JAYLINE IS550 User manual

JAYLINE IS550
ZERO CLEARANCE CABINET
INSTALLATION INSTRUCTIONS
August 2014

Jayline IS550 Zero Clearance Cabinet
Congratulations on the purchase of your Jayline IS550 wood fire and ZC Cabinet.
Introduction
Please read the entire manual before commencing the installation.
The Jayline IS550 wood fire ZC Cabinet system ha e been tested together and complies with
AS/NZS 2918:2001, AS/NZS 4012:1999 & AS/NZS 4013:1999 when installed in accordance with this
manual. Correct installation is critical to the safe operation and performance of this fire.
For your safety, the building regulatory Authorities in New Zealand require any wood fire installation
to comply with Installation Standard AS/NZS 2918:2001. They may also ha e local requirements in
addition to those in the Standard. Check with your local Building Authority before commencing the
installation to find if you require a Building Consent and whether there are extra requirements.
As the safety and emission performance can be affected by altering the appliance, no
modifications are allowed without written permission from the manufacturer.
Jayline recommends the installation only be carried out by a suitably qualified installation technician.
Your dealer or heating specialist will be able to help with recommendations as well as ad ice on
permits / consents required for the installation in your area. Please ensure you ha e all rele ant
permits prior to installation.
CAUTION!
Inspect the house construction at the proposed installation position to erify the flue / liner system will
pass through the house without requiring the remo al of essential roof or ceiling support beams. A
minimum o erall length of 4600mm, of flue pipes and casings must be used abo e the floor of the
appliance to ensure the correct performance of this fire and ZC Cabinet installation. This comprises
of 150mm diameter flue pipes, 200mm diameter inner liners and 250mm diameter outer liners.
De iation from this may alter the heaters performance and may nullify the Jayline warranty if the flue
is excessi ely long or short. If in doubt, contact your Jayline dealer.
•The ZC Cabinet must be secured to the floor / floor protector prior to the firebox being fitted.
•All flue and liner joints must be ri eted. The bottom of the flue must be fully sealed into the
flue spigot and secured through the hole in the spigot.
•The fire must be bolted securely to the floor to comply with the seismic restraint pro isions of
AS/NZS 2918:2001.

Step 1 - Unpack and amiliarisation
The function of the ZC Cabinet is to enable the firebox to be installed into a timber framed wall,
replacing a masonry chimney at a fraction of the cost.
Unpack the items supplied and familiarise yourself with them.
Supplied with the Jayline IS550 ZC Cabinet are:
•1 x Assembly & Installation instructions
•1 x Outer Cabinet assembly
•1 x 200mm / 250mm liner assembly stub
•1 x Fascia spacer frame (3 pieces)
•1 x Firebox / Cabinet alignment tool
•1 x Fastener pack
•2 x Thermal insulation strips
Items not supplied:
•2 x Seismic Restraint fixtures (masonry anchors or wood screws)
•150mm diameter flue pipe
•200mm / 250mm liners
•Flue / Liner spacer brackets
•Cowl
•250mm or 300mm diameter flashing
•Roof flashings
•Non-combustible facade capping
•Non-combustible materials used elsewhere
•Timber and lining products
•Floor Protector / Hearth materials
•Vent / Vents
•Other items as required
•Various fasteners & products dependant on build type
Step 2 – Venting
An air ent or ents are required on the rear of this installation to ensure an air flow can be
maintained in the enclosed ca ity as shown in fig 1 & 2. The bottom edge of the lower ent or ents
must be no more than 100mm abo e the floor and ha e a minimum surface area of 10,000 square
mm e.g. a meshed ent of 200 x 100mm. The ent area must be kept clear at all times and ermin
proofed.
Step 3 – Ceiling and roo
Prepare the ceiling / penetration / roof, false chimney and enting (top or side required) to enable the
250mm outer casing to be easily fitted prior to the ca ity frame being completed as per fig 3 & 4.
The distance from the front edge of the enclosure (non-combustible lining directly behind the fascia)
to the centre of the flue is 365mm as per fig 8. Please allow for any other material being used at the
front, such as bricks etc.

Step 4 – Preparing the wall opening / cavity
Framing out – igures 5, 6, 7 &11
•All timber framing and cladding must comply to NZS: 3604
•If the enclosure is constructed to the full height of the room, and is fully open / ented into the
ceiling ca ity of the house, then the enclosure must be ented as per fig 3.
•If the ZC Cabinet is built into an enclosure that is not open / ented to the ceiling ca ity, the
enclosure must be ented as illustrated in fig 4.
•The timber frame opening (front) must be a minimum of 1160mm high (abo e the floor
protector) x 850mm wide x 645mm deep, as shown in fig 7 & 11.
•The enclosure cladding should only be fitted once the ZC Cabinet, firebox and flue system has
been fitted and checked.
•The cladding immediately behind the fascia must be made from 9mm Promina board (or
thermal equi alent), refer to fig 9 &12.
Please note fire rated Gib board is not an acceptable material.
•The enclosure cladding should only be fitted once the ZC Cabinet, firebox and flue system has
been fitted and checked.
•The remaining enclosure cladding can be standard cladding materials.
•Please be aware the wall surfaces directly abo e the heater may reach 85oC, so materials
such as wallpaper and water based paint may be ad ersely affected by heat. For durability of
finishes and surfaces you should contact the rele ant manufacturer for their specifications and
ad ice.
•The internal areas of the enclosure do not require cladding or insulation.
•Install the lower ent into the rear of the ca ity (required) as per fig 1 & 2.
•Install the upper ent (top or side requirements depend on type of construction) as per fig 3 &
4.
Step 5 – Floor protector
•2 x layers of 9mm Promina, fig 12 (or thermal equi alent) insulation is required under the ZC
Cabinet. The ZC Cabinet may not sit directly onto a timber or particle board floor, or
combustible spacer. Please note: Raise the firebox to suit the required floor protector height
(including decorati e tiles etc).
•Please refer to fig 14 for the ZC Cabinet floor protector requirements.

Step 6 – Installing the Jayline IS550 ZC Cabinet
•Please ensure the floor / base is flat and le el for the ZC Cabinet to sit on.
•Be sure to maintain the minimum air gap to combustibles inside the ca ity as shown in fig 8.
•Use 2 layers (minimum) of 9mm Promina Board, fig 12 (or thermal equi alent), 800mm wide x
620mm deep under the ZC Cabinet.
•Please note: The floor protector must be the same height as the bottom of the ZC Cabinet to
ensure the fascia will fit correctly (including decorati e tiles etc).
•Slide in the ZC Cabinet until the folded front edges are flush with the front framing timber, and
are central within the ca ity.
•Drill & screw the ZC Cabinet to the floor within 50mm of each corner.
•Remo e the door and air control knob from the firebox.
•Fit the firebox into the ZC Cabinet.
•Use the Firebox / Cabinet alignment tool to centralise and set the depth of the firebox into the
ZC Cabinet. If used correctly, the firebox will be central, and will extend 19mm in front of the
ZC Cabinet.
•Drill the holes for the seismic restraint bracket (2) located at the front of the firebox, being
careful not to alter the unit’s location. Re-check all measurements and settings, then fit and
tighten two 6mm x 50mm dyna bolts.
•Fit the 2 x thermal insulation strips directly abo e and in-between the top of the firebox outer
case as per fig 10.

Step 7 – Flue System
•Fit the 200mm / 250mm liner assembly stub central to the hole in the top of the ZC Cabinet
using the self-tapping screws (supplied), and fix to the top of the ZC Cabinet.
•When fitting the 150mm diameter S/S flue pipes, 200mm diameter Gal inner liners & 250mm
Gal outer liners, use only flue components that comply with AS/NZS 2918:2001.
•As the flue system is assembled from the firebox up, one length at a time, start with the
150mm S/S flue pipe. Ensure the first length is fastened and sealed to the firebox. Use the
hole pro ided at the front of the firebox flue spigot. All 150mm S/S flue pipes must be sealed
and ri eted together using at least 3 x S/S ri ets in each joint.
•As the 3 different diameters are joined, one length at a time, use S/S spacers between the S/S
flue pipe and liners to ensure the correct spacing. All flue pipes and liners require at least 3 x
S/S ri ets at each joint.
•Depending upon the type of false chimney / termination being used, will determine the type of
cowl and casing co er being used. This will also dictate the type of enting to use, refer to fig
3 & 4.
•Once the flue system has been fitted and checked, a 25 x 25 x 5mm angle iron support (or
similar non-combustible support) should be secured to the framing, 750mm abo e the floor
protector to support the area directly behind the top of the fascia, refer to fig 10 & 11.
•Now the ca ity can be clad prior to the fascia being fitted, as mentioned abo e in Step 4.
Step 8 – Fitting the Fascia and Fascia Spacer
•Carefully fit the Fascia spacer frame (3 pieces) together using cotton glo es, so as not to mark
the paint. Locate o er the 4 x ball clips and centralise if necessary. The spacer frame is not
screwed together, but is held in place by the fascia.
•Carefully lift and fit the fascia (not under the grill blades) using cotton glo es. Locate centrally
o er the ball studs and gently push onto the studs until all are secure.
•Check the fit of all parts to ensure there are no gaps large enough, to cause a draught or heat
loss.
•Re-fit the door & air control knob.
Step 9 - Mantle details
A mantle can be made from combustible materials and made using the minimum / maximum sizes as
per fig 14.

