Dru Apollo 80 Instructions For Installation Manual

1

English

Apollo 80

Please retain this document carefully

Instructions for installation (GB / IE)

959.011.03.

uK

UK

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English

A po ll o 80 - i n s tr uc ti o n f or i n stA l lAt i on

Contents

page Foreword 2

1. Introduction 3

2. EC Declaration of Conformity 3

3. SAFETY 3

3.1 General 3

3.2 Regulations 3

3.3 Precautionary measures / safety instructions regarding installation 3

4. Instructions 4

5. Unpacking 4

6. Installation 4

6.1 Regulations 4

6.2 Gas type 4

6.3 Gas connection 4

6.4 Positioning the appliance 5

6.5. Flue gas discharge / combustion air supply system 6

6.6 Building the chimney breast 9

6.7 Installing the control box 10

6.8 Adjusting the appliance 10

6.9 Arranging the logs 11

6.10 Glass window 13

7. Wireless remote control 15

7.1 Receiver 15

8. Final inspection 16

8.1 Gastightness 16

8.2 Gas pressure/pre-pressure 16

8.3 Igniting the pilot and main burner 16

8.4 Flame effect 16

9. Maintenance 17

10. Completion 18

11. Troubleshooting 18

Annex 1 Components supplied 20 Annex 2 Technical data 21 Annex 3 Spare parts 21

Foreword

As manufacturer of gas heating appliances, DRU develops and produces products to meet the highest possible quality, performance and safety requirements. As a result of which the user is able to enjoy using your appliance for years to come. This appliance is CE marked; it complies with the essential requirements of the European Appliance Directive. The appliance is supplied with two manuals: the installation manual and the user manual. You the installer should be professionally skilled in the ﬁeld of decorative gas heating. The installation manual gives you all the information you will need to be able to install the appliance in such a way that it works correctly and safely. This manual deals with the installation of the appliance and the appropriate regulations. It also includes the technical data for the appliance and information on maintenance and troubleshooting.

Please read and use this installation manual carefully.

In the manuals the following symbols are used to denote important information:

➠

What to do

!Tip Suggestions and recommendations !N.B. These instructions are important to avoid possible problems during installation and/or use. N.B. These instructions are important to avoid re, personal injury or other serious damage.

Once you have completed the installation you are to hand both the user manual and this installation manual to the user.

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1. Introduction

The Apollo 80 is a closed atmospheric gas heating appliance. A closed appliance does not extract the combustion air from the living environment, but from outside. This is done by means of a combined ﬂue gas discharge system / combustion air supply system. In this concentric system, the outer pipe functions as the air supply and the inner pipe functions as the ﬂue gas discharge. The safe operation of the appliance is guaranteed by the use of a second thermocouple ﬁtted to the main burner. This system can be installed through the wall or through the roof. The appliance is built in a chimney breast. For this, DRU has a number of chimney breasts in its range. In order to reach a proper heat discharge, the chimney breast must be ventilated. DRU is able to supply various ventilation elements. The appliance is supplied with a wireless, battery powered remote control.

2. EC Declaration of Conformity

We hereby declare that the design and construction of the decorative gas heating appliance marketed by DRU conforms with the essential requirements of the Gas Appliance Directive. This declaration will be rendered invalid should the appliance be altered in any way without the written consent of DRU. Product: Decorative gas heating appliance Type: Apollo 80 Applicable EC Directives: 90/396/EEC Applicable harmonised standards: NEN-EN-613, NEN-EN-613/A1 In-house measures guarantee that serially produced appliances always conform with the essential requirements of the current EC Directives and the applicable standards.

R. Gelten General manager DRU VERWARMING B.V. Postbus 1021, 6920 BA Duiven Ratio 8, 6921 RW Duiven www.dru.nl

3. SAFETY

3.1 General

N.B. - Please read this chapter on safety carefully before commencing installation or maintenance;

- Always observe universal regulations and the precautionary measures / safety instructions in this manual.

3.2 Regulations

The appliance should be installed in compliance with current national, local and constructional (installation) regulations.

3.3 Precautionary measures / safety instructions regarding installation

Observe the following precautions / safety regulations precisely:

➠

You may only install and/or service this appliance if your are a qualied installer skilled in installing decorative gas res;

➠

do not adjust the appliance in any way;

➠

Non-combustible and heat-resistant materials should be used to construct the chimney breast, its rear wall, the inte-

rior and the top of the chimney breast;

➠

the minimum internal dimensions required for the chimney breast must be taken into account;

➠

the chimney breast should be ventilated by vents with total free vent area of 200 cm2;

➠

only use the ue /combustion air supply systems supplied by DRU;

➠

use the wall brackets supplied to mount the appliance;

➠

do not install the appliance at against the back wall;

➠

leave the space between the feet free;

➠

do not cover and/or pack the appliance with an insulating blanket or any other material;

➠

Keep combustible objects and/or materials at a minimum distance of 500 mm from the appliance.

➠

only use the log set supplied;

➠

arrange the logs exactly as described;

➠

leave a space around the pilot burner;

➠

make sure thermocouple 2 and the space around it are kept free;

➠

avoid any dirt in the gas pipes and connections;

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➠

test the gastightness of all connections before use;

➠

use heat-resistant electrical connection materials;

➠

install the electrical connections away from the appliance;

➠

replace torn or broken panes;

➠

avoid blocking the explosion hatches;

➠

ensure the explosion hatches on top of the heater are right on their seats, before you close the chimney breast;

➠

do not ignite the appliance until installation has been completed.

