Lopi Zero Clearance Box User manual

Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Suitable for Lopi Flush Wood Medium &
Lopi Flush Wood Large Hybrid-Fyre™ Inserts
Lopi DVL, DVS GS2 & Radiant Plus Large Gas Inserts
Zero Clearance Box Installation Manual
Australia Only
www.lopi.com.au
Dragon Wholesaling Pty Ltd
4/16 Lexington Drive,
Bella Vista
NSW 2153 Australia
© Copyright 2019

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
30
945
550
945
695
695 725
34mm Ventilation Gap
34mm Ventilation Gap
Igniter Installa�on:
Uninstall theinner and outer access
panels and remove the knockouts.
Feed wires and the air hose through the
knockout holes in theaccess plates.
Once the inbuilt is in place, restore the
access panels to their original posi�on.
Zero Clearance Box Dimensions
The Zero clearance box allows all models listed above to be installed into a
combustible wall with minimum clearances and without brick or block work using the
framing dimensions and clearances included in this manual.
Section View
Isometric View
Elevation View
**Dimensions are subject to change at our discretion, please check with our ofce for further details
2
(Wood Models Only)

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Zero Clearance Box Assembly Details
Step 1
Lay down bottom panel with the folded edges
facing upwards and non folded edge to the
front
Step 2
Screw inner left, inner right and inner back panels
together with the returns facing outwards
(Securing to the base is not required)
Step 3
(Lopi DVL Gas Insert Installation Only)
For all other reboxes skip this step
If installing the Lopi DVL gas insert into the ZC
Box it is necessary to remove the following
two perforated sections of the inner top panel
(highlighted in blue) to allow for successful
installation.
Locate the inner top panel and remove the
perforated sections. The sections to be removed
are illustrated in blue on the image below.
Note: Right hand side
panel has the check out
for the power
returns
* Images for illustration purposes only, some details may change
3
Step 4
Screw inner top panel in place

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Step 6
Screw outer left, outer right and outer rear
panels into place ensuring the vent holes are to
the bottom and return facing outwards
Step 7
Screw outer top panel into place with 1 x large
return facing upwards at the front, x 3 small
returns facing downwards
Vent holes
returns
* Images for illustration purposes only, some details may change
Step 5 (Wood Firebox Installation Only)
Screw 200mm collar in place
Zero Clearance Box Assembly Details
Step 7 (Wood Firebox Installation Only)
Screw 250mm collar in place
4

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Zero Clearance Box Assembly Details
NOTE 1: (Wood Firebox Installation Only)
There is a different starter section provided for the
Medium Flush Wood and Large Hybrid-Fyre™ models.
Please use the correct starter for the model being
installed.
The Flush Wood Large Hybrid-Fyre™ Starter must be
secured to the top of the rebox and sealed around
using a replace cement as per installation manual.
NOTE 2:
Use plastic insulating cover where the fan power cable passes through
the inner and outer panels
NOTE 3: (Wood Firebox Installation Only)
A triple skin ue must be installed from zero clearance box as per Australian Standards.
A 25mm clearance from the outer 10” casing to any combustible material must be
maintained.
Please see heater owners manual for other clearances and more information.
* Images for illustration purposes only, some details may change
5
The Flush Wood Medium Starter needs to be secured to
the ue collar, however, it is not required to be sealed.
It has been designed with a check out for the bypass rod
at the front and to rest on the tab inside the ue spigot on
the left.
Medium Starter
Large Hybrid-Fyre Starter

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Knock-Outs for GreenStart™ Ignitor - Wood Inserts Only
When using the GreenStart™ Ignitor, the knock-outs on the inner and outer walls of the zero
clearance box will need to be removed. Follow the directions below to remove.
WARNING: The edges of the steel are sharp. Wear gloves to prevent injury.
WARNING: After the knock-out is removed, make sure any sharp edges or metal strips do not
protrude from the knock-out area. Remove any sharp edges to prevent damage to the ignitor or
its wiring.
(a) Use a wire cutter to remove the small strip of steel holding the knock-out in place.
(b) Pry the knock-out forward (use a screwdriver or pliers).
(c) Bend the knock-out repeatedly until it comes loose. Discard (or recycle) the knock-out.
(d) Repeat steps (a) through (c) for the remaining knock-out.
6

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
When using the ZC Box to install either the gas inserts the following installation methods are
to be used:
Lopi Radiant Plus Large & DVS GS2 - Flue Assembly
Required Parts: 2 x 3” exi ue pipe cut into approx 300mm lengths, Flue Adaptor (Part No.
46DVA-GK) Min 2.4 metres of 4 x 6-5/8 Rigid Flue & Vertical Termination
Step 1:
Secure two 3” exi ue pipes with screws to the air
inlet and exhaust spigots on the rebox.
Ensure that these pipes are not split and there is
enough length of pipe in order to connect to the
ue adaptor in the next step.
Step 2:
Secure ue adaptor to the ue exi pipe
ensuring the exhaust and inlet pipes are in the
correct orientation to the adaptor.
Step 3:
Carefully compress the exi ue pipes so that
they sit inside of the ZC Box and allow for the ue
adaptor to sit ush on top of the ZC Box.
Secure the ue adaptor to the rebox using tek
screws.
Step 4:
Final Flue Connections:
Connect 4” x 6”-5/8 vertical ue and terminate
through the roof. Flue must be a minimum of
3000mm high from the base of rebox and
rise a minimum of 300mm above roof before
termination
Tip!
Secure the rebox to the base of the ZC
box using 2 x Tek Screws.
Fix screws through the oor of the rebox
into the raised sections on the ZC box oor
7
Gas Inserts Flue Set-up Using ZC Box

