Cosmo - Cosmo Tunnel
Contents
1. Cosmo Cosmo Tunnel G20 G25 Installation manual GB IE ar Store this document in a safe place T CE 959 021 01 GB 95902101_GB Install indd 1 27 5 10 15 35 English COSMO INSTALLATION MANUAL English 95902101_GB Install indd 2 page Preface 3 1 Introduction 3 2 CEdeclaration 3 3 SAFETY 4 3 1 General 4 3 2 Regulations 4 3 3 Precautions safety instructions during installation 4 4 Instructions 4 5 Removing the packaging 5 6 Installation 5 6 1 Regulations 5 6 2 Type of gas 5 6 3 Gas connection 5 6 4 Placing the appliance 5 6 5 Flue gas discharge combustion air supply system 6 6 6 Placing the chimney breast 9 6 7 Placing the control box 10 6 8 Adjusting the appliance 10 6 9 Placing the wood set 11 6 10 Glass window 11 7 Wireless remote control 12 7 1 Receiver 12 8 Final check 13 8 1 Gastightness 13 8 2 Gas pressure pre pressure 13 8 3 Ignition pilot and main burner 13 8 4 Flame image 14 9 Maintenance 15 9 1 Parts 15 10 Delivery 16 11 Malfunctions 16 Appendix 1Parts included with the delivery 19 Appendix 2Technical data 19 Appendix 3 Figures 20 2 27 5 10 15 35 COSMO INSTALLATION MANUAL DRU a manufacturer of gas fired heating appliances develops and produces products that comply with the highest quality performance and safety requirements This guarantees that the user will be able to enjoy using his product for many yea2. Donot turn the pilot burner lower by using the settings on the gas control 8 3 1 Pilot burner Check the ignition of the pilot burner the pilot burner should start at the first attempt If the pilot burner does not ignite check if the ignition sparks a If not the ignition cable is probably not lying free from metal parts b If it does there is probably still air in the pipe Bleed the pipe and or Lay the ignition cable free from metal parts Englisi 95902101_GB Install indd 13 13 27 5 10 15 35 COSMO INSTALLATION MANUAL 8 3 2 Main burner Aiton The main burner should ignite smoothly and should not pop as a result of delayed ignition Check the function of the main burner from the standby pilot burner position after opening the gas valve the main burner should burn within a few seconds Tip When the gas valve is opened the motor will run this is audible 1 If the main burner does not burn Check if button A on the gas control is in the position ON gt Check if the space surrounding the pilot burner is free from objects la Check the placement of the wood set La If necessary correct the above mentioned faults Test the main burner 5x for a good operation 2 If the main burner ignites but goes out again after approx 22 seconds please Check the wiring of thermocouple 2 for Loose wiring Wrongly connected wiring Shor
3. receiver belonging to the remote control Proceed as follows when placing the control box see fig 4 for details Make an opening in the chimney breast of 285 x 194 mm h x w Place the inner frame 1 unscrew bolts 5 for this 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 Mount the gas control to the brackets of the inner frame 2 Reconnect the pipes to the gas control Avoid kinks in the pipes Place the aluminium pilot burner pipe free from the floor and or the wall Tighten the flexible gas pipes and the pilot burner pipe until they are gastight If applicable connect the wires of thermocouple 1 to the gas control see fig 5 First tighten the thermocouple by hand and then tighten it a quarter turn using a suitable spanner If necessary blow clean the gas pipe Connect the gas pipe to the gas tap Bleed the gas pipe Place the receiver 3 for connections see section 7 1 Place the data plate 6 Fix the outer frame with door 4 to the inner frame using 2 socket cap screws You can place the outer frame in such a way that the door turns to the left or to the right 6 8 Adjusting the appliance The appliance has to be set in such a way that it works correctly in combination with the concentric system For that purpose if necessary a baffle
4. Cas mig a 22 95902101_GB Install indd 22 27 5 10 15 35 COSMO INSTALLATION MANUAL English o DE 23 95902101_GB Install indd 23 27 5 10 15 35 COSMO INSTALLATION MANUAL 95902101_GB Install indd 24 27 5 10 15 35 COSMO INSTALLATION MANUAL English 25 95902101_GB Install indd 25 27 5 10 15 35 COSMO INSTALLATION MANUAL wi EA PA hb hS n 1 tu 7 lg la English 26 95902101_GB Install indd 26 27 5 10 15 35 COSMO INSTALLATION MANUAL 3 27 5 10 6 95902101 065 Install indd 27 COSMO INSTALLATION MANUAL AN DRU Verwarming B V The Netherlands L Postbus 1021 NL 6920 BA Duiven Ratio 8 NL 6921 RW Duiven 95902101_GB Install indd 28 27 5 10 15 36
5. Place log E see fig 12k Fill the tray surrounding the burner with chips spread the chips evenly Place log F see fig 12m Finally place the rear logs G and H see fig 12n 6 10 Glass window After placing the wood set you can place the glass window as described below Always remove place the glass window with 2 people Avoid damages when removing placing the glass window 95902101_GB Install indd 11 11 27 5 10 15 35 COSMO INSTALLATION MANUAL 6 10 1 Removing the glass window Remove the glass window in accordance with the following instructions see fig 13a up to 13f Remove the vertical decorative strips on the left and right of the glass window by first pulling them out at the top tilting them parallel with the glass window and then loosening them at the bottom IL Remove the horizontal decorative strip by gripping it with 2 hands in the slot and lifting it out IL Unscrew the 6 self tapping screws in the bottom strip of the glass window using the socket spanner supplied IL Take hold of the top and bottom handgrips and lift the glass window Pull on the bottom handgrips to tilt the glass window in its mounting towards you and at the same time pull the top of the glass window towards you as far as possible Gently allow the glass window to drop at an angle until it can be removed entirely from the mounting 6 10 2 Placing the glass window The glass window is