4. Instructions

To ensure the appliance works correctly and safely, always take the following points into consideration during installation:

➠

place the control box supplied as low as possible;

➠

ensure the ignition wire does not lie across the receiver;

➠

ensure the ignition wire does not touch or cross the aerial;

➠

to avoid weakening the spark ensure the ignition wire does not touch anything metal;

➠

if the appliance is to be built in ush with the wall, nish the edges neatly;

➠

do not plaster over the anges;

➠

avoid damaging the glass when removing/tting the window pane;

➠

to prevent dirt burning into the glass, make sure it is clean before use.

➠

make sure that the wires of thermocouple 2 cannot come into contact with hot parts.

5. Unpacking

Please take the following points into consideration when unpacking the appliance:

➠

Check the appliance for transit damage;

➠

Contact DRU Service if necessary.

Once the packaging material has been removed, you should have the following components:

- Socket spanner: You will ﬁnd this in the space between the assembly frame and the combustion chamber;

- Trimmings: These are in the same space.

Once you have removed the glass pane you can remove the box of components from the combustion chamber.

!N.B. Be careful not to damage the glass when removing/tting the window pane.

➠

Remove the window as described in paragraph 6.10.1;

➠

Take the box of components out of the combustion chamber.

Annex 1 / Table 4 speciﬁes the components you should have once everything has been unpacked.

➠

Contact DRU Service if after unpacking the appliance you do not have all the components;

➠

Dispose of the packaging in an appropriate manner.

6. Installation

Please read the manual carefully to ensure that once installed the appliance will work correctly and safely.

!N.B. Install the appliance in the order described in this chapter.

6.1 Regulations

- Observe the current applicable (installation) regulations;

- Observe the regulations/instructions laid down in this manual.

6.2 Gas type

The type plate speciﬁes the type of gas, gas pressure, and the country this appliance is intended for. The type plate is on a chain and that is where it should stay.

N.B. Check that the appliance is suitable for the local gas type and pressure.

6.3 Gas connection

The gas connection should have a gas tap located near the appliance.

N.B. Prevent any dirt getting into the gas pipes or connections.

The following requirements apply for the gas connection:

➠

the size of the gas pipe should be such that no pressure loss can occur;

➠

the gas tap must be CE marked;

➠

the gas tap should be accessible at all times;

➠

Do not twist the gas tap when connecting the gas pipe.

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6.4 Positioning the appliance

Position the ﬁ re as follows:

N.B. - Keep combustible objects and/or materials at a minimum distance of 500 mm from the appliance.

- Do not adjust the appliance in any way.

➠

Determine the position of the appliance;

➠

Create a gas connection in the appropriate position; see section 6.3 for details;

➠

Create a duct for the  ue / combustion air supply system, with the diameter shown below; see section 6.5 for details;

➠

Ø160 mm for a wall duct of incombustible material;

➠

Ø 250 mm for a wall duct of combustible material;

➠

Ø160 mm for a roof duct of incombustible material;

➠

Ø 250 mm for a roof duct of combustible material.

!N.B. - Allow for the depth of the appliance (see

Fig. 2) (The minimum depth at the Apollo is 450 mm);

- Allow for the build-in height; this will depend on the height of the adjustable feet (see

Fig. 1a).

➠

Move the appliance into its intended position.

The gas control block is mounted onto the burner plate at the bottom of the appliance. This should be removed and placed in the control box later. See section 6.7 for information on how to ﬁ t the gas control block. Commence as follows:

➠

Disconnect the hoses from the gas control block ( exible gas hose, aluminium pilot pipe and thermocouple 1);

Caution

The red wire of thermocouple 2 must remain connected to the gas control. Fig. 1b shows how the wires are connected

to the thermocouple.

➠

Unscrew the self-tapping screw in the burner plate and remove the gas control block.

➠

Carefully unwind the red and black wires of thermocouple 2.

➠

Lay the gas control together with the wires of thermocouple 2 in the direction of the control box.

N.B. - Avoid dirt in the hoses;

- Avoid kinks in the hoses.

➠

Unroll the hoses towards the control box;

➠

Unroll the ignition wire towards the control box.

Apollo 80

Front view

Top view

Side view

50

min. 910

max. 935

995

813

15

448

192

504

min. 160

max. 185

Fig. 1a

min 1450 mm inside

min 450 mm inside

=

Control box

38c-1294

max 100 mm

508

817

min

150 mm

min

1350 mm

inside

Total

ventilation

200 cm

2

b

c

Maximal

plaster line

Maximal

plaster line

b

c

A-A

A

Fig. 2

Fig. 1b

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!N.B. The type plate should be connected to the chain.

➠

Lay the chain with the type plate facing the control

box;

➠

Adjust the height of the appliance;

➠

Using a spirit level to ensure it is absolutely level.

N.B. - Do not install the appliance  at against the back

wall;

- Leave the space between the feet free;

- Do not cover and/or pack the appliance with an insulating blanket or any other material.

➠

Secure the appliance against the wall using the wall

brackets and rawplugs supplied (see

Fig. 3).

6.5 Flue gas discharge / combustion air

supply system

6.5.1 General

The appliance is of the C11/C31 type. The appliance is connected to a combined ﬂ ue gas discharge/combustion air supply system, hereafter referred to as the concentric system. The passage to the outside can be made with a wall duct (see section 6.5.2) or with a roof duct (see section 6.5.3). If necessary, you can also use an existing discharge channel (see section 6.5.4).

N.B. - Only use the concentric system supplied by DRU

(Ø100 / Ø150 mm). This system was tested in combination with the appliance; DRU cannot guarantee a proper and safe operation of other systems and cannot accept liability for these systems;

- For connecting to an existing chimney  ue you should only use the installation set supplied by DRU.

