Kinder Nevada Powerflue KCPC00MN Installation and operating instructions

Nevada Powerflue
DECORATIVE FUEL EFFECT POWERFLUE GAS
FIRE
Installation & Maintenance Instructions
Hand these instructions to the user
Model No. KCPC00MN is 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 Terminal Position 5
1.3 Fireplace / surround suitability 6
1.4 Fire place opening / catchment space 6
1.5 Shelf Position 6
1.6 Installation Types 7-9
1.7 Hearths 9
1.8 Spillage Monitoring System 9
Section 2 Installation of Fire
2.1 Unpacking the fire 10
2.2 Marking the Flue Pipe Opening 10
2.3 Marking the Fan Unit Recess on the Outer Wall 11-17
& Fitting the fire box
2.4 Making the Electrical Connections 18
2.5 Gas tightness and Inlet pressure 19
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 20-24
3.2 Lighting the appliance 25
3.3 Checking for clearance of combustion 26
products
Section 4 Maintenance
4.1 Removal of the Burner Assembly 27
4.2 Removal of the Piezo Igniter 27
4.3 Removal of the Control Tap 28
4.4 Removal of the Thermocouple 28
4.5 Removal of the Solenoid 28-29
Spare Parts Shortlist 29
This appliance is manufactured by :-
CFM Europe Ltd.
Trentham Lakes,
Stoke-on-Trent,
ST4 4TJ
2

SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APPLIANCE INFORMATION
Model KCPC00MN
Gas Type G20
Main injectors (2 off) Size 235
Pilot Type S.I.T. Oxystop NG 9022
Max. Gross Heat Input : 6.5 kW
Min. Gross Heat Input : 4.2 kW
Cold Pressure : 20.0 +/-1.0 mbar
Ignition : Push-button Piezo
Supply Voltage : 230V a.c.
Supply Frequency : 50 Hz
Supply Fuse : 3Amp (Fixed Fused Spur) to BS 1362
IP Rating : IP 44
Electrode Spark Gap : 4.0mm
Packed Weight : 12 kg
Fan Unit Packed Weight : 15 kg
Fire box Dimensions (with trim’s fitted)
Nevada Models
Width : (with standard trim, no spacer) 470mm
Height : (with standard trim, no spacer) 586mm
Depth : (overall-without fender) 155mm
Depth : (overall-with spacer fitted) 105mm
Gas Connection : 8mm Compression (Supplied with fire)
3

INSTALLATION REQUIREMENTS
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 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. B.S. 5871 Part 3 Installation of Decorative Fuel Effect Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and V entilation
4. B.S. 1251 Open fire place components
5. B.S. 6461 Part 1 Installation of Chimneys and flues
6. I.S. 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.
4

1.2 FLUE TERMINAL POSITION
The minimum acceptable dimensions from the flue terminal to obstructions and
ventilation openings are shown below in fig. 1 and listed in the table (fig. 2 below)
IT IS IMPORTANT THATTHE POSITION OF THE FLUE ALLOWS THE FREE
PASSAGE OF AIR ACROSS IT AT ALL TIMES.
Fig. 1
Fig. 2
DIMENSION TERMINAL POSITION MINIMUM DIMENSION
ADirectly below an opening, air brick, 300mm (12 in.)
opening window
BAbove an opening, air brick, 300mm (12 in.)
opening window
CHorizontally to an opening, air brick, 300mm (12 in.)
opening window etc.
DBelow gutters, soil pipes or drain pipes 75mm (3 in.)
EBelow eaves 200mm (8 in.)
FBelow balconies or car port roof 200mm (8 in.)
GFrom a vertical drain pipe or soil pipe 150mm (6 in.)
HFrom an internal or external corner 200mm (8 in.)
IAbove ground roof or balcony level 300mm (12 in.)
JFrom a surface facing the terminal 600mm (24 in.)
KFrom a terminal facing the terminal 1200m (48 in.)
LFrom an opening in the car port 1200m (48 in.)
M Vertically from a terminal on the same wall 1500mm (59 in.)
NHorizontally from a terminal on the 300mm (12 in.)
same Wall
OFrom the wall on which the terminal is mounted 50mm (2 in.)
PFrom a vertical structure on the roof N/A
QAbove intersection with roof 150mm
5

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 150o c. 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 FIRE PLACE OPENING
The front opening of the fire place must be between 330 and 430 mm wide, and
between 550 and 565mm 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.3
1.5 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
overhang over 150mm.
6
Fire Opening
330mm Minimum
430mm Maximum
550mm Minimum
565mm Maximum
Minimum Flat
Sealing Area
Fig. 3
610mm Minimum
520mm Minimum

