KASTOR Karhu PK 007, Karhu PK 18 ES, Karhu PK 20, Karhu PK 27, Karhu PK 37 Installation And Usage Manual
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KASTOR KARHU PK
PK- series wood burning sauna stoves
installation and usage manual
(Karhu PK 007, 12, 16, 20, 27, 37,18 ES, 20V, 27V, 27ES,
37V and JK-models)
1
1. Before installing …………………………………………………………………………37
1.1 Contents of the package and checking
1.2 Things to be considered and instructions
2. Installation and implementation…………………………………………….…… …..3 9
2.1. Bringing into service condition and burn-in
2.1.2. Side water tank VO and VV
2.1.3. Front water tank ES
2.1.4. Adjusting the heat-up rate ES heater
2.2. Heater stones, placing the stones…………………………………………………….40
2.3. Heater base
2.3.2. Installing on tiled and waterproofed floor.
2.4. Safety distances and precautions…………………………………………………..41
2.4.1. Safety distances
2.4.2. Reducing safety distances
2.5. Connecting heater to brick chimney and KARHU-JK heater instructions…..42
2.5.1. Connecting from rear, only in KARHU models
2.5.2. KARHU-JK heaters with an extended fire door
2.5.3. Installing through the wall and fitting the front frame JK models 16-20-27-37
2.5.4. Connecting from the top, KARHU and KARHU JK models
2.6. Connecting to a Kastor ready-made flue KARHU and KARHU JK models …….43
2.7. Heater door and changing left/right-handedness
2.8 . Grate
2.9. General advice to prevent damage…………………………………………………44
3. Using the heater ………………………………………………………………….……..45
3.1. Fuels
3.2. Adjusting the air flow
3.3. Adjusting heating efficiency
3.4. Lighting
3.5. Adding a batch
3.6. Continuing heating
4. Maintenance …………………………………………………………………….………..46
4.1. Cleaning the heater
4.2. Removing ashes
4.3 . Chimney sweeping
4.4. Cleaning the heater glass
4.5. Changing broken glass
5. Troubleshooting ………………………………………………………………………….46
6. Manufacturer's declaration …………………………………………………………….48
7. Warranty and manufacturer identification……………………………………………48
Table1…………………………………………………………………………………………..49
Table 2………………………………………………………………………………………….50
Pictures…………………………………………………………………………….………… .70
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KASTOR KARHU PK series wood burning sauna
stoves installation and usage manual
Please save these instructions for later use!
Once the installation is done, this manual should be given to the sauna’s owner or the
person in charge of running it.
Please read these instructions prior to installation and first use!
KASTOR WOOD BURNING SAUNA STOVES
We thank you for your confidence in Kastor’s products. We have manufactured wood burning
sauna stoves for nearly a century now, longer than any other company in the world. Over
these years, we have learned a lot about fire, its handling and its precariousness. Anyone
can light a fire, but nurturing it is nearly a form of art. We have two guidelines in design
and manufacturing: A master’s touch leaves nothing extraneous and a master’s touch
cannot be achieved with low grade material. Our products are simple and reliable,
although their elegant form is based on solutions born from decades of experience and
the latest technology.
QUALITY MATERIAL
Our products contain only the best possible material, procured from reliable suppliers we
have gathered over the years. The steel is Finnish structural steel from Ruukki, which can
be bent into various solutions while retaining its hardness due to its uniform quality. Our
glass covers are Ceram glass, which can withstand up to 800 °C while still allowing the
fire’s warm glow to spread into the room.
WE KNOW FIRE
Our products are heavy, which by itself is a sign of fireproof construction. Still, it is not the
steel’s thickness but its correct use that is important. One needs to know how fire
behaves. The hottest and most stressed part is not necessarily directly above the fire,
depending on how the heat is being channelled. The fire must also be supplied with air to
ensure optimally clean burning and economical heating.
SUPERIOR TECHNOLOGY
Our stoves can be fully heated with just one load of wood and they retain warmth long after
the flame has died down. This unique property is the sum of many factors: High quality
material, the Coanda- air circulation system, the large and deep stone compartments and
the sturdy doors. Read more about these and our other technical innovations as well as
our comprehensive installation supplies at www.kastor.fi or in our prospectus.
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1. Before you install
Inspect both product and the contents of the package as soon as you receive them. Report
any transport damages to the deliverer.
