Kinder Kalahari User manual

alahari
DEC RATIVE FUEL EFFECT GAS FIRE
Installation and Maintenance Instructions
Hand these instructions to the user
Model No’s KRDC00MN and KRDC00SN are for use on Natural Gas
(G20) at a supply pressure of 20 mbar in G.B. / I.E.
Model No’s KRDC00MP and KRDC00SP are for use on Propane Gas
(G31) at a supply pressure of 37 mbar in G.B. / I.E.

C NTENTS
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 Pre-Cast Flues 8
1.9 Hearths 8
1.10 Spillage Monitoring System 9
Section 2 Installation of Fire
2.1 Unpacking the fire 10
2.2 Installing the fire box & gas supply 10-17
2.3 Gas tightness and inlet pressure (MC models) 19
2.4 Gas tightness and inlet pressure (SC models) 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 20-23
3.2 Lighting the appliance (Manual Control model) 24
3.3 Lighting the appliance (Slide Control model) 24-25
3.4 Checking for clearance of combustion products 25
Section 4 Maintenance
4.1 Removal of the Burner Assembly (Manual) 26
4.2 Removal of the Piezo Igniter 26
4.3 Removal of the Control Tap 27
4.4 Removal of the Pilot Assembly 27
4.5 Removal of the Burner Assembly (Slide) 27-28
4.6 Removal of the Battery Ignitor 28
4.7 Repacing the Battery 28
4.8 Removing the Oxy-Pilot Assembly 29
4.9 Replacing the Control Cable 29-30
Parts Shortlist 31
This appliance is manufactured by:-
BFM Europe Ltd, Trentham Lakes, Stoke-on-Trent, ST4 4TJ
2

SECTI N 1
INF RMATI N AND REQUIREMENTS
1.0 APPLIANCE INF RMATI N
Model RDC00MN (MC) RDC00MP (MC)
RDC00SN (SC) RDC00SP (SC)
Gas Type G20 G31
Main injectors (2 off) Size 260 Size 85
Pilot Type Copreci Copreci
21100 / 141 (MC) 21100 / 264 (MC)
21100 / 162 (SC) 21100 / 263 (SC)
Max. Gross Heat Input : 6.9 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : RDC00MN, RDC00SN 20.0 +/-1.0 mbar
RDC00MP, RDC00SP 37.0 +/-1.0 mbar
Ignition : Push Button Piezo (MC models)
1.5V Battery Generator (SC models)
Electrode Spark Gap 4.5 Nominal
Weight (without fender) 15.0 kg
Fire box Dimensions (with trim fitted)
Width : (with standard trim, no spacer) 470mm
Height : (with standard trim, no spacer) 586mm
Depth : (overall-without fender) 170mm
Depth : Flush-fit (from mounting face to rear) 170mm
Depth : Flush-fit (mounting face to rear 120mm
with 50mm spacer fitted)
Gas Connection 8mm Compression (Supplied with fire)
Efficiency Declaration
The efficiency of this appliance has been measured as specified in
BS 7977-1 : 2002 and the result is 48%.
The gross calorific value of the fuel has been used for this efficiency
calculation.
The test data from which it has been calculated has been certified by Advantica.
The efficiency value may be used in the U Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings.
3

INSTALLATI N REQUIREMENTS
1.1 C NDITI NS F INSTALLATI N
It is the law that all gas appliances are installed only by a GAS SAFE 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 Local 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 2 Installation of Inset Live 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 EN 1858 Clay Flue Blocks and Terminals
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 CHIMNEY 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.
Minimum diameter of circular flues 125 mm (Without Flue
Restrictor Fitted)
Minimum effective height of all flue types 3 metres
When fitting to conventional chimneys or 175mm flues it may be desirable to
fit the flue restrictor baffle (supplied) to reduce the flue flow and increase the
efficiency of the fire. Safe clearance of products must always be checked by
carrying out a smoke match test as described.
4

1.3 FIREPLACE / SURR UND 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 P SITI N
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 / CHIMNEY INSPECTI N
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. With pre-cast flues
it is especially important to check the inside of the flue for extruded
cement / sealant protruding from the joints between the flue
blocks. If present, these should be removed by rodding the flue
before proceeding with the installation.
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 PENING AND CHIMNEY CATCHMENT SPACE
The front opening of the fire place must be between 375 and 440 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 space.
Fir Op ning
375mm Minimum
440mm Maximum
610mm
Minimum
490mm Minimum
Fig. 1
550mm Minimum
570mm Maximum
Minimum Flat
S aling Ar a
6

