FUEL EFFECT GAS FIRE
Installation and aintenance Instructions
Hand these instructions to the user
odel No’s KCDW**RN2 & KCDW** N2 are only for use on Natural
Gas (G20) at a supply pressure of 20 mbar in G.B. / I.E.

CONTENTS
Section 1 Information and Requirements PAGE
1.0 Appliance Information 3
1.1 Conditions of Installation 4
1.2 Flue and chimney suitability 4
1.3 Fireplace / surround suitability 5
1.4 Shelf position 5
1.5 Chimney inspection 5
1.6 Fire place opening / catchment space 6
1.7 Fitting to Metal Flue Boxes 8
1.8 Hearths 8
1.9 Spillage Monitoring System 8
1.10 Tactile / Physical Barriers 9
Section 2 Installation of Fire
2.1 Unpacking the fire 9
2.2 Installing the fire box 10-18
2.3 Preparation of the fireplace opening 11
2.4 Gas tightness and inlet pressure (Manual Control models) 19
2.5 Gas tightness and inlet pressure (Remote Control models) 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 20-22
3.2 ighting the appliance (Remote Control model) 23-24
3.3 ighting the appliance (Manual Control model) 25
3.4 Fitting the Concept Fascia 26
3.5 Checking for clearance of combustion 26
products
Section 4 aintenance
4.1 Removal of the Burner Assembly (Manual) 27
4.2 Removal of the Piezo Igniter 27
4.3 Removal of the Control Tap 28
4.4 Removal of the Oxy-Pilot Assembly 28
4.5 Removal of the Burner Assembly (Remote) 28-29
4.6 Removal of the Remote Gas Valve 29
4.7 Repacing the Oxy-Pilot Assembly 29-30
4.8 Removing the Batteries 30
This appliance is manufactured by :-
BFM Europe td, Trentham akes, Stoke-on-Trent, ST4 4TJ
2

SECTION 1
INFOR ATION AND REQUIRE ENTS
1.0 APPLIANCE INFOR ATION
Model KCDW**MN2 (Manual Control)
KCDW**RN2 (Remote Control)
Gas Type G20
Main injector (1 off) Size 380
Pilot Type Copreci 21100 / 141
Max. Gross Heat Input : 6.5 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : All models - 20.0 +/-1.0 mbar
Ignition : RC Models - 9V Battery Generator
MC Models - Push Button Piezo
Electrode Spark Gap 4.5mm Nominal
Packed Weight 20.0 kg
Fire box Dimensions (with trim fitted)
Width : (with standard trim) 605mm
Height : (with standard trim) 610mm
Depth : (overall-without fender) 73mm
Depth : Flush-fit (from mounting face to rear) 250mm
Gas Connection 8mm Compression (Supplied with fire)
3

INSTALLATION REQUIRE ENTS
1.1 CONDITIONS OF INSTALLATION
It is the law that all gas appliances are installed only by a CORGI Registered
Installer, in accordance with these installation instructions and the Gas Safety
(Installation and Use) Regulations 1998 as amended. Failure to install appliances
correctly could lead to prosecution. It is in your own interest and that of safety to
comply with the law.
The installation must also be in accordance with all relevant parts of the ocal and
National Building Regulations where appropriate, the Building Regulations
(Scotland Consolidation) issued by the Scottish Development Department, and all
applicable requirements of the following British Standard Code of Practice.
1. BS 5871 Part 3 Installation of Decorative Fuel Effect Gas Fires
2. BS 6891 Installation of Gas Pipework
3. BS 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. BS 1251 Open fire place components
5. BS 715 / BS EN 1856-2 Metal flue pipes for gas appliances
6. BS 6461 Part 1 Installation of Chimneys and flues
7. IS 813 : 1996 Domestic Gas Installation (Republic of Ireland)
No purpose made additional ventilation is normally required for this
appliance, when installed in G.B. When Installing in I.E. please consult
document I.S. 813 : 1996 Domestic Gas Installation, which is issued by the
National Standards Authority of Ireland. If installing in Northern Ireland,
please consult local building regulations. Any purpose made ventilation
must be checked periodically to ensure that it is free from obstruction.
1.2 FLUE AND CHI NEY SUITABILITY
This appliance is designed for use with conventional brick built or lined chimneys
and fabricated flues and metal flue boxes conforming to BS 715 / BS EN 1856-2.
All flues must conform to the following minimum dimensions.
inimum diameter of circular flues 175 mm
inimum effective height of all flue types 3 metres
The flue baffle must be fitted when installing this product into a
conventional brick built chimney, to prevent debris falling onto the fuelbed.
If fitting into a class 1 (175mm) metal flue box and liner, it is desirable to leave the
baffle in place to reduce the flue flow. Safe clearance of products must always be
checked by carrying out a smoke match test as described on page 26.
4