6. fitted by using the above procedure in reverse order Caution Check that the hook at the top of the glass window is in position in the seating U shaped strip Tip Pull on the upper handgrip to move the glass frame towards you if it does not move then it has been fitted correctly Caution Theself tapping screws must not be over tightened since otherwise they could break or strip the thread tight tight Avoid remove fingerprints on the pane since otherwise they will burn into the surface 7 Wireless remote control The appliance is supplied with a wireless remote control Ignition controlling the flame height and switching off are performed by a remote control that operates a receiver in the control box User Manual chapter 4 Wireless Remote Control describes the operation of the appliance including the way the remote control works Aiton Do not ignite the appliance until it is fully installed Below we will describe how the receiver is connected 7 1 Receiver The receiver should be connected to the appliance before the batteries are installed Follow the procedure below see fig 14 Fit the connection cable s brown plug to the receiver see fig 14 arrow F Connect the white plug to the gas control Tip The plugs have different sizes that correspond with the connectors Connect the cables of thermocouple 1 to the receiver see fig 14 arrows B Tip The size of the eye corresponds with the
7. is defective 8 Checkthe voltage across thermocouple 2 just before the main burner goes out If the voltage is higher than 1 8 mV replace the receiver 18 95902101_GB Install indd 18 27 5 10 15 35 COSMO INSTALLATION MANUAL Appendix 1 Parts included with the delivery In the following table you can find the parts that are supplied with the appliance Table 5 Parts included with the delivery Part Quantity Wood set 1x Control box 1x Manual control box 1x Installation manual 1x User manual 1x Decorative strip left Cosmo 1x Cosmo tunnel 2x Decorative strip right Cosmo 1x Cosmo tunnel 2x Decorative strip below Cosmo 1x Cosmo tunnel 2x Template for baffle 1 Baffle 1x Cap to transfer the flame 1x Spare self tapping screws for mounting the glass window Socket spanner 8 mm 1x Remote control with receiver 1x 9V block battery 1x Penlite battery AA type 4x Pressure coupling 15 mm x G3 8 1x In the following table you can find the technical data of the Cosmo Cosmo tunnel Table 6 Technical data Appendix 2 Technical data Type C11 C31 Type of gas G20 G25 Burner pressure mbar 15 4 19 4 Nominal heat input H kW 22 9 21 Nominal heat input H kW 20 6 18 9 Nominal output kW 15 6 14 4 Consumption L h 2168 2312 Burner injector 5 5x 1 55 5x 1 55 2x 0 95 2x 5 Consumption o
8. is not yet finished 16 95902101_GB Install indd 16 27 5 10 15 35 COSMO INSTALLATION MANUAL Table 4 Diagnosis of malfunctions Possible cause Problem Remedy C No sound signal 1 Receiver is damaged 1 Replace the receiver and confirm the code remedy 1 at A 2 60 second delay before the full 2 Wait until the delay time has passed restart is not yet finished D One continuous sound 1 Loose wiring between receiver 1 Connect the wiring properly signal of 5 sec and gas control Possible 7 short beeps 2 Receiver is damaged 2 Replace the receiver and confirm the code prior to the 5 sec remedy 1 at A sound signal 3 Bent pins of the 8 wire con 3 Make sure that the pins of the 8 wire connec nector tor are straight 4 Damaged magnetic valve 4 Replace the gas control 5 Thermocouple 2 still too hot 5 Wait until the thermocouple has cooled down sufficiently E No pilot burner flame Air in the pilot burner pipe Wires of thermocouple 1 have been cross connected No spark at the pilot burner Injector is blocked up 1 Flush the pipe or start the ignition process several times N Connect the thermocouple wiring properly if necessary 3 1 Check if the ignition cable S is lying free from metal parts see fig 15 If necessary move it away from the metal parts 3 2 If necessary replace the ignition cable 3 3 If necessary replace the ign
9. is placed The conditions for using a wall terminal are described in section 6 5 2 1 and for using a roof terminal in section 6 5 3 1 6 8 1 Baffle R The baffle R is supplied separately see fig 6a 10 95902101_GB Install indd 10 27 5 10 15 35 COSMO INSTALLATION MANUAL ICaution Tip Caution ICaution Tip ICaution This is mounted as follows see fig 6b Place the baffle Use the template supplied to set the distance of the restriction see fig 7 Fix the baffle by using the socket cap screw U 6 9 Placing the wood set The appliance is supplied with a wood set Before you can fit the wood set the glass window must be removed to do so see paragraph 6 10 1 Strictly observe the following instructions to prevent unsafe situations only ever use the supplied wood set place the wood set exactly as described make sure the pilot burner and the space around it are kept free from objects see fig 8 make sure that thermocouple 2 and the space around it are kept free from objects see fig 8 make sure that the slot between the burner tray and the tray surrounding the burner is kept free from objects make sure that the vermiculite s fine dust does not get on the burners 6 9 1 Wood set The wood set consists of black vermiculite see fig 9 chips see fig 10 and a numbe