Tab e A - Insta ation Depth Requirements for a Kinder Ka ahari being
insta ed into a brick bui t chimney, requiring 12.0 itres of debris co ection
vo ume (fig. 2)
When installing this product into a builders opening / brick-built chimney, the depth
required is a minimum of 170mm. The 12.0 litres of debris collection volume is
achieved by the space available taper down the sides of the firebox. This depth
can be reduced to 120mm if the black 50mm spacer frame is used. This spacer
frame can be purchased from inder Fires as an optional extra.
This appliance is suitable for use in fireplaces fitted with an existing chairbrick
without the need for removal of the chairbrick, providing the minimum depth of the
fireplace exceeds 260mm. If the depth is less than 260mm then the spacer
(optional) must be used to give a minimum clearance from the rear of the fire to
the rear of the chairbrick of at least 90mm to allow sufficient space for the
collection of debris which may fall down the chimney. The fireplace must be
checked to ensure that no part of the chairbrick is within 50mm of the flue outlet of
the fire when installed.
For example, if the appliance was to be fitted into a 400mm wide opening (without
a chairbrick), the depth required would be 170mm. See fig. 2 below for
explanatory diagram.
Fig. 2
7
Op ning Width ( .g. 400mm)
D pth R quir d
( .g. 170mm
minimum)

1.7 FITTING T PRE-FABRICATED TWIN WALL METAL FLUE B XES
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
LFE 125 or 175 box). The box must have a minimum flue diameter of 125mm
internal and minimum internal dimensions of 170mm deep by 580mm high by
350mm wide. 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 FITTING T PRE-CAST FLUE INSTALLATI NS
When installing this appliance into pre-cast flues, always ensure that the
spigot restrictor baffle has been removed.
To install the fire box in to pre-cast flue starter blocks, there must be at least
170mm from the mounting face of the fire to the rear of the pre-cast flue
starter block to allow sufficient space for debris collection. It is important to
consider this depth when choosing a fire surround as the thickness of the fire
surround must be sufficient to give a total depth of at least 170 mm to the rear of
the starter block, otherwise there will be insufficient depth. To increase this depth
the optional black 50mm spacer frame may be purchased, this will reduce the
depth required to 120mm or the fire surround may be packed away from the wall
using suitable non-combustible board, providing the installation is correctly sealed.
If in doubt about the suitability of the fire contact inder Fires for advice before
proceeding. This fire has been designed to fit standard 100mm pre-cast
starter blocks with 3 inch rebated surrounds.
It is important to ensure that the pre-cast flue is in good condition and is free from
extruded mortar or sealant from between the flue blocks.
This appliance has been tested for use in a pre-cast flue block complying
with BS EN 1858. In accordance with BS EN 1858, pre-cast flues built with
directly plastered faces (front or rear) are not correctly installed as to ensure
proper operation with any type of gas fire. In some instances of this flue
construction, temperature cracking of surface plaster may occur through no
fault of the appliance. An air gap or some form of insulation material should
be installed to prevent normal flue temperatures from damaging wall
surfaces.
1.9 HEARTHS
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 the appliance is fitted with a black 50mm
spacer frame, then the hearth projection must be increased to 350mm forwards of
the fireplace opening.
8

1.10 SPILLAGE M NIT RING SYSTEM
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 combus-
tion 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.
9

SECTI N 2
INSTALLATI N F 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 List
1off Fire box / burner assembly
1off Boxed ceramic base, front ceramic rail and 18 coals (16 large, 2 small)
coals
1off Loose items bag.
1off each User instruction book and Installation book
2.2 INSTALLING THE FIRE B X
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 or Pre-Cast Flue to BS EN 1858
When installing into 125mm (5 inch) diameter lined brick or stone flue, or
insulated pre-fabricated metal flue box to BS 715 / BS EN 1856-2 and
pre-cast flues the restrictor baffle must not be fitted.
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.
10

For manual control models proceed as follows :-
a) Remove the trim / fret. Remove the burner heat shield from the front of
the fire box to allow access to the burner. See fig. 3 below.
Fig. 3
b) 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.
c) Remove the four retaining screws securing the burner to the firebox.
The base of the burner unit can now be pulled forward, allowing the
burner to be removed from the fire box. See fig. 4 below.
Fig. 4
11

For Slide Control Models Proceed as follows:
d) Remove the trim / fret. Remove the burner heat shield from the front of
the fire box to allow access to the burner. See fig. 5 below.
Fig. 5
e) 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.
f) Remove the burner. To allow burner removal, the control lever operat
ing cable must be removed. The control lever operating cable can be
seen running across the base of the fire, below the burner. To release
the cable, unscrew the cable securing screw located in the centre of the
aluminium operating arm and pull the cable out from its fixing hole.
Release the other end of the cable by pushing the cable forwards to the
right, i.e. into the operating arm so as to release the tension. Pull the
cable nipple out of the retaining hole and remove the cable through the
slot in the operating arm. See fig. 6 overpage
12