1.1. Package contents and its inspection
The stove package contains:
• Stove
• Within the fire compartment
• Installation instructions
• Grate
• Air guide plate
• Connection pipe
• 2 adjustment legs
• Door handle, mounting screw and nuts
• Four steel caps (three sweeping caps in the space intended for stones and the back wall
flue hole has been bolted into place using a drilling screw drilled through the cover).
• Ash pan
1.2. Important matters and regulations
Check the suitability of the heater for the sauna, maximum and minimum cubic contents,
table (1).
Due to stone and glass walls, 3 m3 has to be added to the volume calculations for each
firewall or other stone and glass wall square metre above 2 m2.
In saunas with timber walls , 25% is added to the calculated volume.
In order to avoid damages during transport, the heater must be transported in an upright
position.
All sticker labels and packaging material must be removed before the heater is used. Type
plate and the CE marking must not be removed.
The ash pan must be closed during heating.
BURN IN THE HEATER OUTDOORS BEFORE INSTALLING IN THE SAUNA.
In addition to these instructions, all local regulations must be followed, including those
referring to local and European standards. They must be complied with when installing
the heater.
You must also find out about possible necessary building planning permissions and the floor
load capacity before installing the heater.
Before installing the chimney, you must also check the chimney's temperature class.
• average temperature of combustion gas on nominal output, table (2)
• Maximum temperature of combustion gas in safety test, table (2)
• necessary temperature classification for the chimney is T 600
o
C
Check the following issues and how they affect where the heater should be installed:
• Safety distance to flammable and non-flammable structures (sections 2.3 and 2.4)
• Location of chimney connection (the height of the possible old chimney connection from
the floor and installation route of the chimney
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• Floor material (flammable, non-flammable, tiled, waterproof).
If heater is connected to a divided chimney (another stove has already been connected to the
chimney), each connection must have its own damper. Chimney is sized according to
larger stove.
Before beginning heating, also make sure that the smoke flue draft is sufficient and that the
heater is not damaged.
• Draft in the chimney is -17Pa on nominal output.
• Draft can be roughly checked for example by burning a bit of newsprint in the heater.
• Before lighting, switch off equipment causing negative pressure, such as hood or
machine-operated ventilation. If the ventilation system has been equipped with a
fireplace switch, use it according to the system instructions.
• If heater has its own external delivery pipe for combustion air, make sure it is open and
that there are no items causing a blockage in front of it and that there is a supply of air.
The delivery pipe can be located by the heater on the wall or floor. It must be equipped
with a grille which can be closed or something similar. The pipe size is 120mm. The grille
should be closed after the sauna is no longer used.
• Kastor heaters are meant to be used for heating a sauna. They must not be used for any
other purpose.
• The heater is not meant for continuous 24 hour use.
• Sea water must not be thrown on the stones, only use clean water.
• In the proximity of sea water, there is also the risk of corrosion for the heater; operating
life may be shorter.
• Decorative or other items must not be placed on the heater. The heater must not be
covered when it is heated, or when it is hot. E.g. drying clothes or other flammable
material on the heater is forbidden due to fire risk.
• In order to guarantee full power and safety, the fire door must always be kept shut when
heating. The fire door can be open when heating only when adding more firewood, and
the heater must be continuously observed. Monitor sauna temperature so that the heater
is not overheated. If the heater becomes overheated, open sauna door and allow
ventilation.
• Fire doors and glass surfaces must be handled carefully.
• Fire door handle may be hot; use a tool when opening. (glove)
• If the heater has not been used and if it has been kept in a damp space (e.g. unheated
holiday house) for a long time, it must be carefully checked before use that it has
suffered no corrosion damage and that the chimney is not blocked, for example by a
bird's nest.
• If a chimney fire occurs, or if there is a risk of one, close the fire doors but leave the
damper on the flue open.
• Call the fire brigade if you need help with putting the fire out. After a chimney fire, a local
chimney sweeper must always check the condition of the flue.
• A chimney fire, even one that was put out, must always be reported to the fire authorities.
• Be careful! Handles, fire door glass and the surface of the heater, as well as recirculated
air may be hot!
• Do not let children light fire or stay near burning fire unless supervised by adults.
• Follow the instructions when heating and installing the heater.
• The heater can only be heated using unprocessed firewood.
• Structural changes must not be made to the heater.
• Only use original equipment and parts approved by the manufacturer.
• Place the heater on a non-flammable surface outdoors, without stones.
