Jindara Hamersley Mk2 Insert User manual

Operation & Installation Instructions
Hamersley Mk2 Insert
Please keep these instructions for future reference.Rev* 231551
Hamersley Mk2 Insert 12
A.F. Gason Pty Ltd reserves the right to modify or alter specications, material etc. in the interest of product improvement
WARRANTY
1. Subject to clauses 2 & 3 of this Warranty, A.F. Gason Pty LtdACN 004 667 556 (Gason warrants the follow components of its heaters against defects in workmanship
and/or materials for the following periods from the date of purchase:
a) the rebox for ten years;
b) the paint nish for a period of twelve months if the Purchaser has followed the instructions provided by Gason in the Operation and Installation Instructions manual; and
c) all other components for twelve months except the glass, re brick lining or bae plate if, in the opinion of Gason, these items have been damaged by impact.
2. This extended warranty does not apply;
a) if the heater is purchased from a person who has not been authorised by Gason to sell its products;
b) if, in the opinion of Gason, the heater or any other component has been subject to abuse, misuse, alteration, modication or has not been installed, operated or maintained in
accordance with the instructions provided by Gason; or,
c) to owners other then the original Purchaser.
3. If you believe that the heater you purchased contains a manufacturing defect and you wish to make a claim under this Warranty, please contact an authorised Gason service
centre to arrange for an assessment.
4. If, after assessing the heater, Gason determines that the heater contains a manufacturing fault, Gason may at its discretion:
a) replace the heater;
b) repair or replace specic components of the heater; or
c) provide a full refund.
5. Parts replaced under warranty are warranted for the balance of their original warranty period.
6. If, at the discretion of Gason, the heater or any part needs to be replaced, serviced or repaired at an authorised Gason service centre, then the person claiming under this
Warranty must pay all costs associated with:
a) returning the heater; and
b) the delivery or collection of any new or repaired heater.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for
compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality
and the failure does not amount to a major failure.
Any benets you receive under these warranties are in addition to other rights and remedies that you may have as a consumer under a law in relation to the heater to which
these warranties relate.
These warranties are given by:
A.F. Gason Pty. Ltd.
Blake Street
Ararat VIC 3377
Please contact us if you have any queries on:
Phone: [phone]
or email us via the “Contact Us” section of our website: www.gason.com.au
Heating
A Division of A.F. Gason Pty. Ltd.
Troubleshooting (continued)
•Smoke entering the room from the rebox when the door is open may be caused by
•Insucient length of ue (ue to be 4500mm minimum underneath the base of heater to
underside of cowl)
Increase height of ue
•Flue downdraught
Consult dealer or increase height of ue.
•Creosote buildup in ue
Remove cowl and clean ue as per cleaning instructions. Check moisture content of wood.
•Excessive ash build up
Some woods will give large amounts of ash despite how you run the heater. Others will give you very little.
Use the wood which is most convenient for you as long as it is dry. After a period of time you will get to
know when to empty your unit. Bark will give you excessive ash. Try not to burn it.
If you are burning wood that gives you charcoal, you may nd that after running the heater say for 8 hours
at maximum burn rate, the charcoal builds up excessively. Overnight burn will reduce this charcoal back to
a ne ash. If you are not ready to shut down for overnight burn when you next fuel the stove, load the
stove with only one piece of wood and lay it across the rebox on top of the charcoal. Open the air control
wide open and you will nd the charcoal will burn down with the one piece of wood. Repeat the process
until the ash level is signicantly reduced.

Hamersley Mk2 Insert 2 Hamersley Mk2 Insert 11
Troubleshooting (Continued)
Read and follow these instructions carefully before installing and
u
sing this appliance
S
AVE THESE INSTRUCTIONS
WARNING
!
WARNING
!
Safety Warnings
•
A ue re with resulting damage may occur if the appliance is not installed,
operated and maintained as per this booklet.
•Never place combustible materials such as wood, paper or furniture near the
appliance.