10. plate is connected to a chain It should remain connected to the chain Aiton Check whether the appliance is suitable for the type of gas and the gas pressure used at the location 6 3 Gas connection Place a gas tap in the gas connection close to the appliance Aiton Make sure there is no dirt in gas pipes and connections Prevent twisting the gas tap when connecting the gas pipe The following requirements apply to the gas connection use a gas connection with the right dimensions so that the required pre pressure and burner pressure are ensu red when the appliance is used on full load the gas tap should have the CE marking you should always be able to reach the gas tap 6 4 Placing the appliance Caution Make sure that combustible objects and or materials have a distance from the appliance of at least 500 mm Always place the standard appliance against a wall of non combustible and heat resistant material Take sufficient measures to prevent temperatures of a wall behind the chimney breast becoming too high including the materials and or objects behind the wall Donot make any changes to the appliance Kaution Take the adjustable height of the appliance into account depending on the setting of the adjustable feet the height can vary between 185 and 225 mm see fig 1a and fig 1b Take the minimum construction depth of the appliance into account Cosmo 702 mm Cosmo tunnel 692 mm see fig 2 9
11. reset button of the receiver motor will not run code between receiver and until you hear 2 sound signals see fig 18 remote control must still be Let go of the reset button after the second confirmed longer sound signal and press button 4 small flame or button N large flame on the remote control within 20 sec until you hear an extra long sound signal confirming that the new code has been set 2 Empty batteries 2 Replace batteries Kaution Avoid short circuit between the batteries and metal parts ofthe appliance 3 Receiver is damaged 3 Replace the receiver and confirm the code remedy 1 4 Remote control is damaged 4 Replace the remote control and confirm the code remedy 1 5 Motor cable at valve receiver is 5 Replace the motor cable broken 6 Bent pins of the 8 wire con 6 Make sure that the pins of the 8 wire connec nector tor are straight 7 Ifthe receiver is surrounded by 7 Change the position of the antenna metal this could decrease the transmission range B No ignition spark 1 Button Ain position MAN 1 Switch button A on the gas control to ON see fig 15 2 Ignition cable runs over and or 2 Do not place the ignition cable S over and or alongside metal parts along metal parts This will weaken the spark see fig 15 If necessary replace the ignition cable 3 Ignition pen corroded 3 Replace the ignition pen 4 60 second delay before the full 4 Wait until the delay time has passed restart
12. size of the screw The colours of eye and screw also correspond Connect the black wire with the white plug of thermocouple 2 to the receiver see fig 14 arrow E Kaution Make sure that the wires of thermocouple 2 cannot come into contact with hot parts Make sure the ignition cable cannot come into contact with other wires Connect the ignition cable to the receiver see fig 14 arrow A Connect power a When using batteries see section 7 1 1 below b When using an adapter connect it to the receiver see fig 14 arrow C insert the plug into the wall socket Place the receiver V in the control box as indicated on fig 15 Bend the antenna out of the clips see fig 14 arrow 12 95902101_GB Install indd 12 27 5 10 15 35 COSMO INSTALLATION MANUAL Set the antenna straight Kaution Do not place the antenna N too close to the ignition cable and or metal parts for the correct position see fig 15 Donot place the ignition cable over and or along metal parts this will weaken the spark Donotlay the ignition cable over the receiver this could damage the receiver Avoid dust on or in the receiver cover it when performing work 7 1 1 Placing replacing the batteries Follow the procedure below when placing the batteries Ia Open the door of the control box Pick up the receiver Slide the cover off Place or remove the 4 penlite AA
13. type batteries Caution Avoid a short circuit between the batteries and metal objects parts Observe the and poles of the batteries and the holder Use alkaline batteries TS Slide back the cover Place back the receiver Kaution Batteries are regarded as small chemical waste and may therefore not be disposed with the household rubbish 8 Final check In order to check whether the appliance is working properly and safely you must perform the following checks before the appliance is used 8 1 Gastightness Caution All connections must be gastight Cautiin The gas control can be subjected to a maximum pressure of 50 mbar Check the connections for gastightness 8 2 Gas pressure pre pressure The burner pressure is set at the factory see data plate It is not necessary to check the burner pressure Aiton The pre pressure in house installations should be checked as they can vary Check the pre pressure see fig 16 for the measuring nipple on the gas control Contact the gas company if the pre pressure is not correct 8 3 Ignition pilot and main burner For igniting the pilot and main burners see the User Manual chapter 4 section 4 2 Remote Control Aiton During the ignition process you are not allowed to operate control button B on the gas control manually Always wait 5 minutes after the pilot burner has gone out before you re ignite the appliance
