Yunca Gas XANDER INSERT User manual

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A division of Terry Young Ltd, New Zealand
25 NOVEMBER 2021
Tested as per Appendix E (Thermal Testing of Fireplace Insert Installations) of
AS/NZS 2918: 2001 and confirmed compliant with AS/NZS 2018: 2001.
These instructions cover installations of the Yunca Xander Insert, where the
optional “Zero Clearance Kit” is being used - enabling installation into a
suitably constructed enclosure as per AS/NZS 2918: 2001.
For Masonry, please refer to the separate instruction book.
INSTALLATION INSTRUCTIONS for
XANDER INSERT
WOOD BURNER
• Clean Air Sub 1.0 • Non Clean Air (Rural)
BUILT-IN “ZC” INSTALLATIONS

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SAFETY INFORMATION
General:
This appliance is not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their safety.
For the protection of young children, install an effective fire safety screen around your fire. Always keep
children well away from the wood burner when it is alight.
Supervise young children to ensure they do not play with the appliance.
During initial burns of the appliance, ventilate the rooms well. It is recommended that babies, small
children, pregnant women and pets should not be present in the area during initial burns as this is the
firebox paint curing period.
Do not make any modifications to the unit, and use it only in the manner described in the manual. Using it
in any manner not recommended by the manufacturer may result in injury or death.
For units including electrical connections:
If the wood burner is permanently connected to an electrical source, an isolating switch (wall switch) must
be installed.
New circuits or modifications, if required, but be made using the services of a certified electrician only.
Ensure that the outlets you use are grounded properly, polarised and provided with fuse units.
Ensure that the electrical plug is accessible after installation. The wood burner must not be located
immediately below an electrical socket.
Never operate the appliance with a damaged plug or cord, or if you observe the fan unit is malfunctioning
or the heater has been damaged in any way. Call the authorised service person immediately for repairs or
making electrical or mechanical adjustments. –Isolate the electrical supply in order to alleviate any
potential risk.
If the supply cord is damaged, the manufacturer, its service agent or a suitably qualified person must
replace it in order to avoid electrical hazard. Any cord similar to the original can be used.
IMPORTANT INFORMATION
I. It is imperative that you familiarise yourself with this entire document, and also ensure you have
sufficient knowledge of relevant building regulations prior to proceeding with an installation.
II. The term “Zero Clearance”, or “ZC” is in common parlance, however it refers to reduced rather
than actual nil clearances. Please refer to specifications in this document in conjunction with the
relevant building code if unsure of clearances.
III. The appliance and flue system shall be installed in compliance with AS/NZS 2918:2001 and the
appropriate requirements of the relevant building code or codes.
IV. Appliances installed in accordance with this 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 compliance plate with the marking “tested to AS/NZS 4013”
V. 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
VI. Mixing of appliance or flue system components from different sources or modifying the
dimensional specification of components may result in hazardous conditions. Where such action
is considered, the manufacturer should be consulted in the first instance.
VII. Cracked and broken components e.g. glass panels or fire bricks, may render the installation
unsafe.

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A. Yunca recommends that competent trades persons carry out all installations (e.g. a
NZHHA Registered Installer), to obtain maximum performance and safe, efficient
heating.
B. A consent is required and we suggest you check with local building inspectors as by-laws
do vary from area to area. Also notify your Insurance Company that a solid fuel heater
has been installed.
C. Floor Protector
C1. Built-in (ZC) installations: Floor protector (Promina/Bellis Board or similar non-
combustible material) must be installed so that its leading edge is a minimum of
500mm in front of the appliance base [with fascia attached]. The floor protector
must be a minimum of 860mm wide x 1090mm deep x 9mm thick.
C2. Front floor protector clearances may be reduced if appliance is elevated. (Table 2)
D. Seismic restraint.
D1. Heater must be restrained from seismic movement (Fig. 9) as required by AS/NZS
2918:2001
E. Heat sensitive materials exclusion zone.
E1. Non-combustible front cladding must be used, to a minimum of 600mm above the
top-most panel vent, and a minimum of 30mm either side of the fascia (152mm
either side of the outer casing of the firebox (Zero Clearance Kit). (Fig. 5)
E2. No heat-sensitive material is permitted to contact the fascia forming or surrounding
the front of the installation.
E3. No heat-sensitive material is to be placed any closer than 1315mm from the base of
the Zero Clearance Box, 20mm from either side, or 20mm from the rear.
E4. Where a nogging or lintel is required, a steel angle or other suitable non-combustible
alternative should be used if within the aforementioned exclusion zone.
F. Mantel Clearances.
F1. Built-in Zero Clearance installation must have a minimum of 1300mm from the
underside of the mantel shelf to the top of the appliance hearth. The mantel shelf
must not protrude further than 250mm into the room. Minimum clearance of
1200mm from the underside of the mantel key (first combustible above appliance) to
the top of the appliance hearth. The mantel key must not protrude further than
30mm into the room.
F2. All installations must have a minimum of 600mm vertically from the top vent to the
nearest combustible material.
F3. A 100mm heat deflector must be installed directly above the fascia for the full width
of the appliance if a combustible mantel key or shelf is present.
F4. Mantel uprights must not protrude further than 70mm into the room, and be no
closer than 30mm to the fascia on the side of the appliance where fans are
(internally) hard wired. For units with external wiring using the included cable
through the side panel, the side clearance to mantel uprights should be a minimum
of 100mm to allow for the cable exiting the side panel.

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G. Xander Wood Burner Dimensions
(Fig. 1)
Dimensions given include the Built-in
“Zero Clearance”cabinet and also
the bottom infill fascia panel, which
is required for ZC installations.
Vented fascia top panel must be
used for Built-in (ZC) installations.
(The blank fascia top panel is for masonry installations
only)
H. Cavity Dimensions
H1. Cavity should be prepared based on the
given minimum clearances or greater.
(Table 1) & (Fig. 2)
Increasing the cavity dimensions slightly
will make installation easier.
Non-combustible material must be used
on front wall between appliance and first
nogging/frame of enclosure.
Heat-sensitive structures not to contact
carcass or appliance fascia.
Ensure wiring for fan (Fig. 11) is taken into
account when preparing cavity.
WARNING:
Cavity Dimensions must be determined in conjunction with requirements as per Section E
and Section L, with particular note made to the heat sensitive material exclusion zone.
I. Cavity Venting
I1. A 10,000mm² vent must be installed at least 600mm up from the base of the
enclosure. This can be any configuration as long as it equates to at least 10,000mm².
[For example: 1 hole at 100 x 100mm, 2 holes at 100 x 50mm, or 4 holes at 50 x 50mm].
I2. Suitable precautions should be taken to prevent rodents, birds and/or debris from
entering or obscuring the air vents. If grilles are used; ensure the minimum vent area
is maintained through the grille.
Table 1
BUILT-IN (ZC) CAVITY
MINIMUM DIMENSIONS (mm)
WIDTH
(W)
HEIGHT
(H)
DEPTH
(D)
790
731
555
Min timber cavity framing height 1315mm
Fig. 1
Fig. 2
(Not to scale)

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I3. WARNINGS:
A minimum of 450mm x 450mm space around the flue, in the enclosure ceiling,
through which the flue system passes, should be maintained to provide sufficient
ventilation in order to prevent heat build-up within the enclosure.
The constructed enclosure should not be capped off at ceiling level, as there
would be a considerable risk of fire from the build-up of heat. Such an installation
should be properly vented into the ceiling cavity with sufficient clearances to
comply with relevant building codes and practices.
For standard flue installations(Fig. 3); if any support is required under the chimney
cap, it should be constructed of non-combustible materials only.
J. YUNCA Insert Flue Kit –Zero Clearance (Complies with AS/NZS 2918:2001):
J1. Zero Clearance (Built-in) Flue Kit consists of the following:
4.8m x 150mm stainless steel flue.
4.8m x 200mm galvanised liner.
4.8m x 250mm galvanised liner.
1 x top cap & cowl (cone).
Please Note: All flue joints must be sealed with flue sealing compound. Use stainless steel
screws or rivets to join the flue pipe (three equally spaced places at each joint). The first length
of flue must be fixed to the flue spigot with at least one stainless steel screw or rivet. The
required minimum flue termination height is 4.6 metres above the floor protector.

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K. Typical Built-in (ZC) Flue Installation(Fig. 3)
Complies (with heater) to AS/NZS 2918:2001 (Not drawn to scale)
Fig. 3

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L. Conditions for Flues(Fig. 4)
L1. The FLUE shall extend to:
Not less than 600mm above the highest point on the roof if within 3.0m of that point, or
Not less than 1000mm above the intersection point with the roof and not lower than any point of
the roof within 3.0m.
In any case the length of the flue shall not be less than 4.6m from the ash floor protector.
L2. In some situations the Local Council may vary the above requirements.
L3. The flue system must comply with AS/NZS2918:2001.
L4. A minimum of 25mm clearance must be left between the outer casing of the flue and any surrounding
combustible materials.
L5. For situations where the cavity terminates at ceiling level, suitable measures must be taken to
prevent accidental migration of loose-fill or any combustible material by any action of wind or by
persons moving in the ceiling space. Such installations are not detailed in these instructions, so
please refer to AS/NZS 2918:2001, and your local authorities for requirements.
More than 30003000
or less
600 min.
3000
1000 min. if clear
within 3000 of
flue top
.
3000
Any nearby
structure
.
1000 min. if clear
within 3000 of
flue top
MINIMUM HEIGHT OF FLUE SYSTEM EXIT
NOTE : Dimensions are in millimetres
3000
or less
600 min.
More than 3000
3000
.
Increase from
1000 min. until
clear within
3000 of flue top
Fig. 4

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M. Xander Built-in (ZC) Installation Thermal Clearances
THERMAL CLEARANCES FRONT VIEW
THERMAL CLEARANCES CROSS SECTION
Fig. 5
Fig. 6

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N. Floor Protector Reductions
N1. The floor protector extension from the front of the unitcan be reduced if the unit is
elevated. (Table 2) * Measurements taken from the front of the (35mm thick) fascia.
Elevation Increase (mm)
0
50
100
150
200
* Protector Extension (mm)
500
464
421
366
300
Table 2. Floor Protector Reductions for Built-In Installations
O. Xander ZERO CLEARANCE KIT Assembly
Note: The Xander “Zero Clearance Kit” (for built-in installations) is supplied as a
flat pack and will require assembly before installation:
ITEM
DESCRIPTION
QTY
1
CASING PANEL ASSEMBLY –BASE
1
2
CASING PANEL ASSEMBLY - LEFT SIDE (SIDE-HOLE OPEN WITH RUBBER GROMMETS)
1
3
CASING PANEL ASSEMBLY –RIGHT SIDE (SIDE HOLE COVERED)
1
4
CASING PANEL ASSEMBLY –BACK
1
5
CASING PANEL –TOP INNER
1
6
CASING PANEL –TOP OUTER
1
7
8G x 1/2 PAN POZI SELF TAPPER ZP (0013)
40
8
CASING SPIGOT ADAPTOR
1
Fig. 7 –Zero Clearance Kit parts breakdown

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Fig. 8 - Zero Clearance Kit ASSEMBLY PROCEDURE

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P. Xander Insert Seismic Fixings
P1. Follow local Council’s specifications.
P2. Prior to installation, ensure the cavity floor is level both ways, smooth and bump
free. Also ensure the mantel face is perpendicular in relationship to the cavity floor.
P3. Ensure the unit is securely fixed using sleeve anchors or similar at the locations
shown in the images on this page. (Fig. 9)
Q. Xander Fan - Electrical Supply
Q1. Remove the front fascia from its separate box and packaging and set it aside in a
safe position. You can use the box and polystyrene packing as a work surface to
raise it up if you wish.
Q2. 3-Pin Plug
If the fan is to be plugged into an electrical outlet in the room, take the RS321-174
mains power cable (plastic bag in box) and plug it into the IEC C14 socket on the
underside of the circuit box on the rear of the fascia. Pass the cable through the slot
in the fascia, crimp the cable grip bush (in the plastic bag with the power cable) over
the cable outside the fascia and pull the bush and cable back into the hole in the
fascia.
Q3. Hardwired
Should you wish to “hardwire” the fan unit, as a Registered
Electrician you can use TPS cable. Remove the screw fixed
panel on the rear of the circuit box, remove the internal wiring
and IEC C14 socket and substitute your TPS in place of the
socket. You must be a Registered, Certified Electrical
tradesperson to do this. Plug the slotted hole in the side of
the fascia with the 16mm black, rubber grommet supplied in
the plastic bag
Fig. 9