1.3 FIREPLACE / SURROUND SUITABILITY
The fire must only be installed on a hearth it must not be installed directly onto
carpet or other combustible floor materials.
The fire is suitable for fitting to non-combustible fire place surrounds and
proprietary fire place surrounds with a temperature rating of at least 150oc.
If a heating appliance is fitted directly against a wall without the use of a fire
surround or fire place all combustible material must be removed from behind
the trim. Soft wall coverings such as blown vinyl, wall paper etc. could be
affected by the rising hot air and scorching and/or discoloration may result.
Due consideration should be made to this when installing or decorating.
1.4 SHELF POSITION
The fire may be fitted below a combustible shelf providing there is a minimum
distance of 200mm above the top of the fire and the shelf does not project more
than 150mm. If the shelf overhangs more than 150mm the distance between the
fire and the shelf must be increased by 15mm for every 25mm of additional over-
hang over 150mm.
1.5 FLUE / CHI NEY INSPECTION
Before commencing installation, a flue or chimney should be inspected to ensure
that all the following conditions are satisfied.
1. Check that the chimney / flue only serves one fire place and is clear of any
obstruction. Any dampers or register plates must be removed or locked in
the open position.
2. Brick/stone built chimneys or any chimney or flue which has been used for
an appliance burning fuel other than gas must be thoroughly swept. The
base of the chimney / flue must also be thoroughly cleared of debris etc.
3. Any under-floor air supply to the fire place must be completely sealed off.
4. Ensure that the inside of the chimney / flue is in good condition along it’s
length and check that there is no leakage of smoke through the structure
of the chimney during and after the smoke pellet test.
5. Using a smoke pellet, check that there is an up-draught in the
chimney / flue and that the smoke can be seen issuing from the
terminal / chimney pot outside.
5

There must be no leakage of smoke through the structure of
the chimney during or after the smoke pellet test and it is
important to check inside upstairs rooms adjacent to the chimney /
flue. Check the chimney pot / terminal and general condition of the
brickwork or masonry. If the chimney or flue is in poor condition or if
there is no up-draught do not proceed with the installation. If there is a
history of down-draught conditions with the chimney / flue, a tested and
certificated flue terminal or cowl suitable for the relevant flue type should
be considered.
6. A spillage test must always be carried out during commissioning of
the appliance.
1.6 FIRE PLACE OPENING AND CHI NEY CATCH ENT SPACE
The front opening of the fire place must be between 400 and 450 mm wide, and
between 550 and 570mm high. If the opening exceeds these dimensions then a
surround must be constructed from suitable non-combustible material to produce a
correct size opening. Any surround must be suitably sealed to the fire place to
prevent leakage. See below in fig.1
When installing into a brick built chimney, you must ensure that there is sufficient
depth to accomodate any debris which may fall from the chimney. This depth
must be sufficient to accomodate 12 litres of volumetric debris.
Fire Opening
400mm Minimum
450mm Maximum
580mm
Minimum
470mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
Sealing Area
6

Table A - Installation Depth Requirements for a Kinder Concept being
installed into a bric built chimney, requiring 12.0 litres of debris collection
volume (fig. 2)
Opening Width (mm) Minimum Depth Required (mm)
400 (minimum opening width) 298
410 392
420 285
430 280
440 273
450 (maximum opening width) 269
For example, if the appliance was to be fitted into a 400mm wide opening, the
depth required would be 298mm. See fig. 2 below for explanatory diagram.
Fig. 2
7
Opening Width ( e.g. 400mm)
Depth equired
(e.g. 298mm
minimum)