14. 13 NEN EN 613 A1 Internal measures by the company guarantee that appliances produced in series comply with the essential require ments of the prevailing EEC directives 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 M J M Gelten General manager DRU verwarming B V Postbus 1021 6920 BA Duiven Ratio 8 6921 RW Duiven www dru nl English 95902101_GB Install indd 3 27 5 10 15 35 COSMO INSTALLATION MANUAL 3 SAFETY 3 1 General Caution Carefully read this chapter on safety before you start performing installation or maintenance work Please observe the general regulations and the precautions safety instructions in this manual 3 2 Regulations Please install the appliance in accordance with the applicable national local and constructional installation regu lations 3 3 Precautions safety instructions during installation Carefully observe the following precautions safety regulations you should only install and maintain the appliance if you are a competent installer in the field of atmospheric gas fired heating do not make any changes to the appliance English 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 p
15. 5902101_GB Install indd 5 27 5 10 15 35 COSMO INSTALLATION MANUAL Tip Caution Aiton Kaution You can determine the construction height of the appliance in fig 2 yourself Place the appliance as follows Determine the location of the appliance Determine the construction height of the appliance Provide a gas connection at the location For details see section 6 3 Make a passage for the flue gas discharge combustion air supply system with the following diameters For details see section 6 5 220 mm for a wall terminal through non combustible material 310mm for a wall terminal through combustible material 160 mm for a roof terminal through non combustible material 0 250 mm for a roof terminal through combustible material Place the appliance on its destined location The gas control is mounted under the appliance at the burner plate It should be disconnected and placed in the control box at a later stage For placing the gas control in the control box see section 6 7 Follow the procedure described below Disconnect the pipes from the gas control flexible gas pipes aluminium pilot flame pipe and thermocouple 1 The red wire of thermocouple 2 must remain connected to the gas control Disconnect the gas control from the burner plate by unscrewing the se
16. all terminal G20 25 Total number of Total number of See figure Baffle Distance of meters vertical pipe meters horizontal pipe length restriction length excluding wall terminal inmm 1 4 0 5 3 NO OPEN 6 5 2 2 Placing concentric system with wall terminal 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 material all around it Use heat resistant insulation material when passing through combustible material The rosette mounting inner plate of the wall terminal is too small to seal the 310 mm opening when passing through combustible material That is why you should first apply a sufficiently large heat resistant intermediate plate to the wall Then the rosette is mounted on the intermediate plate Some heat resistant insulation materials contain volatile components that will spread an unpleasant smell for a pro longed time these are not suitable Place the concentric system as follows Build the system up from the connection stump of the appliance Connect the concentric pipe pieces and the bend On each connection apply a clip binding with silicon sealing ring Use a self tapping screw to fix the clip binding to the pipe on locations that cannot be reached after installation Apply sufficient clamps so that the weight of the pipes does not r
17. bends 0 1 2 3 gt 4 5 4 bends 0 1 2 3 4 5 I situation is not allowed Table 3 Conditions for the adjustment of the appliance with a roof terminal G20 G25 Situation Baffle Distance of restriction inmm A NO OPEN B YES 80 6 6 Placing the chimney breast The appliance is designed to be mounted tightly in a new chimney breast 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 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 that the appliance is not carrying the weight of the chimney breast when using stone like materials The ventilation holes which should be mounted as high as possible should have a combined passage of at least 520 cm When placing the chimney breast you should take the following into account see fig 2 the location of the control box K it should be placed with a distance of 850 mm to the left or to the right of the ap pliance as low as possible the measurements of the control box see Placing the Control Box section 6 7 the location of the ventilation holes V measurement of the glass window so it can be placed removed after placing the chimney breast the protection of th