1.6 INSTALLATION TYPES
This fire can be fitted against an outside facing facing flat wall surface or into a
fireplace opening cut into the wall.
When fitting the fire in front of the inner cavity wall , the distance between the
mounting face of the fire and the rear face of the firebox must be a minimum of
170mm, a false chimney breast or fireplace surround should be constructed. The
firebox must then be secured into the fireplace using the method described in
section 2. Any combustible material must be removed from the the area around
the firebox flange. In all installations, ensure that there is no structural damage to
the property or the damp course. See fig. 4 below
When fitting the fire into a cavity wall, this requires the opening of the inner leaf
of brickwork, to recess the firebox into. The opening needs to be sufficient to
accomodate the firebox. T o support the wall above the hole, a suitable lintel must
be inserted across the top of the opening. If fitting the appliance into a cavity wall,
a lintel 750mm long having a thickness of 75mm with a height of the inner wall
should be used. The lintel could be either pre-cast concrete or steel - Catnic
CN52 or CN 46 could be used, depending upon the inner wall thickness. Before
proceeding with the installation of the fire, an assessment of the area immediately
above the fire is required, see Fig. 5 overpage. If there is no existing openings
within either triangle, proceed with forming the opening. However, if opening or
beams occur within either triangle, then you should seek specialist advice from a
structural engineer or consider relocating the proposed position of the firebox.
7
Minimum Hearth
Forward Projection
300mm
Inner Cavity Wall
Outer Cavity Wall
Fan Unit
False Chimney
Breast / Fireplace
155mm
All
Models
550mm Maximum
Fig. 4
Flue Pipe

Fig. 5
To proceed with the installation when the above stated criteria have been
satisfied :-
Mark out where possible, centrally beneath a block joint where the lintel is to be
fitted. Unless lime mortar has been used it will be necessary to drill four holes
with a masonary drill, then use a mechanical cutter such as a “shark saw” to cut
out the correct size of slot in the inner leaf of brickwork for the lintel you have
chosen to install. See fig. 6 below.
Fig. 6
Fit the lintel, ensure that it is bedded on mortar. Do not bed on a dry bed.
Then remove all debris from the cavity and construct the opening to the minimum /
maximum opening sizes as shown overpage (fig. 7) and in section 1.4, (fig. 3)
8
Opening Height
550mm Minimum
565mm Maximum
Firebox recess in
wall
400mm interactive
area
600mm load
triangle
The Interactive Zone -
Openings, beams or joists within
this area need to be assessed.
Load triangle - No beam or
opening permissible within this
area
Lintel
e.g. 750mm x 75mm
50mm Minimum Hearth Thickness Opening Width
330mm Minimum
430mm Maximum

Remove any combustible material from within the area of the opening. No
combustible material can be allowed to come into contact with any area of the
appliance.
Fig. 7
1.7 HEARTHS
This appliance must only be installed on to a concrete or non-combustible hearth.
The hearth material must be a minimum thickness of 12mm 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.
1.8 SPILLAGE MONITORING SYSTEM
This appliance is fitted with an atmosphere sensing spillage monitoring system in
the form of an oxygen sensing burner.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.
Lintel must project
Minimum of 150mm
each side of the
opening
Opening Sizes Width :-
330mm Minimum
430mm Maximum
Opening sizes Height :-
550mm Minimum
565mm Maximum
Ensure that the recess that is cut is to the required
dimensions and is screed level so that the firebox will
sit level within the recess.
9

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 List - All Models
1offFire box / burner assembly,
1offBoxed fuelbed base, fuelbed insualtion mat, 2 piece ceramic front rail,
and 1 piece fuelbed overlay
1offBag of 22 synthetic coals (packed in fuelbed box)
1offLoose items bag.
1offInstallation & Maintenance Instruction Book
1offUser Instruction Book
1off Rope Seal (packed in fan unit - Pack 2 of 2)
1offBoxed Fan Unit & Flue Pipe (Pack 2 of 2)
2.2 MARKING THE FLUE PIPE OPENING ON THE WALL (ALL MODELS)
Drill a pilot hole into the outer leaf of brickwork at a height of 490mm from the
hearth level, centrally about the firebox, then create a square hole 100mm / 4 inch
vertically central to the centre line of the appliance. See fig. 8 below.
NOTE : If the fire is to be fitted against the inner cavity wall, the inner and
outer cavity walls will require the 100mm / 4 inch hole creating
Fig. 8
10
Inner Cavity Wall
Outer Cavity Wall
490mm to
Centre of Flue
Pipe
Maximum 1.4
metre above
ground level
100mm / 4 inch
square hole
IMPORTANT NOTE :
DO NOT FIT THIS APPLIANCE FAN UNIT ABOVE
AHEIGHT OF 1.4M FROM GROUND LEVEL

