Dru Cosmo RCH Manuel utilisateur

English

Store this document in a safe place

Cosmo RCH

Cosmo Tunnel RCH

Installation manual (UK/IE)

DRU-671866-EN-US-0715-2

G20/G25.3 Natural gas

959.077.01.UK

English

INSTALLATION MANUAL

1. Introduction

2. CE declaration

3. SAFETY

3.1 General

3.2 Regulations

3.3 Precautions / safety instructions at installation

3.4 Principle of ignition cycle

4. Removing the packaging

5. Installation

5.1 Type of gas

5.1.1 Reconstruction to different type of gas

5.2 Gas connection

5.3 Electric connection

5.4 Placing the appliance

5.5 Placing a built-in appliance

5.6 Placing the chimney breast

5.7 Placing the control hatch

5.8 Flue gas discharge system appliances open combustion

5.9 Flue gas discharge / combustion air supply system appliances closed combustion

5.10 Additional instructions

5.11 Construction frame

5.12 Glass panes

5.12.1 Removing the glass pane

5.12.2 Placing the glass pane

5.13 Adjustment of the appliance

5.13.1 Restrictor slide

5.14 Placing the wood set

5.14.1 Wood set

6. Control

6.1 Remote controls

6.2 Alternative controls

7. Final inspection

7.1 Gastightness

7.2 Gas pressure/line-pressure

7.3 Ignition main burner

7.4 Flame picture

8. Maintenance

8.1 Parts

9. Delivery

10. Malfunctions

Appendix 1 Malfunctions

Appendix 2 Tables

Appendix 3 Figures

Contents

English

INSTALLATION MANUAL

1. Introduction

DRU, a manufacturer of gas-fired heating appliances, develops and produces products that comply with the

highest possible quality, performance and safety requirements. This appliance has a CE label, which means that it

complies with the essential requirements of the European Gas Appliance Directive. The appliance is supplied with

an installation manual and a user manual. As an installer, you must be certified and competent in the field of

gas-fired heating and electricity. The installation manual will give you the information you need to install the

appliance in such a way that it will operate properly and safely.

This manual discusses the installation of the appliance and the regulations that apply to the installation. In

addition, you will find technical data for the appliance and information on maintenance, any malfunctions that

might occur and their possible causes.

The figures can be found at the back of this booklet, in the appendix.

Please, read and use this installation manual carefully and completely, prior to installing this appliance. If you use

the DRU Powervent system® or the DRU Smartvent system®, you must carefully and fully read and use the

accompanying installation manual as well, prior to its installation.

The following symbols are used in the manuals to indicate important information:

Work to be performed

!Tip

Suggestions and recommendations

!Caution

You will need these instructions to prevent problems that might occur during installation and/or use.

!Caution

You need these instructions to prevent fire, personal injury or other serious damages.

After delivery, you should give the manuals to the user.

2. CE declaration

We hereby declare that the design and construction of DRU's gas-fired heating appliance comply with the

essential requirements of the Gas Appliance Directive.

Internal precautions at the company will guarantee that appliances produced in series comply with the essential

requirements of the EC directives in force and the standards derived from them. This declaration will lose its

validity if adjustments are made to the appliance without prior written permission by DRU.

You will be able to download a copy of the test certificate via www.druservice.com.

M.J.M. Gelten

General manager

Postbus 1021, 6920 BA Duiven

Ratio 8, 6921 RW Duiven

www.dru.nl

Product:

Type:

EEC directives:

Standards:

gas-fired heating appliance

Cosmo RCH / Cosmo Tunnel RCH

2009/142/EC; 2006/95/EC; 2004/108/EC

NEN-EN-613; NEN-EN-613/A1; EN60335-2-102

English

INSTALLATION MANUAL

3. SAFETY

3.1 General

!Caution

• Please observe the general regulations and the precautions/safety instructions in this manual.

• First check the exact technical version of the appliance to be installed in Appendix 2, Table 2.

3.2 Regulations

Please install the appliance in accordance with the applicable national, local and constructional (installation)

regulations.

3.3 Precautions / safety instructions at installation

Carefully observe the following precautions/safety regulations:

You should only install and maintain the appliance if you are a certified and competent installer in the field of

gas-fired heating and electricity;

do not make any changes to the appliance;

if you are installing an appliance that must be built in;

• use non combustible and heat-resistant materials for the chimney breast, including the top of the chimney

breast, the material in the chimney breast and the back wall against which the appliance will be placed.