• Remove water tank by removing the tap and lifting the tank. WTR and WTL models
(2.1.2)
• Front tank model FWT, attach tap and cap and fill tank with water (2.1.3).
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• Remove all extra stickers and protective plastic (excluding type/CE mark stickers).
• Make sure that the grate (chapter 2.8 ) is in place.
• Install the connecting tube to the flue opening above the heater.
• Check the sweeping opening and flue opening lids.
2. Installation and preparation for use
2.1. Preparing for use and burn-in
• Install door handle
• Place the heater on a non-flammable surface outdoors, without stones.
• Remove water tank by removing the tap and lifting the tank. WTR and WTL models
(2.1.2)
• Front tank model FWT, attach tap and cap and fill tank with water (2.1.3).
• Remove all extra stickers and protective plastic (excluding type/CE mark stickers).
• Make sure that the grate (chapter 2.8 ) is in place.
• Install the connecting tube to the flue opening above the heater.
• Check the sweeping opening and flue opening lids.
• Burn-in: The purpose of the burn-in is to remove out of doors any flammable protective
coating substances and to harden the stove’s coating. Burn a few full loads of wood in the
fire compartment. Continue the burn-in until there are no more fumes rising from the
stove.
• Once the stove has cooled down after the burn-in, move it into the sauna.
• See to it that the sauna is well ventilated during the first couple of heating.
2.1.2 SIDE WATER TANK VO and VV
Empty the water tank before outside temperatures drop below zero; the tank is damaged if
water freezes in it.
Water tank lid
Lift the water tank lid (remove protective plastic from the lid) and screw the head in so that it
is outside the lid.
Water tank lid
In order to avoid damage during transport, the heater water tank tap has been stored inside.
A tap, two seals and a nut are included. Water tap is attached on the sauna side. It is
attached as follows: (Image 1)
• Water tank is lifted.
• First seal is placed on the tap thread.
• Tap is pushed into the hole on the heater cover.
• The other seal is placed on the tap thread inside the cover.
• Water tank is lifted into position, and the hole is placed on the threaded part of the tap.
• Place the edge of the water tank on the side bracket.
• Nut for the threaded part of the tap, tightened using a suitable wrench inside the water
tank.
2.1.3 FRONT WATER TANK ES
Empty the water tank before outside temperatures drop below zero; the tank is damaged if
water freezes in it.
Water tank lid
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Lift the water tank lid (remove protective plastic from the lid) and screw the head in so that it
is outside the lid.
Water tank tap (Image 1.1)
• Choose a side to attach the tap.
• Place the seal on the threaded part of the tap.
• Push the tap into the hole in the water tank.
• Tighten nut on the tap.
• Place seal on the plug thread.
• Push the plug into the hole in the water tank.
• Tighten the nut on the tap.
2.1.4 Water heat-up rate adjustment ES heater
When the switch is moved to the right, the water heat-up rate is at its fastest
2.2. Stones and their arrangement
Use peridotite or dunite or darkish natural stones with diameters of over 10 cm. always wash
the stones before installing them. They must not be stacked too tight or heaped up –
arrange them so that plenty of air can pass between them to warm the upper stones, as
well. Fill the space intended for stones until it is full, so that flat stones are placed in an upright
position, (image 2.1) maximum amount of stones, table (1).
By adjusting stone size, amount and adding other types of stone you can balance the steam
consistency to suit the sauna and your preferences. Since these are highly individual, we
cannot give a general rule of thumb – you will find the right mix by trial and error.
For the stove’s proper functioning it is essential that the hot air circulates between the stones
to heat them quickly. If the stones are too small or improperly arranged, you will heat the
sauna instead of the stones!
2.3. Stove base
The stove must be installed horizontally, on a stable and unmoveable non-flammable or
fireproofed base. For this, you may either use Kastor’s separately sold protective stove
base (picture 7)
The front corners of the stove are equipped with adjustment screws, with which it can be
straightened horizontally on an inclined. The adjustable legs are delivered in the
equipment bag in the stove’s fire compartment. Screw them into place and adjust as
needed.
We do not recommend installing the stove directly on a tiled floor, as its moisture sealing, tile
glue etc. may contain components that are not heat resistant.
Fireproofing of the floor on flammable material:
400 mm in front of the stove
On the heater sides 50mm
At the heater back 50mm
(Or, at the sides and back up to a fireproofed wall; picture 2.2.).
