Dru 60 Triple BF G20 User manual

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Global 60 Triple BF
Installation manual (UK/IE)
DRU15798-233787-EN--0914-4
G20/G25(Natural gas) G31(Propane)
UK
959.048.02.UK

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
5.1.1 Reconstruction to different type of gas
5.2 Gas 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
5.7.1 General
5.7.2 Connection flue gas discharge system
5.8 Flue gas discharge / combustion air supply system in appliances with closed combustion
5.8.1 General
5.8.2 Construction of the concentric system
5.8.3 Placing the concentric system
5.8.4 Connection existing chimney
5.9 Additional instructions
5.9.1 Placing a suspended appliance
5.10 Glass panes
5.10.1 Removing the front glass pane
5.10.2 Removing the side glass pane
5.10.3 Placing the glass pane
5.11 Adjustment of the appliance
5.11.1 Restrictor slide
5.11.2 Air inlet guide
5.12 Placing the wood/pebble set
5.12.1 Wood set
5.12.2 Pebble set
6. Wireless remote control
6.1 Connecting the receiver
6.1.1 Connecting the receiver
6.1.2 Placing / replacing the receiver's batteries
6.2 Setting the communication code
7. Final inspection
7.1 Gastightness
7.2 Gas pressure/line-pressure
7.3 Ignition pilot and main burner
7.3.1 First ignition of the appliance after installation or adjustments
7.3.2 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® or the DRU Smartvent system®, you must carefully and fully read and use the
accompanying installation manual as well, prior to its installation.
The following symbols are used in the manual to indicate important information:
Ø 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
Global 60 Triple BF
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:
Ø You should only install and maintain the appliance if you are a certified and competent installer in the field of
gas-fired heating;
Ø Do not make any changes to the appliance;
Ø 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. When placing an appliance with open combustion (type B 11 AS/BS), no chimney breast ventilation is
required, as there is an existing chimney with a brickwork fireplace that is sufficiently able to absorb the heat;
- use heat-resistant electric connections and make sure that they do not make contact with the appliance;
Ø If you are installing an appliance with open combustion: please use a suitable flue gas discharge system provided
with the CE label, and make sure there is sufficient ventilation of the room where the appliance is installed,
according to legislation.
Ø if you are installing an appliance with a closed combustion: only use the concentric systems supplied by DRU;
Ø 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;
- make sure you observe the minimum distance in relation to the side wall(s) and the space above the
appliance (see Appendix 3, fig. 2).
Ø do not cover the appliance and/or do not wrap it in an insulation blanket or any other material;
Ø make sure that combustible objects and/or materials have a distance from the appliance of at least 500 mm
Ø only use the accompanying wood/pebble set and place it exactly as described;
Ø the space surrounding the pilot burner, 2nd thermocouple or ionisation pins must remain free;
Ø make sure there is no dirt in gas pipes and connections;
Ø place a gas tap in accordance with applicable regulations;
Ø prior to putting into operation, check the complete installation for gastightness;
Ø 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;
Ø do not ignite the appliance before the gas and discharge connections have been fully installed, first observe the
procedure described in chapter 7.3.
Ø 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.
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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 and/or if the
discharge system has insufficient thermal draught.
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 in the room where the appliance
is installed.
4. Removing the packaging
Note the following items when removing the packaging:
Ø Remove all packaging materials.
Ø Remove all supplied components in, on and/or at the appliance.
Ø Check the appliance and accessories for damages (during transport).
Ø If necessary, contact your supplier.
Ø Never install an appliance that is damaged !
Ø 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.
Ø Contact your supplier if you do not have all the parts after you finished removing the packaging.
Ø Dispose of packaging in accordance with local regulations.
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.
Ø Please install the appliance in accordance with the applicable national, local and constructional (installation)
regulations.
Ø 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.
5.1.1 Reconstruction to different type of gas
If you want to convert this appliance into a different type of gas, please contact DRU's service department and ask
what is possible. Reconstructions should only be performed by authorized gas installers.
5.2 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.
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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. Attach the appliance, if applicable, to the
wall using the wall brackets and/or fasten the extending 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.
