ruegg Flex-Line series User manual

Flex-Line
INSTALLATION MANUAL

Flex-Line Installation manual
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Table of contents
Principles............................................................................................................................................... 4
Safety.................................................................................................................................................... 4
Transport............................................................................................................................................. 12
Installation........................................................................................................................................... 12
Combustion air..................................................................................................................................... 13
Flue gas system................................................................................................................................... 16
Thermal insulation ............................................................................................................................... 18
Fire-resistant hot air systems............................................................................................................... 20
Fire resistance radiation systems......................................................................................................... 28
Firebox casing..................................................................................................................................... 28
Type plate............................................................................................................................................ 34
Final inspection.................................................................................................................................... 36
Initial start-up....................................................................................................................................... 36
Technical data..................................................................................................................................... 37

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Principles
Pictures
The pictures used in this manual are designed in such a way that they can be applied generally as far
as possible. For this reason, under certain circumstances the details of individual pictures may differ
from those of your product.
Cross hatches
The cross hatches used in this manual have the following meaning:
Safety
Regulations
Rüegg fireplaces have been type-tested and approved in accordance with EN 13229.
Values primarily from the EN test are published. Where the test provides no information, country-
specific values from Switzerland and Germany have been used. The installer is responsible for this
validity.
The appliances are tested only for the closed operation.
All local requirements, including the relevant national and European standards, must be met and take
precedence over the installation manual.
The installer of the system is responsible for meeting country-specific legislation.
Installations may only be undertaken by trained specialists or Rüegg partners. If this is not the case,
Rüegg shall not accept any warranty or liability.
Wood
Air gap; cavity with or without active
rear ventilation
Thermal insulation (mineral)
Thermal insulation;
nbb, RD ≥ 100 kg/m3
Wooden beams
Concrete
Masonry or
porous concrete
Full brick
(chimney bricks)
Fireclay;
casing/external cover
Fire-resistant plate;
nbb

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Warnings
Warnings and safety information indicate the following hazards:
Self-closing door
Balancing weights can be removed from the counterweights until the doors close automatically.
Fireplaces with a self-closing door may only be operated with the doors closed!
Before the installation After the installation
1. Remove cover on the side 1. Remove the two furthermost firebox bricks at the side
2. Remove/add balancing weights 2. Remove air duct
3. Install cover again 3. Remove inspection cover
4. Remove/add balancing weights
5. Install in the reverse order
Designates a potentially hazardous situation. Can result in death or
severe injuries if not avoided.
Designates a potentially hazardous situation. Can result in slight
injuries if not avoided.
Designates a potentially harmful situation. Can result in physical
damage to the product or the surrounding area if not prevented.
Self-closing door
This function is to ensure the system’s operating safety.
►Manipulating the self-closing door is prohibited

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RIII
The device is equipped with a handle with two magnets.
With this handle, the balancing weights can be lifted from the
main weight.
For this, the door must be completely raised. Insert the
handle with the magnets through the gap.
Then rotate 90° so that the magnets adhere to the upper
weight.
Then lift the weight and extend it through the deepening in
the main weight.
Turn the handle with the magnet another 90 ° and remove
the weight.

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Multiple use
Fireplaces with a self-closing door may be used on a chimney designed
for multiple connections.
Fireplaces without a self-closing door may only be fitted individually to a
chimney.
The applicable local regulations and manufacturer’s instructions must
be followed for the installation of the flue gas system.
Precoat
Combustible floors in front of fireplaces must be
protected by a combustible precoat in front of
the pane.
Directive
X
[cm]
Y
[cm]
VKF (Association of Swiss Fire Insurers) fireproof application/
VHP state-of-the-art technology paper (version 1.2/2011)
CH
≥ 40
≥ 10
TR OL (technical rules of stoves and air heating systems) (issue
2010)
D
≥ 50
≥ 30
X
X
X
X
Y
Y

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Substrate
The substrate on which the fireplace insert is installed
with the supporting frame and the casing must be
sufficiently load-bearing.
The adjustable feet are height-adjustable and are used
to align the fireplace insert. The adjustable feet must be
placed directly on the load-bearing substrate.
Load-bearing substrate
The substrate must be sufficiently load-bearing to take the full weight of the
heating insert.
►Check the load-bearing capacity of the substrate
►Place the adjustable feet directly on the load-bearing substrate