Fig. 6
g) Unscrew the burner assembly fixing screws at either side of the firebox,
and the two fixing screws at the base of the fire (See fig. 6
above). Carefully pull the base of the burner forwards from the fuel-bed
support panel. The burner can now be removed from the appliance.
Fig. 7
13

Continue for all models
Whilst the fire box is still in position, decide which side the gas supply is to enter
the fire from. If concealed pipe work is required plan the pipe run to enter the fire
box through one of the openings in the sides of the fire box below the fuelbed
support panel and connect to the isolating / inlet elbow. 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. 8a & 8b below for
suggested concealed pipe layouts.
Fig. 8a
Fig. 8b
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
Fir box
Fir plac
Build rs
Op ning
Gas Supply
Fir box
Approx.
40mm Fir plac
Gas Supply
Approx.
40mm

IMP RTANT : Sealing of the Gas Unused Gas Pipe Inlet Apertures
In line with current GAS SAFE 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. 9 below shows a correctly sealed installation.
Fig. 9
PLEASE NOTE :-
S al off unus d gas inl t
ap rtur s and cabl fixing hol s
as shown
Only hol s to b l ft ar th sp cifically
siz d air r li f hol s as indicat d by th
lab ls position d by th m and th gas
inl t ap rtur that is us d
15
BFM EUR PE LTD. WILL N T BE LIABLE F R
GUARANTEE CLAIMS THAT ARE AS A DIRECT
RESULT F THE UNUSED GAS INLET APERTURES
N T BEING C RRECTLY SEALED.

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.
If the 2 inch black spacer is used, the fire may be secured using the cable method
as described below, or alternatively, in installations where the cable method is not
suitable (eg. loose masonary in rear of fire opening) the spacer may be removed
from the fire box and secured to the fire surround using protruding screws which
engage on to the key hole slots on the rear face of the spacer. The spacer will
then need to be sealed to the fire surround. The fire box can then be refitted to
the spacer.
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. 10
Fig. 10
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 for
a precast flue application, it may be necessary to bend over the lower fixing eyes
after screwing them fully in to the rear of a pre-cast starter block.
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 Fir plac Op ning
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. 11 below
Fig. 11
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.
o) Refit the burner. Fit the four retaining screws and check that the burner
is correctly locked into position. On slide control models refit the control
cable To do this, firstly locate the nipple on one end of the cable into
recess in operating arm and then secure the front part of the operating
arm back onto the rear of the operating arm with the retained screw.
17

This should not be overtightened. Move the control lever fully
downwards and check that the left hand micro-switch operates the
igniter and that the control valve spindle is fully depressed. Move the
control lever upwards to the “off” position and check that the right hand
(cut-off) micro-switch operates. Check that the control lever operates
smoothly and safely.
N TE : The cable is factory set, and therefore should need no adjustment
p) Refit the front burner heat shield to the sides of the fire box (2 Screws)
and secure the trim to the fire using the magnets provided.
q) 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.
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 provided. Below (fig.12) is a diagram to indicate the hole centre
positions available on the firebox to facilitate the screw fixing to the fireplace /
surround.
Fig. 12
18
532mm
260mm
37mm
Fir box
Mounting
Flang
425mm

2.4 GAS TIGHTNESS AND INLET PRESSURE (MANUAL C NTR L
M DELS)
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.) or for LPG models 37.0 mbar
(+/- 1.0mbar) 14.8 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 (SLIDE C NTR L
M DELS).
a) Remove the pressure test point screw from the pressure test point and
fit a manometer.
b) Turn on the main gas supply and carry out a gas tightness test.
c) Depress the control lever to the position marked pilot. Hold down the
control lever for a few seconds to purge the pipe work. The burner
should light, continue to hold the control lever for a few seconds to latch
the valve then lift 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.) or for LPG models 37.0 mbar
(+/- 1.0mbar) 14.8 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

SECTI N 3
ASSEMBLING FUEL BED AND C MMISSI NING
3.1 ASSEMBLING THE CERAMICS AND FUEL BED
a) Place the ribbed ceramic fuelbed base on top of the fuelbed support
and pull fully forwards to the burner. Make sure that the fuelbed
base is located centrally in the fire box.Ensure that the fuelbed
base fit fully down onto the fuel bed support and is not
lodged on the burner. See fig. 13 below.
Fig. 13
b) Position the two halves of the front ceramic (L/H & R/H) on the locating
channel in the front ceramic, ensuring it is located onto the lip on the
burner front ceramic support. (See fig. 14 below)
Fig. 14
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.