Ø Provide a gas connection at the location. For details (see section 5.2).
Ø 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.
!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 DRU built in appliances are supplied with a control hatch. If not included in the delivery, this control hatch
is available separately. In case of appliances with closed combustion (type C11/C31) we always recommend using
the Dru control hatch. In case of appliances with open combustion (type B 11 AS/BS), a control hatch is not required.
In this section we assume an application with 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 55 °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:
Ø 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.
Ø Disconnect the gas control from the burner mounting plate by unscrewing the self-tapping screw.
Ø Carefully unwind the red and black wire of thermocouple 2, if applicable.
Ø 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 - Prevent dirt in gas pipes and connections;
- Avoid kinks in the pipes.
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!Caution - Make sure the ignition cable cannot come into contact with other wires;
- The data plate should remain attached to the chain.
Ø Set the height of the appliance using the adjustable feet (if applicable).
Ø 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.
!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, if available, exept in the case of B 11 AS/BS appliances. If you decide not to take this option, you
will have to make a 100 cm2ventilation hole that is placed as low as possible, for the benefit of the incoming
ventilation.
- the location of the ventilation holes (V) (outgoing);
- maintain a minimum 30 cm distance between the top of the ventilation hole (outgoing) and the ceiling of
the house.
- the measurements of the glass pane, so that it can be placed/removed after placing the chimney breast;
- the protection of the gas control and the pipes against cement and plaster.
- If possible, you should place decorative strips, frames, etc., after any required structural work has been
completed. Avoid the use of painter's tape. If this is not possible: please use good quality painter's tape and
remove it immediately after plastering or painting work has been completed.
!Tip You should preferably apply the ventilation holes (outgoing) on both sides of the chimney breast. You can use
DRU ventilation elements.
- Prior to completely closing the chimney breast, check whether the discharge / concentric system is placed
correctly.
- whether the channels, fixing brackets and possible clip bindings, which cannot be reached after installation,
are fastened by means of self-tapping screws.
Ø 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.
Ø 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.
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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 components belonging to the DRU Powervent system ®.
Place the control hatch as follows; see Appendix 3, fig. 3 for details:
Ø Make an opening in the chimney breast, as described in the manual for the control hatch.
Ø 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.
Ø Mount the gas control to the brackets of the inner frame (2).
Ø Check whether pipes and connections are free from dirt;
Ø 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.
Ø Prevent dirt in gas pipes and connections.
Ø Connect the gas pipe to the gas tap.
Ø Bleed the gas pipe.
Ø Place the receiver in the holder (3); for connecting, see section 6.1.
Ø Place the data plate in its intended clamp (6).
Ø 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. In this situation
we recommend using a stainless steel flexible discharge pipe over the complete length, with a draught increasing
hood.
5.7.1 General
The connection dimensions and the minimum length of the discharge system are indicated in Annex 2, table 2.
The appliance should be connected in accordance with the applicable national, local and constructional
(installation) regulations. You should only install the appliance in a well ventilated room which complies with the
applicable national, local and constructional (installation) regulations, in order to guarantee sufficient air supply.
!Caution - 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 in the room where the appliance is installed;
please observe the gas installation regulations and the local regulations for dimensions and other required
provisions.
- No ventilation of the chimney breast is required in case of an existing chimney with a masonry fireplace that
is sufficiently able to absorb the heat. Therefore the ventilation hole in the chimney breast does not apply to
the class 1 chimney in the UK.
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5.7.2 Connection of flue gas discharge system (if a class 1 chimney is not applicable)
For connection to an existing chimney, a flexible stainless steel discharge pipe is required over the complete
length for the discharge of the flue gases, unless indicated otherwise. A draught increasing hood is recommended
here.
!Caution - Prevent dirt from an existing chimney from entering the flue gas discharge.
- Prevent false draught by carefully closing the space between the existing chimney and the discharge
material.
- Bends of more than 45 degrees are not allowed in the flue gas discharge system, unless indicated otherwise.
- 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:
Ø Connect the pipe pieces or flexible SS discharge.
!Caution - Make sure that the right insertion length is maintained.
- Secure the connections on locations that are impossible to reach after installation by means of self-tapping
screws.
