Redfyre Kensal 40, Kensal 60 Installation and Use Instruction

High Output Boiler Stoves

MODELS: REDFYRE KENSAL 40/60

Instructions for Use,

Installation and Servicing

For use in GB & IE (Great Britain and Republic of Ireland).

This appliance has been certified for use in countries other than those stated. To install this appliance in these countries, it is essential to obtain the translated

instructions and in some cases the appliance will require modification. Contact Stovax for further information.

IMPORTANT

This appliance will become hot whilst in operation, it is therefore recommended that a suitable guard should be used for the

protection of young children, the elderly or infirm. Do not attempt to burn rubbish in this appliance.

Please read these Instructions carefully before installation or use.

Keep them in a safe place for future reference and when servicing the fire.

The commissioning sheet found on page 3 of these instructions should be completed by the Installer.

PM301 Issue 3 (August 2010)

COVERING THE FOLLOWING MODELS:

REDFYRE KENSAL 40/60

APPLIANCE COMMISSIONING CHECKLIST 3

USER INSTRUCTIONS 4

General Points 4 Using the Appliance for the first time 5 Recommended Fuels 6 Lighting the appliance 7 Running the appliance 7 Burning Tips 9 Ash Removal 10 Wood Burning Tray 10 Extended burning 11 Over-Firing 11 Chimney Fire 11 General Cleaning 11 Cleaning Glass 12 Chimney Sweeping 12 Care of Stove 12 Seasonal Use 12 Troubleshooting Tips 13

INSTALLATION INSTRUCTIONS 14

Technical Specification 14 Boiler Output Chart 15 Standard Features 15 Packing List 15 Dimensions 16

COMMISSIONING 30

MAINTENANCE & SERVICING 31

Annual Service 31 Removal of Log Guard 32 Removal of Baffle 32 Removal of Riddling Grate 32 Fitting a New Glass Door 32 Fitting a New Door Seal 33 Adjusting Door Hinges 33

BASIC SPARE PARTS LIST 33

SERVICE RECORDS 35

SITE REQUIREMENTS 17

Flue & Chimney 17 Flue outlet positions 18 Hearth Dimensions 18 Walls Next to Hearth 19

PRE-INSTALLATION 20

Flues 20 Ventilation 21

INSTALLATION 22

Legal Requirements 22 Installing the Appliance 22 Top Flue Installation 22 Rear Flue Installation 23 Removal of Log Guard 23 Fitting & Removal of Baffle 24 Fitting & Removal of Multi-fuel Grate 24 Central Heating System 26 Heating System Controls 27 Link Up Information 28

w a r r a n t y

Your Redfyre retailer provides you with a Two Year Warranty

for your new stove. However, this specifically excludes naturally

wearing parts or consumables such glass and rope seal and the

use of non-authorized fuel such as petro-cokes. Furthermore, for

the warranty to be valid, your stove must have been installed in accordance with the manufacturer’s instructions and the second

year’s warranty is dependent on the appliance being serviced 12

months after installation by a HETAS or other similarly qualified

engineer.

They also provide a Five Year Casting Warranty for the carcass of

all cast iron stoves and the cast iron door of steel stoves. Again, this

excludes naturally wearing cast parts such as grate, dampers, log

retainers and baffles.

You can help your retailer to provide their warranties by returning

the reply card or registering online at www.redfyrecookers.co.uk

APPLIANCE COMMISSIONING CHECKLIST

To assist us in any guarantee claim please complete the following information.

In the unlikely event of a problem, contact your installer or dealer for assistance:

Dealer appliance was purchased from

Name: .................................................................................................................................................................

Address: ...............................................................................................................................................................

............................................................................................................................................................................

Telephone number: .............................................................................................................................................

Essential Information - MUST be completed

Date installed: .....................................................................................................................................................

Model Description: ..............................................................................................................................................

Serial number: .....................................................................................................................................................

Installation Engineer

Company name: .....................................................................................................................................................................

Address: .................................................................................................................................................................................

...............................................................................................................................................................................................

Telephone number: ................................................................................................................................................................

Commissioning Checks (to be completed and signed)

Is flue system correct for the appliance YES NO

Flue swept and soundness test complete YES NO

Smoke test completed on installed appliance YES NO

Spillage test completed YES NO

Use of appliance and operation of controls explained YES NO

Instruction book handed to customer YES NO

Hot water system commissioned YES NO

Signature: ....................................................................................... Print name: ...............................................................

USER INSTRUCTIONS

1. GENERAL POINTS

1.1 Before use of this appliance please read these instructions fully.

The appliance must be fitted by a registered installer*,

or approved by your local building control officer.

1.2 All local regulations, including those referring to national and European Standards need to be complied with when installing the appliance.

1.3 Only use for domestic heating. To achieve the optimum

performance from this appliance it must be installed and operated according to these instructions burning the fuels recommended.

1.4 You must burn only approved fuels. Do not use with liquid fuels or as an incinerator.

1.5 Appliance surfaces become very hot when in use. Use a suitable fireguard if young children, elderly or infirm persons are present. Stovax offer firescreens, sparkguards and hearthgate systems for protection‡. Your Stovax retailer can advise you about these products.

1.6 Do not place photographs, TV’s, paintings, porcelain or other combustible items on the wall or near the appliance. Exposure to hot temperatures will cause damage. Do not place furniture, or other items such as drying clothing, closer than 1m from the front of this appliance.

1.7 Extractor fans or cooker hoods must not be placed in the same room or space as this can cause appliance to emit fumes into the room.

Data Plate

PR7611

THERMOSTAT

1.13 As an optional extra this stove can be controlled by a thermostat which regulates the rate in which the fuel is burned and the amount of heat produced. A trial and error approach will establish settings to suit personal preference.

AIR CONTROLS

Several Stovax appliances have air systems providing

cleaner burning, and greater efficiency and control,

See Diagram 3

1) Airwash - air drawn over the window cleans the glass. The source of Primary Combustion air when burning wood.

2) Primary Air - for use with solid fuel and initially with wood fires.

AIRWASH & PRIMARY AIR CONTROLS

1.8 Do not obstruct inside or outside ventilation required for the safe use of this appliance.

1.9 Do not make unauthorised changes to the appliance.

1.10 The chimney must be swept at least once a year (see Section 12).

1.11 Do not connect, or share, the same flue or chimney

system with another appliance.

1.12 Do not run the appliance without any water in the system.

SERIAL NUMBER

1.12 This number is required when ordering spare parts or

making warranty claims. It is found on the appliance data

plate.

All models

For all models the data plate is found under the front of the

stove ashlip. See Diagram 1

1.14 Use a gloved hand to operate air controls

1. Airwash Control

OPEN CLOSE

PR7615

2. Primary Control

OPEN CLOSE

‡In the U.K. these products must conform to BS 6539,

Fireguards for use with solid fuel appliances.

If appliance is operating unattended they must conform to

BS 3248

*Registered on the Competent Persons Scheme (GB only)

see page 33 / INFO (Republic of Ireland).

USER INSTRUCTIONS

DOOR HANDLE

1.14 Use a protected gloved hand to operate.

DO NOT OPEN THE DOOR WITH BARE HANDS

To Open and Close

Drop tool over knob to fit. Lift and remove

Rotate 1/4 turn anti-clockwise to open.

Rotate 1/4 turn clockwise to close.

1.14 Never open the door with your bare hands.

1.15 Closing the door is the reverse of the previous.

PR7613

HEATING SYSTEM CONTROLS

CONTROLS, GENERAL

1.18 The controls fitted to the system will provide two functions:

—To control the comfort level in the house.

—To maintain safety in the event of misuse or

mechanical failure.

COMFORT CONTROLS

1.19 A programmable timer switches the pump on when heat

is required and off when it is not.

The timer, when combined with a room thermostat and

/ or thermostatic radiator valves, enhances the comfort levels in the house.

Some room thermostats combine the function with

the timer and can be programmed to reduce the room temperature rather than turning the system off. This is effective in not allowing rooms to become too cold and speeding up recovery time.

1.20 The hot water cylinder can also be fitted with a thermostatic valve which turns off the flow when the cylinder has reached the desired temperature, but the heat leak radiator will have to be bigger to cope with the extra load when the tank is isolated.

1.22 It is also recommended to fit a low limit thermostat on

the central heating return set at 45˚C. This thermostat will

turn the pump off if the return temperature falls below 45C. This will prevent corrosion and condensation within the stove.

‡

NOTE – Further information on solid fuel central heating systems can be found in the HETAS engineers training manual.

