Dru Excellence 50xt rch User manual

English

Store this document in a safe placeExcellence 50XT RCH

Installation manual (UK/IE)

DRU-186541-EN-US-0715-6

G20/G25/G25.3 Natural gas

959.045.05.UK

English

INSTALLATION MANUAL1. Introduction2. CE declaration3. SAFETY3.1 General3.2 Regulations3.3 Precautions / safety instructions at installation3.4 Principle of ignition cycle4. Removing the packaging5. Installation5.1 Type of gas5.1.1 Reconstruction to different type of gas5.2 Gas connection5.3 Electric connection5.4 Placing the appliance5.5 Placing a built-in appliance5.6 Placing the chimney breast5.7 Placing the control hatch5.8 Flue gas discharge system appliances open combustion5.9 Flue gas discharge / combustion air supply system appliances closed combustion5.10 Additional instructions5.11 Glass panes5.12 Setting the appliance5.13 Placing the wood set6. Control6.1 Remote controls6.2 Alternative controls7. Final inspection7.1 Gastightness7.2 Gas pressure/line-pressure7.3 Ignition main burner7.4 Flame picture8. Maintenance8.1 Parts9. Delivery10. Malfunctions Appendix 1 MalfunctionsAppendix 2 Various tablesAppendix 3 FiguresContents

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INSTALLATION MANUAL1. Introduction

DRU, a manufacturer of gas-fired heating appliances, develops and produces products that comply with thehighest possible quality, performance and safety requirements. This appliance has a CE label, which means that itcomplies with the essential requirements of the European Gas Appliance Directive. The appliance is supplied withan installation manual and a user manual. As an installer, you must be certified and competent in the field ofgas-fired heating and electricity. The installation manual will give you the information you need to install theappliance 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. Inaddition, you will find technical data for the appliance and information on maintenance, any malfunctions thatmight occur and their possible causes.The figures can be found at the back of this booklet, in the appendix.Please, read and use this installation manual carefully and completely, prior to installing this appliance. If you usethe DRU Powervent system® or the DRU Smartvent system®, you must carefully and fully read and use theaccompanying installation manual as well, prior to its installation.The following symbols are used in the manuals to indicate important information:

Work to be performed

!Tip

Suggestions and recommendations

!Caution

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

!Caution

You need these instructions to prevent fire, personal injury or other serious damages.After delivery, you should give the manuals to the user.

2. CE declaration

We hereby declare that the design and construction of DRU's gas-fired heating appliance comply with theessential requirements of the Gas Appliance Directive.Internal precautions at the company will guarantee that appliances produced in series comply with the essentialrequirements of the EC directives in force and the standards derived from them. This declaration will lose itsvalidity 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. GeltenGeneral managerPostbus 1021, 6920 BA DuivenRatio 8, 6921 RW Duivenwww.dru.nl

Product:Type:EEC directives:Standards:gas-fired heating applianceExcellence 50XT RCH2009/142/EC; 2006/95/EC; 2004/108/ECNEN-EN-613; NEN-EN-613/A1; EN60335-2-102UK

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INSTALLATION MANUAL3. SAFETY

3.1 General

!Caution

•Please observe the general regulations and the precautions/safety instructions in this manual.•First check the exact technical version of the appliance to be installed in Appendix 2, Table 2.

3.2 Regulations

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

3.3 Precautions / safety instructions at installation

Carefully observe the following precautions/safety regulations:

You should only install and maintain the appliance if you are a certified and competent installer in the field ofgas-fired heating and electricity;

do not make any changes to the appliance;

if you are installing an appliance that must be built in;•use non combustible and heat-resistant materials for the chimney breast, including the top of the chimneybreast, the material in the chimney breast and the back wall against which the appliance will be placed.For this you can use both sheet material and stone-like materials;•take sufficient measures to prevent temperature of a wall behind the chimney breast becoming too high,including the materials and/or objects behind the wall;•comply with the minimum required internal sizes of the chimney breast;•vent the chimney breast by means of ventilation holes with a combined passage as stated further down inthe text;•use heat-resistant electrical wiring;•place heat-resistant electrical wiring away from the appliance and as low as possible in the chimney breast.This has to do with the temperature development in the chimney breast.

if you are installing an appliance type B11 with open combustion: please use a suitable flue gas discharge systemthat is provided with the CE label;

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

if you are installing a free-standing appliance: place the appliance away from the back wall by the minimumdistance stated further down in the text;

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

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

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

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

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

place a gas tap in accordance with applicable regulations;

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

if your appliance is provided with explosion hatches on its top and/or bottom, you must make sure that theycannot be blocked and check whether they fit well onto the sealing surface, prior to building in the appliance;

do not ignite the appliance before the gas, discharge and electric connections have been fully installed, firstobserve the procedure described in chapter 7.3;

replace broken or torn glass panes.