NOTE! Always check floor load capacity. Check the heater weight, stones included, from table (2).
2.3.2. Installation on tiled and waterproof floor
The Kastor protective stove base is sufficient, a separate fronting plate is not necessary.
(picture 7)
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2.4. Safety distances and protections
2.4.1. Safety distances
For stone walls, the safety distances are 50 mm from the stove’s outer surfaces, preferably
100 mm to achieve sufficient air circulation. This means the stove will fit a niche of stove
width + 200mm (i.e. for the KARHU 20 that is 490 mm + 200mm = 690mm).
The safety distance to any flammable materials is 400mm from the stove’s outer surfaces. In
front of the stove, due to heat radiation and the working and maintenance space needed,
1,000 mm is a reasonable distance, but 500 mm is sufficient to ensure safety, if the panel
in front of it does not heat up beyond 85oC during the burn-in.
Safety distance upwards, table (1), measured from stone surface. A protective plate with a
30mm air slot must be placed on the ceiling if the measurements are not sufficient.
If the flue pipe starts off from the top of the stove with a no insulated connection pipe, the
required safety distance is 1,000 mm in all directions and 1,200 mm above.
The safe distance between a fitted water tank and the nearest flammable material is 150 mm.
Safety distances can be reduced if protection according to the instructions below is used, so
that the heater can be installed in a gap which is for example 1,100mm wide (e.g. KARHU
20/27's gap is 490mm + 250mm = 740mm). A 30mm air slot is left between the protective
cover's upper and lower edge in order to ensure sufficient ventilation.
2.4.2. Reduction of safety distances
Kastor protective walls and a stand are available. (picture 7)( 2.3). The chimney's isolated part
must reach the protective wall. Other protection is not needed.
If the sauna has a flammable floor in front of the stove, the area to be protected extends 100
mm beyond the door’s sides and a minimum of 400 mm in front of it. In this case, the
protection must be at least a 1 mm thick metal sheet.
If the stove is installed with one side and the back against a brick wall, safety distances of 50
mm to the side and 50 mm at the back are sufficient. If it stands with its back and both
sides next to brick wall, 100 mm should be left on both sides to ensure air circulation. At
the back, 50 mm remains sufficient.
The safety distances around a no insulated connection pipe can be reduced in a similar
manner. The pipe’s insulated part within the sauna must always extend to 400 mm below
the ceiling.
For chimneys, the minimum safety distances to flammable material differs from product to
product. Always check the manufacturer’s instructions. In case of doubt, approach your
local fire safety officials.
2.5. Connecting the stove to a brick chimney and instructions for KARHU-JK
stoves
The Karhu stove can be connected to a brick chimney from the back or the top. JK models
can only be connected from the top. For a brick chimney connection, the safety distances
and protectors named in chapter 2.4. and the chimney’s masonry regulations must be
adhered to.
2.5.1. Connection from the rear, only in KARHU models
Make an opening in the brick chimney that is 2-3cm wider than the connection pipe.
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Use a screwdriver to detach the rounded plate covering the hole in the inner back mantle. Move
this covering plate onto the hindmost hole on top of the stove. Place the connection pipe
delivered with the stove in its rear wall opening. Push the stove into its place. Make sure that the
connection pipe settles well into the hole in the chimney. Tighten the space between connection
pipe and chimney with a flexible, fire-proof material such as fire wool. Neaten the hole with a
Kastor covering, available at your hardware store. The covering is attached to the brick chimney
surface with metal attachments or fireproof glue. (Picture 2.4.)
2.5.2. Heaters installed through the wall, KARHU-JK general
Stoves with extended feed doors must only be installed into walls made of non-
flammable material (brick, concrete etc.).The non-flammable material must be
arranged around the door extension as shown in picture 6. If there is a flammable floor in
the room with the door, the area requiring protection must extend 100mm beyond both
sides of the door and at least 400mm in front of it. The protective layer should be a metal
sheet with a thickness of at least 1mm.(
protective plate on the floor).
The floors of the sauna and the room into which the stove door opens must be on an equal
level. The room with the stove door may also be on a lower level, but never higher than
the sauna's floor!
The stove and its extension must be installed on a sturdy, immovable, fireproof, level
surface. A cast concrete base is the best choice. If the floor of the room with the
door in it is flammable, there must be a non-flammable protective layer (i.e. cast
concrete or masonry) of at least 60mm beneath the door extension. The fire protection
measures on the door side must also adhere to the instructions in chapter 2.3.