‡

WARNING

Properly installed, operated and maintained this appliance will not emit fumes into the room.

Occasional fumes from de-ashing and refuelling may

occur.

Persistent fume emission is potentially dangerous and

must not be tolerated.

If fume emission does persist:

—Open doors and windows to ventilate the room.

—Allow fire to burn out or safely dispose of fuel from the

appliance.

—Check for chimney blockage and clean if required.

—Do not attempt to relight until the cause of the

emission has been identified and corrected.

If necessary seek expert advice.

—All open flued appliances can be affected by

temporary atmospheric conditions which may allow fumes to enter the house. Because of this it is recommended that an electronic carbon monoxide detector conforming to BSEN50291 be fitted and maintained.

2. USING THE APPLIANCE FOR THE FIRST TIME

2.1 To allow the appliance to settle and fixing glues and paint to fully cure:

—Operate the appliance at a low temperature for first

few days.

2.2 Do not touch the paint during the first period of use.

2.3 During this time the appliance may give off some unpleasant odours:

SAFETY CONTROLS

1.21 A high limit thermostat is fitted to the gravity flow pipe

set at 80˚C. This thermostat should be connected to the

pump so that the pump is turned on if the temperature

exceeds 80˚C. This will prevent accidental boiling in the

gravity circuit.

—Keep the room well ventilated to avoid a build-up of

fumes.

CONDENSATION

USER INSTRUCTIONS

CAUTION WHEN FILLING

2.4 When filling the boiler with water for the first time, the cold water entering the water jacket can cause condensation to form on the surfaces of the appliance (inside and outside).

2.5 In certain conditions this condensation could result in a considerable amount of water, in some cases enough to fill the bottom of the appliance. This could be even worse if the house has recently been re-decorated, wet plastered or any other work has been undertaken which could result in high humidity.

2.6 Precautions must be taken to ensure that this build up of condensate does not overflow from the appliance onto any surrounding fabric of the room e.g. carpets.

Appliance Wood Length

Kensal 40 200mm

Kensal 60 500mm

Wood Length

Poor quality timber:

NOTE - THIS CONDENSATION IS NORMAL DURING

FILLING AND DOES NOT INDICATE A FAULTY OR LEAKING STOVE.

NORMAL RUNNING

2.7 During normal running this condensation should be minimal if the system is fitted with the low limit thermostat as detailed in 1.22 (above). This low limit thermostat prevents the system pump from running until the stove has reached temperature.

SEASONAL USE

2.8 If this appliance is unused for lengthy periods of time it should be periodically checked to ensure that condensation is not building up within the stove.

NOTE – THIS CONDENSATION IS NORMAL AND DOES

NOT INDICATE A FAULTY OR LEAKING STOVE.

If the stove is going to be unused for very long periods of

time it is recommended to drain the system.

3. RECOMMENDED FUELS

3.1 Wood Logs:

Burn only seasoned timber with a moisture content of less

than 20%. To ensure this allow cut wood to dry for 12 to 18 months.

—Causes low combustion efficiency.

—Produces harmful condensation.

—Reduces effectiveness of the airwash and life of the

appliance.

Do not burn construction timber, painted, impregnated

/ treated wood, manufactured board products or pallet wood.

3.2 Solid fuel:

Burn only anthracite or manufactured briquette smokeless

fuels listed as suitable for use with closed heating

appliances.

Do not burn bituminous coal, ‘petro-coke’ or other

petroleum based fuels as this will invalidate the product guarantee.

3.3 Fuel consumption: As tested at nominal heat output to the requirements of

EN 13229: 2001 for intermittent operation.

Fuel Consumption

Description

Kensal 40 4.8 2.1

Kensal 60 5.5 3.2

Kg/hour

Wood

Kg/hour

Briquette

Smokeless fuel

*In the U.K:

• Ring the Solid Fuel Association advice line on 0845 601

4406 for details

• Visit their web site at www.solidfuel.co.uk

‡ NOTE – Further information on solid fuel central heating

systems can be found in the HETAS engineers training manual.

3.4 For advice on suitable solid fuels:*

• Contact your local approved coal merchant

A number of factors can affect the performance of the

appliance. See Section 8 for details.

USER INSTRUCTIONS

4. LIGHTING THE APPLIANCE

4.1 For best results:

—Set air controls (see Diagram 5).

Airwash: Fully Open

Base of baffle

Primary Air: Fully Open

—Place firelighters or paper and dry kindling wood on

the grate.

—Light the paper or firelighters (see Diagram 6).

PR7615

Log Guard

—Close the door.

Do not leave the door open as this may cause over-

firing which can damage the appliance.

PR8871

5. RUNNING THE APPLIANCE

BURNING WOOD:

5.1 This appliance gives out its heat in two ways:

—Directly into the room in which it is fitted through

convection and radiation.

—Hot water to heat radiators and domestic hot water.

The output to hot water varies depending on how quickly the fuel is being burnt. Fore more detail see the graph on page 13.

5.2 Only for use with recommended fuels, see Section 3 for full details.

—Close the Primary Air control and use the Airwash to

control the burn rate when the appliance is at optimum operating temperature (see Diagram 8 & 9).

—Leave the door slightly open as the fire establishes and

the glass warms to avoid the build-up of condensation.

—Add larger pieces of solid fuel once the fire is

established. Do not add too much fuel initially as this may smother the fire.

Do not load fuel above the log guard or the base of the

baffle (see Diagram 7).

PR8012

USER INSTRUCTIONS

Airwash

Primary Air

PR7615

—Wood burns best on a bed of ash (approx. 25mm (1")

deep).

—Rake the embers evenly over the firebed and open the

Airwash control fully for a few minutes before re-fuelling.

Do not refuel when a large amount of flames are

present in the firebox as this could cause smoke or flames to spill into the room.

Close the doors immediately after refuelling.

5.3 Burn new logs at a high temperature for a few minutes before adjusting the Airwash control. Refuel little and often for clean, efficient burning.

Do not load above the log guard or base of baffle.

5.4 Do not burn large amounts of fuel with the Airwash control closed for long periods of time. This reduces the glass cleaning effect of the Airwash and causes tars and creosotes to build-up in the appliance and flue system.

5.5 When in use, running the appliance at a high temperature for a short period reduces tars and creosotes.

5.8 De-ash the firebed before re-fuelling (see User Instructions, Section 7).

Open the Primary Air Control fully to establish a glowing

bed before adding new fuel.

Burn new fuel at a high temperature (see Diagram 9) for a

few minutes before adjusting the Primary Air Control to the desired setting.

Refuel little and often for clean, efficient burning.

5.9 Experience establishes settings to suit personal preference.

5.10 Do not burn large amounts of fuel with the Primary Air Control on a low combustion setting for long periods of time. This reduces the glass cleaning effect of the Airwash and causes tars and creosotes to build-up in the appliance and flue system.

5.10 When in use, burning the appliance at a high temperature for a short period reduces tars and creosotes.

5.11 Only anthracite or smokeless fuels suitable for use in closed appliances must be burned in this appliance.

5.12 Do not burn bituminous coal, ‘petro-coke’ or other

petroleum based fuels as this invalidates the product guarantee.

5.13 Do not load fuel above the log guard and the Secondary Air Inlets at the back of the firebox (see Diagram 7).

REFUELLING

5.14 De-ash the fire bed before refuelling, see Ash Removal

—Open the Primary air control fully to establish a

glowing bed before adding new fuel.

—Do not refuel when a large amount of flame is

present in the firebox as this could cause smoke or flames to spill into the room.

—Close the doors immediately after refuelling.

—Burn new fuel at a high temperature for a few minutes

before adjusting the Primary air control to the desired setting.

—Refuel little and often for clean, efficient burning.

5.6 Experience establishes settings to suit personal preference.

Do not burn construction timber, painted, impregnated / treated wood, manufactured board

products or pallet wood.

BURNING SOLID FUEL

5.7 To burn smokeless fuels a cast iron multi-fuel kit must be fitted. Set air controls as shown in Diagram 9.

5.15 Do not re-fuel the stove above the level of the log guard or the base of the baffle.

THERMOSTAT OPERATION

5.16 This appliance can be fitted with a thermostat kit to control the temperature of the boiler. See the instructions included in the kit for operation details.

USER INSTRUCTIONS

6. BURNING TIPS

6.1 Fuel Quality (Wood) Use wood with a moisture content of less than 20%.

Seasoned logs have the bark beginning to lift and peel away and cracks radiating from the centre. They feel lighter than fresh cut wood of a similar size and sound hollow when struck against each other. Logs should not feel damp or have moss or fungal growths.