For this you can use both sheet material and stone-like materials;

• take sufficient measures to prevent temperature of a wall behind the chimney breast becoming too high,

including the materials and/or objects behind the wall;

• comply with the minimum required internal sizes of the chimney breast;

• vent the chimney breast by means of ventilation holes with a combined passage as stated further down in

the text;

• use heat-resistant electrical wiring;

• place heat-resistant electrical wiring away from the appliance and as low as possible in the chimney breast.

This has to do with the temperature development in the chimney breast.

if you are installing an appliance type B11 with open combustion: please use a suitable flue gas discharge system

that is provided with the CE label;

if you are installing an appliance with closed combustion: only use the concentric systems supplied by DRU;

if you are installing a free-standing appliance: place the appliance away from the back wall by the minimum

distance stated further down in the text;

do not cover the appliance and/or do not wrap it in an insulation blanket or any other material;

make sure that combustible objects and/or materials have a distance from the appliance of at least 500 mm;

only use the accompanying wood/pebble set and place it exactly as described;

leave the area around the ionization pin and spark plug free;

make sure there is no dirt in gas pipes and connections;

place a gas tap in accordance with applicable regulations;

prior to putting into operation, check the complete installation for gastightness;

if your appliance is provided with explosion hatches on its top and/or bottom, you must make sure that they

cannot be blocked and check whether they fit well onto the sealing surface, prior to building in the appliance;

do not ignite the appliance before the gas, discharge and electric connections have been fully installed, first

observe the procedure described in chapter 7.3;

replace broken or torn glass panes.

!Caution

In case of broken or torn glass panes, the appliance may not be used.

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INSTALLATION MANUAL

3.4 Principle of ignition cycle

Below you will find a brief description of how this appliance is ignited.

The appliance is off and will be switched on by means of the remote control. The receiver will get the signal to

start the ignition process. This signal is passed on to the burner device, after which, if applicable, the relay for the

Powervent System® is switched. After an 8 second interval, the ignition on the spark electrodes will start. If no

Powervent System® is connected, only the relay will switch and the ignition will start immediately.

The main burner will be ignited at 50% of its capacity.

This will prevent a larger amount of gas in the combustion chamber, if no ignition takes place. When the gas

ignites, ionization will have to be detected. In order to make sure the flame has passed over, this will take place at

the other side of the burner. When ionization is detected, the gas control will modulate to 100%.

If applicable, the second valve is switched (you will be able to hear a 'click') in order to ignite the second burner.

After ignition of the second burner, the appliance will always go to the full position (full capacity).

This will guarantee that the second burner will actually ignite.

The second burner can be switched on and off manually, by means of the remote control.

In case of switching on manually, the appliance will first return to full load.

!Caution

The appliance's control unit is characterized by its stringent safety requirements. It is possible that the burning

appliance switches off automatically and then switches back on again. This is not a failure, but a check. The

moment the appliance's control unit is connected to mains voltage, the control unit will perform this check every

24 hours. If the appliance is burning at that time, the appliance will extinguish and then start again immediately. If

you wish to prevent this, you can remove the plug and insert it again at a time during the 24 hours when the

appliance is never or hardly ever burning.

4. Removing the packaging

Note the following items when removing the packaging:

Remove all packaging materials.

Remove all supplied components in, on and/or at the appliance.

Check the appliance and accessories for damages (during transport).

If necessary, contact your supplier.

Never install if an appliance is damaged!

Remove any screws that are used to fix the appliance to a platform or pallet.

!Caution

Glass is a ceramic material. Very small irregularities in the glass panes cannot be avoided, but are within the

required quality standards.

!Caution

Keep plastic bags away from children.

In Appendix 2, Table 1 you can see which parts you should have after removing the packaging.

Contact your supplier if you do not have all the parts after you finished removing the packaging.

Packaging must be disposed of in accordance with the regulations.

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INSTALLATION MANUAL

5. Installation

Read this manual carefully to ensure the proper and safe installation of the appliance.

!Caution

Install the appliance in the order described in this chapter.

Please install the appliance in accordance with the applicable national, local and constructional (installation)

regulations.

Observe the regulations/instruction in this manual.

5.1 Type of gas

The data plate indicates for which type of gas, gas pressure and for which country this appliance is intended.

The data plate can be found on the appliance or can be attached to a chain to which it should remain attached.

!Caution

Check whether the appliance is suitable for the type of gas and gas pressure used at the location.

5.1.1 Reconstruction to different type of gas

If you want to convert this appliance into a different type of gas, please contact DRU's service department and ask

what is possible. Reconstructions should only be performed by authorized gas installers.

5.2 Gas connection

Place a gas tap in the gas pipe in accordance with the applicable regulations.