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Safety spacing front-opening devices (1-ceramic class pane)
The safety spacing from combustible materials must be maintained in the system’s heat-radiation zone.
If Z > than the value cited in the table, Y is reduced. If Z ≤ than cited in the table, the combustible
components must be insulated by the spacing Y.
*With mantle for hot air
The safety spacing may be halved if a radiation shield ventilated on both sides is installed at a distance
of ≥ 2 cm.
Appliance
X
[cm]
Y
[cm]
Z
[cm]
Violino 45x60
125
63 /56*
33
Violino 45x80
150
80
36
Violino 55x73
130
48
26
Violino 55x98
150
55
35
Violino 65x87
170
75
28

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Safety distance of three-sided devices triple-ceramic glass pane)
The safety distances from combustible materials must be maintained in the radiation area of the
installation.
If Z > than specified in the table, Y is reduced. If Z ≤ than specified in the table, the combustible
components must be insulated by the distance Y.
* With mantle for warm air
The safety distance can be halved by installing a two-sided ventilated radiation protection at a distance
of ≥ 2 cm.
Device
X
[cm]
Y
[cm]
Z
[cm]
RIII 45x56x46
80
70
Not specified
RIII 45x56x60
60
60
Not specified
RIII 45x56x80
60
70
Not specified
RIII 45x80x46
100
70
Not specified
RIII 45x100x46
100
60
Not specified
RIII 55x100x46
130
60
Not specified

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System components
(Symbol icon)
Firebox
Concrete base
Smoke outlet
Door
Casing
Casing
(Active surface)
Cavity
Thermal insulation
Supporting frame
Inactive surface
Covering
Thermal insulation
Connecting piece
Thermal insulation (optional)
Combustible environment
Combustion air
connection
Firebox casing
Primary walling
Baffle plate
Thermal insulation
Flue gas valve
Combustible environment

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Transport
The following points are to be followed when transporting the fireplace insert:
Secure the fireplace insert so that it can be transported safely
Fully screw in or remove adjustable feet
Avoid transporting in a horizontal position
Secure firebox doors with safety screws
Remove loose single parts from the firebox
Use carry handles
The appliances may not be braced over the protective glass box. Otherwise
they will break together.
Installation
Delivery
Check the supplied fireplace insert upon receipt to ensure that it is
complete, for any damage caused during transit and for dimensional
accuracy.
Remove all fixing screws of the counterbalances and other transport
supports.
Check that the doors are working before assembly.
Report any damage to the responsible customer service department
prior to assembly.
Read this manual through carefully prior to assembly.
Alignment
The fireplace insert must be aligned exactly at the installation location with the help of a spirit level.
A functional check must be made of the doors before the casing is fitted. Door mechanism components
can cause noise if the fireplaces are not aligned exactly.
Casing
The casing must consist of non-flammable materials.
A glass tape must be applied in between any contact surfaces of the fireplace insert and the casing.
If must be possible to swing out the door completely when the casing is installed.
The casing need not be thermally insulated if the fireplace system is made in such a way that the free
surfaces of the casing and the surfaces of the recesses for storing fuel can heat up no higher than
85 °C. The value 120 °C replaces the value 85 °C for surfaces made of mineral materials, e.g. tiles,
with the exception of surfaces on which objects can be placed.
The safe distances that apply locally must be adhered to.
The processing materials must be thermally resistant and may not emit any lasting odours when
exposed to heat. We therefore have had to refrain from using any materials that contain plastics.

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Remove perforation
The corresponding perforation must be removed to connect the combustion
air.
Supporting frame
A gap of 2-5 mm must be left between the supporting
frame and the protective glass box/tile stop to enable the
appliance to expand without damaging the casing. This
cavity can be closed with a hollow black fibre-glass gasket
10 mm x 2 mm in diameter.
The supporting frame may not be joined to the appliance.
The supporting frame must lie statically on the side of
masonry or be suspended from the ceiling with connecting
rods.
For freestanding supporting structures, the relevant
manuals must be followed.
Combustion air
Supply
Rüegg fireplaces are designed in such a way that the appliance can be supplied with non-ambient
combustion air for the closed operation. The combustion air is fed from outside the installation room
directly into the appliance and then internally to the fire.
Cross section 175 cm2 (connecting supports 15 cm in diameter)
The pipe can be fed to the connecting supports from below, from behind or from the side. Flat ducts in
sizes 33 cm x 4 cm are necessary for connecting from behind and from the side. Rüegg offers a 15-cm
diameter adapter from Flach as an accessory.
Perforation for Perforation for
Connecting supports 15 cm in diameter Flat duct connections

