I5000 Install & Service Manual

I5000 Install & Service Manual

MASPORT I5000 BUILT-IN FIRE, AUSTRALIAN MODEL

INSTALLATION INSTRUCTIONS

Manufactured in New Zealand by:

GLEN DIMPLEX AUSTRALASIA LIMITED

P.O. Box 58 473, Botany

Auckland 2163

Ph: 0800 666 2824

Fax: 09 274 8472

Email: [email protected]

Web: www.glendimplex.co.nz

23.06.2011 Part. No. 593709

Distributed in Australia by:

GLEN DIMPLEX AUSTRALIA PTY LIMITED

Unit 2, 205 Abbotts Road, Dandenong South

Victoria, 3175

Ph: 1 300 566 816

Fax: 1 800 058 900

Email: [email protected]

Web: www.glendimplex.com.au

1

CONTENTS ZERO CLEARANCE BOX (SHIELDING BOX) KIT

PART NO. QTY DESCRIPTION

523031

521635

521637

521643

521076

593374

2

6

8

36

2

1

WASHER DIA 6

SCREW HEX. 10G X 10mm

SCREW HEX. 12G X 25mm

SCREW HEX. 8G X 13mm

SCREW HEX. M6 X 16mm

ADAPTOR SPIGOT RING

993702 1 L/H SIDE PANEL ASSEMBLY

993703 1 R/H SIDE PANEL ASSEMBLY

993701 1 REAR PANEL ASSEMBLY

993700 1 BOTTOM PANEL ASSEMBLY

993681 1 TOP SHIELD ASSEMBLY

993667V02 1 FASCIA BOTTOM PANEL Z/C

2

DIMENSIONS:

H

HOLES FOR WATER BOOSTER

W

Fig. 1

FW W S1

I5000 INBUILT

526 222 304 740 820 696 714 444 340

424

INTRODUCTION

In the interest of your safety, building regulatory Authorities in Australia and New Zealand require any woodfire installation to comply with Installation Standard AS/NZS 2918:2001. They may also have local requirements in addition to those in the Standard. Check with your local Building Authority before commencing installation to find if you will require a Building Consent and whether there are extra requirements. This woodfire has been tested to ensure that it will meet the appropriate safety Standard requirements when these instructions are followed. As the safety and emission performance can be affected by altering the appliance, no modifications are allowed without written permission from the manufacturer.

The model I9000 has been tested to demonstrate compliance with current general emission requirements in Australia and New Zealand, but some areas have stricter limits. So check before purchasing or installing, the requirements for your area.

3

WE RECOMMEND THAT THE INSTALLATION OF YOUR MASPORT SOLID FUEL BURNING

APPLIANCE BE CARRIED OUT BY A QUALIFIED INSTALLATION TECHNICIAN.

IF ANY ELECTRICAL WORK IS REQUIRED, IT MUST IT MUST BE CARRIED OUT BY A LI-

CENSED ELECTRICIAN.

IN SOME REGIONS POWER POINTS ARE NOT PERMISSIBLE WITHIN THE FLOOR PROTEC-

TOR AREA, PLEASE CHECK WITH YOUR LOCAL AUTHORITY.

IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER OR

ITS SERVICE AGENT OR A SIMILARY QUALIFIED PERSON IN ORDER TO AVOID ELECTRI-

CAL HAZARD.

WARNING: THE APPLIANCE AND FLUE SYSTEM MUST BE INSTALLED IN ACCORDANCE

WITH AS/NZS 2918:2001 AND THE APPROPRIATE REQUIREMENTS OF THE REVELANT

BUILDING CODE OR CODES.

WARNING: APPLIANCES INSTALLED IN ACCORDANCE WITH THE ABOVE STANDARD

SHALL COMPLY WITH THE REQUIREMENTS OF AS/NZS 4013 WHERE REQUIRED BY THE

REGULATORY AUTHORITY, I.E. THE APPLIANCE SHALL BE IDENTIFIABLE BY A COMPLI-

ANCE PLATE WITH THE MARKING ‘TESTED TO AS/NZS 4013’. ANY MODIFICATION OF THE

APPLIANCE THAT HAS NOT BEEN APPROVED IN WRITING BY THE TESTING AUTHORITY

IS CONSIDERED TO BE IN BREACH OF THE APPROVAL GRANTED FOR COMPLIANCE

WITH AS/NZS 4013.