Figure 14
Floor Protector Requirements
Height of top of floor
protector abo e the
exposed floor (mm)
Projection (mm)
From glass
Remember the glass extends
80mm from the face of the 9mm
Promina board
Projection (mm)
From 9mm Promina board
0 525 605
20 480 560
40 427 507
60 380 460

100mm 100mm 200mm
AN AIR VENT OR VENTS ARE REQUIRED ON THE REAR OF THE ENCLOSURE AND MUST BE VENTED TO OUTSIDE AIR.
THE BOTTOM EDGE OF THE LOWER VENT OR VENTS MUST BE NO MORE THAN 100mm ABOVE THE FLOOR AND
HAVE A MINIMUM SURFACE AREA OF 10,000 SQ mm E.G. 200 X 100mm. THE MESHED VENT MUST BE KEPT
CLEAR AT ALL TIMES AND VERMIN PROOFED.
Figure 1
Figure 2

200mm
75mm
275mm
150mm S/S Flue Pipe
Minimum 25mm gap to combustible
materials
25mm gap to vent false chimney
250mm Outer Liner
200mm Inner Liner
Metal Flashing
Non Combustible Top Plate
e.g. 9mm Promina Board
(or thermal equivalent)
Height to suit Cowl
Minimum
FALSE CHIMNEY VENTED THROUGH 150-350 CASING COVER
NOTE: IT IS VERY IMPORTANT THAT THE SPACE BETWEEN THE FLUE PIPE,
INNER CASING AND OUTER CASING ARE VENTED AT THE TOP.
Figure 3

200mm
75mm
275mm
Height to suit Cowl
150mm S/S Flue Pipe
250mm Outer Casing
Weather Proof Vent as close to top
as possible
10,000 sq mm minimum
e.g. 100mm x 200mm
25mm gap to combustible material
minimum
Non Combustible Top Plate
e.g. 9mm Promina Board
(or thermal equivalent)
200mm Inner Liner
Minimum
FALSE CHIMNEY VENTED THROUGH SIDE VENT
NOTE: IT IS VERY IMPORTANT THAT THE SPACE BETWEEN THE FLUE PIPE,
INNER CASING AND OUTER CASING ARE VENTED AT THE TOP.
Figure 4

850mm Minimum
FRAMING REQUIREMENTS AS PER NZS:3604 (SHOWING MINIMUM REQUIREMENTS)
FIGURE 7
645mm Minimum
C
L
545mm Minimum
FIGURE 5
FIGURE 6

C
L
545mm Minimum
9mm PROMINA BOARD
(OR THERMAL EQUIVALENT)
MINIMUM SIZE
1200mm X 1200mm
ALL OTHER CLADDING
ABOVE OR BESIDE THE
PROMINA BOARD CAN
BE STANDARD MATERIALS
Figure 9
80mm
?
C
L
365mm
MINIMUM CLEARANCE
25mm TO COMBUSTIBLES
MINIMUM CLEARANCE
25mm TO COMBUSTIBLES
MEASURED FROM THE GLASS
TO THE 9mm PROMINA BOARD
PLEASE CHECK FIG 14
FOR FLOOR PROTECTOR
PROJECTIONS/HEIGHT
Figure 8

750mm
850mm MINIMUM
1160mm
ABOVE FLOOR
PROTECTOR
Figure 11
DETAIL A
SCALE 1 : 6
DETAIL B
SCALE 1 : 6
2 X THERMAL
INSULATION STRIPS
MINIMUM ABOVE THE
FLOOR PROTECTOR
Figure 10

1200mm
1200mm
640mm
235mm
800mm
620mm
9mm Promina Board
(or thermal equivalent)
To be fitted to timber framing
directly behind the fascia
9mm Promina Board
(or thermal equivalent)
2 layers required
Fitted directly below
the ZC Cabinet onto
combustible surfaces
Figure 12

990mm Minimum
1137mm Minimum or heat shielding will be required
IF HEAT SHIELDING IS REQUIRED, PLEASE
REFER TO AS/NZS 2918:2001
150mm Maximum or heat shielding will be required
100mm Maximum or heat shielding will be required
Figure 13
Mantle Requirements