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Pipelines
For supply lines, round cross sections with smooth inner surfaces are preferable.
Mineral supply lines (e.g. brickwork) must have wear-resistant internal surfaces.
Supply lines must be a minimum 3 cm thick across the entire length, non-flammable and thermally
insulated.
A fine-mesh, removable facade sieve must always be installed as a supply line connection in the
facade. The flow resistances declared by the manufacturer must be taken into account.
The cross section of 175 cm2 (15 cm diameter) may not be reduced.
If lower cross sections are installed because of the calculations, the installer will act at their own risk.
The perfect function of the system is not guaranteed.
External air lines with a cross section of 175 cm2(15 cm) may not exceed the following maximum
lengths:
with semi-rigid aluminium pipes (“Aluflex”): Lmax = 6 m
with smooth-walled pipes (“Aluflex”): Lmax = 8 m
Air valve
To avoid any ingress of cold air, cold bridges and the formation of condensation, we recommend that
you install a tightly sealed air valve close to the facade.

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Optional air connection
An air connection set can be ordered as an accessory. This set is universal and must be installed as
follows:
1. Break loose the desired
perforation.
2. Insert U-shaped duct and seal at
connection points.
3. Secure lid with tapping screw on
the appliance. Then screw lid to
the duct with the other tapping
screws.
4. Cut channel to the required length.
There are markings for different
appliances.
5. Fit supports and seal all
connection points, so that they are
airtight.
6. If the duct is used at the back, the
tab must be bent on the side of the
U-shaped duct. This bracket
serves as the fastening.
1
2
3
4
5
6

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Flue gas system
General
The flue gas system must be designed and approved for use for fireplaces that use wood as a fuel. The
flue gas system must meet national and local regulations and it must at least satisfy the following
requirements:
Temperature class T400 (nominal operating temperature ≥ 400° C)
Soot burning resistance category: G(system with resistance category)
Corrosion resistance class: 2(natural wood)
Length
The draught calculated on the flue gas system must be between 10-12 Pa.
Flue gas systems without a flue gas fan with lengths L ≤ 4 m are not permitted.
The draught conditions must be checked by taking appropriate measurements before lining the
system.
A flue gas fan can be installed inside the flue gas system to achieve stable draught ratios.
Connecting piece
The following requirements must be met when installing the connecting piece.
Permitted materials:
Steel ≥ 2 mm sheet thickness
Chrome nickel steel ≥ 1 mm sheet thickness
The connecting piece must be fed directly from the fireplace insert to the chimney and aid flow.
All connections must withstand long-term thermal resistance and be tight.
Feedthroughs for connecting pieces that feed through flammable environments must be carried out
professionally. The national and local requirements must be met.
Possibilities for regular cleaning must be provided.
Static support
The flue gas system must be erected to be self-supporting. It may not be
supported by the fireplace insert.
►Follow the details provided by the manufacturer
►Check the load-bearing capacity of the building shell involved in the
installation

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Cross section
If smaller or larger cross sections are installed because of a draught measurement or calculation, the
installer will be responsible for any action. It must be guaranteed that the system is running perfectly.
The following faults may occur under certain circumstances:
→ Formation of condensation as flue gases cool down too greatly
→ Formation of smoke because the draught conditions are too poor
Triple-value, front-opening devices
Flue gas valve / butterfly valve
A flue gas valve/butterfly valve is installed in the appliance under the cast dome and forms part of the
appliance. The appliances are tested with this valve in accordance with EN-13229.
Corresponding cut-outs are pre-lasered in the “Rüegg valves”. These can be broken out with a pair of
pliers. All connecting pieces must have long-term thermal resistance and be tight.
The flue gas valve/butterfly valve can be connected by a
flexible shaft or with universal joints and a square 8x8 mm rod.
A 8x8 mm square rod is to be used first because of the high
temperature at the smoke outlet.
Appliance
Standard
Outflow
[cm]
Optional
[cm]
Flue gas flow
rate
[g/sec]
Flue gas
temperatur
e
[°C]
Minimum
pressure
head
[Pa]
Violino 45x60
20
18 / 25
7.9
256
12
Violino 45x80
20
18 / 25
10.6
273
12
Violino 55x73
20
25
12.9
304
12
Violino 55x98
20
25
13.2
305
12
Violino 65x87
20
25
12.1
296
12
RIII 45x56x46
20
18 / 25
7.7
303
12
RIII 45x56x60
20
18 / 25
9.1
320
12
RIII 45x56x80
20
25
9.6
317
12
RIII 45x80x46
20
25
9.9
305
12
RIII 45x100x46
20
25
8.6
301
12
RIII 55x100x46
20
25
14.9
295
12
Flue gas temperature
The flue gas temperature is the maximum measured temperature on the
bracket during the test at nominal thermal performance. This can change if
the firing behaviour changes.