WARNING FOR APPLIANCES WITH WATER HEATING DEVICES: DO NOT CONNECT TO AN

UNVENTED HOT WATER SYSTEM. INSTALL IN ACCORDANCE WITH AS 3500.4.1 OR NZS

4603 AND THE APPROPRIATE REQUIREMENTS OF THE REVELANT BUILDING CODE OR

CODES.

PLEASE ENSURE THAT ONLY COMPONENTS APPROVED BY GLEN DIMPLEX AUSTRAL-

ASIA LTD OR GLEN DIMPLEX AUSTRALIA PTY LTD ARE USED FOR INSTALLATION, as substitutes may adversely affect performance and might nullify compliance with the requirements of

AS/NZS 2918:2001.

CAUTION: MIXING OF APPLIANCE OR FLUE SYSTEM COMPONENTS FROM DIFFERENT

SOURCES OR MODIFYING THE DIMENSIONAL SPECIFICATION OF COMPONENTS MAY RE-

SULT IN HAZARDOUS CONDITIONS. WHERE SUCH ACTION IS CONSIDERED, THE MANU-

FACTURER SHOULD BE CONSULTED IN THE FIRST INSTANCE.

NOTE

The following instructions cover the installation of the model I5000 Built-In Fire complete with a

‘zero clearance’ metal shielding box, ‘zero clearance’ fascia and special ‘zero clearance’ flue kit.

4

INSTALLATION REQUIREMENTS

INSTALLATIONS- FLOOR TO CEILING ENCLOSURE:

1. Inspect the house construction at the proposed installation position to verify that the flue casing (250mm diameter, plus 25mm clearance all around) can pass through the ceiling space without requiring the removal of essential roof or ceiling support beams. The flue centerline will be 305mm from the rear wall and it must be at least 610mm from any side wall. (See Fig. 2).

Fig. 2

FLOOR PLAN

2. Drop a plumb line from the ceiling to the floor to verify the centerline and cut a hole at least

300mm square or round through the ceiling on this centerline. If preferred, there may be no ceiling inside the fireplace enclosure. (See step 21).

3. Ensure that there are suitable noggins at either the ceiling or roof level (or both) to provide anchorage for the outer flue casing bracing angles.

4. Frame up the enclosure using normal 90x45mm dressed timber, verifying that it will be on the flue centerline. (See Fig. 2). The overall depth should be (610 - t) mm, where ‘t’ is the cladding thickness. The distance between the front uprights must be 755mm (use the supplied metal support angle as a spacer). Fix the metal support angle between the two front uprights at a height of 700mm above the base of the shielding (zero clearance) box.

5. For ‘elevated’ installation (See Fig. 6), fix two extra noggins (90x45x955) across the front opening of the enclosure, one at the bottom and the other at the desired ‘elevation’ height.

These extra nogs will carry the front cladding below the heater. Fix two 90x45 bearers running from front to back behind the top extra noggins, positioned 210mm each side of the enclosure centerline to provide support for the shielding box rails. The bearer tops must be flush with the top of the top extra nog. Provide a suitable support at the rear ends of the bearers to carry the weight of the appliance. The shielding box can sit directly on the bearers. No insulation is necessary. The usual three noggins may be fixed at each side of the enclosure. At the front, the lowest wooden nog must have its lower face at least 1470mm above the top of the bearers for an elevated installation. Further wooden nogs can be fitted above this one. to fit two air vents, see fig. 4,5,6,7. You must leave the cladding off at least one side until the flue system has been installed.

7. Fix the cladding to the front of the enclosure, including down each side of the opening. All

front cladding from the floor up must be of heat resistant material such as PROMATECT H,

ETERPAN LD or SUPALUX. The heat resistant cladding shall cover the whole width of the enclosure up to 510mm from the centre of the appliance. The heat resistant cladding must have a minimum height as follows: For installations with a mantel shelf it must go up to the height of the mantle shelf (see fig. 4&5 for min. height of mantle shelf). For installations without a mantle shelf it must go up 1470mm above the base of the shielding (zero clearance) box.

5

8.

Wall surfaces directly above the heater may reach 85 degrees C, so materials such as wallpaper and water based paint may be adversely affected. For durability of finishes and surfaces you should contact the relevant manufacturers for their specifications.