The concentric system is constructed from (the discharge stump of) the appliance. If structural circumstances require that the concentric system is placed ﬁ rst, the appliance can later be connected with a telescopic pipe piece.

6.5.2 Application with wall duct

6.5.2.1 Construction of concentric system with

wall duct

The concentric system with wall duct has to comply with the following conditions:

➠

First, a concentric pipe of at least 1 meter should be connected vertically to the appliance;

➠

The total vertical pipe length can have a maximum of 4 meters;

➠

After the vertical part a bend of 90° is connected;

➠

When using a minimum 1 up to maximum 4 meter vertical pipe length, the total horizontal pipe length may have a

maximum of 3 meters (wall duct not included; see

Fig. 4a).

Depending on the construction of the concentric system, further adjustments should be made to the appliance.

The next 2 conﬁ gurations are allowed for the construction: a) a minimum 1 meter up to maximum 4 meter vertical pipe length in combination with a 90° bend and a wall duct (i.e. no horizontal part; see Fig. 4b). When using this conﬁ guration, you must set the restriction to 60 mm (for this, see section 6.8.1). b) a minimum 1 meter and maximum 4 meter vertical pipe length in combination with a 90° bend and a maximum 3 meter horizontal pipe length and a wall duct (see Fig. 4a). When using this application, you must remove the air inlet guides.

6.5.2.2 Installing the concentric system

Explosion by-pass valves

Wall brackets

38c-1292

Fig. 3

Fig. 4a

Fig. 4b

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To install the concentric system commence as follows:

➠

Construct the system from the (connection stub of the) appliance up.

N.B. - Maintain a distance of at least 50 mm between the outside of the concentric system and the walls and/or the ceiling;

If the system is built-into a cove for example, incombustible material should be applied all around;

- Use heat-resistant insulating material for ducts made of combustible material;

- The rosette (mounting inner plate) of the wall duct is too small to seal the Ø 250 mm opening when passing through combustible material. That is why you should rst apply a suciently large heat-resistant intermediate plate to the wall. Then, the rosette is mounted on the intermediate plate.

➠

Connect the concentric pipe sections and the bend(s);

➠

Fit a clamping strip and silicone sealing ring to every connection;

➠

Secure the clamping strip with a self-tapping screw in places which will be inaccessible after installation;

➠

Use enough brackets to ensure that the weight of the pipes does not rest on the appliance;

➠

Determine the remaining length of the wall duct;

➠

Cut the wall duct to size;

!N.B. - Make sure that the right insertion length is maintained;

- Place the wall duct with the groove/folded seam at the top;

- Make sure the horizontal concentric pipe pieces are sloping towards the wall duct, in order to prevent rain water from entering.

➠

Mount the rosette (mounting inner plate); if necessary, on a heat resistant intermediate plate when passing through

combustible material;

➠

Attach the wall duct from the outside with four screws in their respective holes.

!N.B. Some heat-resistant isolation materials contain volatile components that will spread an unpleasant smell for a pro-

longed time; these are not suitable.

6.5.3 Application with roof duct

6.5.3.1 Construction of concentric system with roof duct

The concentric system with roof duct has to comply with the following conditions

➠

The construction of the chosen system has to be allowed. (See the procedure described below);

➠

First, a concentric pipe of at least 1 meter should be connected vertically to the appliance.

Depending on the construction of the concentric system, the appliance is set by placing the bafﬂe and/or removing the air inlet guides. In the following procedure you can see how the allowability of a concentric system can be determined and which settings are needed.

➠

Determine the following data:

1. The number of bends required (no distinction is made between 45° and 90° bends);

2. The total number of meters of horizontal pipe length;

3. The total number of meters of vertical and/or sloping pipe length (wall duct not included).

With these data and Table 1 you will be able to determine whether the concentric system is allowed. In Table 2 you can see which setting the appliance needs. Follow the procedure described below:

➠

In the rst 2 columns of Table 1, look for the number of bends required and the total horizontal pipe length;

➠

In the 3rd column of Table 1, look for the total vertical and/or sloping pipe length.

If you end up in a box with the letter A, B, C, D or E the concentric system chosen by you is allowed.

➠

Use Table 2 to determine which conditions apply for the bae and/or the air inlet guides (for setting see section 6.8);

Examples

To clarify, we will give 2 examples to determine the allowability of a concentric system and the conditions for setting the appliance. In Table 1 the route to be followed is indicated by arrows. The result is indicated by means of the red frame of the box.

Example 1

1) 2 bends

2) 3 meters horizontal

3) 8 meters vertical/sloping

→ Construction of this concentric system is allowed. → Situation B applies for setting the appliance

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Example 2

1) 3 bends

2) 4 meters horizontal

3) 10 meters vertical/sloping → Construction of this concentric system is not allowed.

Table 1: Conditions for adjusting the equipment with roof ducts

G20 / G25 total number of

meters of horizon-

tal pipe lengths

total number of meters of vertical and/or sloping pipe lengths

1 2 3 4 5 6 7

↓8

9

↓10

11 12

no bends 0 B C C D D D D E E E E E

2 bends 0 A A B C C D D D D E E E

1 A A B C C D D D D E

2 A A B C C D D D

→

3 A A B C C D

4 A A B C

5

3 bends 0 A A A B C C D D D D E E

1 A A A B C C D D D D

2 A A A B C C D D

3 A A A B C C

→

4 A A A B

5

4 bends 0 A A A A B C C D D D D E

1 A A A A B C C D D D

2 A A A A B C C D

3 A A A A B C

4 A A A A

5

5 bends -

n = The situation is not permissible.