The gas connection on the gas control is located next to the receiver (see G Appendix 3, fig. 38).

!Caution

Make sure there is no dirt in gas pipes and connections;

The following requirements apply to the gas connection:

• use a gas pipe with the correct dimensions, so that no pressure loss can occur;

• the gas tap must be approved (in the EU this will be the CE mark);

• you should always be able to reach the gas tap.

5.3 Electric connection

In case of a 230 Volt electrical connection, provide proper grounding, if applicable. Place this electrical connection

away from the appliance, as low as possible in the chimney breast. This has to do with the temperature

development in the chimney breast. If possible, place the receiver after any building work has been completed. If

this is not possible:

!Caution

Protect the receiver against dust and moisture created during the building process!

5.3.1 Connecting the switch contact (if applicable)

It is possible to operate one or more lamps (in case of several lamps, a maximum of 8A/250VAC/30VDC) via the

remote control of the appliance. You could think of the lamps of Dru's lux elements. For this, you can use switch

contact B on the receiver (see appendix 3, fig 36). The switch contact is not polar sensitive.

5.3.2 Connecting the Dru Omivent (if applicable)

If the appliance is equipped with a Dru Lux Omnivent system, it can be operated with the remote control and

connected (see appendix 3, fig 36, (C)). The supply to this connection is equal to the mains voltage.

5.4 Placing the appliance

!Caution

• Always place the appliance with a minimum distance of 500 mm from combustible objects or materials;

• Place the discharge pipes in such a way that situations with risk of fire can never occur;

• Always place the appliance in front of a wall of non combustible and heat-resistant material;

• Always maintain a minimum distance between appliance and back wall, if indicated in the dimensional

drawing (see Appendix 3, Fig. 2);

• Take sufficient measures to prevent temperature of a wall behind the chimney breast becoming too high,

including the materials and/or objects behind the wall;

• Do not cover the appliance and/or do not wrap it in an insulation blanket or any other material;

• Make sure that the appliance to be installed has a stable position. If applicable, this could be done by fixing

the extension legs with self-tapping screws.

English

INSTALLATION MANUAL

!Caution

When installing an appliance that has to be built in, take the following into account;

• The minimum construction measurements according to Appendix 3, Fig. 1 and 2;

• The construction height of the appliance, which you can determine yourself.

Provide a gas connection at the location. For details, see section 5.2.

Make a passage for the flue gas discharge system or the concentric system with the following diameters; for

details, see section 5.8 or 5.9:

• the pipe diameter +10 mm for a passage through non combustible material;

• the pipe diameter +100 mm for a passage through combustible material;

!Caution

Additional instructions, specifically for the appliance that you are installing, start at chapter 5.10.

5.5 Placing a built-in appliance (if applicable)

Not all built in appliances by DRU are supplied with a control hatch. If it is not included, this control hatch is

available separately. We recommend using the Dru control hatch at all times. In this chapter, it is assumed that the

appliance is used with a control hatch.

!Caution

If you do not use a recommended Dru control hatch, please strictly observe the safeguards and necessary

instructions stated in chapters 5.5 to 5.7.

If you are not using the control hatch, please take the following into account as well:

• the accessibility of components that are normally placed in the control hatch;

• the maximum temperature of these components (maximum 60 °C).

The gas control is mounted to the appliance. It must be taken out and placed in the control hatch at a later time.

For placing the gas control in the control hatch, see section 5.7.

Proceed as follows:

Remove the bracket with, amongst other things, the gas control from the appliance by unscrewing the

self-tapping screws.

Place the bracket to which, amongst other things, the gas control is mounted, together with the wiring of the

ignition/ionization cable(s), the flexible gas hose(s) and the data plate with chain in the direction of the control

hatch.

!Caution

• Make sure there is no dirt in gas pipes and connections;

• Avoid kinks in the pipes.

!Caution

• Make sure the ignition cables cannot come into contact with other wires;

• The data plate should remain connected to the chain.

Set the height of the appliance using the adjustable feet (if applicable).

Make the appliance level at the same time.

!Tip

The construction frame for most 2 or 3 sided appliances can be adjusted. This will allow you to connect the

construction frame to the chimney breast correctly. For 2 or 3 sided appliances that cannot be adjusted, we would

like to refer you to chapter 5.10 'Additional instructions'.

!Caution

do not ignite the appliance before the gas, discharge and electric connections have been fully installed, first

observe the procedure described in chapter 7.3.

5.6 Placing the chimney breast (if applicable)

In order to provide proper heat discharge, there should be sufficient space around the appliance.

The chimney breast should be ventilated sufficiently by means of ventilation holes (incoming and outgoing).

!Caution

• When installing an appliance with mantelpiece, specific dimensions may apply for the opening in the

chimney breast.

• When an appliance is built in the floor, please take into account the minimum distances from a combustible

floor.

If this applies to your situation, you'll find more information in chapter 5.10 'Additional instructions'.

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INSTALLATION MANUAL

!Caution

• Use non combustible and heat-resistant materials for the chimney breast including the top of the chimney

breast, the material in the chimney breast and the back wall of the chimney breast;

• Make sure the appliance is not carrying the weight of the chimney breast when using stone-like materials;

• The passage of the ventilation holes (outgoing), which are placed as high as possible, is stated in Appendix 2,

Table 2.

!Caution

When placing the chimney breast, you should take the following into account (see Appendix 3, Fig. 2):

• The location for the control hatch: this must be placed as low as possible;

• The dimensions of the control hatch; see Placing the control hatch section 5.7;

• The Dru control hatch is not supplied with all appliances. Nevertheless, we recommend only using a Dru

control hatch, if available, except in the case of B 11 AS/BS appliances. If you decide not to take this option, you

will have to make a 100 cm

2 ventilation hole that is placed as low as possible, for the benefit of the incoming

ventilation.

• The location of the ventilation holes (V) (outgoing);

• Maintain a minimum 30 cm distance between the top of the ventilation hole (outgoing) and the ceiling of the

house;

• The measurements of the glass pane, so that it can be placed/removed after placing the chimney breast;

• The protection of the gas control and the pipes against cement and plaster.

• If possible, you should place decorative strips, frames, etc., after any required structural work has been

completed. Avoid the use of painter's tape. If this is not possible: please use good quality painter's tape and

remove it immediately after plastering or painting work has been completed.

!Tip

You should preferably apply the ventilation holes (outgoing) on both sides of the chimney breast. You can use

DRU ventilation elements.

Prior to completely closing the chimney breast, check:

• whether the discharge / concentric system is placed correctly;

• whether the channels, fixing brackets and possible clip bindings, which cannot be reached after installation,

are fastened by means of self-tapping screws.

If applicable, do not plaster on or over the edges of the construction frame, because:

• the heat of the appliance could cause cracks;

• it will no longer be possible to remove/place the glass pane.

When using stone-like materials and/or plaster finishing, allow the chimney breast to dry for at least six weeks

prior to taking the appliance into operation in order to prevent cracks.

5.7 Placing the control hatch (if applicable)

The control hatch (also see paragraphs 5.5 and 5.6) is placed as low as possible in the chimney breast.

!Caution

• The bottom of the control hatch may not be placed higher in the appliance than the burner surface.

• Place control hatch and bracket with gas control and accessories indoors in a dry place only!

A number of components are placed in the control hatch, such as data plate, gas control, receiver belonging to the

remote control and, if applicable, the components belonging to the DRU Powervent System®.

Place the control hatch as follows, see Appendix 3, Fig. 3 for details:

Make an opening in the chimney breast, as described in the manual for the control hatch.

!Tip

The opening in the chimney breast may be made horizontal and vertical.

Place the inner frame (A); unscrew bolts (D and F) for this.

!Caution

• The inner frame should be placed in the correct way. Two positions are possible. Placing the inner frame with

a rotation of 180° is not allowed (see Appendix 3, fig. 4).

!Tip

• When the chimney breast is made of bricks, the inner frame can be built with bricks at the same time;

• When using a different material, you can glue the inner frame or fix it with four flush screws.

Remove the bracket with the components (B) from the appliance.

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INSTALLATION MANUAL

Mount the bracket with components to the inner frame (A). Proceed as follows:

• Unwind the cables. This will, amongst other things, prevent a poor operation of the ignition.

• Unwind the flexible gas pipe(s).

• Mount the bracket with components to the inner frame (A). The lock hole will fall into the allen screw (C); the

hole at the bottom will fall over the head of the allen screw (D).

• Fix the bracket with allen screw (C).

!Caution

• Avoid kinks in the pipes.

• Do not lay the cables of the ionization pins and spark electrodes along metal parts.

Make sure there is no dirt in gas pipes and connections.

Connect the gas pipe with gas tap.

Bleed the gas pipe.

!Tip

If the gas tap is closed, you can simply remove the bracket with components by loosening the compression fitting

under the gas control and loosening the allen screw (C) a few strokes. The bracket with components can now be

lifted and removed from the control hatch in a forward movement.

Connect the 230 V mains voltage with earth connection. Various types of plug connections are supplied. The type

of plug depends on the country where the appliance is placed.

