Dru Apollo 80 Guide

English

Apollo 80

Please retain this document carefully

Instructions for installation (GB / IE)

959.011.03.

English

Apollo 80 - instruction for instAllAtion

Contents

page

Foreword 2

1. Introduction 3

2. EC Declaration of Conformity 3

3. SAFETY 3

3.1 General 3

3.2 Regulations 3

3.3 Precautionary measures / safety instructions regarding installation 3

4. Instructions 4

5. Unpacking 4

6. Installation 4

6.1 Regulations 4

6.2 Gas type 4

6.3 Gas connection 4

6.4 Positioning the appliance 5

6.5. Flue gas discharge / combustion air supply system 6

6.6 Building the chimney breast 9

6.7 Installing the control box 10

6.8 Adjusting the appliance 10

6.9 Arranging the logs 11

6.10 Glass window 13

7. Wireless remote control 15

7.1 Receiver 15

8. Final inspection 16

8.1 Gastightness 16

8.2 Gas pressure/pre-pressure 16

8.3 Igniting the pilot and main burner 16

8.4 Flame effect 16

9. Maintenance 17

10. Completion 18

11. Troubleshooting 18

Annex 1 Components supplied 20

Annex 2 Technical data 21

Annex 3 Spare parts 21

Foreword

As manufacturer of gas heating appliances, DRU develops and produces products to meet the highest possible

quality, performance and safety requirements.

As a result of which the user is able to enjoy using your appliance for years to come.

This appliance is CE marked; it complies with the essential requirements of the European Appliance Directive.

The appliance is supplied with two manuals: the installation manual and the user manual.

You the installer should be professionally skilled in the ﬁeld of decorative gas heating.

The installation manual gives you all the information you will need to be able to install the appliance in such a way

that it works correctly and safely.

This manual deals with the installation of the appliance and the appropriate regulations. It also includes the techni-

cal data for the appliance and information on maintenance and troubleshooting.

Please read and use this installation manual carefully.

In the manuals the following symbols are used to denote important information:

➠

What to do

!Tip Suggestions and recommendations

!N.B. These instructions are important to avoid possible problems during installation and/or use.

N.B. These instructions are important to avoid re, personal injury or other serious damage.

Once you have completed the installation you are to hand both the user manual and this installation manual to the user.

English

Apollo 80 - instruction for instAllAtion

1. Introduction

The Apollo 80 is a closed atmospheric gas heating appliance. A closed appliance does not extract the combustion

air from the living environment, but from outside. This is done by means of a combined ﬂue gas discharge system

/ combustion air supply system. In this concentric system, the outer pipe functions as the air supply and the inner

pipe functions as the ﬂue gas discharge.

The safe operation of the appliance is guaranteed by the use of a second thermocouple ﬁtted to the main burner.

This system can be installed through the wall or through the roof.

The appliance is built in a chimney breast. For this, DRU has a number of chimney breasts in its range. In order

to reach a proper heat discharge, the chimney breast must be ventilated. DRU is able to supply various ventilation

elements.

The appliance is supplied with a wireless, battery powered remote control.

2. EC Declaration of Conformity

We hereby declare that the design and construction of the decorative gas heating appliance marketed by DRU con-

forms with the essential requirements of the Gas Appliance Directive.

This declaration will be rendered invalid should the appliance be altered in any way without the written consent of

DRU.

Product: Decorative gas heating appliance

Type: Apollo 80

Applicable EC Directives: 90/396/EEC

Applicable harmonised standards: NEN-EN-613, NEN-EN-613/A1

In-house measures guarantee that serially produced appliances always conform with the essential requirements of

the current EC Directives and the applicable standards.

R. Gelten

General manager

DRU VERWARMING B.V.

Postbus 1021, 6920 BA Duiven

Ratio 8, 6921 RW Duiven

www.dru.nl

3. SAFETY

3.1 General

N.B. - Please read this chapter on safety carefully before commencing installation or maintenance;

- Always observe universal regulations and the precautionary measures / safety instructions in this manual.