Table 2:

Situation Air inlet guide Bafﬂe Dammingg distance

A NO NO OPEN

B YES YES 44 mm

C YES YES 41 mm

D YES YES 37 mm

E YES YES 30 mm

6.5.3.2 Installing the concentric system

The roof duct can be used for either a sloping roof or a ﬂat roof. The roof duct can be supplied with an adhesive plate for a ﬂat roof or with a universally adjustable tile for a sloping roof. Install the concentric system as follows:

➠

Construct the system from the (connection stub of the) appliance up

N.B. - Maintain a distance of at least 50 mm between the outside of the concentric system and the walls and/or the ceiling;

If the system is built-into a cove for example, incombustible material should be applied all around;

- Use heat-resistant insulating material for ducts made of combustible material.

!N.B. Some heat-resistant isolation materials contain volatile components that will spread an unpleasant smell for a pro-

longed time; these are not suitable.

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➠

Connect the concentric pipe sections and any necessary bends;

➠

Fit a clamping strip and silicone sealing ring to every connection;

➠

Secure the clamping strip with a self-tapping screw in places which will be inaccessible after installation;

➠

Use enough brackets to ensure that the weight of the pipes does not rest on the appliance;

➠

Determine the remaining length of the roof duct;

➠

Cut the roof duct to size.

!N.B. Be sure to maintain the correct insertion length.

➠

Connect the roof duct to the concentric pipes.

!N.B. - Make sure the universal roof tile ts well against the surrounding tiles;

- Make sure the adhesive ashing sticks to the at roof properly.

6.5.4 Connection to an existing ﬂue

The appliance can also be connected to an existing ﬂue. A ﬂexible SS pipe is placed in the chimney for discharging ﬂue gases. The surrounding space is used to supply the combustion air. The following requirements apply for connection to an existing ﬂue:

- allowed only if the special DRU chimney connection set is used;

- Installation instructions supplied;

- minimum dimensions 150 x 150 mm;

- maximum vertical length 12 metres;

- maximum horizontal length 3 metres;

- the existing ﬂue must be clean;

- the existing ﬂue must not have any cracks or leaks.

6.6 Building the chimney breast

The appliance is designed to be installed snugly into a newly built chimney breast. There must be sufﬁcient space around the appliance to ensure a good heat distribution. The chimney breast should be ventilated by vents.

N.B. - Use incombustible and heat-resistant material to construct the chimney breast, including rear wall of the chimney

breast;

- The total free vent area of the vents, installed as high as possible, should be at least 200 cm

2

.

!N.B. When building the chimney breast, the following points should be taken into account (see

Fig. 2):

- position of the control box: this should be placed within 850 mm to the left or right of the appliance, as low as possible;

- size of the control box; see section 6.7 Installing the control box;

- position of the vents;

- the size of the glass window so that it can be tted/removed once the chimney breast has been built;

- protecting the gas control block and hoses from cement and plaster.

!Tip The vents should preferably be created in both sides of the chimney breast: you could use DRU ventilation elements.

➠

Check that the concentric system has been installed correctly;

➠

Check that the clamping strips have been secured with self-tapping screws in places which will be inaccessible later;

➠

Allow sucient clearance round the appliance in the chimney breast to enable the heat to disperse:

- minimum internal height: 1350 mm;

- minimum internal width: 1450 mm.

➠

Do not plaster over the anges because:

- the heat from the appliance could cause cracks;

- it will then be impossible to remove/t the glass window.

➠

If the chimney breast is of materials similar to stone, or is nished with plaster, it should be dried-out at least 6 weeks

before commissioning, in order to prevent cracks.

6.7 Installing the control box

The control box is to be installed as low as possible. The control box contains various components such as the type plate, the gas control block, and the receiver for the remote control. (See Fig. 5 for details.)

➠

Make a 285 x 194 mm (h x w) opening in the chimney breast;

➠

Fit the inner frame (1); to do this unscrew the bolts (5).

!Tip - If the chimney breast is brick, the inner frame can be cemented in during building;

- For a chimney breast of any other material, glue/cement the inner frame in place or t it with four countersunk screws.

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➠

Mount the gas control block on the brackets (2) on the inner frame;

➠

Reconnect the hoses to the gas control block.

N.B. - Avoid kinks in the hoses;

- Tighten the  exible hose and aluminium pipe making sure they are gastight;

- Screw the thermocouple 1 on by hand  rst and then;

- then tighten it a quarter turn using a suitable spanner.

➠

Connect the thermocouple1 wiring to the gas control block if necessary; see Photo 1;

➠

Blow through the gas pipe if necessary;

➠

Connect the gas pipe to the gas tap;

➠

Bleed o the air in the gas pipe;

➠

Fit the receiver (3); see section 7.1 for connections;

➠

Fit the type plate (6);

➠

Fit the outer frame with door (4) to the inner frame using the two self-tapping screws (5).

!Tip You can position the outer frame in such a way that the door opens to either the left or right.

6.8 Adjusting the appliance

The appliance has to be set in such a way that it works correctly in combination with the discharge system. For that purpose, a bafﬂ e is placed and/or the air inlet guides are removed. The conditions for using a wall duct are described in section 6.5.2.1, and for using a roof duct in section 6.5.3.1.

Caution

For Belgium, the condition applies that the primary aeration of the burners has to be changed, if the appliance is used

with gas G25 instead of G20; see section 6.8.3.

6.8.1 Bafﬂ e (R)

The bafﬂ e (R) is supplied separately.