Glen Dimplex accepts no responsibility for the deterioration of surfaces of finishes. It is usually convenient to carry the same material right up to the ceiling level. At the lower edge, drill (4.5mm diameter) holes into the metal support angle through the holes in the top flange of the shielding box and fasten with the self threading screws provided.

9.

Mantel Pillars: You are allowed to have combustible mantel pillars. They mast be placed at least 460mm from the centre of the appliance and must not protrude more than 100mm from the wall where the fascia is butting against.

10. For heat sensitive floors, construct an insulating floor protector of the shape shown in the

Floor Plan (Fig.2) and projection sizes on page 11, (see below for concrete floors). The insulating floor protector is constructed of one layer of 6mm thick PROMATECT H or SUPALUX, topped with a layer of tiles or slate. The floor protector must be at least 875mm wide. It is desirable to carry the floor protector all the way inside the enclosure to ensure that the bottom of the shielding box does not rest below the top surface of the floor protector. level), the floor protector (min. size: 300mm from cladding x 875mm wide) may be installed after the appliance is in position as it does not extend into the enclosure. However, its rear edge must butt up against the face of the heat-proof front cladding below the appliance, and the joint at that point must be sealed to prevent the possibility of ember penetration. In this case an ash floor protector is sufficient. Construction requirements for an ash floor protector are: one sheet of 6mm fibre cement board (e.g. Hardies TILE & SLATE UNDERLAY) covered with ceramic tiles or slate.

12. Cement tiles or slate to the top of the floor protector. The part inside the enclosure will not be visible and therefore does not need complete coverage. It is necessary to fix the finishing layer only under the support rails in this area. The visible edges of the floor protector are best finished with wooden trim or tiles after the stove has been installed.

13. Penetrate the roofing material on the flue centerline. Working from the bottom, assemble sections of the flue pipe and the inner and outer casings and pass them up through the hole in the roof. Remember the flue pipe sections must be fixed together at each joint with at least three monel or stainless steel fasteners, and the crimped ends of the flue casings go to the top. The joints of the flue pipes must be sealed with an appropriate fire proof sealant. When the flue system is in its final position, the top of the outer casings must be above the ridge line or roof as follows: If the flue centerline is within 3m from the ridge, the outer casing must end at least 600mm above the ridge. If it is further than 3m from the ridge, the outer casing must extend at least 1000mm above the point of roof penetration. In some cases where there are trees or high buildings in the vicinity, it may be necessary to increase the height to avoid downdraughts. You need to temporary support the flue system so that you can install the appliance.

14. Assemble the base, sides, back, top shield assembly and top panel of the shielding box. The top shield rests on the top edges of the inner heat shields of the cabinet. Make sure the back flange hooks over the shield on the rear panel (See Fig. 3 and 3A).

15. Attach the two standoff brackets to the sides of the shielding box panels (if not already fitted).

Use four pop rivets for each bracket.

16. Slide the assembly into place in the enclosure. After centralizing, fix the flange of the top panel of the shielding box through the cladding into the metal angle support. Use 2/ 12g x

25mm screws.

17. The special adapter spigot ring with holes to ventilate the space between the flue and the inner casing as well as the space between the inner casing and the outer casing has to be attached with 4 screws 8g x 13mm to the top of the shielding box. Both flue casings (inner & outer) will engage with this special adapter spigot ring.

18. In New Zealand and some parts of Australia, Standards require that the appliance be seismic restraint to prevent shifting in the event of an earthquake. To provide seismic restraint, fix

the shielding box to the floor (bearers in an elevated installation) with two 6mm masonry anchors (DYNABOLTS) or two 12 gauge screws . Use the two holes in the bottom of the shielding box spaced 687mm apart.

6

19. Now go to the firebox cabinet and remove the two retaining screws and slide out the top section of the firebox cabinet.

20. Attach the two centralizing brackets to the side panels of the firebox cabinet, flanges facing outwards. Use two screws provided for each bracket.

21. Slide the firebox cabinet into the shielding box. Centralize it and secure the restraint brackets to the shielding box flanges.

22. Complete the seismic restraint of the fire by screwing the base plate of the fire to the bottom of the shielding box with two M6 screws. Use the two holes in the base spaced 464mm apart.