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
When using the ZC Box to install either the gas inserts the following installation methods are
to be used:
Lopi DVL GS2 - Flue Assembly
Required Parts: 3” & 4” Flexible Connectors, Flue Adaptor (Part No. 98900124)
Min 2.4 metres of 4 x 6-5/8 Rigid Flue & Vertical Termination
Step 1:
Secure 3” & 4” Flexi Connectors to DVL Adaptor
using Tek screws. This provides an extension to
ue adaptor 3“ & 4” pipes
Step 2:
Secure Adaptor & Cover Plate to ZC Box & feed
DVL Adaptor through ZC Box lid and secure to
the air inlet and exhaust spigots on the rebox.
Secure in place with tek screws.
Step 4:
Final Flue Connections:
Connect 4” x 6”-5/8 vertical ue and terminate
through the roof. Flue must be a minimum of
3000mm high from the base of rebox and
rise a minimum of 300mm above roof before
termination
Tip!
Secure the rebox to the base of the ZC
box using 2 x Tek Screws.
Fix screws through the oor of the rebox
into the raised sections on the ZC box oor
8
Gas Inserts Flue Set-up Using ZC Box
ADAPTOR COVER PLATE

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
550
735mm*
960
960
Top of Hearth / Base of Gas Firebox
ZC Box
*Allowance must be made for any
finished floor above existing concrete
or timber floor.
SEE HEARTH REQUIREMENTS
Measurements from top of concrete
or timber floor
Framing Dimensions for Zero Clearance Box
Lopi DVS, DVL & Radiant Plus Large Models Only
Plan View - Timber or Concrete Floor
Elevation View
**Dimensions are subject to change at our discretion, please check with our ofce for further details
9
550
735mm*
960
960
Top of Hearth / Base of Gas Firebox
ZC Box
*Allowance must be made for any
finished floor above existing concrete
or timber floor.
SEE HEARTH REQUIREMENTS
Measurements from top of concrete
or timber floor
NOTE:
Finishing panels covers frame opening width
& height from base of rebox
(34mm up from base of ZC box)
Lopi DVS - MUST Use Large 1 Piece Panel - SKU 96100324
Lopi DVL - Use Standard 1 Piece Panel - SKU 96100323
Lopi Radiant Large - Use Small Panel - SKU 96100562

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Hearth Requirements for Zero Clearance Box
Lopi DVS, DVL & Radiant Plus Large Models Only
TIMBER & CONCRETE FLOORS
Firebox
(Shown with Times Square Face)
ZC Box
34mm Hearth to be
set at bottom of firebox
Hearth Section
Timber or Concrete Floor
250
Suggested
550
10
Plaster Wall
FC / Non Combustible
Wall Sheeting
ZC Box
Gas Insert
34
Finished Hearth
Bottom of Gas Insert
Finishing Panel
Timber or
Concrete Floor
Firebox
(Shown with Times Square Face)
ZC Box
34mm Hearth to be
set at bottom of firebox
Hearth Section
Timber or Concrete Floor
250
Suggested
550
10
Plaster Wall
FC / Non Combustible
Wall Sheeting
ZC Box
Gas Insert
34
Finished Hearth
Bottom of Gas Insert
Finishing Panel
Timber or
Concrete Floor
Section View
Isometric View
10
Tip!
If no hearth is required elevate the ZC Box
on a timber base and nish with a 4 sided
panel.
1 Piece Panel

Zero Clearance Box
Flush Wood Medium, Flush Wood Large Hybrid-Fyre™
Lopi DVL, DVS GS2, Radiant Plus Large
Dragon Wholesaling Pty Ltd | 2/16 Lexington Drive, Bella Vista NSW 2153 | Phone. [phone] Fax. [phone]
Section View
**Dimensions are subject to change at our discretion, please check with our ofce for further details
250
Suggested
550
34
25mm Clearance
Around flue to
combustibles
4 x 6-5/8 (168mm) Flue
Internal Stud Wall
Min 50mm clearance
from adaptor to
timber header.
Plaster Wall
Finished
Hearth
ZC Box
*Allowance must be made for any finished floor above existing concrete or timber floor.
SEE HEARTH REQUIREMENTS
SEE HEARTH REQUIREMENTS FOR FURTHER DETAIL
50
FOR SPECIFIC MANTEL &
FACING REQUIREMENTS
SEE INSTALLATION
MANUAL OF THE
RELEVANT PRODUCT
735mm
Adaptor
11
Minimum Clearances & Hearth Requirements
Lopi DVS, DVL & Radiant Plus Large Models Only