It is mounted as follows:

➠

Place the ba e. (see Fig. 6a and 6b)

➠

Use the template supplied to set the distance of the restriction (see Fig. 7) as follows:

- A distance of 30 mm, means that the ba e will be fully closed;

- A distance of 37 mm is set by means of the template;

- A distance of 41 mm is set by means of the template;

- A distance of 44 mm is set by means of the template;

- A distance of 60 mm is set by means of the template;

➠

Fix the ba e by using the socket cap screw (U).

6.8.2 Air inlet guides (L)

The air inlet guides (L) are located at the bottom (side) of the tray around the burner. Remove them as follows; see Fig. 8:

➠

Remove the tray surrounding the burner (M);

➠

Unscrew and remove the self-tapping screws (N);

➠

Remove the air inlet guides;

➠

Replace the tray round the burner.

38c-1078

1

2

4

5

3

6

Fig. 5

Damper

socket-head screw

Fig. 6a

60

44

41

37

Fig. 7

38c-1269

Damper

Fig. 6b

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6.8.3 Primary aeration of the burners

Caution

Adjusting the primary aeration only applies to appliances used in Belgium.

When the tray surrounding the burners is removed, you can see the throttle rings (Pa and Pb) that are mounted on the pipes that are ﬁ xed to the burners (burner pipes); see Fig. 9. The primary aeration of the burners can be adjusted by rotating the throttle rings.

Caution

Rotate the throttle ring at the front left (Pb) with its opening towards the pilot  ame burner. This throttle ring has only

1 hole with a diameter of 6 mm and 1 with a diameter of 12 mm (see

Fig. 9).

The steps to be taken are described below:

➠

Take the tray surrounding the burners (M) out of the appliance; see Fig. 10a.

➠

Unscrew the socket cap screw (O) of a throttle ring (P), see Fig. 11.

➠

Rotate the throttle ring (P) when using gas G25 in such a way, that the holes with the 7 mm diameter are directly op-

posite the 15 mm holes in the burner pipe; see

Fig. 11.

➠

Screw the socket cap screw (O) into the threaded hole above the 7 mm diameter hole.

➠

Repeat this procedure for the other 3 burner pipes.

➠

Return the tray surrounding the burners (M).

6.9 Arranging the logs

The appliance is supplied with a set of logs.

N.B.

Observe the instructions below precisely to avoid unsafe situations.

- only use the log set supplied;

- arrange the logs exactly as described;

- do not cover the pilot burner or the surrounding area;

- make sure that thermocouple 2 and the space around it are kept free from objects (see photo 4c and photo 4d);

- do not cover the slot between the burner tray and the tray surrounding the burner.

Photo 1 Photo 2 Photo 3

Fig. 8 Fig. 9

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Photo 4a

Photo 6a

Photo 5

Photo 4b

Foto 4c Foto 4d

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6.9.1 Wood set

The wood set consists of vermiculite (see Fig. 2), chips (see Fig. 3) and a number of logs.

➠

Fill the burner tray with vermiculite; equally spread

the vermiculite (see

Fig. 5).

!Caution

- You can in uence the  ame image by moving the vermiculite, yet

- the burner deck has to remain covered with vermiculite in order to prevent that the life expectancy of the burner is reduced.

➠

Fill the tray around the burner with chips; equally spread the chips (see Fig. 5);

➠

Identify logs A up to E by using Fig. 6a.

!Tip

Use the burn stains on the logs for identi cation.

Photo 6b Photo 6c

Photo 6d Photo 6e

Photo 6f Photo 6g

Photo 6iPhoto 6h

Photo 6j

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Photo 7a

Photo 10e

Photo 7b

Photo 8

Photo 9 Photo 10f

Photo 10c Photo 10d

Photo 10a Photo 10b

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➠

First place log A as indicated in Fig. 4a en 4b.

➠

Place log A up to E over the burners (see Fig. 6b up to 6j);

Caution

- Make sure log A is lying correctly in relation to the ridge, see the arrow.

➠

Next, you should place log B;

Caution

Make sure log B is lying correctly in relation to the ridges.

➠

Proceed with logs C, D and E.

Caution

- The logs should be placed exactly as indicated in Fig. 6j;

- The logs should not completely cover the burner deck, because:

- the main burner will not ignite properly; which could result in unsafe situations;

- the appliance will become  lthy more quickly, as a result of soot;

- the  ame image may be a ected.

The log set consists of vermiculite (see Photo 2), chippings (see Photo 3) and a few logs.

➠

Fill the burner tray with the vermiculite, spreading it out evenly.

!N.B. - You can alter the  ame e ect by moving the vermiculite but;

- the burner cap must remain covered by vermiculite to help preserve the useful life of the burner.

➠

Fill the tray surrounding the burner with chippings; spreading them out evenly;

➠

Identify the logs A - D using Photo 4 for reference.

!Tip The burn marks on the logs will help you identify them.

➠

Place block A around the (main) burner. This can only be done in one way (see Photo 5);

➠

Install block B, C and D (see Photo 6, 7 and 8).

6.10 Glass window

Once the logs have been arranged the glass window can be ﬁ tted as described below.

6.10.1 Removing the glass window

Remove the glass frame in accordance with the following instructions (see Photos 7 to 12):

➠

Remove the vertical decorative strips on the left and right of the glass frame by pushing the lip at the top of each strip

up, tilting the top of the strip parallel with the glass frame, and then removing the strip.

➠

Remove the horizontal decorative strip by gripping it with 2 hands in the slot and lifting it out.

➠

Unscrew the 4 self-tapping screws in the bottom strip using the socket spanner supplied with the appliance.

➠

Loosen the 3 self-tapping screws in the fastening strips on both sides 2 turns.

!N.B. Do not remove the self-tapping screws: leave them in place in the fastening strips.