!Caution

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

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INSTALLATION MANUAL3.4 Principle of ignition cycle

Below you will find a brief description of how this appliance is ignited.The appliance is off and will be switched on by means of the remote control. The receiver will get the signal tostart the ignition process. This signal is passed on to the burner device, after which, if applicable, the relay for thePowervent System® is switched. After an 8 second interval, the ignition on the spark electrodes will start. If noPowervent System® is connected, only the relay will switch and the ignition will start immediately.The main burner will be ignited at 50% of its capacity.This will prevent a larger amount of gas in the combustion chamber, if no ignition takes place. When the gasignites, ionization will have to be detected. In order to make sure the flame has passed over, this will take place atthe other side of the burner. When ionization is detected, the gas control will modulate to 100%.If applicable, the second valve is switched (you will be able to hear a 'click') in order to ignite the second burner.After ignition of the second burner, the appliance will always go to the full position (full capacity).This will guarantee that the second burner will actually ignite.The second burner can be switched on and off manually, by means of the remote control.In case of switching on manually, the appliance will first return to full load.

!Caution

The appliance's control unit is characterized by its stringent safety requirements. It is possible that the burningappliance switches off automatically and then switches back on again. This is not a failure, but a check. Themoment the appliance's control unit is connected to mains voltage, the control unit will perform this check every24 hours. If the appliance is burning at that time, the appliance will extinguish and then start again immediately. Ifyou wish to prevent this, you can remove the plug and insert it again at a time during the 24 hours when theappliance is never or hardly ever burning.

4. Removing the packaging

Note the following items when removing the packaging:

Remove all packaging materials.

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

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

If necessary, contact your supplier.

Never install if an appliance is damaged!

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

!Caution

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

!Caution

Keep plastic bags away from children.In Appendix 2, Table 1 you can see which parts you should have after removing the packaging.

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

Packaging must be disposed of in accordance with the regulations.

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INSTALLATION MANUAL5. Installation

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

!Caution

Install the appliance in the order described in this chapter.

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

Observe the regulations/instruction in this manual.

5.1 Type of gas

The data plate indicates for which type of gas, gas pressure and for which country this appliance is intended.The data plate can be found on the appliance or can be attached to a chain to which it should remain attached.

!Caution

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

5.1.1 Reconstruction to different type of gas

If you want to convert this appliance into a different type of gas, please contact DRU's service department and askwhat is possible. Reconstructions should only be performed by authorized gas installers.

5.2 Gas connection

Place a gas tap in the gas pipe in accordance with the applicable regulations.The gas connection on the gas control is located next to the receiver (see G Appendix 3, fig. 38).

!Caution

Make sure there is no dirt in gas pipes and connections;The following requirements apply to the gas connection:•use a gas pipe with the correct dimensions, so that no pressure loss can occur;•the gas tap must be approved (in the EU this will be the CE mark);•you should always be able to reach the gas tap.

5.3 Electric connection

In case of a 230 Volt electrical connection, provide proper grounding, if applicable. Place this electrical connectionaway from the appliance, as low as possible in the chimney breast. This has to do with the temperaturedevelopment in the chimney breast. If possible, place the receiver after any building work has been completed. Ifthis is not possible:

!Caution

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

5.3.1 Connecting the switch contact (if applicable)

It is possible to operate one or more lamps (in case of several lamps, a maximum of 8A/250VAC/30VDC) via theremote control of the appliance. You could think of the lamps of Dru's lux elements. For this, you can use switchcontact B on the receiver (see appendix 3, fig 36). The switch contact is not polar sensitive.

5.3.2 Connecting the Dru Omivent (if applicable)

If the appliance is equipped with a Dru Lux Omnivent system, it can be operated with the remote control andconnected (see appendix 3, fig 36, (C)). The supply to this connection is equal to the mains voltage.

5.4 Placing the appliance

!Caution

•Always place the appliance with a minimum distance of 500 mm from combustible objects or materials;•Place the discharge pipes in such a way that situations with risk of fire can never occur;•Always place the appliance in front of a wall of non combustible and heat-resistant material;•Always maintain a minimum distance between appliance and back wall, if indicated in the dimensionaldrawing (see Appendix 3, Fig. 2);•Take sufficient measures to prevent temperature of a wall behind the chimney breast becoming too high,including the materials and/or objects behind the wall;•Do not cover the appliance and/or do not wrap it in an insulation blanket or any other material;•Make sure that the appliance to be installed has a stable position. If applicable, this could be done by fixingthe extension legs with self-tapping screws.

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INSTALLATION MANUAL!Caution

When installing an appliance that has to be built in, take the following into account;•The minimum construction measurements according to Appendix 3, Fig. 1 and 2;•The construction height of the appliance, which you can determine yourself.

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

Make a passage for the flue gas discharge system or the concentric system with the following diameters; fordetails, see section 5.8 or 5.9:•the pipe diameter +10 mm for a passage through non combustible material;•the pipe diameter +100 mm for a passage through combustible material;

!Caution

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

5.5 Placing a built-in appliance (if applicable)

Not all built in DRU appliances are supplied with a control hatch.

!Caution

Built in appliances must be installed with the DRU control hatch. This is necessary to ensure a durable, safe andproper operation. The DRU control hatch can be ordered separately. Exceptions are:•B11 AS/BS appliances (open appliances).•Appliances with supplied DRU guard cabinet. The DRU guard cabinet is intended for installation with asuspended platform. If the appliance will be connected to the DRU PowerVent system, the DRU control hatchhas to be used after all.The gas control is mounted to the appliance. It must be taken out and placed in the control hatch at a later time.For placing the gas control in the control hatch, see section 5.7.Proceed as follows:

Remove the bracket with, amongst other things, the gas control from the appliance by unscrewing theself-tapping screws.

Place the bracket to which, amongst other things, the gas control is mounted, together with the wiring of theignition/ionization cable(s), the flexible gas hose(s) and the data plate with chain in the direction of the controlhatch.

!Caution

•Make sure there is no dirt in gas pipes and connections;•Avoid kinks in the pipes.

!Caution

•Make sure the ignition cables cannot come into contact with other wires;•The data plate should remain connected to the chain.

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

Make the appliance level at the same time.

!Tip

The construction frame for most 2 or 3 sided appliances can be adjusted. This will allow you to connect theconstruction frame to the chimney breast correctly. For 2 or 3 sided appliances that cannot be adjusted, we wouldlike to refer you to chapter 5.10 'Additional instructions'.

!Caution

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

5.6 Placing the chimney breast (if applicable)

In order to provide proper heat discharge, there should be sufficient space around the appliance.The chimney breast should be ventilated sufficiently by means of ventilation holes (incoming and outgoing).

!Caution

•When installing an appliance with mantelpiece, specific dimensions may apply for the opening in thechimney breast.•When an appliance is built in the floor, please take into account the minimum distances from a combustiblefloor.If this applies to your situation, you'll find more information in chapter 5.10 'Additional instructions'.

!Caution

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

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INSTALLATION MANUAL

breast, the material in the chimney breast and the back wall of the chimney breast.•The appliance is not a support structure. Make sure the appliance does not have to bear the weight of thechimney breast for example.•The passage of the ventilation holes (outgoing), which are placed as high as possible, is stated in Appendix 2,Table 2.

!Caution

When placing the chimney breast, you should take the following into account (see Appendix 3, Fig. 2):•The location for the control hatch: this must be placed as low as possible.•The dimensions of the control hatch; see Placing the control hatch section 5.7.•The 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 thehouse.•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 beencompleted. Avoid the use of painter's tape. If this is not possible: please use good quality painter's tape andremove 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 useDRU ventilation elements.Prior to completely closing the chimney breast, check:•whether the discharge / concentric system is placed correctly;•whether the channels, fixing brackets and possible clip bindings, which cannot be reached after installation,are fastened by means of self-tapping screws.

If applicable, do not plaster on or over the edges of the construction frame, because:•the heat of the appliance could cause cracks;•it will no longer be possible to remove/place the glass pane.

When using stone-like materials and/or plaster finishing, allow the chimney breast to dry for at least six weeksprior to taking the appliance into operation in order to prevent cracks.

5.7 Placing the control hatch (if applicable)

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

!Caution

•The bottom of the control hatch may not be placed higher in the appliance than the burner surface.•Place control hatch and bracket with gas control and accessories indoors in a dry place only!A number of components are placed in the control hatch, such as data plate, gas control, receiver belonging to theremote control and, if applicable, the components belonging to the DRU Powervent System®.Place the control hatch as follows, see Appendix 3, Fig. 3 for details:

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

!Tip

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

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

!Caution

•The inner frame should be placed in the correct way. Two positions are possible. Placing the inner frame witha rotation of 180° is not allowed (see Appendix 3, fig. 4).

!Tip

•When the chimney breast is made of bricks, the inner frame can be built with bricks at the same time;•When using a different material, you can glue the inner frame or fix it with four flush screws.

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

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INSTALLATION MANUALØ

Mount the bracket with components to the inner frame (A). Proceed as follows:•Unwind the cables. This will, amongst other things, prevent a poor operation of the ignition.•Unwind the flexible gas pipe(s).•Mount the bracket with components to the inner frame (A). The lock hole will fall into the allen screw (C); thehole at the bottom will fall over the head of the allen screw (D).•Fix the bracket with allen screw (C).

!Caution

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

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

Connect the gas pipe with gas tap.

Bleed the gas pipe.

!Tip

If the gas tap is closed, you can simply remove the bracket with components by loosening the compression fittingunder the gas control and loosening the allen screw (C) a few strokes. The bracket with components can now belifted and removed from the control hatch in a forward movement.

Connect the 230 V mains voltage with earth connection. Various types of plug connections are supplied. The typeof plug depends on the country where the appliance is placed.

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

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

!Tip

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

!Caution

Always close the control hatch with the lock (H) because of the electricity behind the door (230V).You can operate the lock with a fitting flat object.

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

For connection to an existing chimney without a discharge pipe or flexble SS discharge - only allowed in GreatBritain - the instructions provided in the separately supplied booklet 'Fitting into a conventional class 1 chimney'apply. In addition to the installation instructions, this booklet also contains supplementary tests.

5.8.1 General

The appliance's type of discharge system is stated in Appendix 2, Table 2.The appliance must be connected to an existing or newly to be built chimney, according to the applicable,national, local and constructional (installation) regulations.

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

At least a 3 metre discharge pipe or a flexible SS discharge should be connected to the appliance.Bends in the flue gas discharge system are not allowed.

!Caution

•Maintain a distance of at least 50 mm between the outside of the concentric system and the walls and/orceiling. If the system is built in (for instance) a cove, it should be made with non combustible material allaround it;•Use heat-resistant insulation material when passing through combustible material;•Use a flue gas discharge system with the correct diameter, and which is provided with the CE mark;

!Caution

Some heat-resistant insulation materials contain volatile components that will spread an unpleasant smell for aprolonged time; these are not suitable.Place the flue gas discharge system as follows:

Connect the pipe pieces or flexible SS discharge.

You should only install the appliance in a well ventilated room which complies with the applicable national, localand constructional (installation) regulations, in order to guarantee sufficient air supply.

!Caution

•In case of a house with a mechanic exhaust system and/or an open kitchen with cooker hood, a permanentventilation hole is required in the area surrounding the appliance; for this application, please refer to the gasinstallation regulations and local legislation.

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INSTALLATION MANUAL5.9 Flue gas discharge /combustion air supply system at appliances with a closed

combustion

5.9.1 General

The appliance's type of discharge system is stated in Appendix 2, Table 2.The appliance is connected to a combined flue gas discharge/combustion air supply system, hereafter referred toas the concentric system.The passage to the outside can be made with both a wall terminal and roof terminal.If necessary, you can also use an existing chimney (see section 5.9.4).

!Caution

•Only use the concentric system supplied by DRU This system has been tested in combination with theappliance. DRU cannot guarantee a proper and safe operation of other systems and does not accept anyresponsibility or liability for this;•For connecting to an existing chimney you should only use the chimney kit supplied by DRU.•DRU's concentric system is intended for indoor use and may therefore not be used outdoors, with theexception of the sections intended for that purpose such as roof and wall terminals.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 applianceby means of a telescopic pipe piece.

5.9.2 Construction of the concentric system

Depending on the construction of the concentric system the appliance will have to be further adjusted withpossibly a restrictor slide or air inlet guide.See Tables 4 and 6 for determining the correct adjustment and section 5.9, 'Adjustment of the appliance' for themethod 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 theminimum 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 inAppendix 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 findin Appendix 2, Table 4 (without wall terminal; see Appendix 3, Fig. 5).When using a roof terminal the following applies:•The construction of the chosen system, when using a roof terminal, must be permissible according toAppendix 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 aroof 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.