By adding fireproofing the stove and its door extension may also be installed on
wooden floors. Nevertheless, the dividing wall must be non-flammable (brick, concrete
or similar). For the sauna and the extended door, a concrete slab with a thickness of
60mm is usually acceptable (remember to take care of moisture draining). The
fireproofing on the sauna side floor must extend 100mm in front of the stove, 50mm at its
sides and 50mm behind it or, at the back and sides, up to a fireproofed wall. The fire
protection measures on the door side must also adhere to the instructions in chapter 2.3.
In unclear cases consult the local fire safety officials.
2.5.3. INSTALLATION THROUGH THE WALL AND FITTING THE FRAME , KARHU-12–
20-27-37 JK models, also with water tank
See also the instructions in chapter 2.6. concerning flue pipe installation.
Make sure that you have received the frame that belongs to the door extension (behind the
stove, between the packing hoop and the stove).
Installation through the wall:
• Make a hole in the wall. Its size should leave about 10-20mm of clear space all around
the door extension.
• Remove the stove door by taking the hinge pin off (note the 2 base plates between door
and frame).
• Remove the ash door.
• Install the stove from the sauna side and push it as far as possible through the wall, so
that the door extends about 40mm beyond the wall.
• Insulate the gap between feed door and wall with fireproof mineral wool. Follow the
instructions of the mineral wool manufacturer!
• Install the frame into place via the door (do not yet attach it to the wall).
• Attach the door. Remember the base plates. At this point, you may choose the door's
opening direction.
• Place the rivet in the upper part of the frame in the remaining hole.
• Put the ash door into place.
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• Ensure that a gap of 5-10mm remains between extended door and the frame on top of it
to allow for heat expansion.
• Attach the frame to the wall with six 5mm screws using metal attachments that are
embedded in the wall.
2.5.4. Connecting from the top. Karhu and Karhu-JK
Place the heater's own connecting pipe to the heater's upper flue opening. (Check 2.4)
Make a hole in the brick chimney which is 2–3mm bigger than the connecting pipe.
Use a 45° bent pipe for the connection from the top of the stove, which can be turned to align
with the chimney. Suitable 45° bent pipes are available at the hardware store. Extend the
bent pipe with an extension piece, if necessary. Install the stove’s own connection pipe in
the flue opening on top of the stove according to stove model instructions. The bent pipe
is then attached to the stove’s own connection pipe. Saw the bent pipe and any extension
pipe down to a suitable size where necessary. Make sure the pipe extends sufficiently into
the chimney (but not so far that it blocks up the chimney).
Seal the empty space between connection pipe and chimney with flexible, fireproof material
such as stone wool. The lead-through is then tidied up with a Kastor covering plate, which
is available at your hardware store. The covering plate is attached to the wall with metal
bolts or fireproof paste. See picture 2.5.2.
2.6. Connecting to a Kastor chimney. Karhu and Karhu-JK
The Kastor stove can be connected from the top to a factory built Kastor chimney. (check
2.4).
Make sure to choose the correct chimney type with regard to your stove model, chimney
height, temperature class T 600, exterior circumstances etc. For best results we
recommend that you install a chimney valve.
• Install the heater's own connecting pipe to the upper flue opening on top of the heater.
• Install a no insulated connection pipe and any necessary extension piping on top of the
stove’s own connecting pipe. Where necessary, saw the connection pipe and the
extension pipe down to suitable size.
• Karhu JK-model: Install the stove’s own connecting pipe into the stove’s door-side flue
opening on the top.
• Install a no insulated connection pipe and any necessary extension piping on top of the
connecting pipe.Where necessary saw the connection pipe and the extension pipe down
to suitable size.
• The chimney valve goes between the insulated and no insulated sections or into the first
insulated pipe section.
• Continue from the chimney valve with an insulated pipe. The insulated pipe section must
start at least 400 mm beneath the ceiling. Follow the installation and usage instructions
for Kastor chimneys.
Remember to keep all safety distances to flammable and non-flammable materials named
above. Helo Oy does not guarantee the suitability and functioning of other manufacturers’
factory-built chimneys with Kastor stoves. Helo Oy does not accept liability for the quality
of other manufacturers’ factory-built chimneys. The chimney must fulfil the requirements
of temperature class T 600.
2.7. The stove door and changing the opening direction
The opening direction is changed by turning the door upside down.
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