Dru Diablo G25.3, G20, Diablo G25, Diablo G20 Installation Manual

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Diablo

Installation manual (UK/IE)

DRU15798-495858-EN--0414-3

G20/G25/G25.3 Natural gas

959.059.00.NL

English

INSTALLATION MANUAL

1. Introduction

2. CE declaration

3. SAFETY

3.1 General

3.2 Regulations

3.3 Precautions/safety instructions during installation

3.4 Second thermocouple safety

3.5 Oxypilot safety

4. Removing the packaging

5. Installation

5.1 Type of gas

5.2 Connection

5.3 Placing the appliance

5.4 Placing a built-in appliance

5.5 Placing the chimney breast

5.6 Placing the control hatch

5.7 Flue gas discharge system in appliances with open combustion

5.8 Flue gas discharge / combustion air supply system in appliances with closed combustion

5.9 Additional instructions

5.10 Glass pane

5.11 Setting the appliance

5.12 Placing the wood set

5.13 Mantelpiece

6. Control

6.1 Connecting the receiver

6.2 Setting the communication code

6.3 Alternative operation

7. Final inspection

7.1 Gastightness

7.2 Gas pressure/line-pressure

7.3 Ignition pilot and main burner

7.4 Flame picture

8. Maintenance

8.1 Parts

9. Delivery

10. Malfunctions

Appendix 1 Diagnosis of malfunctions Appendix 2 Various tables Appendix 3 Figures

Contents

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INSTALLATION MANUAL

1. Introduction

DRU, a manufacturer of gas-fired heating appliances, develops and produces products that comply with the highest 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. 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 the appliance’s technical data as well as information on maintenance, possible malfunctions that might occur and what may cause them.

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®, the DRU Smartvent system® or the DRU Maxvent 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 manual 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 method of the gas-fired heating appliance issued by Dru complies 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 Diablo 2009/142/EC NEN-EN-613 NEN-EN613/A1

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INSTALLATION MANUAL

3. SAFETY

3.1 General

!Caution

- Please observe the generally applicable regulations and precautions/safety instruction 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 during 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;

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 material for the chimney breast, including the top of the chimney breast, the material inside 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 high temperatures of the wall behind the chimney breast, including the materials and/or objects that are behind the wall;

- comply with the minimum required internal measurements 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 electric connections and make sure that they do not make contact with the appliance;

If you are installing an appliance with an open combustion: use a suitable flue gas discharge system that is provided with the CE label;

if you are installing an appliance with a 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;

the space surrounding the pilot burner, 2nd thermocouple or ionisation pins must remain 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, 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 and discharge 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 application may not be used.

3.4 Second thermocouple safety (if applicable, see Appendix 2, Table 2)

It is possible, that the appliance to be installed has 2 thermocouples. Thermocouple 1 is always next to the pilot burner, thermocouple 2 is always elsewhere above the main burner. If the appliance is provided with a second thermocouple safety on the main burner, you need to know that it will intervene if no proper transfer has taken place from the pilot burner to the main burner or from the main burner itself. The gas supply will be interrupted after 22 seconds. In order to solve a poor or non-existent transfer from the pilot burner to the main burner, please use the malfunction search diagram in Appendix 1.

3.5 Oxypilot safety (if applicable, see Appendix 2, Table 2)

If the appliance is provided with an oxypilot safety, you need to know that it will intervene (the pilot flame and the gas supply to the main burner will be switched off) if insufficient combustion air (oxygen) is supplied. Once the supply of combustion air is sufficient again, the appliance can be restarted. The supply of fresh air can be controlled by installing/opening ventilation holes.

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INSTALLATION MANUAL

4. Removing the packaging

Note the following items when removing the packaging:

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

If necessary, contact your supplier.

Never install an appliance that is damaged !

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

!Caution

Heat-resistant glass is a ceramic material. Very small irregularities in the glass pane(s) 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.

Dispose of packaging in accordance with local 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/instructions 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 the gas pressure used at the location.

!Tip

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

5.2 Connection

5.2.1 Gas connection

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

!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.

5.2.2 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 chmney 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 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 (Appendix 3, fig. 2);

- Take sufficient measures to prevent high temperatures of a possible wall behind the chimney breast, including the materials and/or objects that are 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 also be done by fixing the extension legs with self-tapping screws.

!Caution

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

- The minimum construction dimensions 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 5.7 or 5.8:

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

- the pipe diameter +100 mm for a passage through combustible material.

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INSTALLATION MANUAL

!Caution

Starting at section 5.9, you will find additional instructions that are specifically needed for the installation of your appliance.

5.4 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 5.4 to 5.6.

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 under the appliance, at the burner mounting plate. 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 5.6.

Follow the procedure described below:

Disconnect the pipes from the gas control (flexible gas pipe, aluminium pilot burner pipe and thermocouple 1);

!Caution

The red wire of thermocouple 2, if applicable, must remain connected to the gas control.

Disconnect the gas control from the burner mounting plate by unscrewing the self-tapping screw.

Carefully unwind the red and black wire of thermocouple 2, if applicable.

Carefully lay the gas control together with the wires of thermocouple 2, the ignition cable, the flexible gas hose, the aluminium pilot burner pipe and the type plate plus 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 cable cannot come into contact with other wires;

- The data plate should remain attached to the chain.

Set the height of the appliance using the adjustable feet and

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 5.9 'Additional instructions'.