3.2 Regulations

The appliance should be installed in compliance with current national, local and constructional (installation) regulations.

3.3 Precautionary measures / safety instructions regarding installation

Observe the following precautions / safety regulations precisely:

➠

You may only install and/or service this appliance if your are a qualied installer skilled in installing decorative gas res;

➠

do not adjust the appliance in any way;

➠

Non-combustible and heat-resistant materials should be used to construct the chimney breast, its rear wall, the inte-

rior and the top of the chimney breast;

➠

the minimum internal dimensions required for the chimney breast must be taken into account;

➠

the chimney breast should be ventilated by vents with total free vent area of 200 cm2;

➠

only use the ue /combustion air supply systems supplied by DRU;

➠

use the wall brackets supplied to mount the appliance;

➠

do not install the appliance at against the back wall;

➠

leave the space between the feet free;

➠

do not cover and/or pack the appliance with an insulating blanket or any other material;

➠

Keep combustible objects and/or materials at a minimum distance of 500 mm from the appliance.

➠

only use the log set supplied;

➠

arrange the logs exactly as described;

➠

leave a space around the pilot burner;

➠

make sure thermocouple 2 and the space around it are kept free;

➠

avoid any dirt in the gas pipes and connections;

English

Apollo 80 - instruction for instAllAtion

➠

test the gastightness of all connections before use;

➠

use heat-resistant electrical connection materials;

➠

install the electrical connections away from the appliance;

➠

replace torn or broken panes;

➠

avoid blocking the explosion hatches;

➠

ensure the explosion hatches on top of the heater are right on their seats, before you close the chimney breast;

➠

do not ignite the appliance until installation has been completed.

4. Instructions

To ensure the appliance works correctly and safely, always take the following points into consideration during installation:

➠

place the control box supplied as low as possible;

➠

ensure the ignition wire does not lie across the receiver;

➠

ensure the ignition wire does not touch or cross the aerial;

➠

to avoid weakening the spark ensure the ignition wire does not touch anything metal;

➠

if the appliance is to be built in ush with the wall, nish the edges neatly;

➠

do not plaster over the anges;

➠

avoid damaging the glass when removing/tting the window pane;

➠

to prevent dirt burning into the glass, make sure it is clean before use.

➠

make sure that the wires of thermocouple 2 cannot come into contact with hot parts.

5. Unpacking

Please take the following points into consideration when unpacking the appliance:

➠

Check the appliance for transit damage;

➠

Contact DRU Service if necessary.

Once the packaging material has been removed, you should have the following components:

- Socket spanner: You will ﬁnd this in the space between the assembly frame and the combustion chamber;

- Trimmings: These are in the same space.

Once you have removed the glass pane you can remove the box of components from the combustion chamber.

!N.B. Be careful not to damage the glass when removing/tting the window pane.

➠

Remove the window as described in paragraph 6.10.1;

➠

Take the box of components out of the combustion chamber.

Annex 1 / Table 4 speciﬁes the components you should have once everything has been unpacked.

➠

Contact DRU Service if after unpacking the appliance you do not have all the components;

➠

Dispose of the packaging in an appropriate manner.

6. Installation

Please read the manual carefully to ensure that once installed the appliance will work correctly and safely.

!N.B. Install the appliance in the order described in this chapter.

6.1 Regulations

- Observe the current applicable (installation) regulations;

- Observe the regulations/instructions laid down in this manual.

6.2 Gas type

The type plate speciﬁes the type of gas, gas pressure, and the country this appliance is intended for. The type plate

is on a chain and that is where it should stay.

N.B. Check that the appliance is suitable for the local gas type and pressure.

6.3 Gas connection

The gas connection should have a gas tap located near the appliance.

N.B. Prevent any dirt getting into the gas pipes or connections.

