Dru Apollo 80 Instructions For Installation Manual
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English
Apollo 80
Please retain this document carefully
Instructions for installation (GB / IE)
959.011.03.
uK
UK
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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 qualied 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
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 suciently 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 bae 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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