!Caution

do not ignite the appliance before the gas and discharge connections have been fully installed, first observe the procedure described in chapter 7.3.

5.5 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

- Use non combustible and heat-resistant material for the chimney breast, including the top of the chimney breast, the material inside the chimney breast and the back wall of the chimney breast;

- Make sure that 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.

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INSTALLATION MANUAL

!Caution

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

- the location of the control hatch: this must be placed as low as possible;

- the dimensions of the control hatch; see Placing the control hatch section 5.6;

- the Dru control hatch is not supplied with all appliances. Nevertheless, we recommend only using a Dru control hatch, which can be supplied separately, if necessary. If you decide not to take this option, you will have to make a 100 cm

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.

!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 a plaster finishing, allow the chimney breast to dry for at least six weeks prior to using the appliance in order to prevent cracks.

5.6 Placing the control hatch (if applicable)

The control hatch (also see paragraphs 5.4 and 5.5) 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 control panel of the DRU Maxvent system

or 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 of 285 x 194 mm (h x w).

Place the inner frame (1); unscrew bolts (5) for this.

!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.

Mount the gas control to the brackets of the inner frame (2).

Reconnect the pipes to the gas control.

!Caution

- Avoid kinks in the pipes;

- Tighten the flexible gas pipe and the pilot burner pipe until they are gastight.

- First tighten the thermocouple by hand and;

- Then tighten it a quarter turn using a suitable spanner;

- The pilot burner pipe must be protected against possible corrosive influences as a result of, for example, humidity, cement that has fallen down, dirt that has fallen down from the chimney, etc. The pilot burner pipe should remain permanently free from the ground and the walls of the room in which the appliance is built in. When installing in an existing fireplace, or if it is not possible to keep the pipes free, the pipe should be protected against corrosion by means of a jacket.

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

Connect the gas pipe to the gas tap.

Bleed the gas pipe.

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INSTALLATION MANUAL

Place the receiver in the holder (3); for connecting, see section 6.1.

Place the data plate in its intended clamp (6).

Fix the outer frame with door (4) to the inner frame using 2 socket cap screws (5).

!Tip

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

5.7 Flue gas discharge system in appliances with open combustion

For connection to an existing chimney without a discharge pipe or flexible 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.

5.7.1 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 built chimney, in accordance with the applicable national, local and constructional (installation) regulations.

5.7.2 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 during a longer period; 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.

!Tip

When the appliance is installed in a house with a mechanical air extraction system and/or an open kitchen with cooker hood, you will need a permanent ventilation hole near the appliance; for this application, please observe the gas installation regulations and the local instructions.

5.8 Flue gas discharge / combustion air supply system in appliances with closed combustion

5.8.1 General

The appliance's type of discharge system is stated in Appendix 2, Table 2. The appliance will be connected to a combined flue gas discharge / combustion air supply system, hereafter to be 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 5.8.4).

!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.

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INSTALLATION MANUAL

5.8.2 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 'Adjustment of the appliance' for the method of working.

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

- First, a concentric pipe of minimum length should be connected vertically to the appliance, according to Appendix 2, Table 4 or 5.

- 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. In that case, a 90° bend will be connected after the vertical part;

- 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. 4).

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

5.8.3 Placing the concentric system

!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;

- The rosette of the wall terminal is too small to seal the opening when passing through combustible material. That is why you should first apply a sufficiently large heat-resistant intermediate sheet to the wall. Then, the rosette is mounted on the intermediate sheet.

The roof terminal can end in a sloping and a flat roof. The roof terminal can be supplied with a glue plate for a flat roof or with a universally adaptable tile for a sloping roof.

!Caution

Some heat-resistant insulation materials contain volatile components that will spread an unpleasant smell during a longer period; these are not suitable.

Place the concentric system as follows:

Build the system up from (the flue spigot of) the appliance.

Connect the concentric pipe pieces and, if necessary, the bend(s).

On each connection, apply a clip binding with silicon sealing ring.

Use a self-tapping screw to fix the clip binding to the pipe on locations that cannot be reached after installation.

Apply sufficient wall brackets, so that the weight of the pipes does not rest on the appliance.

Attach the wall terminal from the outside by means of four screws.

Determine the remaining length for the wall or roof terminal and cut it to size, make sure the correct insertion length is maintained.

Place the wall terminal with the (groove/folded) seam at the top;

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INSTALLATION MANUAL

!Caution

- When using the wall terminal, place the terminal with a downward slope of 1 cm / metre towards the outside, in order to prevent rain water from raining in.

5.8.4 Connection to an existing chimney

It is possible to connect the appliance to an existing chimney. A flexible SS pipe is placed in the chimney with a fitting diameter at the flue gas discharge pipe, for the discharge of flue gas. The surrounding space is used to supply combustion air.

The following requirements apply when connecting to an existing chimney:

- only allowed when used in combination with the special DRU chimney kit. The installation regulation is also supplied;

- the internal dimensions should be at least 150 x 150 mm;

- the vertical length has a maximum of 12 metres;

- the total horizontal pipe length may have a maximum length that you can find in Appendix 2, Table 4;

- the existing chimney has to be clean;

- the existing chimney has to be tight.

For adjusting the appliance, the same conditions/instructions apply as for the concentric system described above.

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Dru Diablo G25.3, G20, Diablo G25, Diablo G20 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual