Dru Cosmo RCH User manual

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Cosmo RCH
Cosmo Tunnel RCH
Installation manual (UK/IE)
DRU-671866-EN-US-0715-2
G20/G25.3 Natural gas
UK
959.077.01.UK

English
INSTALLATION MANUAL
1. Introduction
2. CE declaration
3. SAFETY
3.1 General
3.2 Regulations
3.3 Precautions / safety instructions at installation
3.4 Principle of ignition cycle
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 Electric connection
5.4 Placing the appliance
5.5 Placing a built-in appliance
5.6 Placing the chimney breast
5.7 Placing the control hatch
5.8 Flue gas discharge system appliances open combustion
5.9 Flue gas discharge / combustion air supply system appliances closed combustion
5.10 Additional instructions
5.11 Construction frame
5.12 Glass panes
5.12.1 Removing the glass pane
5.12.2 Placing the glass pane
5.13 Adjustment of the appliance
5.13.1 Restrictor slide
5.14 Placing the wood set
5.14.1 Wood set
6. Control
6.1 Remote controls
6.2 Alternative controls
7. Final inspection
7.1 Gastightness
7.2 Gas pressure/line-pressure
7.3 Ignition main burner
7.4 Flame picture
8. Maintenance
8.1 Parts
9. Delivery
10. Malfunctions
Appendix 1 Malfunctions
Appendix 2 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 possible 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 and electricity. 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 technical data for the appliance and information on maintenance, any malfunctions that
might 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 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 manuals 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 of DRU's gas-fired heating appliance comply 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
Cosmo RCH / Cosmo Tunnel RCH
2009/142/EC; 2006/95/EC; 2004/108/EC
NEN-EN-613; NEN-EN-613/A1; EN60335-2-102
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3. 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:
Ø You should only install and maintain the appliance if you are a certified and competent installer in the field of
gas-fired heating and electricity;
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 materials for the chimney breast, including the top of the chimney
breast, 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 in
the 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.
Ø if you are installing an appliance type B11 with open combustion: please use a suitable flue gas discharge system
that is provided with the CE label;
Ø if you are installing an appliance with 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;
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 leave the area around the ionization pin and spark plug 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 and/or bottom, 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, discharge and electric 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 appliance may not be used.
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3.4 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 to
start the ignition process. This signal is passed on to the burner device, after which, if applicable, the relay for the
Powervent System® is switched. After an 8 second interval, the ignition on the spark electrodes will start. If no
Powervent 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 gas
ignites, ionization will have to be detected. In order to make sure the flame has passed over, this will take place at
the 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 burning
appliance switches off automatically and then switches back on again. This is not a failure, but a check. The
moment the appliance's control unit is connected to mains voltage, the control unit will perform this check every
24 hours. If the appliance is burning at that time, the appliance will extinguish and then start again immediately. If
you wish to prevent this, you can remove the plug and insert it again at a time during the 24 hours when the
appliance is never or hardly ever burning.
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 if an appliance is damaged!
Ø 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 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 Packaging must be disposed of in accordance with the regulations.
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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/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 ask
what 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 connection
away from the appliance, as low as possible in the chimney 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!
5.3.1 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 the
remote control of the appliance. You could think of the lamps of Dru's lux elements. For this, you can use switch
contact 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 and
connected (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 dimensional
drawing (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 fixing
the extension legs with self-tapping screws.
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!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.
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 5.8 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 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 5.5 to 5.7.
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 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:
Ø Remove the bracket with, amongst other things, the gas control from the appliance by unscrewing the
self-tapping screws.
Ø Place the bracket to which, amongst other things, the gas control is mounted, together with the wiring of the
ignition/ionization cable(s), the flexible gas hose(s) and the data plate with 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 cables cannot come into contact with other wires;
• The data plate should remain connected 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 5.10 'Additional instructions'.
!Caution do not ignite the appliance before the gas, discharge and electric connections have been fully installed, first
observe 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 the
chimney breast.
• When an appliance is built in the floor, please take into account the minimum distances from a combustible
floor.
If this applies to your situation, you'll find more information in chapter 5.10 'Additional instructions'.
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!Caution • Use non combustible and heat-resistant materials for the chimney breast including the top of the chimney
breast, the material in the chimney breast and the back wall of the chimney breast;
• Make sure 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 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 Dru control hatch is not supplied with all appliances. Nevertheless, we recommend only using a Dru
control hatch, if available, except in the case of B 11 AS/BS appliances. If you decide not to take this option, you
will have to make a 100 cm
2 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.
• 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 plaster finishing, allow the chimney breast to dry for at least six weeks
prior 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 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.
!Tip The opening in the chimney breast may be made horizontal and vertical.
Ø 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 with
a 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.
Ø Remove the bracket with the components (B) from the appliance.
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Ø 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); the
hole 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.
Ø Make sure there is no dirt in gas pipes and connections.
Ø Connect the gas pipe with gas tap.
Ø Bleed the gas pipe.
!Tip If the gas tap is closed, you can simply remove the bracket with components by loosening the compression fitting
under the gas control and loosening the allen screw (C) a few strokes. The bracket with components can now be
lifted and removed from the control hatch in a forward movement.
Ø Connect the 230 V mains voltage with earth connection. Various types of plug connections are supplied. The type
of plug depends on the country where the appliance is placed.
Ø Place the data plate in its intended clamp (G).
Ø 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 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.
5.8.1 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/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 for a
prolonged time; these are not suitable.
Place the flue gas discharge system as follows:
Ø Connect the pipe pieces or flexible SS discharge.
Ø 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 • In case of a house with a mechanic exhaust system and/or an open kitchen with cooker hood, a permanent
ventilation hole is required in the area surrounding the appliance; for this application, please refer to the gas
installation regulations and local legislation.
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5.9 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 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 5.9.4).
!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.
5.9.2 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 5.9, '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. 5).
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.
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5.9.3 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 the
ceiling. If the system is built in (for instance) a cove, it should be made with non combustible, heat-resistant
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 an adhesive plate for a flat roof or with a universally adjustable tile for a
sloping roof.
!Caution Some heat-resistant insulation materials contain volatile components that will spread an unpleasant smell for a
prolonged time; 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 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;
Ø Attach the wall terminal from the outside by means of four screws.
!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.
5.9.4 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 gases. 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 set. The installation regulation is parat
of the delivery;
• the internal size should be at least 150 x 150 mm;
• the vertical length has a maximum of 12 meters;
• the total horizontal pipe length may have a maximum length that you can find in Appendix 2, Table 4;
• the existing chimney should be clean;
• the existing chimney should be tight.
For setting the appliance, the same conditions/instructions apply as for the concentric system described above.
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5.10 Additional instructions
!Tip Use the castors to roll the appliance to its location easily.
Prior to placement, the appliance should be removed from its pallet.
Proceed as follows (see appendix 3, fig. 28).:
Ø Place the appliance plus pallet on a pallet truck.
!Caution In order to move the pallet, you must place the pallet truck directly below the appliance (see appendix 3, fig. 28).
Ø Raise the pallet truck as high as possible in order to provide space to install the castors.
Ø Place the 4 castors as indicated (see appendix 3, fig. 28).
Ø Mount one of the supplied nuts in each castor.
Ø Remove the pallet truck from below the appliance.
Ø Remove the 8 screws that are screwed in the pallet.
Ø Remove the two boards at both sides of the pallet.
Ø It will now be possible to roll the appliance off the pallet.
Ø Roll the appliance to the desired location.
Ø Extend the 6 adjustable feet of the appliance.
Ø Remove the castors.
It is now possible to install the appliance.
5.11 Construction frame
The construction frame of the Cosmo RCH can be adapted from the “4S setting” to the “3S setting”
(see appendix 3, fig. 2 and 6). The 3S setting allows the bottom side of the pane to connect to the floor or the
platform.
!Caution When using the 3S construction frame, observe a minimum distance of 350 mm from combustible material (see
the red-shaded area in appendix 3, fig. 2 (3S)).
!Caution We are unable to provide further information on, or assume responsibility for the way in which floor covering or
other materials are affected by use of the fire (e.g. how a wooden floor may ‘work’). Regardless of whether the
minimum required distances from combustible floor covering or other materials are observed.
If the 3S setting is selected, the lower strip must be removed before the appliance is installed.
Proceed as follows (see appendix 3, fig. 6):
Ø Unscrew the Allen screws (M) using a 2 mm Allen key.
Ø Hold the strip and unscrew the self-tapping screws (O).
Ø Remove the strip.
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5.12 Glass pane
!Caution The glass pane must be removed/placed by two persons.
!Caution • Avoid damaging the glass panes when removing/placing them;
• avoid/remove fingerprints on the glass panes, as they will burn into the glass.
5.12.1 Removing the glass pane
When removing the glass pane, please observe the following steps (see appendix 3, fig. 7 up to 9):
Ø Loosen the bolt (T) in the lock bracket (U) by 3 turns (see appendix 3, fig. 7a (1)).
Ø Turn the lock bracket (U) to the left by a quarter turn. This will unlock the handle (X), by means of which the glass
pane can be opened.
!Caution Always prevent the glass pane from falling forwards!
Ø Pull the lever (X) down, using your index fingers. Press down the glass pane while the lever (X) is moved to the
right 180° and hold on to the glass pane! This will prevent the glass pane from falling forwards and getting
damaged (see appendix 3, fig. 7a (2 and 3)).
Ø Carefully pull the glass pane towards the front with the two handles located at the left and right top side of the
glass pane frame and then allow the glass pane to drop (see appendix 3, fig. 7b).
!Caution • The following actions should be performed by 2 persons.
• Prevent stresses on the glass pane by performing the following actions simultaneously on the left and right
side.
Ø Simultaneously loosen the left and right brackets (Y) that guide the glass pane and connect it to the appliance.
Push close the glass pane with 2 persons at both sides, to such an extent that the brackets (Y) can be lifted from
the guides (see appendix 3, fig. 8).
Ø Then, carefully remove the glass pane with 2 persons from the lower glass pane guides at both sides of the
appliance (see appendix 3, fig. 9).
5.12.2 Placing the glass pane
The glass pane is fitted by using the above procedure in reverse order (see appendix 3, fig. 7 up to 9).
!Caution Avoid/remove fingerprints on the glass pane, as they will burn into the glass.
Pay attention to the following when fitting the glass window:
!Caution Make sure the cams at the bottom on both sides of the glass pane frame are correctly placed in the guides at the
bottom of the combustion chamber by 2 persons (see appendix 3, fig. 9)!
!Caution Check whether the 2 “clips” (C) are still properly attached around the bottom of the glass pane before the glass
pane is closed, in order to prevent it from getting damaged.
!Caution First press the glass pane in its place at the upper corners and then hold the glass pane with 1 hand before sliding
the handle to the left again. Otherwise, the projections will not fall over the glass pane, as a result which it will not
close properly.
Ø Turn the lock bracket (U) back to its position and re-tighten the bolt (T).
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5.13 Adjustment of the appliance
The appliance has to be set in such a way that it works correctly in combination with the used discharge system.
For that purpose, it is possible to place a restrictor slide.
The conditions for using a wall terminal and roof terminal can be found in appendix 2,
tables 4, 5 and 6.
5.13.1 Restrictor slide
The restrictor slide (R) must be adjusted to the right position (see Appendix 3, fig. 10).
Proceed as follows:
!Caution The restrictor slide should be placed in the correct manner. Therefore, accurately observe the instructions in
Appendix 3, fig. 10.
Ø Loosen the 3 self-tapping screws by a few turns.
Ø Adjust the position of the restrictor in accordance with tables 4, 5 and 6.
In the restrictor slide, 4 of the 5 possible positions are indicated by means of the 4 cut out letters B up to E.
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 Now tighten the 3 self-tapping screws.
At position A, the restrictor slide should be fully removed from the combustion chamber.
Proceed as follows:
Ø Remove the 3 self-tapping screws of the restrictor slide from the combustion chamber (see appendix 3, fig. 10).
Ø Remove the restrictor slide (R).
Ø Screw back the self-tapping screws in the combustion chamber.
!Caution The self-tapping screws of the restrictor slide must have been screwed back in the combustion chamber.
!Tip If you are installing an appliance, whereby a wood set has to be placed, do not yet place back the glass pane.
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5.14 Placing the wood set
The appliance is supplied with a wood set.
!Caution • The figures do not always show the correct colours.
• Before placing the wood set in a Cosmo Tunnel RCH, first determine what is the front of the appliance. Make
sure the positions of the burners are exactly the same as indicated in figure 18 in appendix 3.
!Caution Strictly observe the following instructions to prevent unsafe situations.
Ø Only ever use the supplied wood set.
Ø Place the wood set exactly as described.
Ø Make sure the ionization pin and spark electrode and the surrounding space remain free
(see appendix 3, fig. 13 and 14).
Ø Make sure the slot between the burner and the vermiculite tray is kept free from objects.
Ø Make sure there is no vermiculite's dust on the burner.
5.14.1 Wood set
The wood set consists of vermiculite (see appendix 3, fig. 15), chips (see appendix 3, fig. 16) and a number of logs
(see appendix 3, fig. 17).
Ø Fill the burners with vermiculite; evenly spread the vermiculite (see appendix 3, fig. 18). The vermiculite may not
get higher than the edge of the burners.
!Caution You can influence the flame picture by moving the vermiculite, but the burner deck should remain covered with
vermiculite in order to avoid reducing the burner's life span.
Ø Check whether the insulating rope around the 2 central burners has been applied correctly
(see appendix 3, fig. 18).
Ø Check whether the ends of the insulating rope around the 2 central burners connect to each other
(see appendix 3, fig. 18).
Ø Identify logs A to H (see appendix 3, fig. 17).
!Tip Use the burn stains on the logs for identification.
Ø Place logs A and B, using the positioning cams (see appendix 3, fig. 19 and 20).
Ø Place log C, using the positioning pins (see appendix 3, fig. 21).
Ø Continue with central log D (see appendix 3, fig. 22).
!Caution • Always place central log D with 2 people, to prevent breakage;
• make sure that the space surrounding the central burners is distributed evenly, so that it is possible for
secondary air to flow around the burners;
• make sure the insulating rope around the central burners properly connects to log D.
!Tip Check the sealing by lighting it from below using a torch.
Ø Then place the cap on the left central burner. This cap will make sure that the flame will transfer smoothly
(see appendix 3. 23).
Ø Place log E (see appendix 3, fig. 24).
Ø Fill the vermiculite tray with chips; spread the chips evenly (see appendix 3, fig. 25).
Ø Identify logs F to H (see appendix 3, fig. 26).
!Caution The logs may not completely cover the burner pattern (see appendix 3, fig. 27), because:
• the main burner will not ignite properly; which could result in unsafe situations;
• the appliance will become filthy more quickly, as a result of soot;
• the flame picture will be affected.
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6. Control
The appliance is supplied with a wireless black remote control for the user (see appendix 3, fig. 35 (B)). As an option,
an orange remote control can be supplied for the installer (see appendix 3, fig. 35 (O). Controlling the flame height,
igniting and switching off take place through the black remote control controlling a receiver. Some fires can also be
controlled in an alternative way. These options are described further down in this chapter.
The User Manual describes the operation of the appliance. Including the operation of the remote control and
alternative methods of operation.
!Caution Do not ignite the appliance before the gas, discharge and electric connections have been fully installed, first
observe the procedure described in chapter 7.3.
6.1 Remote controls
6.1.1 Black remote control for the user
Proceed as follows to make the black remote control ready for use:
Ø Place the two penlite batteries (AA) in the battery holder of the remote control.
Ø Make sure the voltage of the atmospheric fire is not switched off for longer than 5 minutes.
Ø If the remote control does not have the "BND" state, the following operations must be performed: Press the menu
button (button with square symbol) on the remote control for at least 10 seconds and then press a few times until
“BND” appears on the screen with the receiving symbol.
Ø Press the “arrow up” and “arrow down” buttons briefly and simultaneously, so that a (flashing) warning triangle and
an hourglass appear in the screen as well.
Ø As soon as logging on is finished, the start screen will appear
!Tip Ale functions are extensively explained in the supplied user manual.
6.1.2 Orange remote control for the installer
By means of the optionally available orange remote control, it is possible to read all information stored in the
receiver. In this way, the last 20 error messages can be retrieved, and it will also be possible to read how many
times an error occurred. Moreover, this remote control can also be used to adjust the basic settings and to read the
size of the ionization flow. It is also required for a wired Domotics control.
6.2 Alternative control (if applicable)
In addition to the remote control, it is also possible to operate the fire in alternative ways. For this purpose, a
Domotics system can be connected to the receiver. This can be a wired or a wireless system. The various
possibilities are described below (see appendix 3, fig. 35, 36 and 37).
6.2.1 Wired
Wired connection of the Domotics system to the receiver takes place via a 0-3VDC direct current
(see appendix 3, fig. 36 (D)).
!Caution A higher voltage than 3V will damage the receiver and is therefore not permitted.
Tip! In case of Domotics systems with an output voltage of 0-10V, you should switch the voltage back to 0-3VDC.
Use a voltage distributor made of resistors. For example, 2200 ohms and 680 ohms. The voltage above 680 ohms
resistance can be used on the input of the 0-3VDC. Low ohmic resistors must be used.
By controlling the height of the voltage, the receiver will be able to calculate the position of the fire. Table “B1” in
appendix 3, fig. 37 shows the relationship between the voltage and the height of the flame. If you have an
appliance with 2 burners, table “B2” will apply. It shows the relationship between the voltage, the height of the
flame and the number of burners.
Proceed as follows when connecting the Domotics system to the receiver:
Ø Connect the 0-3VDC signal to the connector, to which a black and yellow wire are connected (see appendix 3, fig.
36 (D)).
Ø Use the orange remote control to select the option for a wired connection: go to position 8 in the first menu and
select an appliance with single burner (option 2) or an appliance with two burners (option 3). For this, read the
manual of the orange remote control.
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!Caution The yellow wire is the + pole, the black wire is the - pole. Always connect ‘- to -‘ and ‘+ to +’ .
6.2.2 Wireless
The wireless connection is divided into 2 types:
• Connection via a ‘modbus’ protocol.
• Control via an application.
!Caution Only 1 type of wireless connection is possible on the communication module.
6.2.2.1 Connection via ‘modbus’ protocol
Wireless connection of a Domotics system to the receiver is possible via a connection according to the ‘modbus’
protocol. Such a connection can only be established with a communication module (see Appendix 3, fig. 35 (W)).
This module can be ordered from DRU. This communication module translates the ‘modbus’ protocol from the
Domotics system into a wireless signal to the receiver.
When connecting a Domotics system via the communication module to the receiver, proceed as follows:
Ø Using the remote control, test whether the location where you want to place the communication module is within
the receiver's range.
Ø Place the remote control on this location and test the reception sensitivity (RSSI).
Ø Press the on/off button and down arrow at the same time. The value that is now visible, must be between -20 and
-70 (see User Manual, "Reception Sensitivity"). If needed, hold the remote control closer to the appliance in order
to improve the reception.
Ø Connect the communication module by means of an RJ45 plug, according to the instructions in the manual that is
supplied with this module.
Ø Now follow the steps described in the ‘modbus’ protocol manual. It is available from the supplier of the domotics
system.
6.2.2.2 Control via application
If the fire is operated via a tablet using the application (iOS or Android), a communication module is required. This
module can be ordered from DRU.
In order to control the fire via an application, proceed as follows:
Ø Using the remote control, test whether the location where you want to place the communication module is within
the receiver's range.
Ø Place the remote control on this location and test the reception sensitivity (RSSI).
Ø Press the on/off button and down arrow at the same time. The value that is now visible, must be between -20 and
-70 (see User Manual, "Reception Sensitivity"). If needed, hold the remote control closer to the appliance in order
to improve the reception.
Ø Connect the communication module by means of an RJ45 plug, according to the instructions in the manual that is
supplied with the communication module.
Ø Use the instructions for the application in order to install it.
The application 'DRU Control' is available in the AppStore, at GooglePlay or our website: www.drufire.co.uk
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 put into operation.
7.1 Gastightness
!Caution All connections must be gastight. Check the connections for gastightness.
The gas control may be subjected to a maximum pressure of 50 mbar.
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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 38 (P1) for the measuring nipple on the gas control.
Ø Contact the gas company if the line-pressure is not correct.
7.3 Ignition main burner
For igniting the main burner, see the User Manual.
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 as described in the user manual;
Ø If the main burner does not ignite:
• Reset the system by pressing the buttons ‘arrow up’ and ‘arrow down’ simultaneously;
• Repeat the ignition procedure until the main burner ignites;
!Caution After each attempt to ignite, the system must be reset.
Ø Consult the diagram with error messages (Appendix 1) if this does not succeed after a few attempts;
The appliance ignites at 50%. After ionization has been detected, the appliance will modulate to 100%. This
detection will have to take place within 15 seconds, or else the appliance will enter error mode.
If applicable, the second valve will switch to ignite the second burner. Here, you can hear a clear ‘click’ sound.
Ø Check whether the main burner continues to burn;
Ø If the main burner does not continue to burn:
• Reset the system as described and repeat the ignition procedure until the main burner continuous to burn.
!Caution The system can be reset and re-ignited three times in a row at maximum. After that the system will enter hard
lock-out and you will have to wait for half an hour before you can make a new attempt.
Ø 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 from 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 main burner should ignite smoothly.
!Tip When checking whether the main burner continuous to burn, it is possible that it switches off after 15 seconds. In
that case, this will be caused by the fact that there is no ionization detection and because the glass window has
not been placed. In this case you may presume that the main burner continuous to burn.
!Caution • Always wait 5 min. before re-igniting the appliance;
• No changes may be made to the gas control.
7.3.2 Main burner
!Caution • The ignition electrode 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.
• If the appliance does not ignite after three restarts and enters hard lockout, it may never be reset by
disconnecting it from the power supply. If a restart is necessary after all: remove the glass pane and make sure
the gas is able to escape from the appliance. After this, the appliance may be disconnected from the power
supply for 10 seconds. After these 10 sec., the power supply may be reconnected. Ignite the appliance in the
same way as the first ignition, as indicated in section 7.3.1.
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Ø Check operation of the main burner from a cold condition.
Ø If sparks are determined between the ignition electrodes, the main burner should burn within a few seconds.
!Tip 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
above-mentioned 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 is 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, in order to solve the
problem.
8. Maintenance
Once a year the appliance should be checked, cleaned and, if necessary, repaired by a competent installer in the
field of gas heating and electricity.
Check at least whether the appliance is working properly and safely.
!Caution • Close the gas tap when performing maintenance work;
• Check the gastightness after repair;
• Make sure there is no voltage on the appliance.
Ø If required, clean the following components:
• the glass pane(s).
!Caution • Remove/place the glass pane(s) as described from 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 ceramic hot plate cleaner;
• Avoid/remove fingerprints on the glass pane(s), since otherwise they will burn into the surface;
• Replace broken and/or cracked glass panes as described from section 5.10.
!Caution If necessary, place back the wood or pebble set correctly; for this, see from section 5.10.
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 to be replaced are available at 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 into
operation, the safety measures, the operation of the remote control and the annual maintenance (see the User
Manual).
!Caution • Tell the user to close the gas tap immediately in case of malfunctions/bad performances and contact the
installer in order to prevent dangerous 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;
• Point out the 230 Volt connection.
Ø Instruct the user about the appliance and the remote control.
Ø When the appliance is taken into operation, 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..
(Also first read chapter 3 of the user manual !);
• when evaporating, the appliance should preferably be set at 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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