➠

Push the 2 top wedges (left and right) down as far as possible.

➠

Push the 2 bottom wedges upwards as far as possible.

➠

Press the two fastening strips outwards with your hands as far as possible to avoid damage to the sealing cord.

➠

Take hold of the top and bottom handgrips and lift the glass frame.

➠

Pull on the bottom handgrip to tilt the glass frame in its mounting towards you and, at the same time, pull the top of

the glass frame towards you as far as possible.

Photo 11

Photo 12

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!N.B. - Make sure you hold the upper handgrip rmly. If you let go of the handgrip then the glass frame could fall inwards

and cause severe damage to both the glass and the appliance;

- Make sure that you lift the glass frame out of its mounting as straight as possible to avoid damage to the paintwork and the sealing cord.

➠

Gently allow the glass frame to drop at an angle until it can be removed entirely from the mounting.

6.10.2 Fitting the glass window

The glass frame is ﬁtted by using the above procedure, in reverse order.

!N.B. - Avoid/remove ngerprints on the glass, since otherwise they will burn into the surface;

- The self-tapping screws must not be over-tightened, since otherwise they could break or strip the thread: tight=tight;

- Replace the fastening strip if the sealing cord has come loose.

Pay attention to the following when ﬁtting the glass frame:

➠

Begin by checking that the two fastening strips are pressed outwards as far as possible to avoid damage to the sealing

cord.

➠

Fit the glass frame.

➠

Check that the hook at the top of the glass frame is in position in the seating / U-shaped strip.

!Tip Pull on the upper handgrip to move the glass frame towards you: if it does not move, then it has been tted correctly.

!N.B. Fix the glass frame’s bottom strip in place with the 4 self-tapping screws.

➠

Push both bottom wedges downwards.

➠

Push the top wedges upwards until the sealing cord of both fastening strips press against the glass.

➠

Tighten each wedge’s self-tapping screw.

!N.B. Press on the wedge with your hand to hold it in place while you tighten the screws.

➠

Tighten the middle self-tapping screw in each fastening strip.

➠

Fit the horizontal decorative strips.

➠

Fit the vertical decorative strips.

7. Wireless remote control

See Chapter 4 of the User Manual, ‘Remote Control’, for details of how to operate the system.

The remote system consists of a remote control system and a receiver. The procedure for connecting the receiver has been described below; the working of the remote control system has been explained in detail in Chapter 4, 4.2 of the User Manual 4, 4.2

7.1 Receiver

The receiver must be connected to the appliance before the batteries are inserted. Do this as follows (see Photo. 13):

➠

Slide the brown plug o the lead at the back on the PCB of the receiver;

➠

Connect the white plug to the gas control block.

!Tip the plugs are dierent sizes and correspond with the connectors.

➠

Connect the thermocouple 2 wires to the receiver (see Photo 13, arrows B).

!Tip - the size of the eye corresponds with the size of the screw;

- the colour of the eye and screw also correspond.

➠

Connect the black wire with the white plug of thermocouple 2 to the receiver (see Photo 13, arrow E).

Caution

Make sure that the wires of thermocouple 2 cannot come into contact with hot parts.

➠

Connect the ignition wire to the receiver (see Photo 13, arrow A);

➠

Connect the power supply:

a) For batteries see section 7.1.1 below; b) For an adapter:

- connect the adapter to the receiver (see

Photo 13, arrow C);

- plug the adapter into the wall socket.

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➠

Place the receiver in the control box:

- Position the receiver as shown in

Photo 14.

➠

Bend the aerial out of the clips, see Photo 13, arrow D;

➠

Put the aerial straight up.

!N.B. - Do not put the aerial too close to the ignition wire and/or metal parts (see

Photo 14 for the correct position);

- Do not lay the ignition wire across and/or beside metal parts: this will weaken the spark;

- Do not lay the ignition wire across the receiver: this could damage the receiver;

- Avoid dust accumulating on or in the receiver: cover it during servicing or maintenance.

7.1.1 Fitting/replacing the batteries

To ﬁ t the batteries:

➠

Open the  ap on the control box;

➠

Take the receiver;

➠

Slide the lid o ;

➠

Fit or remove the 4 penlight (AA size) batteries.

!N.B. - Avoid short circuits between the batteries and metal objects/components;

- Note the “+” and “-” positions of the batteries in the holder;

- Use alkaline batteries.

➠

Slide the lid back on;

➠

Replace the receiver.

!N.B. Do not throw batteries in the dustbin, they are considered “domestic chemical waste” and should be disposed of

accordingly.

Photo 13

Photo 14

Photo 16Photo 15 Photo 17

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8. Final inspection

To ensure the appliance is working correctly and safely, check the following before use:

8.1 Gastightness

N.B. All connections must be gastight. !N.B. The maximum pressure to which the gas control block may be exposed is 50 mbar.

➠

Test the connections for gastightness.

8.2 Gas pressure/pre-pressure

The burner pressure is factory adjusted; see type plate. It is not necessary to test the burner pressure. The pre-pressure in domestic installations should be tested however, as this can vary.

➠

Check the pre-pressure; see Photo 16 for the measuring nipple on the gas control block;

➠

Contact the power company if the pre-pressure is not right.

8.3 Igniting the pilot and main burner

8.3.1 Pilot

➠

Test that the pilot ignites properly, see section 0 Remote control:

- the pilot burner should ignite at the  rst attempt.

If the pilot does not light, then

➠

Check whether or not the ignition sparks:

a) If not, the ignition wire is probably touching something metal; b) If it does, there is probably air in the pipes.