23. Lower the assembled flue pipe (sections must be sealed and held together with three S/S fasteners) and seal and fix it to the flue socket of the appliance. Use stainless steel screws.

Lower the inner casing and engage it with the special adaptor spigot ring, repeat this step with the outer casing. See Fig. 8 & 9 for flue pipe and casing lengths.

24. Fit the two casing bracing angles at either ceiling or roof level as appropriate. Fix a suitable flashing where the outer casing penetrates the roof.

ROUNDING THE OUTER CASING AT CEILING LEVEL WITH WIRE NETTING WHICH HAS

A MESH SMALL ENOUGH TO PREVENT THE ENTRY OF BIRDS OR VERMIN INTO THE

ENCLOSURE.

26. At the top of the flue pipe, fix the flashing cone and fit the cowl in the usual way. There must be a 25mm gap between the top of the two casings and the flashing cone, so that the spaces between the flue pipe, inner and outer casings are properly vented.

27. Re-fit the removable top section of the firebox cabinet and secure it with two screws.

28. Fix the cladding to the enclosure side(s).

29. Fit the fascia. See instructions supplied with the fascia.

30. Ensure that the ceiling baffle, secondary air tube and the two side bricks and the two rear bricks are in the correct position.

31. Check and ensure that the fan rests on four rubber grommets and that the front two grommets are resting over the two upturned lugs of the cabinet base plate. (Australian models only).

32. Finish the floor protector by installing an edge trim if desired.

7

FIG. 3

SIDE PANEL ASSEMBLY

LEFT HAND

REMOVE KNOCK OUT SLUG ON INNER

PANEL AND FIT GROMMET STRIP TO

THE FRONT HOLE OF BOTH PANELS

OF THE ASSEMBLY.

THESE HOLES ARE USED TO PASS

THE ELECTRICAL LEAD THROUGH.

GROMMET STRIP

FIG. 3A

8

NOTES TO VENT OPENING:

The opening must be covered with an appropriate mesh or similar to prevent vermin etc entering the enclosure. A sample opening with

7’900mm² net open area is shown below.

Fig. 4

INSTALLATION ON

COMBUSTIBLE FLOOR

WITH MANTLE SHELF

NOTES TO VENT OPENING:

The opening must be covered with an appropriate mesh or similar to prevent vermin etc entering the enclosure. A sample opening with

7’900mm² net open area is shown below.

Fig. 5

INSTALLATION ON

CONCRETE FLOOR

WITH MANTLE SHELF

9

NOTES TO VENT OPENING:

The opening must be covered with an appropriate mesh or similar to prevent vermin etc entering the enclosure. A sample opening with 7’900mm² net open area is shown below.

Fig. 6

INSTALLATION-

ELEVATED

WITHOUT MANTLE SHELF

NOTES TO VENT OPENING:

The opening must be covered with an appropriate mesh or similar to prevent vermin etc entering the enclosure. A sample opening with 7’900mm² net open area is shown below.

Fig. 7

INSTALLATION ON

COMBUSTIBLE FLOOR

WITHOUT MANTLE SHELF

10

HEIGHTS OF FLUE PIPE & CASINGS FOR

STANDARD CASING COVER & COWL & TOP FLUE PIPE

SPACER BRACKET BY GLEN DIMPLEX

FALSE CHIMNEY VENTED THROUGH 150-350 CASING COVER

Fig. 8

HEIGHTS OF FLUE PIPE & CASINGS FOR

STANDARD CASING COVER & COWL & TOP FLUE PIPE

SPACER BRACKET BY GLEN DIMPLEX

FALSE CHIMNEY VENTED THROUGH SIDE VENT

Fig. 9

NOTE:

It is very important that the space between the flue pipe and the inner casing and the space between the inner casing and the outer casing are ventilated at the top.

11

NOTES FOR VARIATIONS

CONCRETE FLOORS

The above instructions assume that the appliance is being installed on a heat sensitive floor such as timber or particle board. Where the floor is not heat sensitive (e.g. concrete), the insulating floor protector may be omitted. However, if heat sensitive floor coverings (e.g.carpet) are fitted it will be necessary to keep them at a safe distance. The most practical way to do this is to fix tiles to the floor where the floor protector normally would be. This will make the top of the floor protector approximately flush with the floor covering, so a larger floor protector will be needed. It must extend the min. of 440mm from the face of the front cladding, but the 875mm width will be sufficient (see Fig. 5).