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Q4. Although the fan is controlled automatically by a thermostat, an isolator switch must
be installed in conjunction with the fire.
R. Xander Install Firebox and Fascia
R1. Position firebox in front of fireplace and remove any remaining packaging and
desiccants from the flue and front of the air slide.

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R2. Unlatch door, open it slightly, lift door off from firebox and set it aside in a safe
position where it cannot fall down.
R3. Undo the two fastening screws from the air slide handle flip it 180 degrees, reinstall
and tighten the screws again.
R4. Remove fan by removing M8 button head socket screws, 2 positions. Withdraw fan,
on its mounting plate, from under the fire box. Set the fan aside in a safe position.

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R5. Remove the two self tapping screws at the top outer corners of the firebox cowl and
remove the Primary Outer Casing Top Panel and set it aside. (The panel is a slip fit
under the panel at the rear of the flue spigot.)
R6. Manoeuvre the firebox carefully into the previously prepared “zero clearance” box
and use the M6 seismic retaining bolts (2 pos’ns) to attach firebox to the box at the
bottom front, at each side.
R7. Reinstall fan unit on its mounting plate, back under the firebox. The two padded tabs
on the mounting plate insert into brackets and the plate is retained by the two M8
button head socket screws you removed earlier. Reinstall the screws complete with
split washers and tighten securely but do not over tighten.
R8. Insert the fan power cable grommet into the notch in the side cowl of the firebox and
hang the cable outside the firebox ready to plug into the circuit box on the rear of the
fascia.
R9. Apply fire cement sealant as required to the flue spigot and lower the Flue into the
spigot on top of the firebox and ensure it is fully seated.

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R10. Rivet or screw fasten the Flue Spigot, reinsert the Primary Outer Casing Top Panel,
slipping the rear edge under the rear top panel and fasten with the two screws at the
outer corners as below:
Note: Primary Outer Casing Top Panel must be installed after the flue is fixed in
place.
R11. Remove the four loosely fitted, black, mushroom washer, self tapping screws from
the front edges of the firebox cowls and set them aside where you can reach them.
R12. Set the Front Fascia temporarily in front of the fire, ready to be lifted up into position.
R13. Reach over the top, or round the side and insert the fan power cable into the 4 pole
socket on the underside of the circuit box mounted on the rear of the fascia panel.
(The plug is shaped so it will fit only one way round.)
R14. Lift the fascia panel, slide it over the air slide handle and sit it over the 2 pins which
project out from the side cowls. (The pins take the weight of the fascia while the
fastening screws are reinstalled and enable the fascia to easily be aligned during
installation.)
Fig. 26

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R15. Reinstall the 4 screws, leveling the front fascia to align with the firebox (which you
have previously leveled) and centralising it about the firebox, so there is an equal
gap at the sides for the door to fit neatly into. Tighten the screws when you have
everything aligned correctly.

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R16. Take the door, prise up the hook latches and insert the shaft of a screwdriver under
the arms to make the hooks project. Reinstall the door (remove screwdrivers) and
confirm the fascia is positioned to provide equal spaces either side of the door and
that the door is “square” with the fascia panel when closed and latched.

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R17. Install the air slide handle Knob. (From the plastic bag.)
R18. When you are complete and confident everything is electrically safe, plug the power
cable in or if hard-wired, turn on the isolation switch to liven the unit prior to lighting a
fire and conducting initial burns.
WARNING:
It is important that the fire should NOT be operated without the fan powered up to be
operational.
The fan has been factory tested to confirm that it starts when the temperature of the
thermostat reaches 40 degrees Celsius.
Confirm that the fan starts and runs during your initial burns.
< END >
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