The following requirements apply for the gas connection:

➠

the size of the gas pipe should be such that no pressure loss can occur;

➠

the gas tap must be CE marked;

➠

the gas tap should be accessible at all times;

➠

Do not twist the gas tap when connecting the gas pipe.

English

Apollo 80 - instruction for instAllAtion

6.4 Positioning the appliance

Position the ﬁ re as follows:

N.B. - Keep combustible objects and/or materials at a minimum distance of 500 mm from the appliance.

- Do not adjust the appliance in any way.

➠

Determine the position of the appliance;

➠

Create a gas connection in the appropriate position; see section 6.3 for details;

➠

Create a duct for the ue / combustion air supply system, with the diameter shown below; see section 6.5 for details;

➠

Ø160 mm for a wall duct of incombustible material;

➠

Ø 250 mm for a wall duct of combustible material;

➠

Ø160 mm for a roof duct of incombustible material;

➠

Ø 250 mm for a roof duct of combustible material.

!N.B. - Allow for the depth of the appliance (see Fig. 2) (The minimum depth at the Apollo is 450 mm);

- Allow for the build-in height; this will depend on the height of the adjustable feet (see Fig. 1a).

➠

Move the appliance into its intended position.

The gas control block is mounted onto the burner plate at the bottom of the appliance. This should be removed and

placed in the control box later. See section 6.7 for information on how to ﬁ t the gas control block.

Commence as follows:

➠

Disconnect the hoses from the gas control block (exible gas hose, aluminium pilot pipe and thermocouple 1);

Caution

The red wire of thermocouple 2 must remain connected to the gas control. Fig. 1b shows how the wires are connected

to the thermocouple.

➠

Unscrew the self-tapping screw in the burner plate and remove the gas control block.

➠

Carefully unwind the red and black wires of thermocouple 2.

➠

Lay the gas control together with the wires of thermocouple 2 in the direction of the control box.

N.B. - Avoid dirt in the hoses;

- Avoid kinks in the hoses.

➠

Unroll the hoses towards the control box;

➠

Unroll the ignition wire towards the control box.

Apollo 80

Front view

Top view

Side view

min. 910

max. 935

995

813

448

192

504

min. 160

max. 185

Fig. 1a

min 1450 mm inside

min 450 mm inside

Control box

38c-1294

max 100 mm

508

817

min

150 mm

min

1350 mm

inside

Total

ventilation

200 cm2

Maximal

plaster line

Maximal

plaster line

A-A

Fig. 2

Fig. 1b

English

Apollo 80 - instruction for instAllAtion

!N.B. The type plate should be connected to the chain.

➠

Lay the chain with the type plate facing the control

box;

➠

Adjust the height of the appliance;

➠

Using a spirit level to ensure it is absolutely level.

N.B. - Do not install the appliance at against the back

wall;

- Leave the space between the feet free;

- Do not cover and/or pack the appliance with an in-

sulating blanket or any other material.

➠

Secure the appliance against the wall using the wall

brackets and rawplugs supplied (see Fig. 3).

6.5 Flue gas discharge / combustion air

supply system

6.5.1 General

The appliance is of the C11/C31 type.

The appliance is connected to a combined ﬂ ue gas

discharge/combustion air supply system, hereafter

referred to as the concentric system.

The passage to the outside can be made with a wall

duct (see section 6.5.2) or with a roof duct (see sec-

tion 6.5.3).

If necessary, you can also use an existing discharge

channel (see section 6.5.4).

N.B. - Only use the concentric system supplied by DRU

(Ø100 / Ø150 mm). This system was tested in com-

bination with the appliance; DRU cannot guarantee

a proper and safe operation of other systems and

cannot accept liability for these systems;

- For connecting to an existing chimney ue you

should only use the installation set supplied by

DRU.

The concentric system is constructed from (the di-

scharge stump of) the appliance.

If structural circumstances require that the concen-

tric system is placed ﬁ rst, the appliance can later be

connected with a telescopic pipe piece.