•This appliance is designed to burn dry hardwood. Do not burn rubbish,
driftwood, ammable liquids or any substance containing salts or corrosives.
•This appliance must not be installed and operated in an area where kerosene,
petrol, paint thinner or other ammable liquid is used or stored.
•The ue system must be inspected and cleaned annually or sooner if required.
Failure to do so could result in an excessive build up of creosote which may
result in a ue re which may damage the ue or cause damage to your home.
•The surface of the appliance becomes hot during operation. Do not touch the
surface of this appliance. Keep children away from this appliance during
operation. Do not allow anyone to operate this appliance who is not familiar
with this instruction booklet.
WARNING
!
Paint Curing and Care
Your heater is coated with the best available heat resistant paint. Even though
t
he paint has been baked after application, it may require further temperature
c
uring. It may, if you overre the heater on its rst re, discolour. For your rst
t
wo or three rings, never exceed the medium air setting and always have the fan
o
n when above low burn. Do not wipe the heater while the paint is curing. After
t
he paint has cured the only maintenance required to maintain the heater’s nish
i
s to wipe it with a soft cloth. Do not use any commercial cleaners or solvents on
t
he paint nish.
W
e are proud of the presentation of our products. If at any time you need to
f
reshen up the paint, your local dealer has touch up paint available for purchase.
Y
ou may even change the colour of your heater if you wish.
If you have any enquiries, please contact the dealer from whom you purchased your heater:
P
LEASE COMPLETE:
D
ealer Name
D
ealer Address
Phone:
P
lease attach your original purchase dockets to this booklet for future reference.
Turn the power o and remove the three pin plug from the power point.
Remove the two screws that hold the front fan access panel. Remove the panel.
Disconnect the wiring loom via the plastic joiner. Unscrew the two nuts which holds the fan in position and remove the fan.
Clean any dust with a dry paint brush and vacuum the fan blades. Clean around the motor.After completion place two
or three drops of sewing machine oil on the shafts at the bearings. Replace the fan in reverse to the removal.
•Fan not working
Check the power connection with another appliance. If the power point is okay assume the fan or the switch is
defective. Isolate the power as above. Check that the terminals on the loom and the switch are rmly connected. If the
fan then fails to function, remove the fan and switch by rstly removing the knob o the fan switch by pulling it away
from the heater. Undo the holding nut and pull the switch out. Disconnect the wiring from the power lead and remove
the fan and switch. Convey the same to the authorised Jindara dealer from whom you purchased your unit for service.
Replace in the reverse order.
• Air Control Jamming
Lift up and remove the top plate.
Remove the air control knob by turning anti-clockwise. Lift air control panel out of the way.
There are three bolts holding the air slide in place. Undo them and remove the air slide.Wipe any ash or dust that may
have accumulated on the back of the air slide or on the face of the heater. If any burrs have developed on the back of the
air slide or on the face of the heater, rub them o with ne wet and dry sand paper till you have a smooth surface and
edges. Replace the air slide and make sure the washers, spacers and springs are on the bolts when you screw the bolts back
into the face of the heater. Do not apply any type of lubricant to the air slide whatsoever as this will attract dust and make the
slide stick.
• No Overnight Burn
Remove the air slide as per air control jamming and check that the air slide is hard against the face of the heater. If it is
loose, tighten up the bolts holding the air slide to the face of the heater. Do not overtighten.
Check that the door rope has an even indentation from the sealing strip, which is on the face of the rebox. If it is uneven
and it appears as though air could leak through the seal, adjust the thickness of the door rope to suit. Stretch the rope to
make it thinner where the indentation is the heaviest and bunch up the excess where the indentation is smaller.
The door may become loose through the door seal shrinking. Refer “Door handle adjustment” instructions above.
WARNING
!
Overring
NEVER OPERATE THE HEATER WITH THE DOOR LOOSE OR NOT AIR TIGHT.
OVERFIRING COULD RESULT IN DETRIMENTAL WEAR AND TEAR ON THE FIREBOX.