18. cally After the first metre the system will be reduced to a 100 150 mm diameter 6 5 3 1 2 Concentric system with bends A concentric system with bends must comply with the following conditions The construction of the chosen system is allowed For this see section 6 5 3 1 4 Onthe appliance at least 1 metre of concentric pipe with a diameter of 130 200 mm is initially connected verti cally Up to and including the last bend the system is made with pipe pieces with a 130 200 mm diameter After the last bend the system will be reduced to pipe pieces with a 100 150 mm diameter 6 5 3 1 4 Acceptability of concentric systems with accompanying settings Depending on the construction of the concentric system the appliance is set by placing the baffle 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 roof terminal excluded With these data and Table 2 you will be able to determine whether the concentric system is allowed In Table 3 you can see which setting the appliance requires Follow the procedure described below In the first 2 columns of Table 2 look for the number of bends required and th
19. ctions for gastightness before using the appliance mp use heat resistant electrical wiring place the electrical wiring in such a way that they are free from the appliance gt replace torn or broken panes gt avoid blocking of the pressure equalization hatch es on top of the appliance check whether the pressure equalization hatch es fit well onto the sealing surface prior to building in the appliance do not ignite the appliance until it is fully installed 4 Instructions Observe the following items during installation in order to guarantee a proper and safe operation of the appliance mount the control box supplied as low as possible avoid that the ignition cable runs over the receiver avoid that the ignition cable touches or crosses the antenna avoid that the ignition cable runs alongside metal parts in order to prevent weakening of the spark IL make sure the ignition cable cannot come into contact with other wires properly finish the edges in case of a tight construction do not apply plaster on or over the flanges always remove place the glass window with 2 people avoid damaging the pane when removing placing the glass window clean the pane before you use the appliance in order to prevent dirt from burning in the glass gt make sure that the wires of thermocouple 2 cannot come into contact with hot parts always place the large central
20. e gas control and the pipes against cement and plaster 95902101_GB Install indd 9 English 27 5 10 15 35 COSMO INSTALLATION MANUAL Tip ICaution Tip Tip You should preferably apply the ventilation holes on both sides of the chimney breast You can use DRU lux lignum elements Check whether the concentric system is placed correctly Check the fixture of the clip binding with self tapping screws on places that cannot be reached later on Maintain sufficient space around the appliance in the chimney breast so the heat can escape minimum internal height 2000 mm minimum internal width 2400 mm Do not apply plaster on or over the flanges see fig 2 maximum plaster line M because the heat of the appliance could cause cracks it will no longer be possible to remove place the glass window When using stone like materials and or plaster finishing the chimney breast should dry for at least 6 weeks before it is taken into operation in order to prevent cracks 6 7 Placing the control box The control box K is placed as low as possible in the chimney breast see fig 2 The bottom of the control box may not be placed higher in the appliance than the burner bed A number of components are placed in the control box such as data plate gas control
21. e total horizontal pipe length In the 3rd column of Table 2 look for the total vertical and or sloping pipe length If you end up in a box with the letter A or B the concentric system chosen by you is allowed Use Table 3 to determine which conditions apply for the baffle 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 2 the route to be followed is indicated by arrows The result is indicated by a box with a red border Example 1 1 2 bends 2 3 meters horizontal 3 8 meters vertical sloping Construction of this concentric system is allowed gt Situation A applies for the adjustment of the appliance Example 2 1 3 bends 2 4 meters horizontal 3 9 meters vertical sloping Construction of this concentric system is not allowed 95902101_GB Install indd 8 27 5 10 15 35 COSMO INSTALLATION MANUAL AA tion ICaution Table 2 Determination of the permissibility of a concentric system with a roof terminal G20 25 Total number of Total number of meters vertical and or sloping pipe length meters horizontal pipe length 1 2 3 4 5 6 7 8 J9 10 11 12 2 bends 0 B 1 A A A A A 2 A A A A A 4 A A 5 3
22. el is a look through ap pliance it has a pane at the font and back This version of the Cosmo and the Cosmo tunnel is suitable for natural gas The safe operation of the appliance is guaranteed by the use of a second thermocouple fitted to the main burner Main burner refers to the combination of burners with the exception of the pilot burner The Cosmo and the Cosmo tunnel are room sealed atmospheric gas fired heating appliances A room sealed ap pliance 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 This system can be installed through the wall or through the roof The appliances are built within a chimney breast In order to reach a proper heat discharge the chimney breast must be ventilated DRU is able to supply ventilation elements lux lignum elements The appliances are supplied with a wireless remote control that works on batteries 2 CEdeclaration We hereby declare that the design and construction of DRU s atmospheric gas fired heating appliance comply with the essential requirements of the Gas Appliance Directive Product atmospheric gas fired heating appliance Type Cosmo Cosmo tunnel Applicable EEC directives 2009 142 EC Applied harmonized standards NEN EN 6
23. ery You must explain to the user how he should operate the appliance You should instruct her him for instance on using the appliance for the first time the operation of the remote control annual maintenance Auton Tell the user to close the gas tap immediately in case of malfunctions bad performance 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 concerning unintended ignition by other remote controls such as car keys and garage door openers Instruct the user about the appliance and the remote control When the appliance is started for the first time point out that in order to avoid cracks in a chimney breast made of stone like materials or finished with plaster it should dry for at least 6 weeks prior to putting the appliance into operation English when the appliance is stoked up for the first time volatile components evaporate from paint materials etc when evaporating the appliance should preferably be set at the highest level the room should be well ventilated Give the user manual and installation manual to the user the installation manual should be kept near the appliance In the following table you will find an overview of malfunctions that might occur the possible causes and the remedies Problem Possible cause Remedy A No transmission 1 The new communication 1 Hold down the
24. est on the appliance Determine the remaining length of the wall terminal Make sure the wall terminal has the right dimensions Make sure that the right insertion length is maintained Place the wall terminal with the groove folded seam at the top Make sure the horizontal concentric pipe pieces are sloping towards the wall terminal 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 terminal from the outside with four screws in their respective holes 6 5 3 Application with roof terminal 6 5 3 1 Construction of concentric system with roof terminal When using a roof terminal we distinguish Concentric system without bends see section 6 5 3 1 1 Concentric system with bends in the vertical plane see section 6 5 3 1 2 In section 6 5 3 1 4 it will be determined whether the concentric system is allowed and what baffle settings apply 95902101_GB Install indd 7 27 5 10 15 35 COSMO INSTALLATION MANUAL 6 5 3 1 1 Concentric system without bends A concentric system without bends must comply with the following conditions The construction of the chosen system is allowed for this see section 6 5 3 1 4 On the appliance first 1 metre of concentric pipe with a diameter of 130 200 mm is connected verti
25. ition pen 4 1 Clean the injector 4 2 necessary replace the injector Check the polarity of the thermocouple wiring F Electronics keep spar king while the pilot burner is ignited Receiver is damaged 1 Replace the receiver and confirm the code remedy 1 at A G Pilot burner is burning but magnetic valve clo ses after ca 10 seconds or when the appliance gets hot 2 Thermocouple 1 does not function Batteries almost empty 1 1 Measure the voltage using a digital multime ter set to mV range by connecting the cables to the cable shoe The cable shoe is located on the outside directly next to the magnet nut at the rear of the gas control see fig 19 The voltage should be at least 5mV within 20 seconds lt may not be lower when the appliance is warm If the voltage is too low the thermocouple should be placed better in the flame or the thermocouple should be replaced 1 2 Check the size of the pilot burner flame Correct a flame that is too small 1 3 Check the wiring of the thermocouple to the receiver If necessary replace the wiring 2 Replace the receiver s batteries Caution Avoid short circuit between the batteries and metal parts of the appliance H There are short sound signals but no sparks and no sound clicks can be heard of the magnet opening the valve 1 Batteries almost empty 1 Replace the receiver s batteries Kautio
26. laced take sufficient measures to prevent temperatures 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 measurements of the chimney breast ventilate the chimney breast by means of the ventilation holes which will form a combined passage of at least 520 cm 2 lux lignum elemements place the ventilation holes as high as possible in the chimney breast only use the flue gas discharge combustion air supply system supplied by DRU gt do not place the standard appliance too tightly against the back wall gt make sure the space between the adjustable feet is kept free do not cover the appliance and or do not wrap it in an insulation blanket or any other material make sure that combustible objects and or materials have a distance from the appliance of at least 500 mm only ever use the supplied wood set place the wood set exactly as described Ia make sure the pilot burner and the space around it is kept free Ina make sure thermocouple 2 and the space around it are kept free Ina make sure there is no dirt in gas pipes and connections mount 2 gas tap directly next to the appliance IL use a gas connection with the right dimensions so that the required pre pressure and burner pressure are ensured when the appliance is used on full load IL check the conne
27. lf tapping screw 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 Make sure there is no dirt in gas pipes and connections Avoid kinks in the pipes Roll out the pipes in the direction of the control box Roll out the ignition cable in the direction of the control box Make sure the ignition cable cannot come into contact with other wires The data plate should remain connected to the chain Place the chain with the data plate in the direction of the control box Set the height of the appliance using the adjustable feet and Make the appliance level at the same time Do not place the appliance too tightly against the back wall this is guaranteed by means of the spacer brackets Make sure the space between the adjustable feet is kept free Donot cover the appliance and or do not wrap it in an insulation blanket or any other material 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 flue gas discharge combustion air supply system hereafter referred to as the concentric system The passage to the outside can be made with a wall terminal see section 6 5 2 or a roof terminal see section 6 5 3 Only use the concentric system supplied by DRU This system has been tested together with the appliance DRU can not guaran
28. log with 2 people to prevent breakage 95902101_GB Install indd 4 27 5 10 15 35 COSMO INSTALLATION MANUAL 5 Removing the packaging Note the following items when removing the packaging Check the appliance for damages during transport If necessary contact DRU Service After removing the packaging you should have the following components Socket spanner you will find it in the space between the assembly frame and the combustion chamber Decorative strips you will find them in the above mentioned space as well Box with parts 2 boxes with logs Kaution Always use two people to lift and or move the boxes with logs in order to avoid damage and or breakage In appendix 1 table 5 you can see which parts you should have after removing the packaging Contact DRU Service if you do not have all the parts after you finished removing the packaging English Dispose packaging in accordance with local regulations Installation 6 Read this manual carefully to ensure a proper and safe operation of the appliance Kaution Install the appliance in the order described in this chapter 6 1 Regulations Observe the applicable installation regulations Observe the regulations instructions in this manual Type of gas 6 2 The data plate indicates for which type of gas gas pressure and for which country this appliance is intended The data
29. n Avoid short circuit between the batteries and metal parts of the appliance 95902101_GB Install indd 17 17 27 5 10 15 35 COSMO INSTALLATION MANUAL Problem Table 4 Diagnosis of malfunctions Possible cause Remedy I Pilot burner is burning but there is no gas flow Button A in position MAN 1 Turn button A on the gas control to ON see fig 15 to the main burner 2 Appliance inthe pilot flame 2 Increase the flame height by pressing button position large flame on the remote control 3 Pre pressure of the gas is too 3 Check pre pressure low If necessary contact gas company 4 Damaged magnetic valve 4 Replace the gas control J Main burner ignites 1 Wiring of thermocouple 2 is 1 Connect the wiring properly but goes out again af loose ter approx 22 seconds 2 Wires of thermocouple 2 have 2 Connect the wiring properly been cross connected 3 Short circuit in the wiring of 3 Replace wiring thermocouple 2 4 Broken wire in the wiring of 4 Replace wiring thermocouple 2 5 Thermocouple 2 is dirty 5 Clean the thermocouple 6 Thermocouple 2 is not posi 16 Position the thermocouple correctly in the tioned correctly in the flame flame see fig 17 7 Thermocouple 2 is defective 7 Check the voltage across thermocouple 2 just before the main burner goes out If the voltage is lower than 1 8 mV replace thermocouple 2 8 Receiver
30. n low output L h 1350 1432 Low setting injector mm adjusting screw adjusting screw Pilot burner injector Code 51 51 Efficiency class 2 2 English 95902101_GB Install indd 19 19 27 5 10 15 35 COSMO INSTALLATION MANUAL Appendix 3 Figures English 38C 1390 1852 FAL 30 200 MIN 1299 MAX 1349 380 1 IN 192 MAX 252 ci 20 95902101_GB Install indd 20 27 5 10 15 35 COSMO INSTALLATION MANUAL 5 3 Soa N 1 7 Il il 5 1 il 4 il il I il i 6 7 Ty i 7 Il 1 i 5 N N JA Us XW N N 9 ac N N 1 7 aaa p aS 390 380 3 27 5 10 5 95902101 065 Install indd 1 COSMO INSTALLATION MANUAL English e dl mi
31. ppliance should be checked cleaned and if necessary repaired by a competent installer in the field of atmospheric gas fired heating Check at least whether the appliance is working properly and safely Aiton Close the gas tap when performing maintenance work Check the gastightness after repair After replacing thermocouple 1 you should first tighten the swivel by hand and then give it another quarter turn with a suitable spanner Donot turn the pilot burner lower by using the settings on the gas control If required clean the following components the pilot burner the space surrounding the pilot burner English thermocouple 2 the pane Caution Remove place the glass window as described in section 6 10 Remove the deposit on the inside of the pane with a damp cloth or a non abrasive detergent such as copper polish Avoid remove fingerprints on the pane since otherwise they will burn into the surface Replace a broken and or cracked glass window as described in section 6 10 Aiton If necessary place back the wood set correctly for this see section 6 9 Inspect the flue gas discharge combustion air supply Aiton You must always perform a final check Perform a check as described in chapter 9 1 Parts Parts that must be replaced can be obtained from your supplier 15 95902101_GB Install indd 15 27 5 10 15 35 COSMO INSTALLATION MANUAL 10 Deliv