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.
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:
- In appendix 2, table 4 or 5 you can find whether a concentric pipe should be connected and what the
minimum vertical length would have to be.
- Determine the permissibility of the required discharge.
When using a wall terminal, the following applies:
- The total vertical pipe length, when using a wall terminal, may have a maximum length that you can find in
Appendix 2, Table 4.
- The minimum vertical pipe length, when using a wall terminal, can be found in appendix 2, table 4.
- The total horizontal pipe length, when using a wall terminal, may have a maximum length that you can find
in Appendix 2, Table 4 (without wall terminal; see Appendix 3, fig. 4).
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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:
Ø Build the system up from (the flue spigot of) the appliance.
Ø Connect the concentric pipe pieces and, if necessary, the bend(s).
Ø On each connection, apply a clip binding with silicon sealing ring.
Ø Use a self-tapping screw to fix the clip binding to the pipe on locations that cannot be reached after installation.
Ø Apply sufficient wall brackets, so that the weight of the pipes does not rest on the appliance.
Ø Attach the wall terminal from the outside by means of four screws.
Ø Determine the remaining length for the wall or roof terminal and cut it to size, make sure the correct insertion
length is maintained.
Ø Place the wall terminal with the (groove/folded) seam at the top;
!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.
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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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5.9 Additional instructions
The construction frame of this appliance cannot be adjusted.
Ø Attach the appliance to the wall by means of wall brackets (B) (see appendix 3, fig. 1).
!Tip Extension legs are available for this appliance.
5.9.1 Placing a suspended appliance.
This appliance is suitable for being suspended from a wall;
Ø Determine the location and height of the appliance (see appendix 3, fig. 1a and 1b).
Ø Attach the building wall bracket (C) to the wall, using the key bolts supplied.
Caution! Attach the appliance to a vertical wall of solid, non combustible and heat-resistant material.
Ø Use the key holes of the building wall brackets to level the appliance.
Ø Unscrew the 2 adjustable feet with lock nuts from the bottom of the appliance and place them at the back of the
appliance (A).
Caution! Make sure the appliance is not resting on the gas control.
Ø Place the appliance in the building wall bracket. The appliance wall bracket (B) will catch inside the building wall
bracket (C).
Ø Use the adjustable feet (A) to level the appliance vertically and secure them with the nut.
Caution! For a correct placement of the gas control and other components to be placed, DRU recommends the separately
available control hatch (also see chapters 5.4 to 5.6).
5.10. Glass panes
After placing the wood set you can place the glass pane as described below.
!Caution - Avoid damaging the glass pane during removal/placement;
- Use the socket spanner supplied for loosening/tightening the self-tapping screws;
- Avoid/remove fingerprints on the glass panes, as they will burn into the glass.
5.10.1 Removing the front glass pane
When removing the front glass pane, you should follow the instructions below (see appendix 3, fig. 5 to 8):
Ø Unscrew the self-tapping screw from the standing decorative strip (A) and remove the decorative strip.
Repeat this on the other side;
Ø Slide the lower decorative strip (B) towards the front.
Ø Remove the lower decorative strip;
!Caution The lower decorative strip is kept in place by 2 hooks. Keep this in mind when removing the lower decorative strip.
Ø Unscrew the 3 self-tapping screws of the bottom pane clamp (C) from the frame and remove the bottom pane
clamp;
!Caution At the following action, you must hold the glass window in order to prevent it from falling forwards.
Ø Unscrew the 2 upper self-tapping screws from the frame and remove the upper pane clamp strip (D);
Ø Grab the glass pane at both sides.
Ø Slightly tilt the top of the glass pane towards you.
Ø Remove the glass pane;
5.10.2 Removing the side glass pane
The side glass panes should be removed in case of torn or broken panes.
Ø Remove the front glass pane; see section 5.10.1 above.
Ø Remove the self-tapping screws from the lower and rear clamp strip using the supplied socket spanner.
!Caution At the following action, you must hold the side glass pane in order to prevent it from falling forwards.
Ø Unscrew the self-tapping screw from the upper pane clamp strip and remove the upper glass strip.