Troubleshooting
•Noisy Fan
D
oor handle adjustment
W
hen the door gasket become loose and leaking occurs it is necessary to adjust the door handle.
•Ensure heater is cold – open door.
•Undo M20 locknut, note that roll pin may need to be oset.
•Unscrew hex head screw in door handle shaft.
•Rotate handle shaft anti-clockwise – 1 turn = 1 millimetre of adjustment.
•Replace M20 locknut.
•Centralize roll pin.
•Close door, engaging handle to check for seal
•Trying to rip a small piece of paper inbetween door rope and rebox will help determine if sealing is
sucient. If paper is removed without resistance, repeat adjustment process until resistance is achieved..
•Replace hex head screw when adjustment process is complete.
Operating your Jindara Wood Heater (continued)

Hamersley Mk2 Insert 10 Hamersley Mk2 Insert 3
Installation
WARNING
!
Installation THE INSTALLATION OF THIS APPLIANCE MUST BE CARRIED OUT AS PER THIS
MANUAL AND THE FLUE MANUFACTURER’S SPECIFICATIONS.
WE RECOMMEND THAT YOU USE A QUALIFIED INSTALLER TO CARRY OUT
THE INSTALLATION.
If you have any other enquiries, please contact the dealer from whom you
purchased your heater.
THIS APPLIANCE WEIGHS IN EXCESS OF 140 KILOGRAMS. EXTREME CARE
SHOULD BE TAKEN WHEN HANDLING THE APPLIANCE.
This heater is to be installed into a masonry replace or a Jindara ZCV
Clearance cabinet.
Section showing Installation
Figure 1. Masonry Installation
WARNING
!
Brick Removal
IF BRICKS REQUIRE REMOVAL WHEN PREPARING THE FIREPLACE, ENSURE
THAT YOU DO NOT EXPOSE COMBUSTIBLE MATERIALS BEHIND THE
BRICKWORK OR WEAKEN THE INTEGRAL STRUCTURE OF THE CHIMNEY.
Operating your Jindara Wood Heater
Cleaning the glass
Generally the only time you will possibly need to clean your glass is after a long overnight burn. If you nd that you have
a wet sticky black lm on your glass (creosote), it is better to burn the heater as normal for one load of wood.When the
wood has burnt down to a hot bed of embers, open the door and leave it wide open until the glass cools suciently to
be wiped with a damp cloth.This should clean all the white smoky lm o the glass. Creosote on the glass is normally a
sign that you have tried to get too long an overnight burn or you have burnt excessively wet or green wood. If the lm on
the glass won’t come o with a wet cloth, you can use wet ash from the ash bed as a cleaner or commercial products
such as Crystal Clear, Johnson Foam Clean or Windex.
Normal Operations
When you get up in the morning, open up the air control of the heater to high position to start the embers glowing. Place
some wood on top of the embers and leave the door open 25mm. Once the fuel starts to ame close the
door.As the heater starts to heat up turn the fan on to low, (approx 20 minutes) and begin reducing the air control
towards a lower setting.
You will nd with the fan on low you will only need to run the heater between low and medium to maintain the
temperature you desire in your home.To obtain the maximum heat dissipation from the heater it is necessary to run the
fan at any time the heater is running above the low position.
For best results it is best to burn 290mm long wood and load your wood straight into the rebox front to rear.This will
give optimum eciency and recoverable heat, and minimise creosote formation and smoke emissions.
Overnight burn
Approximately 30 minutes before turning the heater down to overnight burn it is recommended to load the heater with
fuel for the overnight burn. Leave the air control in the medium to high position. Let the heater run for about thirty
minutes. This will reduce the moisture content in the fuel before shut down. (This will help reduce the creosote formation
in the rebox and ue.) Set the air control to the setting you have found best for your requirements. Turn the fan o and
retire. The aim when overnight burning is to have only a few hot embers left in the bottom of the rebox in the morning,
not huge lumps of wood.