1.7 FITTING TO PRE-FABRICATED TWIN WALL ETAL FLUE BOXES
The appliance may be fitted to twin wall metal flue boxes conforming to the
constructional requirements of BS 715 / BS EN 1856-2, (for example the Selkirk
FE 175 box). The box must have a minimum flue diameter of 175mm internal
and minimum internal dimensions of 300mm deep by 580mm high by 400mm
wide. There are no maximum dimensional requirements for the box. The top face
of the box must be insulated with a minimum thickness of 50mm of non-
combustible mineral wool insulation or similar material. The flue box must stand
on a non-combustible base of minimum thickness 12mm.
1.8 HEARTHS
If Fitting Into a “Conventional” Installation :-
This appliance must only be installed on to a concrete or non-combustible hearth.
The hearth material must be a minimum thickness of 13mm with the top surface at
least 50mm above the floor. The hearth must be fitted symmetrically about the fire
opening and have a minimum width of 760mm and a minimum projection of
300mm forwards from the fire opening.
If Fitting Into a “Hole in the Wall” Installation :-
This appliance must only be installed at a minimum height of 225mm above the
floor level, (measured from the bottom edge of the 4 sided trim) e.g. above the
level of the carpet or floor covering. Also see section 1.10 (Tactile Barriers)
1.9 SPILLAGE ONITORING SYSTE
This appliance is fitted with an atmosphere sensing spillage monitoring system in
the form of an oxygen sensing pilot. This is designed to shut the fire off in the
event of a partial or complete blockage of the flue causing a build up of
combustion products in the room in which the fire is operated. The following are
important warnings relating to this spillage monitoring system :-
1) The spillage monitoring system must not be adjusted by the installer.
2) The spillage monitoring system must not be put out of operation.
3) When the spillage monitoring system is exchanged only a complete original
manufacturers part may be fitted. It is not possible to replace individual parts on
the pilot system on this appliance, only a complete pilot assembly (including the
thermocouple) may be fitted.
8

1.10 TACTILE / PHYSICAL BARRIERS
This appliance must be fitted on a flat, non-combustible base of minimum
thickness 12mm. In addition, a non-combustible hearth or physical barrier should
be provided in front of the fire.
With “hole in the wall” type installations, where it may be desirable not to fit a
hearth panel or physical barrier, the product may be installed in accordance with
Document J of the building regulations so that every part of theflame or
incandescent material is at least 225mm above the floor level. For the customers
safety, and in accordance with BS 5871-2, the fitting of a hearth panel or physical
barrier should be carried out. Should this advice not be followed however, please
give consideration to the safety of the occupants in the room to which the
appliance is installed.
Any hearth panel or physical barrier that is fitted should project a mnimum of
300mm forwards from the fire opening and 150mm either side of the fire
opening, as shown below in Fig. 3 Any physical barrier must be securely fixed and
be of robust design.
Fig. 3
9
Example of Wall
Mounted Physical /
Tactile Barrier
Example of Floor Mounted
Physical Barrier i.e. Hearth
Panel
Fireplace Opening
300mm
Minimum
300mm
Minimum
150mm Minimum each
side of fireplace
opening

SECTION 2
INSTALLATION OF FIRE
2.1 UNPACKING THE FIRE
Carefully lift the fire out of the carton. Remove the loose item packaging carefully
from the front of the appliance. Check the contents as listed :-
Packing Check ist
1off Fire box / burner assembly
1off Boxed ceramic logs (3 pieces)
1off oose items bag.
1off Flue baffle (packed inside side fitting)
1off Fascia (Hearth Mount or Wall Mount dependent upon model purchased)
1off each User instruction book and Installation book
2.2 INSTALLING THE FIRE BOX
Establish which type of flue you are intending to install the fire in to :-
225 x 225mm (9 inch x 9 inch) brick built chimneys
175mm (7 inch) diameter lined brick or stone flue, insulated pre-fabricated
metal flue box to BS 715 / BS EN 1856-2
A spillage test must always be carried out to check satisfactory
clearance of flue products, regardless of the type of flue the
appliance is being fitted to.
NOTE : As stated above in section 2.1, the flue baffle that is supplied is
located in the loose items pack. This baffle is secured to the firebox lid with
the 2 off self tapping screws provided.
10