6.5.2 Application with wall duct

6.5.2.1 Construction of concentric system with

wall duct

The concentric system with wall duct has to comply with the following conditions:

➠

First, a concentric pipe of at least 1 meter should be connected vertically to the appliance;

➠

The total vertical pipe length can have a maximum of 4 meters;

➠

After the vertical part a bend of 90° is connected;

➠

When using a minimum 1 up to maximum 4 meter vertical pipe length, the total horizontal pipe length may have a

maximum of 3 meters (wall duct not included; see Fig. 4a).

Depending on the construction of the concentric system, further adjustments should be made to the appliance.

The next 2 conﬁ gurations are allowed for the construction:

a) a minimum 1 meter up to maximum 4 meter vertical pipe length in combination with a 90° bend and a wall duct

(i.e. no horizontal part; see Fig. 4b).

When using this conﬁ guration, you must set the restriction to 60 mm (for this, see section 6.8.1).

b) a minimum 1 meter and maximum 4 meter vertical pipe length in combination with a 90° bend and a maximum

3 meter horizontal pipe length and a wall duct (see Fig. 4a).

When using this application, you must remove the air inlet guides.

6.5.2.2 Installing the concentric system

Explosion by-pass valves

Wall brackets

38c-1292

Fig. 3

Fig. 4a

Fig. 4b

English

Apollo 80 - instruction for instAllAtion

To install the concentric system commence as follows:

➠

Construct the system from the (connection stub of the) appliance up.

N.B. - 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-into a cove for example, incombustible material should be applied all around;

- Use heat-resistant insulating material for ducts made of combustible material;

- The rosette (mounting inner plate) of the wall duct is too small to seal the Ø 250 mm opening when passing through

combustible material. That is why you should rst apply a suciently large heat-resistant intermediate plate to the

wall. Then, the rosette is mounted on the intermediate plate.

➠

Connect the concentric pipe sections and the bend(s);

➠

Fit a clamping strip and silicone sealing ring to every connection;

➠

Secure the clamping strip with a self-tapping screw in places which will be inaccessible after installation;

➠

Use enough brackets to ensure that the weight of the pipes does not rest on the appliance;

➠

Determine the remaining length of the wall duct;

➠

Cut the wall duct to size;

!N.B. - Make sure that the right insertion length is maintained;

- Place the wall duct with the groove/folded seam at the top;

- Make sure the horizontal concentric pipe pieces are sloping towards the wall duct, in order to prevent rain water

from entering.

➠

Mount the rosette (mounting inner plate); if necessary, on a heat resistant intermediate plate when passing through

combustible material;

➠

Attach the wall duct from the outside with four screws in their respective holes.

!N.B. Some heat-resistant isolation materials contain volatile components that will spread an unpleasant smell for a pro-

longed time; these are not suitable.

6.5.3 Application with roof duct

6.5.3.1 Construction of concentric system with roof duct

The concentric system with roof duct has to comply with the following conditions

➠

The construction of the chosen system has to be allowed. (See the procedure described below);

➠

First, a concentric pipe of at least 1 meter should be connected vertically to the appliance.

Depending on the construction of the concentric system, the appliance is set by placing the bafﬂe and/or removing

the air inlet guides.

In the following procedure you can see how the allowability of a concentric system can be determined and which

settings are needed.

➠

Determine the following data:

1. The number of bends required (no distinction is made between 45° and 90° bends);

2. The total number of meters of horizontal pipe length;

3. The total number of meters of vertical and/or sloping pipe length (wall duct not included).

With these data and Table 1 you will be able to determine whether the concentric system is allowed.

In Table 2 you can see which setting the appliance needs.

Follow the procedure described below:

➠

In the rst 2 columns of Table 1, look for the number of bends required and the total horizontal pipe length;

➠

In the 3rd column of Table 1, look for the total vertical and/or sloping pipe length.

If you end up in a box with the letter A, B, C, D or E the concentric system chosen by you is allowed.

