DON-BAR Inserts Installation, Operation & Maintenance Manual

Keep these instructions for future use

Installation, Operation

and Maintenance Manual

LES FOYERS

DON-BAR

FIREPLACES

REV. 2014-11

INSERTS

Les foyers DON-BAR Fireplaces, inc.

Shop and Showroom: 741, St-Vallier Ouest, Quebec (Quebec) G1N 1E2

Phone: [phone] - Fax: [phone]

Website: www.don-bar.com - Email: [e-mail]

LES FOYERS

DON-BAR

FIREPLACES

Installation, Operation,

and Maintenance Manual

The manual is divided into 6 parts:

PART 1: Installation ...............................................

PART 2: Security, Operation and Maintenance ...

PART 3: Parts List .................................................

PART 4: Chimney Fires ..........................................

PART 5: Warranty ..................................................

APPENDIX 1: Requirements for existing fireplaces ....

This document in its entirety is the intellectual property of Les Foyers Don-Bar inc.

Any unauthorized use will expose its author or authors to legal and financial penalties.

Copyright © 2014 - Les Foyers Don-Bar inc.

THE INSERT SERIES FIREPLACES MEET THE REQUIREMENTS OF:
ULC S627 in Canada, UL 1482 in the USA
EPA: Certified EPA Exempt

Page 3
Page 15
Page 22
Page 23
Page 24
Page 25

REV. 2014-11

Page 2

PART 1: INSTALLATION

1. Warnings and cautions 8. Finishing frames installation

1.1. Modifications

1.2 Installation instructions

1.3 Applicable Codes

1.4 Professional installation

1.5 Before your first fire

1.6 Installation prohibited

1.7 Chimney damper

2. Listed chimneys

2.1 Approved chimney liners

3. Before beginning the
installation

3.1 Inspection of the existing hearth

3.2 Chimney sweeping

3.3 Preparation, insulation and painting of the existing
hearth

3.4 Cleaning the ash shaft

3.5 Existing hearth minimum dimensions

3.6 Chimney minimum height

8.1 Flat and ventilated frames

9. Floor protection installation

9.1 Non-combustible floor protection

10. Combustible mantel

10.1 Required clearances

11. Anti-smoke flap (optional)

11.1 Anti-smoke flap installation

12. Installation in a large-sized hearth

12.1 Non-combustible materials

12.2 Metal framing

12.3 Insert must be removable

12.4 Non-combustible finishing materials

13. Lateral clearances

13.1 Lateral clearances to combustible walls

4. Chimney liner installation

4.1 Chimney liner required

4.2 Manufacturer's instructions

4.3 Chimney throat too narrow for the liner

4.4 Jointing the liner sections

4.5 Watertight flashing

4.6 Chimney top

5. Insert installation

5.1 Putting the insert in place

5.2 Air space for the optional basement fan

5.3 Jointing the liner to the insert adaptor

5.4 Bolting the insert adaptor

5.5 Last adjustments

6. Fan installation (optional)

6.1 Fan installation

7. Exterior air intake installation
(optional)

7.1 Exterior air intake

7.2 Outside hood

REV. 2014-11

Page 3

PART 1: INSTALLATION

1. Warnings and Cautions

DO NOT OVERIFRE THE UNIT.

BURN WOOD ONLY. DO NOT USE OTHER
FUELS.

REQUIRE THE USE OF THE PROVIDED
INSULATION MATERIALS.

ALWAYS PROVIDE A SOURCE OF FRESH AIR
IN THE ROOM. AN EXTERIOR FRESH AIR
SOURCE MAY BE REQUIRED.

DO NOT ALTER THE AIR CONTROL.

HANDLE THE GLASS DOOR WITH CARE. DO
NOT HIT OR CLOSE THE DOOR SUDDENLY.

DO NOT BUILD FIRE TOO CLOSE TO THE
GLASS. DO NOT CLEAN GLASS WHEN STILL
HOT.

DO NOT USE THE UNIT IF THE GLASS IS
BROKEN OR DAMAGED.

REPLACE GLASS ONLY WITH CERAMIC
GLASS.

IINSPECT AND CLEAN CHIMNEY
FREQUENTLY. UNDER CERTAIN CONDITIONS
OF USE, CREOSOTE BUILDUP MAY OCCUR
RAPIDLY.