2.3 PREPARATION OF THE FIRE OPENING
If installing the product into a hole in the wall type installation, create an opening
as shown in Fig. 4 below. If installing into a conventional opening with a hearth
panel, create an opening as shown in Fig. 5 below.
Fig. 4 - Hole in the Wall Installations
Fig. 5 - Conventional Installations
Minmum225mm
See Fig. 2
on page 7
Min. 550mm
Max. 570mm
See Fig. 2
See Fig 2
on page 7
Min. 550mm
Max. 570mm
See Fig 2
50mm
300mm
Minimum
760mm Minimum
11

For remote control models proceed as follows :-
a) Remove the “Concept” fascia if necessary. Remove the glass panel
retaining brackets (4 screws) and lift the glass panel clear. Unscrew the
black painted pilot shield. See fig. 6 below.
Fig. 6
b) ift the ceramic fibreboard base from the firebox. Unscrew the burner
retaining screw as shown below in Fig. 7 and lift the burner engine clear
of the firebox. Ensure that the hearth is protected from damage and
carefully lift the fire box into the fire opening, then slide it back into
position. Check that the fire box flange fits flush to the sealing face of
the fire surround or wall with no gaps present.
Fig. 7
12
Glass Panel etaining Bracket Screws
Pilot heat shield screws
Burner etaining Screw

For manual control models proceed as follows:
d) Remove the “Concept” fascia if necessary. Remove the glass panel
retaining brackets (4 screws) and lift the glass panel clear. Unscrew the
black painted pilot shield. See fig. 8 below.
Fig. 8
e) ift the ceramic fibreboard base from the firebox. Unscrew the burner
retaining screw as shown below in Fig. 9 and lift the burner engine clear
of the firebox. Ensure that the hearth is protected from damage and
carefully lift the fire box into the fire opening, then slide it back into
position. Check that the fire box flange fits flush to the sealing face of
the fire surround or wall with no gaps present.
Fig. 9
13
Glass Panel etaining Bracket Screws
Pilot heat shield screws
Burner etaining Screw

Continue for all models
Whilst the fire box is still in position, decide which side the gas supply is to enter
the fire from. The inlet elbow position is at the /H side of the firebox for MC
variants and the R/H side for RC variants. The gas connection to the appliance
should be made to the isolating / inlet elbow using 8mm rigid tubing. There must
be no soldered joints within the firebox. See fig. 10 & 11 below for
suggested concealed pipe layouts.
Fig. 10 - Position of gas supply for RC variants
Fig. 11 - Position of gas supply for C variants
Note : Before breaking into the gas supply a pressure drop test should be
carried out to establish that the existing pipework is sound.
Carefully withdraw the fire box from the opening to enable the gas supply and fire
fixing to be completed.
14
Firebox
Fireplace
Builders
Opening
Gas Supply
Firebox
Approx.
40mm
Fireplace
Gas Supply
Approx.
40mm
Builders
Opening

I PORTANT : Sealing of the Gas Unused Gas Pipe Inlet Apertures
In line with current CORGI regulations, it is imperative that the gas supply inlet
apertures that are not utilised during the installation are sealed with the foil
tape as supplied. Failure to seal these inlet apertures could lead to flame
reversal, which in turn will damage the burner and control systems of the product.
Fig. 12 below shows the location of the gas supply inlet apertures that require
sealing
Fig. 12
PLEASE NOTE :-
Seal off unused gas inlet
apertures as shown
BF EUROPE LTD. WILL NOT BE LIABLE FOR
GUARANTEE CLAI S THAT ARE AS A DIRECT
RESULT OF THE UNUSED GAS INLET APERTURES
NOT BEING CORRECTLY SEALED.
15