WARNING
!
Operation of the fan
If rebox failure is reported and it is found that the rebox has been abused
through improper use of the fan, Jindara reserve the right to disallow any
warranty claims in relation to rebox failure.
WARNING
!
The Door
Leaving Door Open
As stated previously in relation to leaving the door open 25mm to encourage the re
to pick up at a faster rate, your heater has been tested to ensure that no
structural damage can take place if the door is inadvertently left open. However
your paint nish can be damaged if the door is left open for a long period with a
full rebox of fuel with the fan o. Closely supervise your heater while the door is
left open.
Closing the Door
Always ensure that before you close your door there is no wood protruding
beyond the front of the rebox opening. Do not use the door glass as a ’battering
ram’ to push the wood back into the rebox.Damage to the glass by such
impact is not covered by your warranty.
(continued)
AF Gason Pty Ltd accepts no liability whatsoever for any interpretation of
A
S/NZS 2918:2001. It is important you understand these installation
i
nstructions, and minimum clearances to combustibles before installing
y
our Jindara Hamersley Insert.
A
ll dimensions used in this document are in millimetres and are minimum
u
nless otherwise stated. These dimensions state the minimum distance the
J
indara Hamersley Insert can be placed in relation to any combustible
m
aterials – plaster, wallpaper, timber, MDF etc.
I
nstallation Permit
D
epending on your local authority requirements, a permit may be required for
t
he installation of your heater. It is your responsibility to arrange the same.
I
nstallation into existing or masonry replace
T
he Jindara Hamersley Insert can be installed into a masonry replace with a ue
s
ystem that is in accordance with the relevant sections of AS/NZA 2198:2001. No
c
ombustible or heat sensitive material may be placed closer than 975mm from
t
he top of the hearth/base of appliance and 150mm either side of the
a
ppliance’s fascia.
I
n a masonry replace installation, the minimum hearth depth of 600mm from
t
he front of the fascia panel must be achieved. In the instance the fireplace is
r
aised above a combustible oor, and it is desired to reduce the hearth depth,
p
lease refer to the elevated installation instructions on page 7 for hearth
r
eduction information.
F
or detailed mantle clearance dimensions, refer Figure 4.

Hamersley Mk2 Insert 4 Hamersley Mk2 Insert 9
Installation (continued)
100
690
660
1063
836545
763
50
Zero
Clearance
Box
50
18mm Bellis Board
or Cement Sheet min.
Triple skin
Flue
VentVent
Villaboard can overlap clearance gap
betweenZCB and frameing, and run
over the front of the ZCB. Do not silicon or
adhere villaboard to ZCB as heatexpansion
of ZCB will cause cracking.
Figure 2. ZCB Installation detail
WARNING
!
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE WITHOUT READING AND
UNDERSTANDING THESE OPERATING INSTRUCTIONS THOROUGHLY. FAILURE TO
OPERATE THIS APPLIANCE PROPERLY MAY CAUSE UNDUE DAMAGE TO THE
APPLIANCE OR RESULT IN A FLUE FIRE.
Read these instructions
Operating your Jindara Wood Heater
Starting your re
Place a or paper in the bottom of the and place a large amount of small kindling on top. Ignite the
paper or the r. Set the air control to high and leave the main door open approximately 25mm.When the kindling
is burning, place about four pieces of small wood on top of the burning kindling. Once the wood is alight,close the main
door.After approximately 20 minutes, turn the air control down to medium and turn the fan on to low speed.
On the initial -up you may detect smoke coming from the paint and from any oils that may be on the steel on
the outside of the .This is normal. It is suggested to well ventilate your home on the initial up. Please refer to
our section ‘Paint Curing and Care’.
The glass door
Always operate your heater with the door closed and locked.The only time you can leave the door open is on initial
lighting, or when reloadingthe heater.
Care of your glass
If you are burning good dry hard wood,you will have very little discolouration of your glass in a normal burning cycle.
If you aim for an overnight burn, you should not get much discolouration.You can control this by adjusting the air
control, moving from the left and slowly creeping the control to the right.After a number of days you will the right
position to suit your requirements and the fuel that you are using.
30
Flue pipe casing
Flashing
3 x diameter
from active to
heat sensitive
surface
Batten
Flue
pipe
Flashing
Flue pipe casings
Heat sensitive roof
25mm
25mm
25mm
Flue pipe
Gap 25mm
Gap 25mm
Batten
Ceiling
Ceiling Plate
See clause 4.6.3(b) of AS/NZS 2918:2001
25mm
12mm
25mm
150mm dia
Example of sloped ceiling penetration
Example of roof penetration
Rafter
See clause 4.8 of AS/NZS 2918:2001
Installation (continued)
Clearance to combustibles & Gason Zero Clearance Box (ZCV) installation
T
he Jindara Hamersley Insert conforms to AS/NZS 2918:2001 Appendix B, when the appliance is placed in relation
t
o combustible surfaces. For additional clearance details, or to access the Jinidara Hamersley Insert thermal
c
learance test report – HCMG-15-067 – please contact the Jindara dealer from whom you purchased your heater.
T
he Gason ZCV box is an approved cabinet that allows certain Jindara Insert wood heaters, in conjunction with a
t
riple skin ue system to be installed within a non-masonry replace in accordance with AS/NZS 2918:2001.

Hamersley Mk2 Insert 5
Installation (Continued) Installation (continued)
• Select the position that you wish to install your ZCV, carefully allowing for ue clearances of 305mm in the roof
cavity (the outer ue being 255mm requires a 25mm clearance on either side to combustibles, making overall
clearance of 305mm).
• Place hearth (cement bre sheet) under the position desired for the zero box. Place the zero box into position.
• Fit ue upstands to zero box.
• Fit ue to the upstands and terminate at the required height above the roof line.
• Fit 300mm x 100mm vermin proof vent directly behind where the zero box will be located, as near as
practicable to the oor. This vent will allow air access to the zero box either from another room or external air.
Note: If installed on a timber oor, an additional two vents are required. i.e. either through the oor, one each
side of the ZCV, or alternatively, through the side wall(s) if applicable.
• Build your frame around the ZCV maintaining the clearances listed above.
• Cover the front with a 4mm cement sheet or non-combustible material for the rst 300mm above the
appliance.
• Install the mantle if required. Note: If mantle is made out of combustible material the following dimensions
must be adhered to.
ZCV installation notes
Non-combustible
hearth
Minimum 4mm thick
cement sheet, villaboard
or non-combustible
material on front face
of framing.
Figure 3. ZCB Installation Step 1.
Vent may be located
in the wall or on the
oor.
Tripleskin Flue
Hamersley Mk2 Insert 8
Installation (continued)
Final inspection prior to use
•Ensure the bae plate is rmly located.
•Ensure cast iron liners – side and back – are positioned correctly.
•Ensure re bricks are sitting at and covering entire base.
•Ensure ash deector is positioned correctly.
•Check fan cord has not been damaged during transit.
•Plug in fan cord and ensure cord does not touch stove surface.
•Check all door seals are tting correctly.
Bae Plate
Fire Bricks
Ash Deector
Cast Iron Liner
Rear liner
Side liner
3000mm 3000mm
3000mm 1000mm
min if clear
within
3000mm of
ue top
Increase from
1000mm min
until clear
within 3000mm
of ue top
600mm min
More than 3000mm
600mm min
More than 3000mm
or less
3000mm
or less
Increase as
necessary
until
nothing
within
3000mm of
ue top
Any nearby
structure
3000mm
The ue pipe shall extend not less than 4.6m above the top of the oor protector. Note: Installation must be
carried out by a licensed installer in accordance with AS/NZS 2918:2001.
Flue and chimney requirements
e.