DO NOT USE GRATE TO ELEVATE FIRE.
BUILD FIRE DIRECTLY ON TH HEARTH.

REV. 2014-11

REV. 2014-11

Page 4

PART 1: INSTALLATION

1. Warnings and Cautions (con’t)

1.1 Modifications: Any modification, change, or
substitution of any fireplace component and/or
not following the installation, operation, and
maintenance instructions will void the warranty
and can put your security at risk.

1.2 Installation instructions: Before installation
begins, carefully read the manual and contact
your local building department to determine
whether a building permit is required to install a
fireplace.

1.3 Applicable Codes: The installation must
follow the instructions in this manual and local
building codes. If there is a conflict, you must
follow the more restrictive measures.

1.4 Professional Installation: For your security,
enlist the services of a professional fireplace fitter
for the installation.

1.5 Before your first fire: Before lighting your
first fire, read the instructions in Part 2 regarding
operating the fireplace.

1.6 Installation prohibited: DO NOT
INSTALL THIS INSERT INTO A ZERO­CLEARANCE INSULATED
PREFABRICATED FIREPLACE: Your insert
is designed to be installed only inside a
traditional solid masonry fireplace. If it is
installed in an insulated zero-clearance
fireplace, the high temperatures produced by
the insert can cause a fire.

1.7 Chimney damper: The existing chimney

damper must be set permanently in the open
position.

Typical installation inside
an existing masonry fireplace
(with a rigid liner)

Stainless steel
round top
and flashing

Metal plate with
insulation at
the damper level
to solidify the liner
and make it airtight

Outside air intake
with insulated flexible
duct (optional)

Insulation

(for basement fan

airtightness)

Basement

Acoustical
case
(optional)

Don-Bar
Insert

Centrifugal fan
(optional)

Stainless
steel rigid
and/or flexible
liner into the
existing
chimney

Rockwool
insulation
secured with
a steel sheet
(see art 3.3)

Fan thermodisc
(optional)

The existing
ash shaft can
be used with
a fan in the
basement
(optional)

Anti-turbulence
deflector (curved
metal sheet)

REV. 2014-11

DRAWING 1

Page 5

2. Listed chimney liners

mm) air space for expansion.

2.1 Approved chimneys liners: Your Don-Bar
insert is designed to be installed with any rigid or
flexible stainless steel chimney liner bearing the
ULC label S-635 (2100 degrees). For liner
diameters, see Page 14.

3. Before beginning the installation

3.1 Inspection of the existing hearth: Before
beginning the installation, inspect the existing
fireplace hearth to be sure that it is in good
condition. Strengthen any loose or unstable part.
See Appendix 1 (page 25) for the requirements.

3.2 Chimney sweeping: Sweep the existing
chimney. Don't forget the smoke shelf.

3.3 Cleaning, insulation and painting of the
walls of the existing hearth: Brush the walls of

the existing hearth to remove all the loose soot
particles. This will prevent your home from
being soiled by the circulation of the air around
the insert. Next, insulate the walls of the existing
hearth with 1" (25 mm) thick semi-rigid rockwool
insulation pads secured in place with a screwed
galvanized steel sheet (note: insulation is not
required on the masonry walls of the existing
hearth which are visible on both sides and are at
least 2" (50 mm) away from any combustible
material). At last, apply a coat of black stove
paint to seal the surfaces and make the colour of
the walls uniform because they may remain
visible around the insert.

3.4 Cleaning the ash shaft: If the ash shaft is to
be used as a duct for an optional fan installed in
the basement, be sure to clean it first. (Drawing

1).

3.5 Existing hearth minimum dimensions: Use
the dimensions indicated in the tables on the Page
14 and comply with the following requirements:
At the rear, provide a continuous 1" (25 mm) air
space for air circulation and 2" (50 mm) at the
top. On the sides, allow a minimum 1/2" (12

3.6 Chimney minimum height: 15 feet (4600
mm) for easy operation. This height is measured
from the floor where the insert is installed to the
top of the chimney.

4. Chimney liner installation

4.1 Chimney liner required It is mandatory to
connect your insert to a ULC-listed stainless steel
chimney liner (flexible, rigid or a combination of
the two). The liner must be continuous from the
insert to the top of the chimney.