Ø Slide the glass pane towards the side (you are now located at the side of the appliance).
Ø Slightly tilt the top of the glass pane towards you and remove the glass pane.
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5.10.3 Placing the glass pane
Placing the glass pane will take place in reverse order of removing the glass pane, as described above.
!Caution - Avoid/remove fingerprints on the glass pane, as they will burn into the glass;
- The self-tapping screws should not be over-tightened, since otherwise they could break or strip the thread:
tight = tight;
- Place the glass pane with the logo at the bottom right.
!Caution Make sure the front glass pane fully connects with the side pane (there should be no opening between the side
and front pane).
If the front and side pane do not fully connect;
Ø Loosen the self-tapping screws in the side pane's clamp strips by a few turns.
Ø Slide the side pane tightly against the front pane.
!Caution Make sure there is no sealing tape between the front and side pane (on the location where the two panes
connect).
Ø Tighten the self-tapping screws of the clamp strips.
5.11 Setting the appliance
The appliance has to be set in such a way that it works correctly in combination with the used concentric system.
For that purpose, a restrictor slide is placed and/or the air inlet guide is removed. The conditions for using a wall
terminal and roof terminal can be found in appendix 2, tables 4, 5 and 6.
This appliance is suitable for PowerVent®. For more information, see the PowerVent® installation manual.
5.11.1 Restrictor slide (R)
The restrictor slide (R) is supplied separately. It is mounted as follows (see appendix 3, fig. 9):
Ø Unscrew the 2 already placed self-tapping screws (U) from the combustion chamber.
Ø Install the restrictor slide (R). It partly covers the hole of the exhaust pipe.
Ø At the same time, tighten the 2 self-tapping screws (U) by a few turns, but not yet fully tight;
!Caution When mounting, the arrow on the restrictor slide should point away from you (see appendix 3, fig. 9).
Ø Adjust the position of the restrictor slide (R) using situations B to D in appendix 2, table 6. The letter of the position
on the restrictor slide corresponds with the letter of the situation in table 6;
Ø Make sure that the point of the triangle belonging to the position that you want and the centre of the self-tapping
screw are exactly aligned;
Ø Tighten the 2 self-tapping screws (U).
5.11.2 Air inlet guide (L)
The air inlet guide (L) is located at the back of the combustion chamber, under the plate (M).
If you want to remove it, proceed as follows (see appendix 3, fig. 10):
Ø Unscrew the self-tapping screws from the plate (M) and remove the plate from the combustion chamber.
Ø Loosen the 2 self-tapping screws (N) of the air inlet guide (L) and remove the air inlet guide;
!Caution Then, re-tighten the 2 self-tapping screws (N) of the air inlet guide in the combustion chamber;
Ø Place the plate (M) back in the combustion chamber.
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5.12 Placing the wood or pebble set
The appliance is supplied with a wood set or a pebble set.
!Caution Strictly observe the following instructions to prevent unsafe situations:
Ø only ever use the supplied wood or pebble set;
Ø place the wood and pebble set exactly as described;
Ø make sure the pilot burner and the surrounding space remain free (see appendix 3, fig. 11);
Ø make sure thermocouple 2 and the surrounding space remain free (see appendix 3, fig. 12.
Ø In case of a wood set, keep the air openings between the burner and the vermiculite tray completely free.
5.12.1 Wood set
The wood set consists of chips (see appendix 3, fig. 13) and a number of logs.
Ø Identify logs A to D using appendix 3, fig. 14.
!Tip Use the burn stains on the logs for identification.
Ø Place log A behind the (main) burner against the position bracket and distribute the chips (see appendix 3, fig. 15).
Ø Place log B on the position bracket. Log B makes contact with both the protruding edge of the hood around the
pilot flame and log A (see appendix 3, fig. 16);
Ø Place log C, it rests on log B.
Ø Place log D on the position bracket. The point of log D makes contact with log A (see appendix 3, fig. 17);
!Caution The logs should not completely cover the burner deck, because
- The main burner will not ignite properly; which could result in unsafe situations;
- Appliance will become filthy more quickly, as a result of soot;
- The flame picture will be affected.
Ø If applicable and required, distribute the glow material over the burner(s).
!Caution Fasten the glow material under chips and/or wood set.
5.12.2 Pebble set
The pebble set consists of white carrera pebbles.
Ø Remove the 3 position brackets (P) by unscrewing the self-tapping screws (O). It is not necessary to place the
self-tapping screws back (see appendix 3, fig. 18);
Ø Fill the burner and the vermiculite tray with carrera pebbles.
Ø Spread the carrera pebbles evenly over one layer (see appendix 3, fig. 19).
!Caution Incorrect placement of the pebbles, e.g. on top of each other, could have the following consequences:
- the main burner will not ignite properly, which could result in unsafe situations;
- the flame picture will be affected.
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6. Control
The appliance is supplied with a wireless remote control.
Controlling the flame height, igniting and switching off take place through a remote control controlling a receiver.
Chapter 4, Wireless remote control, in the User Manual describes the operation of the appliance and how you
should use the remote control.
!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;
Below, we will describe how the receiver is connected.
6.1 Connecting the receiver
Your appliance is equipped with an electronic ignition through the remote control.
The receiver should be connected to the appliance, before the batteries are installed.
Ø Connect the receiver according to Appendix 3, fig. 38.
Ø Bend the antenna (N) out of the clips and place it erect (Appendix 3, fig. 39).
!Tip - The plugs have different sizes that correspond with the connectors.
- The size of the eye corresponds with the size of the screw;
- The colours of eye and screw correspond as well.
- Place the batteries as described below in section 6.1.1.
!Caution - Do not place the ignition cable over and/or along metal, stone or concrete parts: this will weaken the spark.
Make sure the cable is hanging freely.
- Make sure that the wires of thermocouple 2 cannot come into contact with hot parts
- Keep the ignition cable at least 10 cm away from the antenna, in order to avoid damaging the receiver.
- Avoid formation of dust on or in the receiver: cover it when performing work.
- Place the receiver in its intended holder under the appliance or in the control hatch according to Appendix 3,
fig. 39.
- If you want to use an adapter, only an adapter supplied by DRU will guarantee a proper operation of the
receiver.
6.1.1 Placing / replacing the receiver's batteries
Follow the procedure below when placing the batteries:
Ø Pick up the receiver and slide off the cover.
Ø Place or remove the 4 penlite (AA type) batteries.
!Caution - Observe the "+" and "-" poles of the batteries and the receiver;
- Use alkaline batteries; rechargable batteries are not allowed.
- Batteries are regarded as "small chemical waste" and may therefore not be disposed with the household
rubbish.
Ø Slide back the cover.
Ø Place back the receiver.
6.2 Setting the communication code
Prior to putting the application into operation, a communication code must be set between the remote control
and the receiver. If the receiver or the remote control are replaced, a new code will have to be set.
Follow the procedure described below:
Ø If necessary, place the batteries in the receiver's battery holder; see section 6.1.1.
Ø If necessary, place the 9V block battery in the remote controle; see User Manual.
Ø Hold down the reset button on the receiver, until you hear two consecutive sound signals
(see Appendix 3, fig. 40).
Ø After the second, longer signal, let go of the reset button.
Ø Press the 'small flame' button on the remote control for 20 seconds, until you hear two short
sound signals: this is the confirmation of a good communication.
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6.3 Alternative operation
Appliances made with an electronic ignition and radio remote control can be connected to an alternative external
control system (e.g. Domotics). For this purpose, there are 4 connection points at the side of the receiver (see
Appendix 3, fig. 44). For connecting an external control unit, you will need a “Domotics connection cable for
GV60”. Consult DRU's service website.
The following contacts are possible:
- Ignition: connect both contacts 1 + 3, for one second (if there is a 2nd thermocouple, the appliance should
burn at full power for at least 20 sec. before the required position can be chosen).
- Flame high(er): briefly close contact 1 once per step, or 12 seconds for the highest position.
- Flame low(er) until switch-off (pilot flame remains on): briefly close contact 3 once per step, or 12 seconds for
the lowest position.
- Completely switching off the appliance (pilot flame included): close all three contacts 1 + 2 + 3, for one
second.
The appliance will always continue to respond to the radio remote control supplied with it. The external control
system is able to use one of the two modes of this remote control.
1. Manual mode
This mode of the remote control is passive and will not take any action unless it is operated. The external control
system is able to control the functions for high/low position, ignition and switching off.
!Tip If the external control system has an intelligent clock function and/or thermostat function, the remote control
supplied with the appliance should have the manual mode in order to prevent interruption of these functions.
2. Clock/thermostat mode
This mode of the remote control is active and will be responsible for the clock function and thermostat function.
The external control system is able to control the functions for high/low position, ignition and switching off.
!Tip - If the appliance is switched off (the pilot flame included) manually or by one of the safeguards, ignition of the
appliance will be blocked for a period of 3 minutes for reasons of safety.
- If it is no longer possible to operate the appliance with the external control system, you must switch it off and
then switch it on again with the supplied remote control.
7. Final inspection
In order to check whether the appliance is working properly and safely, you must perform the following
inspections before the appliance is used.
7.1 Gastightness
!Caution All connections must be gastight. Check the connections for gastightness.
The gas control can be subjected to a maximum pressure of 50 mbar.
7.2 Gas pressure/line-pressure
The burner pressure is set at the factory; see data plate.
!Caution The line-pressure in house installations must be checked, because it can be wrong.
Ø Check the line-pressure; see Appendix 3, fig. 41 for the measuring nipple on the gas control.
Ø Contact the gas company if the line-pressure is not correct.
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7.3 Ignition pilot and main burner
For igniting the pilot and main burner, see the User Manual, chapter 4, section 4.2, Remote control.
7.3.1 First ignition of the appliance after installation or adjustments
!Caution After installation, or after work has been performed, you should ignite the appliance for the first time without the
glass window. If necessary, bleed the gas pipe.
Follow the procedure described below:
Ø If required, remove the glass window;
Ø Start the ignition procedure according to chapter 4 in the User Manual;
Ø If the pilot flame does not ignite:
- repeat the ignition procedure until the pilot burner ignites;
- consult the malfunction search diagram (Appendix 1) if this does not happen after a few attempts;
Ø After igniting the pilot flame, the main burner will ignite during the ignition procedure;
Ø Check whether the main burner continues to burn;
Ø If the main burner does not continue to burn:
- repeat the ignition procedure until the main burner continues to burn
- consult the malfunction search diagram (Appendix 1) if this does not happen after a few attempts;
Ø Switch off the appliance;
Ø Then mount the glass window as described in chapter 5.10;
Ø Repeat the ignition procedure a few times and perform the checks described in chapter 7.3.2;
Ø From now on, the pilot flame should ignite smoothly.
!Tip When checking whether the main burner continues to burn, it is possible that it still switches off after 22 seconds.
This happens because the appliance is equipped with a second thermocouple and the glass window has not been
placed. In this case you may presume that the main burner will continue to burn.
!Caution - During the ignition process, you are not allowed to operate control button B on the gas control manually.
- Always wait 5 minutes after the pilot flame has gone out, before you re-ignite the appliance.
- You are not allowed to turn the pilot flame lower by using the settings on the gas control.
7.3.2 Main burner
!Caution - The pilot burner should ignite the main burner within a couple of seconds, and without popping.
- The main burner(s) must cross the full burner smoothly and without popping and continue to burn.
Ø Check operation of the main burner from a cold condition (pilot flame off):
Ø After opening the gas valve, the main burner should burn within a few seconds.
!Tip When the gas valve is opened, the motor will start to run; this is audible.
The flame picture and a good flame transfer can only be properly judged if the glass window is installed.
Use the malfunction search diagram (Appendix 1) if the ignition of the main burner does not comply with the
abovementioned requirements.
7.4 Flame picture
The flame picture can only really be assessed when the appliance has been burning for several hours. Volatile
components from paint, materials, etc., which evaporate in the first hours, will affect the flame picture.
!Caution If the chimney breast has been made of stone-like materials or has a plaster finish, the appliance may only be put
into operation 6 weeks after the chimney breast has been placed, in order to prevent shrinkage cracks.
Ø Check whether the flame picture is acceptable.
Ø Consult the malfunction search diagram (Appendix 1) if the flame picture is not acceptable.
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8. Maintenance
The appliance must be inspected once per year by a skilled installer in the field of gas-fired heating, and repaired if
necessary.
Check at least whether the appliance is working properly and safely.
!Caution - Always close the gas tap during maintenance work;
- Check the gastightness after repair;
- After replacing thermocouple 1 you should first tighten the gland nut by hand and then give it another
quarter turn with a suitable spanner;
- You are not allowed to turn the pilot flame lower by using the settings on the gas control.
Ø If required, clean the following components:
- the pilot burner (malfunction search diagram, Appendix 1);
- the space surrounding the pilot burner;
- the glass pane(s).
!Caution - Remove/place the glass pane(s) as described in section 5.10;
- Remove the deposit on the inside of the glass pane(s) with a damp cloth or a non-abrasive detergent such as
copper polish or a ceramic hot plate cleaner;
- Avoid/remove fingerprints on the glass pane(s), since otherwise they will burn into the surface;
- Replace a broken and/or cracked glass pane(s) as described in section 5.10.
!Caution If necessary, replace the wood or pebble set correctly; for this, see section 5.12.
Ø Inspect the flue gas discharge system.
!Caution You must always perform a final inspection.
Ø Perform the inspection as described in chapter 7.
8.1 Parts
Parts requiring replacement can be obtained from your supplier.
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9. Delivery
You must explain to the user how to operate the appliance. You must give him/her instructions on putting it in
operation, the safety measures, the operation of the remote control and annual maintenance (see the User
Manual).
!Caution - Tell the user to close the gas tap immediately and contact the installer in case of malfunctions/poor
operation. This to prevent unsafe situations;
- Indicate the location of the gas tap;
- Point out the precautions in the user manual against unintended ignition by other wireless remote controls
such as car keys and garage door openers.
Ø Instruct the user about the appliance and the remote control.
Ø When the appliance is started for the first time, point out that
- In order to avoid cracks in a chimney breast made of stone-like materials or finished with plaster, it should
dry for at least 6 weeks prior to putting the appliance into operation.
- When the appliance is stoked up for the first time, volatile components evaporate from paint, materials, etc.
(First read chapter 3 of the User Manual as well !);
- When evaporating, the appliance should preferably be set to the highest level;
- The room should be well ventilated.
Ø Give the manuals to the user (all manuals should be stored near the appliance).
10. Malfunctions
In Appendix 1 you will find an overview of malfunctions that might occur, the possible causes and the remedies.
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Start
2.01 Can pilot be lit?
2.03 Only one spark?
2.02 Sparking? 2.09 Ignition procedure
- Oval knob on gas control is
on "MAN". Set to "ON" and
restart.
Retarded ignition of main
burner(s)
Gas to main burner opens ca. 3-5
seconds after servo motor,
operating the gas valve, starts
running (sound of motor!). After
this the main burner is to ignite (at
least partially) within 10 seconds
and not with a firm noise WHOOF.
If not: no or delayed cross lighting
of main burner.
Hazardous situation.
Stop ignition procedure straight
away and first check for:
- Position of logs or pebbles.
- Burner holes (locally)
blocked.
Remove vermiculite dust.
- Vermiculite missing.
- Chips on burner.
- Vermiculite not distributed
evenly across burner(s).
PowerVent® (if present)
Burner does not light. Consult
PowerVent® installation manual
how to carry out the checks below.
Check:
- 230 V to fan controller unit
and fan.
- Silicon pressure
measurement hoses:
- swapped;
- leaking or barred.
- Pressure difference set too
high.
- Resistance of flue system too
high:
- adjustment (of appliance
damper and air inlet guides);
- flue length or number of
bends too large;
- dirty (e.g. cobwebs).
- Operation of the fan.
- Operation of solenoid gas
valve.
- Operation of fan controller
unit.
- Operation of pressure
measurement gauge.
2.11 No proper cross lighting
of main burner(s).
Go to box 2.09 and take
actions act as described for
'retarded ignition of main
burner'.
2.06 Pilot can be lit.
Does it stay alight?
2.10 Do(es) main burner(s)
ignite smoothly and across
its/their full length after first
ignition by pilot burner?
2.08 Does main burner ignite
immediately?
2.04 Check:
Receiver
- Replace missing, weak or
rechargeable batteries (not
enough power to open
thermoelectric valve).
Presence of gas on pilot burner
Check pilot on presence of gas at
normal ignition cycle or in Manual
Mode (turn oval knob on gas control
to MAN and keep safety shut off
valve opened with a screwdriver) and
ignite pilot with a lighter.
- Pilot flame not on: Step 1.
- Pilot flame on: Step 2.
Step 1: Pilot has no gas
Check:
- Gas tap open?
- Gas at gas control (line
pressure at measuring point on
gas control).
- Gas flowing out of gas control?
(by loosening pilot tube at gas
control).
If not: check adjustment screw
pilot flame (under black cover):
sealing not to be broken.
Sealing broken: screw should
be fully open.
- Blocking of pilot tube (kink or
dirt).
- If this does not help: replace
gas control.
Step 2: Pilot has gas, but no
ignition
- Electrode with 90° bended tip:
bend tip 1 mm higher.
- Spark too weak (thin and
reddish).
Act as if 'no spark' in box 2.05
and perform actions described
for ignition cable and ignition
electrode.
- Pilot flame too weak (dirty).
Remove injector (remove
gland nut and the pilot tube).
See that it does not fall away.
Clean with compressed air.
Rectify. Retry.
2.05 Check:
Ignition cable
- Present and connected.
- Being free from metal parts or
concrete.
- Too long: cut away all
excessive length at receiver
end, and reconnect.
- Shorting out to earth: replace
ignition cable.
- Spark in wrong position:
- slide rubber sleeve on
ignition cable over ceramic of
electrode.
- Replace electrode if
neccessary.
Ignition electrode
-Straight electrode:
- oxidation (roughen electrode
with file or sand paper);
- position (4 mm from pilot
burner).
- Cracks in ceramic (not always
visible): replace electrode.
Starting procedure
After switching off/going out the
remote is locked for 120 sec. (older
versions 60 sec).
Wait 2 minutes before reigniting.
2.07
Pilot out when servomotor starts
to run? Check the thermocouple
system.
- Measure thermocouple
voltage in mV just after
servomotor starts to run and
the voltage goes down.
- Measure between red dot on
receiver and earth point on
gas control (fig. 42).
- 0 mV
- 2-3 mV
- 3-5 mV
- 6 mV and higher
- Requirement: after
rectification actions
thermocouple voltage should
be 6 mV at least, just after
motor starts running!
Voltage 0 mV
- Thermocouple defective.
Check by replacing or
measuring voltage at end
whilst heating (tip: with a
lighter).
- Short circuiting or
interruptions in circuit:
Check:
- thermocouple tight in
interruptor;
- interruptor tight in gas
control;
- black wires (yellow/red end)
connected to interruptor +
receiver;
- interruptor (mount
thermocouple directly in gas
control and ignite in Manual
Mode (see 2.04).
If pilot stays on: interruptor
defective.
Voltage 2-3 mV
- Check pilot flame.
Too small:
- pilot dirty.
Clean up (see 2.04).
- check for pilot gas tube
tightness;
- pilot tube kinks or dirt inside;
- line pressure too low.
- Tip: thermo couple not in
(correct!) pilot flame.
Bend into flame.
Voltage 3-5 mV
- Appliance may work, but is
too critical.
Perform actions as described
for 2-3 mV.
Voltage 6 mV and higher
Voltage OK, so different cause.
- Receiver defective. Check by
dismounting black-red and
yellow control cables from
receiver and link together.
Ignite fire in Manual Mode
(see 2.04). Pilot stays on:
receiver defective.
- Gas control defective if
receiver is not defective.
Replace gas control.
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no
no
no
no no
Fires with electronic ignition, fault finding: Ignition and burning
Appendix 1 diagnosis of malfunctions
GBUK
2.03a
- Loosen and retighten
earthing screw on gas
control.
- If this does not work:
replace receiver.
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yes