32. r of logs Fill the burner trays with vermiculite equally spread the vermiculite Make sure that the burner deck of the right hand burner at the location of the pilot burner is covered with vermicu lite in order to avoid a high flame peak You can influence the flame image by moving the vermiculite yet the burner deck has to remain covered with ver miculite in order to prevent that the life expectancy of the burners is reduced Check if the sealing cord surrounding the 2 central burners is applied correctly Check if the ends of the sealing cord surrounding the 2 central burners connect see fig 11a and fig 11b Identify logs A up to H by using fig 12a Use the burn stains on the logs for identification When fitting the logs please use the attached tools such as the brackets supports and pins Place the rear logs A and B see fig 120 to 12d Place log C on the appropriate pins see fig 12e Continue with the central log D see fig 12f to 12h 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 secundary air to flow around the burners Make sure the sealing cord surrounding the central burners properly connects to log D Check the sealing by lighting it from below using a torch Then place the cap on the left central burner This cap will make sure that the flame will transfer smoothly see fig 12j
33. rs to come This appliance has a CE marking which means that it complies with the essential requirements of the European gas appliance directive Two manuals are supplied with the appliance the installation manual and the user manual As an installer you must be competent in the field of atmospheric gas fired heating The installation manual will give you the information you need to install the appliance in such a way that it will operate properly and safely This manual discusses the installation of the appliance and the regulations that apply to the installation In addition you will find technical data for the appliance and information on maintenance any malfunctions that might occur and their possible causes The figures are included at the back of this booklet Appendix 3 Please carefully read and use this installation manual The following symbols are used in the manual to indicate important information IS 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 user manual and this installation manual to the user 1 Introduction The appliance is supplied in two versions the Cosmo and the Cosmo tunnel The Cosmo is a standard appliance It is always mounted against a wall The Cosmo tunn
34. t circuit Broken wire m gt Check if thermocouple 2 is dirty Check if thermocouple 2 is positioned correctly in the flame see fig 17 u gt Check if thermocouple 2 is defective see chapter 11 table 4 under J7 Check if the receiver is defective see chapter 11 table 4 under J8 Ta If necessary correct the above mentioned faults Test the main burner 5x for a good operation 8 4 Flame image The flame image can only really be assessed when the appliance has been burning for several hours Volatile compo nents from paint materials etc which evaporate in the first hours will affect the flame image Caution If the chimney breast is made of stone like materials or has a plaster finish this may only take place 6 weeks after pla cing the chimney breast in order to prevent shrinkage cracks Check whether the flame image is acceptable If the flame image is not acceptable this can be due to the evaporation of volatile substances improper connection of the sealing cord around the two central burners indicated by vague fluttering flames incorrect placement of the wood set not placing the cap on the left central burner at log D see fig 12j incorrect settings of the appliance for this see paragraph 6 8 If necessary correct the above mentioned faults 14 95902101_GB Install indd 14 27 5 10 15 35 COSMO INSTALLATION MANUAL Once a year the a
35. tee a proper and safe operation of other systems and does not accept any 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 connection stump of the appliance If structural circumstances require that the concentric system is placed first the appliance can later be connected with a telescopic pipe piece 95902101_GB Install indd 6 27 5 10 15 35 COSMO INSTALLATION MANUAL ICaution ICaution 6 5 2 Application with wall terminal 6 5 2 1 Construction of concentric system with wall terminal The concentric system with wall terminal has to comply with the following conditions The complete system s diameter is 130 200 mm First a concentric pipe of at least 1 meters should be connected vertically to the appliance The total vertical pipe length may have a maximum of 4 meters A 90 bend is connected to the other end of the vertical part When using a minimum of 1 meter up to a maximum of 4 meters of vertical pipe length the total horizontal pipe length can have a maximum of 5 meters excluding wall terminal see fig 3 Table 1 shows that if the aforementioned conditions are observed the appliance does not have to be adjusted any further the baffle will not be mounted Table 1 Conditions for the adjustment of the appliance with a w
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