➠

Use Table 2 to determine which conditions apply for the bae and/or the air inlet guides (for setting see section 6.8);

Examples

To clarify, we will give 2 examples to determine the allowability of a concentric system and the conditions for setting

the appliance.

In Table 1 the route to be followed is indicated by arrows. The result is indicated by means of the red frame of the box.

Example 1

1) 2 bends

2) 3 meters horizontal

3) 8 meters vertical/sloping

→ Construction of this concentric system is allowed.

→ Situation B applies for setting the appliance

English

Apollo 80 - instruction for instAllAtion

Example 2

1) 3 bends

2) 4 meters horizontal

3) 10 meters vertical/sloping

→ Construction of this concentric system is not allowed.

Table 1: Conditions for adjusting the equipment with roof ducts

G20 / G25

total number of

meters of horizon-

tal pipe lengths

total number of meters of vertical and/or sloping pipe lengths

1 2 3 4 5 6 7 ↓89↓10 11 12

no bends 0 B C C D D D D E E E E E

2 bends 0 A A B C C D D D D E E E

1 A A B C C D D D D E

2 A A B C C D D D

→3 A A B C C D

4 A A B C

3 bends 0 A A A B C C D D D D E E

1 A A A B C C D D D D

2 A A A B C C D D

3 A A A B C C

→4 A A A B

4 bends 0 A A A A B C C D D D D E

1 A A A A B C C D D D

2 A A A A B C C D

3 A A A A B C

4 A A A A

5 bends -

n = The situation is not permissible.

Table 2:

Situation Air inlet guide Bafﬂe Dammingg distance

A NO NO OPEN

B YES YES 44 mm

C YES YES 41 mm

D YES YES 37 mm

E YES YES 30 mm

6.5.3.2 Installing the concentric system

The roof duct can be used for either a sloping roof or a ﬂat roof.

The roof duct can be supplied with an adhesive plate for a ﬂat roof or with a universally adjustable tile for a sloping roof.

Install the concentric system as follows:

➠

Construct the system from the (connection stub of the) appliance up

N.B. - 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-into a cove for example, incombustible material should be applied all around;

- Use heat-resistant insulating material for ducts made of combustible material.

!N.B. Some heat-resistant isolation materials contain volatile components that will spread an unpleasant smell for a pro-

longed time; these are not suitable.

English

Apollo 80 - instruction for instAllAtion

➠

Connect the concentric pipe sections and any necessary bends;

➠

Fit a clamping strip and silicone sealing ring to every connection;

➠

Secure the clamping strip with a self-tapping screw in places which will be inaccessible after installation;

➠

Use enough brackets to ensure that the weight of the pipes does not rest on the appliance;

➠

Determine the remaining length of the roof duct;

➠

Cut the roof duct to size.

!N.B. Be sure to maintain the correct insertion length.

➠

Connect the roof duct to the concentric pipes.

!N.B. - Make sure the universal roof tile ts well against the surrounding tiles;

- Make sure the adhesive ashing sticks to the at roof properly.

6.5.4 Connection to an existing ﬂue

The appliance can also be connected to an existing ﬂue.

A ﬂexible SS pipe is placed in the chimney for discharging ﬂue gases. The surrounding space is used to supply the

combustion air.

The following requirements apply for connection to an existing ﬂue:

- allowed only if the special DRU chimney connection set is used;

- Installation instructions supplied;

- minimum dimensions 150 x 150 mm;

- maximum vertical length 12 metres;

- maximum horizontal length 3 metres;

- the existing ﬂue must be clean;

- the existing ﬂue must not have any cracks or leaks.

6.6 Building the chimney breast

The appliance is designed to be installed snugly into a newly built chimney breast.

There must be sufﬁcient space around the appliance to ensure a good heat distribution.

The chimney breast should be ventilated by vents.

N.B. - Use incombustible and heat-resistant material to construct the chimney breast, including rear wall of the chimney

breast;

- The total free vent area of the vents, installed as high as possible, should be at least 200 cm2.