2.3 MARKING THE FAN UNIT RECESS ON THE OUTER WALL (ALL
MODELS)
Fig. 9
a) The recess and mounting holes as detailed above will require
cut ting into the outer cavity of the wall to accept the fan unit cast
iron body.
b) T o proceed with the installation, take the flue pipe (380mm in length)
and secure to the firebox as shown below in Fig. 10, with the 3 off fixing
screws supplied.
Fig. 10
c) Carefully place the firebox and flue pipe together into the builders
opening and allow the flue pipe to protrude through the hole in the outer
cavity wall.
100mm / 4 inch
Flue Pipe Hole
230mm
280mm
75mm
15mm
2 off cut outs
75mm x 15mm about
horizontal centre line,
required to clear the
lugs on the
cast iron fan unit body 280mm
340mm
4 off holes to be drilled to
accept the No. 10 x 40mm
screws and rawlplugs
supplied in loose items pack,
that are used to secure the
fan unit.
11
Secure flue pipe
to rear of firebox
with 3 screws
provided
Seal hole that is
not utilised in this
application with
suitable sealent

d) Mark the flue pipe in line with the flue spigot so that it can be cut to
length.
NOTE :- When cutting the flue pipe to length, allowance for the rebate
on the fire surround used or false chimney breast constructed must be
taken into account.
e) The cover of the fan unit must now be removed to proceed with the
installation. Remove the four of f screws as shown below in Fig. 1 1
Fig. 11
f) Remove the 2 off screws for the electronic control board mounting plate
as shown below in Fig. 12
Fig. 12
4 off fan cover
mounting screws
2 off screws for
electronic control
board mounting
plate
12

f) With the fan cover removed, disconnect the air pressure switch tubes
from the outlet venturi as shown below in Fig. 13, ensuring that you
make a note of their location for when you re-fit them.
Fig. 13
NOTE : If you re-fit the air pressure switch tubes the wrong way around, the
appliance will not operate as a positive flue pressure cannot be generated,
and hence the gas solenoid valve will not open.
g) W ith the electronic control board mounting plate tilted forward,
disconnect the positive, negative and earth wires from the fan unit as
shown below in Fig. 14, ensuring that you make a note of their position
for when you re-fit them.
Fig. 14
h) Remove the 3 off fan mounting plate screws as shown overpage in
Fig. 15
Removing pipes
from the air
pressure switch
13

Fig. 15
i) Remove the firebox and flue pipe assembly from the false chimney
breast or fire surround as applicable. Run the gas supply in from the
right hand side of the firebox as shown below in Fig. 16
Fig. 16
j) Screw the cast iron fan unit housing to the outer cavity wall, using the
screws and rawlplugs supplied.
k) The preferred method of fixing the firebox into place which is
suitable for almost all situations is the cable fixing method which
is described in the following section in detail.
3 off Fan
Mounting Plate
Screws
Firebox
Approx.
40mm
Fireplace
Gas Supply
Flue Pipe
Fan Unit
14

To fit using the preferred cable method proceed as follows-
l) Mark out and drill 4 off No 14 (6mm) holes in the back face of the fire
opening (inner face of the outer cavity wall in most instances) in the
positions shown below in fig. 17
Fig. 17
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 powerflue application, it may be necessary to bend over the lower fixing eyes
after screwing them fully in to the rear of the outer cavity wall inner face.
Proceed as follows to remove the burner assembly from the firebox :-
m) Remove the trim. Remove the burner heat shield from the
front of the fire box to allow access to the burner, as shown below in fig. 18
Fig. 18
i) Break the connection between the pressure test point elbow and the
solenoid block. 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. 19 overpage
20mm
325mm
100mm
500mm Fireplace Opening
15

Fig. 19
m) 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. Electrical Wiring Loom - Bring the 5 core cable from the fire
box (with small 6 way plug attached) through the cable entry hole in the
cast iron fan unit body, and secure to the wall plate with the strain relief
bush, allowing at 150mm / 6 inches of wire to protrude into the wall
plate.
n) 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.
o) 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).
p) 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. 20 below
16
Fig. 20

q) 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.
r) W ith the fire securely in place, if a concealed gas connection has been
made through the access holes in the R/H side of the fire, the hole
should be closed around the pipe to prevent leakage of air
through the gap around the pipe.
s) Connect the gas supply pipe to the solenoid valve on the burner
assembly , and carry out a gas tightness test up to the isolation valve,
which is attached to the solenoid valve pipe.
t) Refit the burner. Fit the four retaining screws and check that the burner
is correctly locked into position. Before making the final gas connection
to the solenoid valve, 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. Ensure correct orientation of the
restrictor valve behind the burner is obtained
NOTE :- Failure to correctly purge the pipework will invalidate the
guarantee
u) It is now necessary to fit the rope seal between the spigot on the fan
unit cast iron body and the flue pipe, as shown below in Fig. 21
Fig. 21
w) Proceed to section 2.4 to make the electrical wiring connection
17
Rope Seal
Flue Pipe
Ensure rope seal is
fitted evenly around
the flue pipe to provide
a satisfactory seal