Place the data plate in its intended clamp (G).

Mount the outer frame with door (E) to the inner frame using two allen screws (D and F).

!Tip

You can place the outer frame in such a way, that the door turns to the left or to the right.

!Caution

Always close the control hatch with the lock (H) because of the electricity behind the door (230V).

You can operate the lock with a fitting flat object.

5.8 Flue gas discharge system at appliances with an open combustion (type B11)

For connection to an existing chimney without a discharge pipe or flexble SS discharge - only allowed in Great

Britain - the instructions provided in the separately supplied booklet 'Fitting into a conventional class 1 chimney'

apply. In addition to the installation instructions, this booklet also contains supplementary tests.

5.8.1 General

The appliance's type of discharge system is stated in Appendix 2, Table 2.

The appliance must be connected to an existing or newly to be built chimney, according to the applicable,

national, local and constructional (installation) regulations.

5.8.2 Connection of flue gas discharge system (if a class 1 chimney is not applicable)

At least a 3 metre discharge pipe or a flexible SS discharge should be connected to the appliance.

Bends in the flue gas discharge system are not allowed.

!Caution

• Maintain a distance of at least 50 mm between the outside of the concentric system and the walls and/or

ceiling. If the system is built in (for instance) a cove, it should be made with non combustible material all

around it;

• Use heat-resistant insulation material when passing through combustible material;

• Use a flue gas discharge system with the correct diameter, and which is provided with the CE mark;

!Caution

Some heat-resistant insulation materials contain volatile components that will spread an unpleasant smell for a

prolonged time; these are not suitable.

Place the flue gas discharge system as follows:

Connect the pipe pieces or flexible SS discharge.

You should only install the appliance in a well ventilated room which complies with the applicable national, local

and constructional (installation) regulations, in order to guarantee sufficient air supply.

!Caution

• In case of a house with a mechanic exhaust system and/or an open kitchen with cooker hood, a permanent

ventilation hole is required in the area surrounding the appliance; for this application, please refer to the gas

installation regulations and local legislation.

English

INSTALLATION MANUAL

5.9 Flue gas discharge /combustion air supply system at appliances with a closed

combustion

5.9.1 General

The appliance's type of discharge system is stated in Appendix 2, Table 2.

The appliance is connected to a combined flue gas discharge/combustion air supply system, hereafter referred to

as the concentric system.

The passage to the outside can be made with both a wall terminal and roof terminal.

If necessary, you can also use an existing chimney (see section 5.9.4).

!Caution

• Only use the concentric system supplied by DRU This system has been tested in combination with the

appliance. DRU cannot guarantee a proper and safe operation of other systems and does not accept any

responsibility or liability for this;

• For connecting to an existing chimney you should only use the chimney kit supplied by DRU.

The concentric system is constructed from (the flue spigot of) the appliance.

If, due to constructional circumstances, the concentric system is placed first, it is possible to connect the appliance

by means of a telescopic pipe piece.

5.9.2 Construction of the concentric system

Depending on the construction of the concentric system the appliance will have to be further adjusted with

possibly a restrictor slide or air inlet guide.

See Tables 4 and 6 for determining the correct adjustment and section 5.9, 'Adjustment of the appliance' for the

method of working.

The concentric system with wall or roof terminal has to comply with the following conditions:

• In appendix 2, table 4 or 5 you can find whether a concentric pipe should be connected and what the

minimum vertical length would have to be;

• Determine the permissibility of the required discharge.

When using a wall terminal the following applies:

• The total vertical pipe length, when using a wall terminal, may have a maximum length that you can find in

Appendix 2, Table 4;

• The minimum vertical pipe length, when using a wall terminal, can be found in appendix 2, table 4;

• The total horizontal pipe length, when using a wall terminal, may have a maximum length that you can find

in Appendix 2, Table 4 (without wall terminal; see Appendix 3, Fig. 5).

When using a roof terminal the following applies:

• The construction of the chosen system, when using a roof terminal, must be permissible according to

Appendix 2, Table 5 (See the method of working described below).

The working method below indicates how the permissibility is determined of a concentric system when using a

roof terminal.

1) Count the number of 45° and 90° bends required;

2) Count the total number of whole metres of horizontal pipe length;

3) Count the total number of metres of vertical and/or sloping pipe length (roof terminal excluded);

4) In the first 2 columns of Table 5, look for the number of bends required and the total horizontal pipe length;

5) In the top row of Table 5, look for the required total vertical and/or sloping pipe length;

6) If you end up in a box with a letter, the concentric system chosen by you is permissible;

7) Use Table 6 to determine how the appliance should be adjusted.

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