Symptoms related to wet wood: —Difficulty starting and keeping a fire burning well. —Smoke and small flames. —Dirty glass. —Rapid creosote build-up in the chimney. —Low heat output. —Short burn times, excessive fuel consumption and blue/

grey smoke from the chimney.

Burn at a high temperature for a short period each day

to avoid large build-ups of tars and creosotes within the appliance and the flue system.

Use Stovax Protector chimney cleaner to reduce this

problem.

6.2 Fuel Quality (Solid Fuel) Use recommended solid fuels approved for use with closed

appliances.

Symptoms related to unsuitable fuels include: —Difficulty starting and keeping a fire burning well. —Smoke and small flames. —Dirty glass and/or fire bricks. —Short life span for grate and baffles. —Permanent staining of glass.

6.3 Air inlets puffing smoke Combustion gases can build up in the firebox and ignite

as small explosions, causing smoke to puff out of the air inlets and other openings. This occurs if the air controls are shut soon after adding new fuel to a very hot fire. Stop by opening the air controls to increase combustion air and burning rate.

6.4 Flue Draught The chimney has two main functions:

1) To safely remove the smoke, gases and fumes from the house.

2) To provide a sufficient amount of draught (suction) in the appliance ensuring the fire keeps burning.

Draught is caused by the rising hot air in the chimney

when the appliance is lit.

—Difficulty getting a fire going and keeping it burning

well (low flue draught).

—Low heat output (low flue draught). —Smoke entering room when doors are opened (low flue

draught).

The construction, position, size and height of the chimney

all affect the performance of the flue draught.

Other factors effecting the flue draught include: —Nearby trees or buildings causing turbulence. —Outside temperature. —Outside weather conditions. —Incorrect additional ventilation to building. —Blocked flue or chimney.

For advice on the correction of persistent flue problems

consult a qualified heating engineer before continuing to use the appliance.

6.5 Weather conditions

The weather conditions outside the building can effect

the burning performance of the appliance. These could include:

Weather Conditions Problem Effect

Windy days

Calm days

Damp / Rainy days

To reduce these problems:

—Use good quality kindling wood to start the fire. —Burn initially at a high temperature for a short period. —Fit a rain cowl to the chimney.

Your installer should advise you on possible solutions.

If the appliance emits smoke into the room continuously: —Close the air controls and allow the appliance to go

out.

—Ventilate the room to clear the fumes.

Do not re-light the appliance until the problem is

solved.

Buildings/obstacles cause turbulent air around chimney

Oversized chimney Smoky appliance

Flue temperature not hot enough / rain water inside chimney

Smoky appliance

Lighting and burning problems

Symptoms of poor performance related to flue draught

include:

—Excessive fuel consumption (high flue draught). —Poor burning control and/or overheating (high flue

draught).

—Wind noise from air controls (high flue draught).

USER INSTRUCTIONS

7. ASH REMOVAL

Warning: Ash can remain hot long after appliance has

been in use.

7.1 Wood:

—Open Doors (see Section 1.14)

—Leave a layer of ash to start the new fire on. Wood

burns best on a bed of ash (approx. 25mm (1") deep).

—Remove ash with a small shovel and place into a Stovax Ash Caddy (Stovax Part No. 4227) or other

suitable container.

Do not place hot ash in any container made from

plastic or any other combustible material.

—De-ash at least once a week.

7.2 Multi-fuel:

De-ash the appliance before filling with new fuel. Do not

allow ash to build up on the underside of the grate as this can cause premature failure.

—Insert the Riddling Tool into the socket as shown in

Diagram 10.

PR8031

—Place the ash into a Stovax Ash Caddy (Stovax Part No.

4227) or other suitable container.

—Check and remove ash as often as required when

burning solid fuel.

—De- ash at least once a week.

—Do not place hot ash in a container made from plastic

or any other combustible material.

8. WOOD BURNING TRAY

8.1 In order to burn wood continuously in this appliance a Wood Burning Tray should be fitted (see Diagram 12).

Push/Pull to

operate

PR8030

—Rotate the Riddling Tool backward and forward 3 or 4

times to remove the ash. Do not force the handle beyond its natural stop point. The ash will fall into the ashpan.

—Open door(s).

Warning: Ash can remain hot long after appliance has

been in use.

—Using gloves, carefully remove ashpan (see Diagram

11).

Front edge

8.2 Remove the multi-fuel grate from the appliance (see Installation Instructions, Section 4).

8.2 To fit the Wood Burning Tray:

—Remove the log bar and ashlip,

—Hold the tray flat with the front edge pointing forwards

(see Diagram 12).

—Tilt diagonally and insert through the front of the stove

(see Diagram 13).

PR8891

USER INSTRUCTIONS

—Place tray flat on the fixings on the firebed (see Diagram 14).

PR8892

9. EXTENDED BURNING

9.1 It is possible to get the appliance to burn for extended periods. In order to do this:

—De-ash prior to final refuelling.

—Set air controls to low combustion settings. This will

blacken the glass over night but it will clear when

operated at high output for a short period.

—Use smokeless fuel or small, thick logs depending on

fuel desired.

10. OVER-FIRING

10.1 Do not over-fill with fuel or use at maximum output for long periods or over-firing can occur. If the flue pipe, flue collar or top plate glow red the appliance is over-firing:

• Close the air controls to reduce the output

10.2 Over-firing can cause permanent damage to the appliance.

11. CHIMNEY FIRE

PR8893

—Fit the plug supplied into the hole where the

riddling mechanism is normally located and secure with bolt and clamp (also supplied, see Diagram 15).

Clamp

Bolt

—Replace the log bar and the ashlip.

* Registered on the Competent Persons Scheme (UK only)

see page 14 / INFO (Republic of Ireland).

**This should be done by a HETAS Approved Chimney

Sweep (UK only) see page 33 / INFO registered (Republic of Ireland only) who will issue you with a certificate.

Plug

PR8454

11.1 If a chimney fire occurs:

—Shut all air controls immediately.

—Evacuate the building.

—Call the fire brigade.

—Do not re-enter the building until it is confirmed safe.

11.2 Do not use the appliance after a chimney fire until:

a) It has been inspected by a registered installer,

confirming the appliance is safe to use*.

b) The chimney system inspected and swept by a chimney

sweep, confirming the system is structurally sound and free from obstruction before re-use**.

c) It is repaired as required before re-use. Use only

genuine Stovax replacement parts to keep your appliance in safe and efficient working order.

12. GENERAL CLEANING

12.1 Clean and inspect the appliance regularly, especially in periods of heavy use. Regular cleaning and maintenance will help give many years of safe use.

Allow appliance to cool thoroughly to avoid risk of

burns.

Clean regularly, according to level of use.

USER INSTRUCTIONS

—Remove the ash completely (see User Instructions,

Section 7).

—Check the internal components for damage (grates,

bricks, baffles and log guard). Do not use the appliance if any parts are broken or damaged. Replace

damaged parts with genuine Stovax replacement parts

to keep the appliance in safe, efficient working order.

—Check for obvious build up of soot, ash or debris above

the flue baffle(s) (these can be found in the upper part of the firebox). Use a torch if necessary.

—If there are any signs of a build up of debris above the

flue baffle(s) either:

—Arrange for the chimney to be swept (see User

Instructions, Section 13).

—Remove the baffles and clear the debris (see Installation

Instructions, Section 4).

—Clean matt black appliances using Stovax Colloidal

black or Stovax Grate Polish.

—To refresh painted finishes use Stovax Thermolac paint.

—Clean enamel finishes using warm soapy water and a

soft clean cloth.

—Wipe dry with a soft clean cloth be fore relighting.

Always dry appliance to avoid rust.

—Do not use abrasive cleaner or cleaning pads.

—Check that the door shuts properly and creates an

effective seal. Leaking door seals prevent the appliance working properly.

14. CHIMNEY SWEEPING

14.1 To maintain safe and efficient use of the appliance the chimney/flue must be inspected and swept at least once a year by a qualified chimney sweep.*

If the appliance is used continuously throughout the

year or it is used to burn wood or smokeless fuel, more frequent sweeping is recommended.

The best time to have the chimney swept is at the start of

the heating season.

The above applies even if burning smokeless fuels.

14.2 The chimney, any connecting flue pipe and the appliance flue ways if incorporated, must be regularly cleaned.

14.3 Ensure adequate access to cleaning doors where it is not possible to sweep through the chimney.

14.4 If the appliance is believe to have previously served an open fire the chimney must be swept a second time within a month of regular use after installation.

15. CARE OF STOVE

Stovax has a range of cleaning and maintenance products

and accessories to keep your appliance in good working order. Your Stovax retailer can advise you on suitable items for your stove and provide genuine spare parts such as replacement glass and door sealing rope. View the extensive range at www.stovax.com by clicking on Accessories. In addition, an annual service by a competent engineer is recommended to keep your stove in the best possible condition.

—Do not use aerosol sprays near an operating

appliance.

13. CLEANING GLASS

13.1 Keep the glass clean with correct use of the Airwash system and good quality fuel. Sometimes additional cleaning may be required. This can be done as follows:

—Allow appliance to cool fully. Do not clean hot glass.

—Use a soft cloth and Stovax Glass Cleaner.

13.2 Before re-lighting the appliance:

—Dry the glass fully.

13.3 Do not use abrasive cleaner or cleaning pads.

16. SEASONAL USE

16.1 Clean and service the appliance if it is not used during the warmer periods of the year as detailed in the Maintenance and Servicing section.

16.2 Set the air controls 50% open to keep the appliance ventilated and stop the build-up of any moisture inside.

16.3 Before re-lighting the appliance:

—Remove the baffles.

USER INSTRUCTIONS

—Clear any debris that may have accumulated.

—Check the flue is clear of any blockages.

16.4 If this appliance is unused for lengthy periods of time it should be periodically checked to ensure that condensation is not building up within the stove.

NOTE – THIS CONDENSATION IS NORMAL AND DOES

NOT INDICATE A FAULTY OR LEAKING STOVE.

16.5 If the stove is going to be unused for very long periods of time it is recommended to drain the system.

17. TROUBLESHOOTING TIPS

17.1 Stove glass blackening

This has four possible causes:

1. Incorrect use of Airwash

See User Instructions, Sections 1, 4 and 5 for the correct

use of the air controls.

2. Burning unseasoned wood

See User Instructions, Section 3 to identify when wood is

ready for burning.

3. Stove operated at too low a temperature

A stove pipe thermometer can identify this problem

(Stovax part no. 3046). The ideal working temperature range is 130°C - 250°C (270°F - 480°F). Failing to close down the Primary Air Control once the appliance has heated up to this range may cause the appliance to exceed the ideal temperature range and to over-fire. Over-firing can cause permanent damage to the appliance and invalidates your warranty. Burn with the Airwash Control fully open for approximately 20 minutes to cure this.

The problem may be caused by damping down the

appliance during periods of extended burning.

4. Problems with the flue, in particular insufficient air pull. If the flue is not working efficiently the glass can blacken. A flue which has too much downdraft may be too short, needs lining, or has too many bends. This can also cause blackening of the stove glass. Contact the installer or a flue specialist for advice.

17.2 Riddling mechanism jamming

This occurs when fine ash builds up under the riddling

bars preventing movement. To prevent this:

—Follow a regular cleaning routine for the inside of your

appliance.

—Lift out the riddling mechanism and remove all ash.

—Replace riddling mechanism when cleaning is complete

17.3 Glass cracking Do not over tighten the screws on the glass clips when

replacing the glass. This causes stress and the intense temperature changes can cause the glass to crack. For replacement glass contact your local Stovax retailer.

17.4 Appliance is producing tar This can be identified by:

—A very strong pungent smell shortly after the appliance

is lit and heats up.

—Glass blackening. —Thick, brown, sticky tar oozing from the pipe joints.

This is caused by burning damp wood and running the

appliance at too low a temperature.

Use well seasoned wood and operate the appliance within

the ideal temperature range.

Tar is a major cause of chimney fires. If the appliance

experiences problems with tar build up consult a chimney sweep before continued use of the appliance.

17.5 All or some of the radiators do not get hot

Open up the airwash to make

a hotter fire

If fitted set the thermostat to a

Burning wood Wood is burning too

Burning Solid

Mineral fuels

All Fuels

slowly

Fuel is burning too

slowly

Stove is not producing

much heat.

System faults

higher setting

Burn dryer wood

Burn better quality wood

Reduce ashbed to 1" thick

Open up the primary air to make a hotter fire. If fitted,

set the thermostat to a higher

The fire needs riddling to

remove ash. De-ash the fire

Bleed the radiators to ensure

Incorrect system design seek

Too many radiators in the

system exceeding the stoves

setting

Empty the ash pan.

Not enough fuel.

there are no air locks.

professional assistance

capabilities.

17.6 In the unlikely event of a problem that cannot be solved

by these tips contact your installer or retailer for help.

Model

Kensal 20

Kensal 60

TECHNICAL SPECIFICATION

KENSAL

Kensal 40

Nominal Heat Output to Room Solid Fuel kW 5.0 7.0

Nominal Heat Output to Water kW 8.0 11.0

Flue Draught at Nominal Heat Output All Fuels

Flue Outlet Size (Top or Rear option)

Minimum Hearth Type Required

Weight kg 135 172

Recommended Fuels Solid Fuels

Constructional = CH 12mm hearth = 12mm

mm Wg 1.25 1.25

inch Wg 0.05 0.05

mm 150 150

inch 6 6

CH CH

Briquette smokeless fuel suitable for closed appliances. (Ancit - Phurnacite - Taybrite - Homefire ovals)

Kensal 60

TECHNICAL SPECIFICATION

1. BOILER OUTPUT CHARTS

KENSAL 40 HO BOILER STOVE

KENSAL 60 HO BOILER STOVE

1. STANDARD FEATURES

• Primary air (under grate air for full multi-fuel use)

• Airwash (for wood burning / clean glass)

• Riddling grate system for clean de-ashing (when fitted

with multi-fuel kit)

• Top or rear flue exit option

2. PACKING LIST

• User Instructions

• Installer Instructions

• Guarantee card

• Pair leather gloves

• Door handle tool

• Fire bricks

• Ashpan (MF Only)

• Riddling tool (MF Only)

TECHNICAL SPECIFICATION

KENSAL DIMENSIONS

Description A B C D E F G I H (dia)

Kensal 40

Kensal 60

587 597 117 365 105 407 236 317 150

679 717 170 405 117 411 289 357 150

PR8248

SITE REQUIREMENTS

1. FLUE OR CHIMNEY

1.1 The flue or chimney system must be in good condition. It must be inspected by a competent person and passed for

use with the appliance before installation.

Products of combustion entering the room can cause

serious health risks.

1.2 The following must be checked:

—The construction of the masonry chimneys, flue block

chimneys and connecting flue pipe system must meet the requirements of the Building Regulations†.

—A flexible flue liner system can be used if certified for

use with solid fuel systems and installation complies with manufacturer’s instructions and Building Regulations†.

The flue liner must be replaced when an appliance is

replaced, unless proven to be recently installed and in good condition.

—If it is necessary to fit a register plate it must conform to

the Building Regulations†.

—The minimum height of the flue or chimney must

be 4.5m from the hearth to the top of the flue, with no horizontal sections and a maximum of 4 bends. Bends must have angles of less than 45 degrees from the vertical.

—Ensure the connecting flue pipe is kept a suitable

distance from any combustible material and does not form part of the supporting structure of the building.

and removal of debris.

1.5 The flue must be swept and inspected when the appliance is installed.

1.6 The flue draught must be checked with all windows and doors closed and any extraction fans in this, or adjoining rooms, running at maximum speed (see next section for additional ventilation requirements).

Max. Draught = 2.0mm Wg

Min. Draught = 1.0mm Wg

In the U.K.

*The design of the flue and chimney systems and products

used should meet the requirements of ADJ along with any other relevant, National or European standards that may apply. Products should be specified with regard to the type of appliance, position within the building, fuels to be used and appliance operating temperatures.

**This should be done by a HETAS Approved Chimney

Sweep (UK only) see page 14 / INFO registered (Republic of Ireland only) who will issue you with a certificate.

†

Building Regulations Document J

—Make provision to remove the appliance without the

need to dismantle the chimney.

—Any existing flue must be confirmed as suitable for

the new intended use as defined in the Building Regulations†.

—The flue or chimney systems must be inspected and

swept to confirm the system is structurally sound and free from obstructions**.

—If the chimney is believed to have previously served

an open fire it must be swept a second time within a month of regular use after installation to clear any soot falls that may have occurred due to difference in combustion levels.

—The flue exit from the building must comply with local

building control rules†.

—Do not connect or share the flue or chimney system

with another heating appliance.

1.3 Do not connect to systems containing large voids or spaces over 230mm square.

1.4 Suitable access must be provided to enable the collection

Flue Plate:

Where a hearth, fireplace, flue or chimney is provided or

extended (including cases where a flue is provided as part of refurbishment work) information essential to the correct appliance and use of these should be permanently posted in the building, to meet Requirement J4 of the Building Regulations (England and Wales) F3.12 (Scotland).

Additional:

A new factory made system that complies to EN 1856; Part 1

can be used providing installation is to the requirements of: i) BS 7566 Parts 1 - 4 ii) the manufacturer's instructions iii) Building Regulations.

For a guide containing information on Chimneys and Flues

contact:

The British Flue & Chimney Manufacturers’ Association, FETA 2 Waltham Court Milley Lane Hare Hatch Reading Berkshire RG10 9TH

Tel: 0118 9403416 e-mail: info@feta.co.uk

SITE REQUIREMENTS

1. FLUE OUTLET POSITIONS

Position On Roof Minimum Clearances

On ridge or within 600mm 600mm above ridge

Elsewhere on roof 2300mm horizontally from roof surface and:

On pitched, within 2300mm horizontally to

openable window, dormer

Within 2300mm of another building 600mm above top of building

Measurement

a) 1000mm above highest point of flue exit

from roof or

b) as high as the ridge

1000mm above top of opening

Terminal

Flue

Vertical

The vertical measurement is the lowest from either the point of discharge or 150mm above insulation.

IMPORTANT: Seek specialist advice if installing in a dwelling with a thatched roof

Measurement

150mm

max

Insulation

Horizontal

Adjacent

Building

150mm

minimum

225mm

minimum

Constructional Hearth

840mm minimum

1. HEARTH DIMENSIONS

150mm

minimum

Constructional Hearth

840mm minimum

150mm

minimum

PR7205

2.1 The appliance must stand on a constructional hearth which

is at least 125mm thick with the minimum dimensions as

shown in the diagram opposite.

2.2 The building must have a suitable load-bearing capacity for

the hearth and appliance.

• Consult a structural engineer for advice before proceeding

Caution: These appliances are heavy

2.3 When fitting into an existing hearth check:

• That the appliance complies with current construction

regulations and is at least the minimum sizes shown

2.4 If there is no existing fireplace or chimney it is possible to

construct a suitable non-combustible housing and hearth

setting. The flue must be installed in accordance with all

local and national regulations and current rules in force .

• Check if adding a new chimney to your property requires

planning permission

SITE REQUIREMENTS

WALLS NEXT TO A HEARTH

Solid, non-combustible material e.g. masonry or concrete

150mm

minimum

Thickness W

150mm

minimum

PR7204

Position of Appliance & Hearth in relation to walls Requirement for the walls

Distance of hearth from wall

'C'

0mm 0mm - 50mm 200mm Height of appliance + 300mm

0mm 51mm - 300mm 75mm

0 - 150mm 150mm + 75mm 1200mm

150mm + 300mm + No Minimum Requirement

Suitable clearance should be allowed around the stove to enable the correct fitting and maintenance of the appliance.

Any clearances should be confirmed by making a site survey and a physical check of wall thickness and dimensions.

80mm

Distance of Appliance to wall Min thickness of Wall

'W'

Note:

Min height of wall

'H'

1200mm from the hearth (take largest

dimension)

When installing a Multi-fuel appliance a minimum gap of 80mm must be left on the Right Hand Side so that the riddling tool can be comfortably engaged in the socket.

PR8589

Model

Kensal 40

Kensal 60

PRE-INSTALLATION CHECKS

1. FLUES

Kensal 40

Without Liner System (round)

Flue / Chimney Size

Flue / Chimney minimum height*

* When measured from the top of the flue, with no horizontal sections and a maximum of 4 bends with angles of less than 45°

Without Liner System (square)

With Liner or Factory Made System

Diameter

Minimum Dimension

(diameter)

mm 150 150

inch 6 6

mm 135 135

inch 5½ 5½

mm 150 150

inch 6 6

m 4.5 4.5

feet 13 13

Kensal 60

PRE-INSTALLATION CHECKS

2. VENTILATION

2.1 Additional ventilation will be required to suit the requirements of Building Regulations. This must be provided using a permanently open air vent, of the size listed, which is positioned so that it is not liable to be blocked both inside and outside the building.

2.2 The appliance will require additional ventilation as listed*:

A) Building design permeability greater than 5.0m³ (h.m²).

B) Building design permeability less than 5.0m³ (h.m²).

Model

Kensal 40 Kensal 60

Kensal 40

mm² 2750 4400

2.3 Permanent air vents should be non-adjustable and positioned

2.4 If vents open into adjoining rooms or spaces there must be an

2.5 Site the vents where cold draught is unlikely to cause

Additional Ventilation

where they are unlikely to be become blocked.

air vent of at least the same size direct to the outside.

discomfort. This can be avoided by placing vents near ceilings or close to the appliance, see diagram.

cm² 27.50 44.00

in² 4.44 7.10

mm² 5500 7150

cm² 55.00 71.50

in² 8.87 11.54

Kensal 60

2.6 Extractor fans or cooker hoods must not be placed in the same room or space as this can cause the appliance to emit fumes into the room.

2.7 Increase air supply provisions where a room contains multiple appliances.

2.8 The need for additional ventilation may also be identified during the commissioning procedure and should be provided if needed.

An inadequate air supply to the room is potentially

dangerous.

2.9 If any checks reveal problems do not proceed with the fitting of the appliance until they have been rectified.

* Changes to Document J, England & Wales, from 01/10/2010

INSTALLATION INSTRUCTIONS

LEGAL REQUIREMENTS

Before installation and/or use of this appliance please

read these instructions carefully to ensure that all requirements are fully understood.

The appliance must be fitted by a registered installer*,

or approved by your local building control officer.

It is very important to understand the requirements of the

national Building Regulations† and standards‡, along with any local regulations and working practices that may apply. Should any conflict occur between these instructions and these regulations then the regulations must apply.

Your local Building Control Office can advise regarding the

requirements of the regulations.

The appliance must be fitted by a registered installer* or

approved by your local building control officer.

Works must be carried out with care to meet the

requirements of Health and Safety** and comply with the Health and Safety rules**, and any new regulations introduced during the lifetime of these instructions. Particular attention should be drawn to:

—Handling: The appliance is heavy. Adequate facilities

must be available for loading, unloading and on site handling.

—Fire Cement: Some fire cement is caustic and must not

come into contact with the skin. Protective gloves must be worn. Wash hands thoroughly with plenty of water after contact with skin.

—Asbestos: This appliance contains no asbestos. If there

is the possibility of disturbing any asbestos in the course of installation seek specialist guidance and use appropriate equipment.

—Metal Parts: Take care when installing or servicing the

stove to avoid personal injury.

1.1 Take care when installing the appliance. Careless

handling and use of tools can damage the finish and/or area.

—Choose top or rear flue exit:

Top

—Fit flue collar and blanking plate to suit.

Note: The Stockton 7 Inset does not have or require a

flue collar.

—Attach flue collar to top or rear with hexagonal bolts (see

Diagram 1).

—Seal with fire cement if desired.

—Secure blanking plate with hexagonal bolts (see Diagram 2).

PR8007

Rear

PR8008

A faulty installation can cause danger to the inhabitants

and structure of the building.

For users of this appliance:

Your building insurance company may require you to

inform them that a new heating appliance has been installed on your property. Check that your cover is still valid after installing the appliance.

1. INSTALLING THE APPLIANCE

Each installation is unique to the property so it is not

possible to give details to suit every setting. The installation must comply with Building Regulations and be made using "best practice" construction methods.

Many fireplace openings have a supporting lintel. Do not

remove without supporting the remaining structure of the building. Do not support the structure with the appliance or the flue system.

PR8008

1.2 Top flue pipe installation

—Lift appliance into position taking care not to damage

the hearth finish.

—Level the appliance.

—Connect appliance to the chimney using flue pipe.

—Secure with self tapping screw.

—Seal the connecting joints.

† England and Wales – Document J / Scotland - Part F/

Document J (Republic of Ireland only)

‡ BS 8303, BS 6461, BS 7566 *Registered on the Competent Persons Scheme (GB only)

see page 33 / INFO (Republic of Ireland).

**Health and Safety at Work Act 1974

INSTALLATION INSTRUCTIONS

—Secure with self tapping screw.

—Seal the connecting joints.

Do not use a 90˚ elbow to make this connection.

The Flue must be installed in accordance with

manufacturers instructions.

The Flue must be installed in accordance with

manufacturers instructions.

Flue Pipe 915mm (3ft)

Size Stovax Part No.

6" 4602

Self tapping screw at rear

Seal flue collar with Fire Cement

To chimney connection as detailed in building regulations

Elbow with access cover

Size Stovax Part No.

6" 4612

600mm min

1000mm max

unsupported

7" 4712

Flue Pipe 915mm (3ft)

Size Stovax Part No.

6" 4602

7" 4702

PR8009

PR7196

Seal Collar with Fire Cement

Self Tapping Screw

600mm min

1000mm max

unsupported

2. REMOVAL OF THE LOG GUARD

2.1 To remove the Log guard:

Tee

Size Stovax Part No.

6" 4616

Cap

PR7218

To chimney connection as detailed in building regulations

Elbow with access cover

Size Stovax Part No.

6" 4612

7" 4712

Flue Pipe 915mm (3ft)

Size Stovax Part No.

6" 4602

7" 4702

PR7195

PR7193

1.3 Rear flue pipe installation

—Insert a tee into the flue collar. The tee piece is used as

cleaning access.

—Lift appliance into position taking care not to damage

the hearth finish.

—Level using adjustable bolts (see Diagram 1).

—Connect tee to the chimney using flue pipe.

—Lift Log Guard clear of the supporting brackets.

—Rotate to clear the sides of the door opening.

Do not use appliance without the log guard in position.

INSTALLATION INSTRUCTIONS

3. FITTING AND REMOVAL OF THE BAFFLE

No tools are required.

3.1 To maintain efficient combustion the appliance is fitted with a baffle system that allows for secondary combustion (see Diagram 4).

PR8885

3.2 First remove the log guard from the stove to give access to the firebox.

3.3 Use both hands to lift the baffle vertically and slide to one side (see Diagram 5). Always wear gloves when handling appliance parts.

Front support

Rear support

Ensure baffle sits on front supports

Do not modify the baffle.

Baffle In Place

4. FITTING AND REMOVAL OF THE MULTI-FUEL GRATE

4.1 The Multi-fuel grate can be removed for cleaning to maintain good working condition.

To remove the grate:

AR2405

AR2406

AR2404

—Using both hands rotate the baffle to remove from the

firebox through the door opening.

3.4 To replace the baffle repeat the above steps in reverse, ensuring the baffle fits over the supports on the sides of the interior (see Diagram 6).

—Remove the baffle (see Section 3).

—Remove the log guard to enable access (see Section 2).

—Remove the ashpan.

—Remove the riddling bars (see Diagram 7).

FOR CLARITY, THE FOLLOWING DIAGRAMS DO NOT

INCLUDE ILLUSTRATIONS OF THE DOORS.

INSTALLATION INSTRUCTIONS

Lift bars to remove

—Remove Rear Bar (see Diagram 8).

—Remove Riddling Cam Bar (see Diagram 10).

PR8894

PR8897

To remove Multi-fuel frames:

—Lift frames from the front.

—Remove right hand side first through the front of the

stove.

To remove the Riddling Boss:

—Use the 5mm hex key as shown in Diagram 9.

—Unscrew the boss.

Fixing

Bolt

PR8895

5mm

Hex Key

Spring

Washer

—Repeat for the left hand side.

PR8898

—Replace in reverse order.

Riddling

Boss

PR8896

INSTALLATION INSTRUCTIONS

CENTRAL HEATING SYSTEM

1. General

This appliance gives out heat in two ways:

—Directly into the room in which it is fitted through

convection and radiation.

—Hot water to heat radiators and domestic hot water.

The installation must comply with building regulations and

use best practice advice.

2. Boiler Sizing

2.1 It is very important to determine the correct size of appliance for the house:

—Too big a boiler will run too hot and will not be efficient.

—Too small a boiler will not maintain the desired

temperature.

2.2 Size the boiler correctly by calculating the following heat loads:

RADIATORS - the amount of heat required to run the

radiators efficiently. The correct size of radiator depends on the required temperature for the room, the room heat losses and the radiator manufacturer’s guides.

3. Hot Water Cylinder

3.1 The domestic hot water cylinder must be an indirect vented double feed type to meet national standards** and should have a minimum capacity of 117 litres. Houses with more than one bathroom or a separate shower will need a bigger tank.

Fully insulate the tank.

The water draw off pipes to the taps should be in a dead

leg connection from the vent pipe.

4. Open Vent And Cold Feed System

4.1 This system must be fitted with a minimum of 22mm diameter open vent discharging into a heat resisting feed and expansion tank. There must be at least 25mm air gap between the end of the pipe and the water level. The cistern tank should have an overflow with a minimum diameter of 22mm

The cold feed must be a minimum 22mm and enter the

system as the last connection on the common boiler return.

The open vent and cold feed must not be fitted with any

valves, manual or automatic.

Do not use plastic pipe in any part of the flow and

return.

5. Heat Leak Radiator

HOT WATER - the amount of heat required to provide the

desired amount of domestic hot water.

LOSSES – the amount of heat lost in pipe work - typically

10% of the combined radiators and hot water loads.

There are national guidelines for calculating these figures*.

2.3 Careful consideration must be given to where the appliance is fitted. It must be sized correctly for the heat load required and the size of the room. These requirements can be found in the Technical Specifications.

2.4 All Stovax appliances are thermostatically controlled. The burning rate is adjusted to the demands of the connected heat load. If the radiators do not require heat then the thermostat will act to shut down the appliance and the direct heat output to the room where it is fitted will reduce (see heat output graph on page 15 to show the ratio between direct heat output and water heat output). To prevent the room becoming too cold, fit a thermostatically controlled radiator as well as the appliance.

In the UK: * See BS 5449:1 ** See BS1566 Part 1 grade 3 minimum

5.1 A heat leak radiator must be fitted in the gravity circuit to dissipate any excess heat produced from the boiler when connected demand is low. The domestic hot water cylinder may not be able to disperse heat at all times due to modern insulation. This radiator is commonly fitted in the bathroom and should be rated at 2kW (6500 btu) or 10% of the total boiler output.

This radiator ensures that the appliance is not shut down

completely for long periods resulting in the fire going out.

Fit the heat leak radiator in the gravity circuit using 22mm

pipe reducing to 15mm for no more than 300mm before the radiator.

Fit the radiator with two ‘lock-shield’ valves that are set

in the fully open position and cannot be shut down. Use diagonal connections. Do not fit thermostatic valves or manually adjustable valves to the heat leak radiator.

6. Pump

6.1 Where a pump is fitted into the circuit it should be adjustable so that the flow can match the system requirements. Fit isolation valves to enable removal for servicing. The pump must have at least 1.5 meters of static head.

INSTALLATION INSTRUCTIONS

7. Electrical Supply

7.1 Electrical connections must meet the requirements of national Building Regulations* and standards**, along with any European, local regulations and working practices that may apply. Should conflict occur between these instructions and these regulations then the regulations must be followed.

The connection to the mains supply should allow

complete electrical isolation and only serve the heating circuit pump.

All water connections should be completed by a competent

person to meet the requirements of local water authority by-laws.

CONVENTIONAL PIPE WORK SYSTEMS

All pipe work must be able to operate at above 100

degrees Celsius. Any pipe work installed in an exposed position e.g. loft space must have provision to prevent freezing.

Ensure the pipe work system has sufficient drain

points to enable the complete removal of water for the purposes of servicing.

9.2 When installing a system that has pumped central heating and gravity hot water it is recommended to use all 4 boiler tappings. Each flow and return should be diagonally opposite each other.

10. Fully Pumped System

10.1 In many installations (especially new build) a fully pumped system is the best choice to give increased control.

WARNING - To prevent the risk of boiling it is essential

to arrange the pipe work and position the hot water cylinder and heat leak radiator so that gravity circulation can take place when the pump is not running. Any motorised valves fitted in this circuit must return to the fully open position when the power is interrupted.

11. Sealed (Pressurised) System

11.1 Do not fit this appliance to sealed or pressurised systems or an unvented hot water cylinder.

12. Pipe work Diagrams

12.1 See over for a typical layout of a pumped central heating and gravity hot water circuit.

8. Gravity Pipe Circuit

8.1 To prevent the risk of boiling it is essential to arrange the pipe work and position the hot water cylinder and heat leak radiator so that gravity circulation can take place when the pump is not running. Position the cylinder and the radiator vertically above the boiler with sufficient height to encourage gravity flow.

8.2 Horizontal pipe work in a gravity system must have an incline of at least 5mm in every 1000mm and a minimum diameter of 28mm. Vertical pipe must have a minimum diameter of 22mm.

8.3 Any motorised valves fitted in this circuit must return to the fully open position when the power is interrupted.

9. Pump Assisted Central Heating

9.1 The most common arrangement is to have a pumped central heating circuit combined with a gravity hot water circuit. This arrangement requires careful balancing of the two in order to avoid the gravity circuit being starved when the pump is running.

To overcome this problem it is common practice to fit

an injector tee where the pumped central heating return re-joins the gravity return from the hot water cylinder. This injector tee induces a much stronger gravity flow when the pump runs.

Only use proprietary injector tees, homemade ones are

difficult to get right.

HEATING SYSTEM CONTROLS

CONTROLS GENERAL

1.1 The controls fitted to the system will provide two functions:

— To control the comfort level in the house. — To maintain safety in the event of misuse or mechanical

failure.

COMFORT CONTROLS

1.2 This primarily consists of a time clock wired into the pump. The pump is switched on when heat is required and when it is not, the pump is switched off.

The time clock, when combined with a room thermostat

and or thermostatic radiator valves, enhances the comfort levels in the house.

Some room thermostats combine the function with the

time clock and can be programmed to reduce the room temperature rather than turning the system off. This is effective in not allowing the rooms to become too cold and speeding up recovery time.

In the U.K: * England and Wales – Document P / Scotland - Part N,

Building Regulations,

** Registered body: HETAS (GB only)/INFO (Eire)

INSTALLATION INSTRUCTIONS

COMFORT CONTROLS

9.2 This primarily consists of a time clock wired into the pump. The pump is switched on when heat is required and when it is not, the pump is switched off.

The time clock when combined with a room thermostat

and or thermostatic radiator valves enhances the comfort levels in the house.

Some room thermostats combine the function with the

time clock and can be programmed to reduce the room temperature rather than turning the system off. This is effective in not allowing the rooms to become too cold and speeding up recovery time.

9.3 The hot water cylinder can also be fitted with a thermostatic valve which turns off the flow when the cylinder has reached the desired temperature but the heat leak radiator will have to be bigger to cope with the extra load when the tank is isolated.

SAFETY CONTROLS

9.4 This primarily consists of a high limit thermostat fitted to the gravity flow pipe set at 80 degrees Celsius, this thermostat should be connected to the pump so that the pump is turned on if the temperature exceeds 80 degrees. This will prevent accidental boiling in the gravity circuit.

9.5 It is also recommended to fit a low limit thermostat on the central heating return set at 45 degrees Celsius, this thermostat will turn the pump off if the return temperature falls below 45 degrees. This will prevent corrosion and condensation within the stove.‡

NOTE – Further information on solid fuel central heating

systems can be found in the HETAS engineers training manual.

LINK UP SYSTEMS

For information on how to link solid fuel boilers to other

heating appliances see Redfyre Part No. PM310 Information For Dual System Link Up Methods.

This can be obtained through Stovax. Contact (03192) 474011 or info@stovax.com for details.

Always seek the advice of a competent person* before

linking another heating system to a solid fuel boiler.

In the U.K: *• Registered body: HETAS (GB only)/INFO (Eire)

See below typical layout of a pumped central heating hot water circuit with gravity.

Feed and Expansion Cistern

Cold Water Storage Cistern

Two port

normally open motorized valve controlled by cylinder thermostat

Heat Leak radiator

with two full way lock shield valves

Thermostatic radiator valves

to provide temperature zoning

Programmable room thermostat

Double Feed indirect cylinder

High limit pipe thermostat

to bring on circulator in an overheat situation

Low limit pipe thermostat

to prevent the pump coming on until a minimum temperature is reached

Pump and isolating valves

Stovax High Output Boiler

installed to BS8303, ADJ and these installation instructions

Injector tee

to pump assist the thermosyphon circuit when the pump is operating

INSTALLATION INSTRUCTIONS

See below typical layout of a fully pumped central heating and hot water circuit.

Cold Water Storage Cistern

Feed and Expansion Cistern

Double Feed indirect cylinder

Circulator and isolating valves

Two port

normally open motorized valve controlled by room thermostat and programmer

Stovax High Output Boiler

installed to BS8303, ADJ and these installation instructions

High limit pipe thermostat

to bring on circulator in an overheat situation

Two port

energised closed when pump activated

Two port

normally open motorized valve controlled by cylinder thermostat and programmer

Heat Leak radiator

with two full way lock shield valves

Two channel programmer

Low limit pipe thermostat

to prevent the pump coming on until a minimum temperature is reached

Thermostatic radiator valves

to provide temperature zoning

COMMISSIONING

1.1 To commission: — Replace the log retainer. — Check the door alignment and catch operation, adjust if

required, see Installation Instructions, Section 6,

Adjusting Door Hinges. — Check the soundness of door seals, castings and joints. — Check the operation of the air controls. — Ensure the system has been filled with water and

includes a suitable inhibitor.

1.2 Now carry out a final smoke draw test: — First warming the flue with a blowlamp, or similar, for

about 10 minutes. — Place a smoke pellet on the centre of the grate, with the

air controls open. — Close the door. Smoke should now be drawn up the flue

and be seen to exit from the flue terminal. — Complete test with all doors and windows closed in the

room where the appliance is fitted. — If there are any extractor fans in adjacent rooms, the test

must be repeated with the fans running on maximum

and interconnecting doors open. — Check the effect of ceiling fans during the test.

If the test fails, re-check the suitability of the flue system

and ventilation. An inadequate air supply to the room is

potentially dangerous.

— Light the appliance and slowly increase the temperature

to operating levels. — Ensure no combustion products enter the room. — Open the main fire door when the appliance reaches

operating condition and carry out a spillage test with a

smoke match or pellet around the door opening. — Run the system up to temperature.

BALANCING THE SYSTEM

It is essential to balance the central heating system in order

to achieve an even heating performance across all of the

radiators in the house. Balanced means each radiator having

a 10˚C difference in temperature between the flow and the

return, ideally 80˚C flow and 70˚C return.

Have the system running and adjust the appliance

thermostat so that the flow temperature measured near

the appliance is approximately 80˚C. Ensure that all valves

including lock-shield valves are in the fully open position

and the pump is at its estimated correct speed. If there are

thermostatic radiator valves, have these on maximum setting

and ensure that they do not activate.

Ensure that the radiators have been bled of air.

Write down the return temperature of each radiator in turn

and its difference to the flow temperature at the appliance.

Make sure that the flow temperature remains constant.

The radiator with the greatest difference (the index radiator)

and any other radiator within 1 degree should be left with

the lock-shield fully open. The remainder of the lock-shield

valves should be closed to about 1/3 open. Leave the

system to stabilise, this could take some time.

When the system has stabilised, write down the new

difference between the flow and return temperatures and any which differ from the index radiator by more than 1 degree will need further adjustment, some valves will have been closed too much and others not enough, usually the adjustments need to be only a fraction of a turn at a time. Leave sufficient time for the system to stabilise after each adjustment.

When the radiator temperatures are starting to become

consistent, but before final adjustments, the index radiator needs to be considered, if the return temperature of this radiator is not near 70 degrees then the pump will need to be adjusted to either provide more (to increase the temperature) or less flow to decrease the temperature. Again, sufficient time will need to be left to allow the system to stabilise after adjusting the pump speed.

When the radiator flow and return temperatures are correct

the final adjustments can be made and the lock-shield covers replaced.

Knowing how far to shut down a valve to get the desired

change in flow and return temperature, and knowing how long to wait for the system to stabilise, takes a little time and practice.

1.3 If excessive spillage occurs:

— Allow the appliance to cool and re-check the flue system

and ventilation.

1.4 Finally:

— Explain the safe operation of the appliance and the

use of the controls to the user and the importance of only using suitable fuels.

All open flued appliances can be affected by temporary atmospheric conditions which

may allow fumes to enter the house. Because of this it is recommended that an electronic carbon monoxide detector conforming to BSEN50291 be fitted and maintained.

— Explain the cleaning and routine maintenance

requirements.

— Explain the requirement to use a suitable fireguard

when children, elderly or infirm persons are near the appliance.

—Record dealer/supplier and installer details in

Appliance Commissioning Checklist (page 3, Instructions for Use).

—Record serial number in Appliance Commissioning

Checklist (page 3, Instructions for Use). This number

is required when ordering spare parts and making warranty claims.

— Give the copy of the Instructions to the customer.

MAINTENANCE and SERVICING

For a complete list of spare parts and accessories contact your Redfyre retailer or call 01392 474011

1.2 Use genuine Stovax replacement parts to keep the

1. ANNUAL SERVICE

1.1 Before the start of the heating season strip, inspect and

clean the appliance as detailed:

—Allow appliance to cool.

—Remove all internal parts; baffle, log guard and, for

multi-fuel versions, grate system and ashpan

(see Installation Instructions, Sections 2, 3 & 4).

—Sweep the flue at this point if necessary.

appliance in safe, efficient working order. This is a list of the maintenance products that may need be required:

Task Product name

Glass cleaning

Preventing buildup of creosote in flue

Stove glass cleaner (spray on)

Protector (15 sachets) 7002

Protector (1kg tub) 7025

Stovax Code

Number

4103

—Vacuum clean any remaining ash and debris from the

inside of the appliance. Stovax offer a filter/collection

attachment for vacuum cleaners to protect them from fire

ash: Ash Clean (Stovax Part No. 2091).

—Clean the internal surfaces of the appliance using a

wire brush and scraper as required. Vacuum and brush

the resulting debris from the appliance.

—Clean the grate parts with a wire brush, and check the

parts for any damage. Replace any damaged parts using

genuine Stovax replacements parts (see below

for details).

—Re-fit cleaned internal parts.

—Remove glass from door, discard all old rope seals and fit

new (see Maintenance and Servicing, Section 4).

—Clean the door glass using Stovax Glass cleaner and a

soft cloth. Do not use abrasive cleaners on glass.

Do not use acidic cleaners on printed glass.

—Fit new door rope seal (see Maintenance and Servicing,

Section 5).

—Lightly oil the door catch mechanism and hinge pins.

Avoid getting oil onto the door seals and glass.

—To refresh painted finishes use Stovax Thermolac paint.

Sealing flue pipe joints

Re-painting

Cleaning matt black Appliances

Protecting your hands

Door sealing rope

Glass sealing tape

Thermic seal glue (50ml bottle) 5037

Soft rope 10mm diameter 4965

Ash Clean Vacuum Cleaner Attachment 2091

These products, available from your local Stovax retailer,

along with regular maintenance and use of correct fuels, will keep the appliance in the best possible condition.

Fire Cement (500g tub) 2020

Fire Cement (600g cartridge) 2021

Thermolac Black (400ml aerosol)

Thermolac Black (200ml brush-on)

Colloidal black (85ml) 7000

Heat resistant leather gloves 4008

14mm Black rope seal (handy pack)

14mm Black rope seal (25m reel)

3mm Black rope seal (handy pack)

3mm Black rope seal (25m reel)

2019

2057

5000

4670

4975

4974

1.3 For more information about the Stovax Group products please visit our web site at www.stovax.com

1.4 Burn at a low temperature for the first day of use after any maintenance. This allows the seals, fixing glues and paint to fully cure.

1.5 During this time the appliance may give off some unpleasant odours. Keep the room well ventilated to avoid

MAINTENANCE and SERVICING

a build-up of fumes.

1.6 Your Stovax retailer can carry out service and maintenance.

2. REMOVAL OF THE LOG GUARD

2.1 To remove the Log guard:

— Lift Log Guard clear of the supporting brackets.

— Rotate to clear the sides of the door opening.

Do not use appliance without the log guard in position.

3. FITTING AND REMOVAL OF BAFFLE

3.1 It is important to remove and clean the baffle system to ensure the flue ways are clear of soot and debris and to ensure the safe and efficient operation of the stove. The frequency of cleaning will depend on the stove operating conditions. See Installation Instructions, Section 4, Fitting & Removal of Baffle.

3.2 The baffle system is designed to give safe and efficient operation of the stove. Replace any damaged baffles immediately.

Single Door

Fixing Screws (x4)

Fixing Clips (x4)

Glass

Glass Seal

Door

PR7080

Double Door

Fixing Screws (x10)

4. RIDDLING GRATE

4.1 See Installation Instructions, Section 4, Fitting and Removal of Grate

5. FITTING A NEW DOOR GLASS

5.1 To maintain the safe use of your stove you may need to replace a damaged door glass.

5.2 To complete this operation:

— Open the door.

— Lift it free of the hinge blocks.

— Lie the door face down on a soft flat surface, to protect

the paintwork and glass.

Fixing Clips (x4)

Fixing Clip Long (x2)

Glass (x2)

Glass Seal (3mm)

Door (x2)

PR7081

— Remove the 4 x glass clip fixing screws.

— Lift the old glass can then be lifted clear of the door. (Note how the 3mm sealing rope is placed between the

glass and the door.)

— Dispose of the old glass safely.

— Clean and re-paint the rear of the door if required.

— Clean the screws with light oil.

— Coat with high temperature anti-seize grease to aid

future removal.

— Fit new sealing rope between the new glass and the

door.

MAINTENANCE and SERVICING

— Place the glass into position in the door.

— Place the glass fixing clips into position.

— Re-fix with the clean fixing screws.

— Tighten the screws evenly until the clips hold the glass. Do not over tighten the clips as this could break the

glass.

5.3 Fit only Stovax ceramic glass, which is suitable to use in high temperature applications.

5.4 Using the appliance with damaged door glass could allow dangerous fumes to enter the room, or the appliance to over-fire and cause damage.

6. FITTING A NEW DOOR SEAL

6.1 To maintain the safe use of your appliance you may need to replace a damaged or worn door sealing rope.

6.2 To complete this operation:

— Open the door.

— Remove the old rope.

— Scrape old glue from the locating groove.

— Clean the locating groove with a clean dry cloth

removing all dust and debris.

— Apply Stovax Thermic Seal glue (Stovax Part No. 5037)

into the rope locating groove.

— Press the new Stovax rope into the locating groove

placing the joint in the middle of the lower edge of the door.

— Refit the door. — Close to apply pressure on the new rope.

— Leave the appliance closed for at least 12 hours before

lighting the stove.

— Use at a low output for approximately one day.

6.3 Using the stove with a damaged door seal could allow dangerous fumes to enter the room, or the appliance to over-fire and cause damage.

— Lift it free of the hinge blocks.

— Lie the door face down on a soft flat surface to protect

the paintwork and glass.

Single Door

Joint

Double Door

Seal 14mm

Seal 10mm x 2mm

Seal 14mm

PR7084

7. ADJUSTING DOOR HINGES

7.1 To maintain the safe use of your appliance, you may need to adjust the door hinges to ensure the door closes safely and correctly.

7.2 To complete this operation:

— Open the door to give access to the fixed part of the

door hinge as shown.

Fixing Nut Lock Nut

PR7087

— Use a 19mm A/F spanner to loosen the fixing nuts.

— Reposition the hinge blocks to achieve a correct fit This may require several adjustments to find the correct

position.

PR7086

PR7085

BASIC SPARE PARTS LIST

KENSAL 40

Description Part No.

Gloves K4027A Door Operating Tool SM2.23

Riddling Tool ST8-MEC8158 Ash Pan Tool ST8-MEC8159 Log Retainer SM 62 Fixed Grate Bar ST8-CA7479 Moving Grate Bar ST8-CA7480 Bafe ST8-MEC8076 Ashpan ST8-MEC8155 Door Glass GL0227 Rope Seal For Door Glass 5000 Rope Seal For Glass 7019

KENSAL 60

Description Part No.

Gloves K4027A Door Operating Tool SM2.23

Riddling Tool ST8-MEC8158 Ash Pan Tool ST8-MEC8155 Log Retainer ST11 SD25 Fixed Grate Bar ST11-CA7485 Moving Grate Bar ST11-CA7486 Bafe ST11-MEC7941 Ashpan ST11-MEC8161 Door Glass GL0227 Rope Seal For Door Glass 5000 Rope Seal For Glass 7019

Organisations authorised to certify competence in the installation of domestic solid fuel appliances (Competent Persons Scheme):

aPHC - Association of Plumbing and Heating Contractors (Certification) Ltd. www.aphc.co.uk

BESCA - Building Engineering Services Competence Accreditation Ltd. www.besca.org.uk

HETAS - Heating Equipment Testing and Approval Scheme Ltd. www.hetas.co.uk

NAPIT - National Association of Professional Inspectors and Testers Ltd. www.napit.org.uk

NICEIC - NICEIC Group Ltd. www.niceic.org.uk

HETAS Approved Chimney Sweeps:

NACS - The National Association of Chimney Sweeps www.chimneyworks.co.uk

APICS - The Association of Master Chimney Sweeps Ltd. www.apics.org

The Guild of Master Chimney Sweeps guildofmasterchimneysweeps.co.uk

SERVICE RECORDS

1ST SERVICE

Date of Service:...........................................................................

Next Service Due:.......................................................................