!N.B. When building the chimney breast, the following points should be taken into account (see Fig. 2):

- position of the control box: this should be placed within 850 mm to the left or right of the appliance, as low as possible;

- size of the control box; see section 6.7 Installing the control box;

- position of the vents;

- the size of the glass window so that it can be tted/removed once the chimney breast has been built;

- protecting the gas control block and hoses from cement and plaster.

!Tip The vents should preferably be created in both sides of the chimney breast: you could use DRU ventilation elements.

➠

Check that the concentric system has been installed correctly;

➠

Check that the clamping strips have been secured with self-tapping screws in places which will be inaccessible later;

➠

Allow sucient clearance round the appliance in the chimney breast to enable the heat to disperse:

- minimum internal height: 1350 mm;

- minimum internal width: 1450 mm.

➠

Do not plaster over the anges because:

- the heat from the appliance could cause cracks;

- it will then be impossible to remove/t the glass window.

➠

If the chimney breast is of materials similar to stone, or is nished with plaster, it should be dried-out at least 6 weeks

before commissioning, in order to prevent cracks.

6.7 Installing the control box

The control box is to be installed as low as possible.

The control box contains various components such as the type plate, the gas control block, and the receiver for the

remote control. (See Fig. 5 for details.)

➠

Make a 285 x 194 mm (h x w) opening in the chimney breast;

➠

Fit the inner frame (1); to do this unscrew the bolts (5).

!Tip - If the chimney breast is brick, the inner frame can be cemented in during building;

- For a chimney breast of any other material, glue/cement the inner frame in place or t it with four countersunk

screws.

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Apollo 80 - instruction for instAllAtion

➠

Mount the gas control block on the brackets (2) on the inner frame;

➠

Reconnect the hoses to the gas control block.

N.B. - Avoid kinks in the hoses;

- Tighten the exible hose and aluminium pipe making sure they are gastight;

- Screw the thermocouple 1 on by hand rst and then;

- then tighten it a quarter turn using a suitable spanner.

➠

Connect the thermocouple1 wiring to the gas control block if necessary; see Photo 1;

➠

Blow through the gas pipe if necessary;

➠

Connect the gas pipe to the gas tap;

➠

Bleed o the air in the gas pipe;

➠

Fit the receiver (3); see section 7.1 for connections;

➠

Fit the type plate (6);

➠

Fit the outer frame with door (4) to the inner frame using the two self-tapping screws (5).

!Tip You can position the outer frame in such a way that the door opens to either the left or right.

6.8 Adjusting the appliance

The appliance has to be set in such a way that it works correctly in combination with the discharge system.

For that purpose, a bafﬂ e is placed and/or the air inlet guides are removed. The conditions for using a wall duct are

described in section 6.5.2.1, and for using a roof duct in section 6.5.3.1.

Caution

For Belgium, the condition applies that the primary aeration of the burners has to be changed, if the appliance is used

with gas G25 instead of G20; see section 6.8.3.

6.8.1 Bafﬂ e (R)

The bafﬂ e (R) is supplied separately.

It is mounted as follows:

➠

Place the bae. (see Fig. 6a and 6b)

➠

Use the template supplied to set the distance of the restriction (see Fig. 7) as follows:

- A distance of 30 mm, means that the bae will be fully closed;

- A distance of 37 mm is set by means of the template;

- A distance of 41 mm is set by means of the template;

- A distance of 44 mm is set by means of the template;

- A distance of 60 mm is set by means of the template;

➠

Fix the bae by using the socket cap screw (U).

6.8.2 Air inlet guides (L)

The air inlet guides (L) are located at the bottom (side) of the tray around the burner.

Remove them as follows; see Fig. 8:

➠

Remove the tray surrounding the burner (M);

➠

Unscrew and remove the self-tapping screws (N);

➠

Remove the air inlet guides;

➠

Replace the tray round the burner.

38c-1078

Fig. 5

Damper

socket-head screw

Fig. 6a

Fig. 7

38c-1269

Damper

Fig. 6b

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