• Insert your Jindara Hamersley Insert into the ZCV. It is important that the base of the appliance is sitting on 2x
galvanized C-section strips supplied with ZCV. These strips allow a correct installation height and fresh air to
circulate around the appliance base.

Hamersley Mk2 Insert 6 Hamersley Mk2 Insert 7
Installation (continued) Installation (continued)
600
Minimum hearth sizes
A B C D
1225 975 150 250
Mantle Clearances
1000 1300 18
Vent
Breast plate no
thicker than
30mm
C (appliance to
mantle upright)
Hearth Depth
D (max)
BA
Figure 4. ZCB Installation Step 2
Hearth Depth Width Depth Overall Thickness
Plaster, timber, MDF etc.
combustible material can
be used on sides of framing
MinimumAppliance
Hearth Depthraised by
X Y
1000mm
Table 1. Appliance height
vs hearth requirements
X
Y
600
575
550
525
500
475
450
425
400
375
350
325
300
300
Elevated installation details
Figure 5.
- Ref. page 8.
- Ref. page 8.
- Ref. page 8.
- Ref. page 8.
Fitting the Bae Plate
1. Feed bae plate through the door opening with front edge folded up, feeding plate all the way to the rear
of the heater.
2. Lift front over Pin A and slide towards front of heater.
3. Lift rear so bale plate is horizontal and move towards back of heater.
4. Lower over Pin B.
5. Bae plate must be sitting on Pins A & B.
P
lacement of Cast Iron Liners into rebox
T
he rear cast iron liner is to be positioned to the rear with rib and logos facing into the rebox. Side cast liners
ar to
be positioned on the appropriate side and interlock into the rear cast plate. Fire bricks can then be installed.
P
lacement of Fire Bricks into rebox
F
ire bricks must be sitting at on the bottom of the rebox, covering base.
P
lacement of Ash Deector into rebox
A
fter cast iron plates and re bricks are tted correctly into position, slide ash deector inbetween the cast plates
a
nd down in front of the re bricks. The deector should be positioned such that the 100mm leg is placed within
t
he rebox, and the 50mm leg faces towards the door to prevent ash build up on the door.
0
25
50
75
90
110
130
145
160
175
185
195
205
>205
Elevated installation
M
asonry
I
n some instances it may be desirable, or required that the Jindara Hamersley Insert wood heater be installed into
a
n existing replace which is raised above a combustible oor. In this situation, the minimum required hearth can
b
e reduced to the corresponding elevated height dimensions mentioned in Table 1.
S
cenario 1 – If the appliance is installed onto a non-combustible replace (or step), which is 120mm above a
c
ombustible oor, the minimum required hearth depth is 475mm. (refer Table 1.)
S
cenario 2 – If the appliance is installed onto an existing non-combustible replace (or step) 80mm above a
c
ombustible oor, and the existing replace (or step) extends 350mm in front of the appliance’s fascia, some
a
dditional hearth maybe required.
U
sing Table 1, the closest minimum height related to 80mm is 75mm. The reective hearth depth required for a
r
aised installation of 80mm is 525mm.
F
or this installation to conform with AS/NZS2918:2001, a minimum 175mm of 18mm thick villaboard (or similar
n
on-combustible material –Bellis Board, tiles etc.) must extend in front of the replace (or step) to achieve a
c
ombined hearth depth of 525mm. It must also include a minimum overall width of 1000mm.
Z
CV
I
t is essential that the information contained in the ZCV installation notes (page 5) are followed to ensure safe and
c
orrect installation is achieved. By raising the ZCV (with the Jindara Hamersley Insert inside it), the minimum heart
h
d
epth in front of the appliance fascia can be reduced in accordance with Table 1. In the instance the ZCV is raised,
a
ny structured used to support the appliance must be constructed of non-combustible material and withstand the
c
ombined weight of the Jindara Hamersley wood heater and ZCV.
W
hen the appliance is raised 209mm or more above a combustible oor, a 300mm non-combustible hearth or

oor protector is always required as per AS/NZS 2918:2001.