➠

Bleed o any air in the pipes and/or;

➠

Move the ignition wire so that it does not touch anything metal.

8.3.2 Main burners

Caution

The burners should ignite smoothly and should not pop as a result of postponed ignition.

➠

Check the function of the main burners from the standby (pilot  ame) position:

- after opening the gas valve, the main burners should burn within a few seconds.

!Tip

When the gas valve is opened, the motor will run; this is audible.

1) If the main burners does not burn:

➠

Check if button A on the gas control is in the position ON;

➠

Check if the space surrounding the pilot burner is free from objects;

➠

Check the placement of the wood/pebble set.

➠

If necessary, correct the above mentioned faults.

➠

Test the main burner 5x for a good operation.

2) If main burners ignites, but go out again after approx. 22 seconds, please:

➠

Check the wiring of thermocouple 2 for:

- Loose wiring;

- Wrongly connected wiring;

- Short-circuit;

- Broken wire.

➠

Check if thermocouple 2 is dirty.

➠

Check if thermocouple 2 is positioned correctly in the  ame;

see  g. 10.

➠

Check if thermocouple 2 is defective; see chapter 11, table 4

under J7.

➠

Check if the receiver is defective; see chapter 11, table 4

under J8.

➠

If necessary, correct the above mentioned faults.

➠

Test the main burner 5x for a good operation.

C

SECTION

B-B

25

15

38C-1894 /0

Fig 10

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8.4 Flame effect

The ﬂame effect cannot really be assessed until the ﬁre has been on for several hours. Volatile elements in paint, materials, etc., which evaporate during the ﬁrst hours of use, will initially inﬂuence the ﬂame effect.

!N.B. If the chimney breast is of materials similar to stone, or is nished with plaster, it should be dried-out at least 6 weeks

before commissioning, in order to prevent cracks.

➠

Check that the ame eect is symmetrical.

An asymmetrical ﬂame effect could be caused by:

- volatile substances evaporating;

- incorrectly arranged logs.

➠

Rearrange the logs as necessary.

9.

9. Maintenance

a

inte

The appliance should be inspected, cleaned and if necessary repaired by a qualiﬁed installer with professional

experience of decorative gas ﬁres at least once a year.

The appliance should at least be tested to check it works correctly and safely.

N.B. - Switch o the gas before commencing any maintenance;

- Test the gastightness after any repairs;

- After replacing thermocouple 1 you should rst tighten the swivel of the gas control block by hand and then give it another quarter turn with a suitable spanner.

➠

Clean the following components if necessary:

- the pilot burner;

- the combustion chamber;

- the glass

!N.B. - Remove the glass as described in section 6.10

- Remove the deposit on the inside of the glass with a damp cloth or a non-abrasive cleaning product such as copper polish;

- Avoid/remove ngerprints on the window as they will burn into the glass;

- Replace broken and/or cracked glass.

N.B. If necessary, place back the wood set correctly; see section 6.9.

➠

Inspect the ue / combustion air supply system;

➠

Test the system as described in chapter 8.

10. Completion

Familiarise the user with the appliance. You should instruct him/her on such things as how to use the appliance and how it works, how to use the remote control, and about the need for annual maintenance.

N.B. - Tell the user to switch o the gas immediately and to contact the installer in the event of a failure / malfunction, to

avoid unsafe situations;

- Show him/her where the gas tap is.

➠

Explain how to use the appliance and the remote control;

➠

Point out the precautions in the user manual concerning unintended ignition by other remote controls such as car keys

and garage door openers;

➠

Point out that when the appliance is used for the rst time:

- If the chimney breast is of materials similar to stone, or is nished with plaster, it should be dried-out at least 6 weeks before commissioning, in order to prevent cracks;

- volatile elements in paint, materials etc. will evaporate the rst time the re is used;

- the re should preferably be used at the highest setting so that these elements will evaporate more quickly;

- the room should be well ventilated.

➠

Hand the user the user manual and the installation manual (the installation manual should be kept near the appliance).

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11. Troubleshooting

A number of faults which could occur, their possible causes and solutions are shown in the table below:

Table 3: Troubleshooting

Problem Possible cause Solution

A. No transmission (motor doesn’t work)

1. The (new) communication code between the receiver and the remote control has not been conﬁrmed.

2. Dead batteries.

3. Receiver is damaged.

4. Remote control is damaged

5. Motor wiring broken at the valve

6. Bent pins on the 8-pin connector.

7. If the receiver is surrounded by metal, the transmission range may be reduced.

1. Press and hold the reset button on the receiver until you hear 2 bleeps.

After the second, longer bleep, release

the reset button and, within 20 seconds press

/ t on the remote control until

you hear an extra long bleep which conﬁrm the new code; see Photo 15.

2. Replace the batteries.

!N.B. Avoid short circuits between the batte-

ries and metal parts of the appliance.

3. Replace the receiver and conﬁrm/change the code (solution 1)

4. Replace the remote control and conﬁrm/ change the code (solution 1)

5. Replace the motor wiring at the valve.

6. Straighten the pins on the 8-pin connector.

7. Change the position of the aerial.

B. No ignition (spark) 1. Button A is set to MAN.

2 Ignition wire lying across

and/or beside metal components.

3. Ignition pen corroded

1. Switch button A on the gas control block to ON, see Photo 14

2 Do not let the ignition wire touch any-

thing metal: This will weaken the spark; see 2 Ignition wire lying across and/or along beside metal components.

Replace the ignition wire if necessary.

3. Replace the ignition pen

C. No bleep 1. Receiver is damaged.

2. 60-second delay before the full restart is not yet ﬁnished.