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Activation can be from both sides. This changes the direction of rotation.
Thermal insulation
General
Only non-flammable insulating materials that have a long-term resistance of at least 700°C may be
used.
Thermal insulating materials that come into contact with circulating hot air must also have a wear-
resistant coating (e.g. with sheet metal deflectors). The coating must be permanently temperature-
resistant.
The binding agents of the thermal insulation materials used may volatilize under the effects of
temperature only to a small extent. Otherwise, strong odours may be generated. Details about the
composition of thermal insulation can be obtained from the manufacturers.
The fireplace insert may not be placed directly on the thermal insulation.
A continuous convection gap of at least 2 cm must be provided to enable the free circulation of air.
The installer is responsible for adhering to national and locally valid regulations when setting up the
system.
Flexible shaft!
Flexible shafts may not lie directly on the fireplace insert.
►Fit spacers
Check function!
Before installing the casing check that the flue gas valve is working properly.
►Open and close several times
Muffled explosions!
Dangerous muffled explosions can occur when using sealed flue gas
valves.
►Install non-tightly closing flue gas valves that have a mandatory
opening of at least 20 cm2of connecting area or at least 3% of the
smoke outlet cross-section.

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Mineral insulation materials
Insulation
Shape
Application
Thermal
conductivity
Maximum
application temperature
Bulk
density
W/(m K)
°C
kg/m3
Mineral wool
Panels
Fireplace insert
insulation
0.035
700 - 900
100 - 180
Mineral wool
on the side with reinforced
pure aluminium coating
mats
insulation
connecting pipe
0.035
750
80
Alternative insulating materials
Alternative insulating materials with a certificate of use (e.g. silica, promate, Isoboard, etc.) are able to
replace the primary walling and the mineral thermal insulation.
The insulation thickness can be reduced by up to 50%. To determine the insulation thickness, the
information provided by each manufacturer must be followed.
The materials used must have long-term inherent stability.
Alternative design
An alternative design of thermal insulation must meet the following
requirements:
►Thickness ≥ 8 cm
►At least 2 layers
►Offset joint layout of the boards

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Fire-resistant hot air systems
Hot air cross sections
The cross sections of hot air openings in hot air systems may not be closable and the cross section may
not undercut the specification. The hot air openings must be optimally designed in terms of circulating
air to create as little resistance as possible.
For appliances with a hot-air mantle, the connecting supports must be connected to the hot-air grille by
a flexible aluminium hose. Insulate the connecting piece with 3 cm mineral wool. If the supports for the
mantle have not been fed to the hot air grille with flexible aluminium hose or the connecting piece is not
insulated, the hot air cross section must be used by the appliance without a mantel. The hot air inlet
does not have to be connected to the appliance. The cross sections in the cavity may then not exceed
700 cm2, however.
Venting the cavity
Aluminium flexible tubing
Connecting support device
Appliance including mantle
Front-opening appliances
* Cavity ventilation
Appliance
Including mantle
Excluding mantle
Inlet
[cm2]
Outlet
[cm2]
Inlet
[cm2]
Outlet
[cm2]
Violino 45x60
350
350+ 175*
600
600
Violino 45x80
350
350 + 175*
800
800
Violino 55x73
700
700 + 175*
730
730
Violino 55x98
700
700 + 175*
980
980
Violino 65x87
700
700 + 175*
1000
1200
RIII 45x56x46
-
-
350
350
RIII 45x56x60
-
-
350
350
RIII 45x56x80
-
-
350
350
RIII 45x80x46
-
-
350
350
RIII 45x100x46
700
700 + 175*
1000
1000
RIII 55x100x46
700
700 + 175*
1000
1000