The preferred method of fixing which is suitable for almost all situations is
the cable fixing method which is described in the following section in detail.
To fit using the preferred cable method proceed as follows :-
h) Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire
opening in the positions shown below in fig. 13
Fig. 13
Fit the wallplugs provided and screw the fixing eyes securely into the rear of the
fire opening. If the clearance at the rear of the fire is at the minimum specified, it
may be necessary to bend over the lower fixing eyes after screwing them fully in to
the rear of the fireplace opening.
i) Uncoil the two fire fixing cables and thread one end of each of the
cables through one of the two holes on each side of the flue outlet
shroud.
j) Position the fire carefully on the (protected) surface of the hearth and
reach into the fire opening. Thread each of the cables vertically
downwards through the pair of fixing eyes on the same side of the fire.
Thread the free end of the cables through the corresponding circular
hole on each side of the lower rear of the fire. Carefully slide the fire
box back into the fire opening and pull both cables tight.
16
20mm
500mm Fireplace Opening
100mm
250mm

k) Thread a tensioning screw over each of the cables and ensure that the
tensioning nut is screwed fully up against the hexagon shoulder of the
tensioning screw (this provides maximum travel for the tensioning nut).
l) Fit a screwed nipple on to each of the cables and pull hand tight up
against the tensioning screw, then secure each nipple with a flat
bladed screwdriver. See fig. 14 below
Fig. 14
m) Evenly tighten the tensioning nuts to tension both cables and pull the
fire snugly against the wall. Do not overtighten, it is only necessary to
pull the seal up against the sealing face of the wall, it does not need to
be compressed. Check that there are no gaps behind the seal.
n) With the fire securely in place, if a concealed gas connection has been
made through either of the access holes in the sides of the fire, the
holes should be closed around the pipe to prevent leakage of air
through the gap around the pipe, see page 13 for further details.
o) Refit the burner. Fit the retaining screw and check that the burner
is correctly locked into position. Refit the fibre base panel, refit the pilot
shield and the glass panel that is held in position by 4 screws and 2
retaining brackets.
p) Before making the final gas connection, thoroughly purge the gas
supply pipework to remove all foreign matter, otherwise serious
damage may be caused to the gas control valve on the fire.
17

The other firebox fixing method is as follows :-
In installations where the cable method is not suitable (e.g. loose masonary in rear
of fire opening) the firebox can be secured to the fire surround using four screws
and wall plugs (not provided). Below (fig.15) is a diagram to indicate the hole cen-
tre positions available on the firebox to facilitate the screw fixing to the fireplace /
surround.
Fig. 15
18
532mm
260mm
37mm
Firebox
Mounting
Flange
425mm

2.4 GAS TIGHTNESS AND INLET PRESSURE ( ANUAL CONTROL
ODELS)
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress the control knob and turn anti-clockwise to the position marked
pilot. Hold in the control knob for a few seconds to purge the pipe work
then press the igniter button. The burner should light, continue to hold
the control knob for a few seconds then turn to the full-on position.
d) Check that the gas pressure for Natural Gas (G20) models is 20.0 mbar
(+/- 1.0mbar) 8.0 in w.g.(+/- 0.4 in w.g.)
e) Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
2.5 GAS TIGHTNESS AND INLET PRESSURE (RE OTE CONTROL
ODELS).
a) Remove the pressure test point screw from the inlet elbow and fit a
manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress both the round buttons on the handset. The fire will then
commence its ignition sequence and will light to high. See page 23 / 24
for full details of the operating method for the fire.
d) Check that the gas pressure is 20.0 mbar (+/- 1.0mbar) 8.0 in w.g.(+/-
0.4 in w.g.)
e) Turn off the fire, remove the manometer and refit the pressure test point
screw. Check the pressure test point screw for gas tightness with the
appliance turned on using a suitable leak detection fluid or detector.
19

SECTION 3
ASSE BLING FUEL BED AND CO ISSIONING
3.1 ASSE BLING THE CERA ICS AND FUEL BED
a) Place the log piece marked “A” on it’s underside in the position
as shown below in Fig. 16, ensuring the log is positioned on the cut out
provided in the ceramic base panel. See fig. 19 overpage that displays
the cut out positions for each log.
Fig. 16
b) Position the log piece marked “B” on it’s underside in the position
shown below in Fig. 17, ensuring the log is positioned on the cut out
shown in the ceramic base panel
Fig. 17
20
NOTE : The position of the fuel-bed components are critical to the
performance of the product. Therefore please ensure that the fuel-bed
components are positioned as described in the following section prior to
requesting a service call due to soot build up, poor flame pattern etc.
A
B