1. Replace the receiver and conﬁrm/change the code (solution 1 at A)

2. Wait until the delay time has passed.

D. One continuous 5 second bleep (There may be 7 short bleeps

before the 5 second bleep)

1. Loose wiring

2. Receiver is damaged.

3. Bent pins on the 8-pin connector.

4. Magnetic valve is damaged.

5. Thermocouple 2 still too

hot.

1. Connect the wiring correctly.

2. Replace the receiver and conﬁrm/change the code (solution 1 at A)

3. Straighten the pins on the 8-pin connector.

4. Replace the gas control block.

5. Wait until the thermocouple has cooled

down sufﬁciently.

E. No pilot 1. Air in the pilot pipes.

2. Wires of thermocouple 1 have been cross-connected.

3. No spark at the pilot burner.

4. Injector is blocked up

1. Purge the pipes or restart the ignition process several times.

2. Check the polarity of the thermocouple wiring.

Connect the thermocouple correctly.

3. Check that the ignition wire is not touching anything metal.

Move it if necessary; see Photo 14 Replace the ignition wire if necessary If necessary, replace the ignition pen

4.1 Clean the injector

4.2 If necessary, replace the injector

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F. Electronics keep sparking when

the pilot burner is burning

1. Receiver is damaged. 1. Replace the receiver and conﬁrm/change the code (solution 1 at A)

G. Pilot burner is burning but

the magnetic valve closes after approx. 10 seconds or when the appliance gets too hot

1. Thermocouple 1 does not

function.

2. Batteries (almost) dead

1.1 Measure the voltage with a digital multimeter, set to mV range, by connecting the wires to the cable terminal. The cable terminal is on the outside, right next to the magnetic nut, see 2: Batteries (almost) dead (see Photo 17). The voltage should be at least 5mV within 20 seconds. This must not be any lower when the appliance is hot.

If the voltage is too low then

- the thermocouple should be moved so

that it is in the ﬂame more, or

- the thermocouple should be replaced.

1.2 Check the size of the pilot.

Adjust the pilot if it is too low.

1.3 Check the wiring between the thermocouple and the receiver.

Replace the wiring if necessary.

2. Replace the battery.

H. There are short bleeps but

no sparks and is no sound / ticking can be heard of the magnet opening the valve

1. Batteries (almost) dead 1. Replace the batteries.

!N.B. Avoid short circuits between the batte-

ries and metal parts of the appliance.

I. Pilot burner is on but there is

no gas ﬂow to the main burner

1. Button A is set to MAN.

2. Appliance is set to pilot mode.

3. Pre-pressure is too low.

4. Magnetic valve is damaged.

1. Switch button A on the gas control block

to ON, see Photo 14

2. Increase the ﬂame height by pressing

/

t button

on the remote control.

3. Test the pre-pressure Contact the power company if necessary.

4. Replace the gas control block.

J. Main burners ignites, but go

out again after approx. 22 seconds.

1. Wiring of thermocouple 2 is loose.

2. Wires of thermocouple 2 have been cross-connected.

3. Short-circuit in the wiring of thermocouple 2.

4. Broken wire in the wiring of thermocouple 2.

5. Thermocouple 2 is dirty.

6. Thermocouple 2 is not positioned correctly in the ﬂame (see ﬁg. 23.)

7. Thermocouple 2 is defective.

8. Receiver is defective.

1. Connect the wiring properly.

2. Connect the wiring properly.

3. Replace wiring.

4. Replace wiring.

5. Clean the thermocouple.

6. Position the thermocouple correctly in the ﬂame.

7. Check the voltage across thermocouple 2 just before the main burner goes out.

If the voltage is lower than 1.8 mV, re-

place thermocouple 2.

8. Check the voltage across thermocouple 2 just before the main burner goes out.

If the voltage is higher than 1.8 mV,

replace the receiver.

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Annex 1 Components supplied

The table below speciﬁes the components supplied with the appliance.

Table 4: Components supplied

Component Quantity Order number

Set of Logs 1x 806748

Control box 1x 26280

Control box manual 1x 957.577.06

Installation manual 1x 959.011.01

User manual 1x 958.009.00

Trim left 1x 38724476

Trim right 1x 38724475

Trim bottom 1x 38741412

Damper template 1x 38714665

Damper 1x 38741224

Raw plugs M8x140x50 2x 509330

Hexagonal nut M8 4x 521308

Washer 8.4 mm 4x 525070

Spare self-tapping screws for the glass window 519419

Socket spanner 8 mm 1x 790811

Remote control with receiver 1x 806277

9V square battery 1x 923001

Penlight battery (AA type) 4x 923100

Pressure coupling 15 mm x G3/8” 1x 149234

Annex 2 Technical data

The technical data for the Apollo 80 are given in the table below.

Table 5: Technical data

Type C11/C31

Gas type G25 G20

Burner pressure mbar 21,0 17,0

Nominal Load (Hs) kW 9,3 10,1

Nominal Load (Hi) kW 8,4 9,1

Nominal Capacity kW 5,8 6,5

Consumption L/h 1009 947

Burner jet burner front mm 3x Ø 1,15 3x Ø 1,15

Burner jet burner back-right mm 1x Ø 1,25 1x Ø 1,25

Consumption on stand-by L/h 621 586

Fine adjustment jet mm 2,0 2,0

Pilot jet Code 51 51

Efﬁciency category 2 2

Annex 3 Spare parts

Spare parts are available from www.druservice.co.uk

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Notes

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

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DRU Verwarming B.V. The Netherlands

Postbus 1021, NL-6920 BA Duiven Ratio 8, NL-6921 RW Duiven

UK

Dru Apollo 80 Instructions For Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual