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
2
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: ...............................................................
3
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).
4
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
5
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.
6
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
7
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.
8
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).
9
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).
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).
10
PR8891
USER INSTRUCTIONS
13
—Place tray flat on the fixings on the firebed (see
Diagram 14).
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).
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.
11
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