Remember to raise the shielding box by the same amount as the thickness of the tiles on the concrete floor.

BRICK FACED INTERNAL ENCLOSURES

The flue system installation and clearance requirements are as detailed above. Brick wall construction will normally require a cast concrete base slab, so this slab could be extended to provide the necessary floor protection.

CAUTION. If your local Building Requirements permit laying the concrete slab on top of a wooden floor, it should be made of lightweight concrete and even then foundation support may be required. In any case, the slab should be poured on top of one layer of 16mm thick Micore 160 board (covered with plastic sheet to keep it dry) to prevent heat damage to the wooden floor.

The top surface can be finished with bricks or tiles etc. In all cases the floor protector dimensions must be as previously shown.

EXTERNAL INSTALLATIONS

In the case where the enclosure is to be erected outside the house, the shielding and flue system installation details will still apply. It is important to remember that the aperture in the wall of the house will need to be sufficient high to permit the installation of heat resistant paneling around the appliance to at least 1470mm above the bottom of the shielding box rails. Suitable foundations will be required to support the weight of the enclosure and the appliance and weatherproofing of the entire assembly will be necessary.

HEARTH REQUIREMENTS:

You need an insulating floor protector (hearth). The minimum requirement for an insulating floor protector (hearth) is one layer of 6mm thick ‘PROMATECT H’, SUPALUX, or ETERPAN LD (or similar with a heat transition coefficient of 5 W/m³ K), and a layer of tiles or slate. This will give a thickness of approximately 14mm, and the extension from the face of the glass must be at least 441mm

(or 440mm from fireplace surround) if the floor protector is flush with the surrounding heat sensitive material. The floor protector must be at least 875mm wide. It is desirable to carry the floor protec-

tor all the way inside the fireplace to ensure that the bottom of the zero clearance box does

not rest below the top surface of the floor protector.

The projection distance for the floor protector can be reduced if the height of the hearth is more than

0mm above combustible materials. Please refer to the following table:

HEARTH HEIGHT

ABOVE EXPOSED

FLOOR mm

0

10

20

30

40

50

60

65

PROJECTION

FROM GLASS mm

441

420

396

375

357

333

312

300

PROJECTION

FROM FIRE PLACE

SURROUND mm

440

419

395

374

356

332

311

300

12

INSTALLING THE FASCIA

Preparing the appliance:

Remove the door: Open door and lift door until the top pivot disengages and then lower the door to free the bottom of the hinge.

Preparing the fascia:

Unpack the fascia and fit the Zero Clearance Infill Panel to the bottom panel of the fascia. Use 4 screws provided. The Zero Clearance Infill Panel is supplied with the Zero Clearance Enclosure, not with the fascia.

Fit switch to fascia if not already done in factory. This involves removing a rectangular ‘knock-out’ at the upper left hand fascia panel. Clean hole with file and push switch in from outside, the ‘high’ II marking should be above the ‘off’ O marking.

Take the three pin plug and feed it through the large round hole at the bottom left side of the shielding box, so that the plug and the cord are outside the shielding box. Do not disturb the protective edging around the hole in the sheet metal panel.

Now bring the fascia in its upright position close to the fire and connect the earth lead to the tag on the lower end of the left hand fascia bracket. This is a quick connect push-on connection.

Connect the three terminals at the end of the loom to the switch. See sketch for position of wires.

Ensure the loom rests in the notch behind the left hand fascia.

HIGH

FAN SWITCH

LOW

BLACK

BROWN

ORANGE

Fig. 12

Position the power cord with the three pin plug at the end through the slot at the bottom end of the left hand fascia panel. Make sure the small rubber grommet is inserted into the slot to protect the mains lead against possible damage..

13

Now you can gently slide the fascia assembly inwards. Secure with 4 screws to the cabinet. The screws are positioned either side of the door opening.

Fit the air slide extension bracket to the air slide using two 8 gauge x 10mm black screws.

Push the air slide knob over the air slide extension bracket. Arrow must point to the left.

Fit the door. Hook the bottom pivot over the lower end of the hinge pin and lift the door up until the top pivot drops over the top end of the hinge pin.

Check the installation including the operation of the fan.

Hand over the owner’s manual to the occupier of the home.

14

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