Typical installations

Flexible liner

Stainles steel
flexible liner

Don-Bar
Insert

Fflexible liner
section to pass
through the
chimney troat

DRAWING 2

:

Flexible liner
section to pass
through the
chimney troat

Combination of
flexible and rigid liners

Stainless
steel rigid
liner sections
(female end up)

Don-Bar
Insert

REV. 2014-11

Page 6

4.2 Manufacturer's instructions: The
installation must follow the instructions in this
manual and the chimney liner manufacturer's
instructions. If there is a conflict, you must follow
the more restrictive measures.

Insert installation

Installation directly on the floor (without the levelling plate)

A

Choose this method if the hearth floor is sound and the height limited

4.3 Chimney throat too narrow for the liner: If
the chimney throat is too narrow to permit the
passage of the liner cut a hole of the required
diameter in the chimney throat to allow for the
passage of the liner (Drawing 2).

4.4 Jointing the liner sections: Always fix the
liner sections together with the female end up.
This way the condensation water will drip inside
the liner, not outside

(Drawing 2).

4.5 Watertight flashing: Install a metal roof
flashing at the top of the chimney. Seal the joint
between the chimney and the flashing.

4.6 Chimney top: Install a chimney round top at
the end of the chimney.

5. Insert installation

Gasket
(see Drawing 4)

Don-Bar
Insert

Installation with the levelling plate

B

Choose this method if the hearth floor is not in good condition or if
the hearth is too high

Levelling bolts

Garket
(see Drawing 4)

5.1 Putting the insert in place: There are three
ways to install the insert in a masonry hearth:

1. Installation directly on the hearth floor

(Drawing 3A): If the floor of the hearth is
sound and level, simply slip the insert inside
the hearth. Adjust the level with the four
levelling bolts located at each corner under
the insert.

2. Installation of the optional levelling plate

(Drawing 3B): Put the Don-Bar levelling

plate on the hearth floor (use only the
approved Don-Bar steel levelling base for
this) and adjust its level with the four (4)
levelling bolts. Secure the plate in place on
the floor with expansion bolts to prevent
slipping.

REV. 2014-11

Levelling
bolts

C

Exterior
wall cap

Thermodisc
(to splip under
the base)

DESSIN NO 3

Page 7

Optional

levelling
Expansion
bolts to secure
the plate on the floor

Installation with the raised base

Choose this method to raise the insert, or when an exterior air
intake ond/or a base fan are needed. The raised base then replaces the
levelling plate of the Drawing B above.

plate

Fan control

Don-Bar
Insert

Exterior air intake (Optional):
4" (100 mm) flexible metal
duct with insulated jacket
and non-combustible vapour
barrier

Sliding control for
the air intake

Axial fans (2)

Ready to be connected
into a wall outlet

Securing the liner to the
insert

Stainless liner
(flexible or
rigid)

3 Stainless
screws
equally
spaced)

Note: some insert
models are shipped
with a pyramidal
adaptor

Retaining
collar

Adaptor

with the provided collar. The liner must be
sandwiched between the collar and the insert
adaptor. As indicated, use at least three (3)
stainless steel screws to firmly secure these parts
together (Drawing 4). Then install the adaptor
cover. The 98-78 and 98-87 models, and the
corner and see-through inserts are shipped with a
special pyramidal adaptor.

5.4 Bolting the insert adaptor: Firmly secure
the insert adaptor to the insert top with the two
(2) specially provided bolts and the gasket.

Fiberglass

stove gasket

1/2" (6 mm)

Adaptor

cover

Bolt for securing the adaptor
to the insert from inside

DRAWING 4

3. Installation with the raised base

(Drawing 3C): The Don-Bar raised base is

used to increase the height of the insert in the
existing hearth, and is also required when
installing an exterior air intake and/or base
fan (use only the approved Don-Bar steel

raised base for this). Put the raised base in
the hearth, adjust the levelling bolts, and
secure it in place.

5.2 Air space for the optional basement fan: If
the existing ash shaft is to be used as an air duct

for a centrifugal fan installed in the basement
(Drawings 1 and 5C), don't forget to fill the gap
under the levelling plate with insulation in order
to block the outflow of the air under the front of

the insert (Drawing 1).

5.5 Last adjustments: Slip the insert into the
hearth and adjust its position. No securing is
necessary. The insert's weight is sufficient to
maintain it in place.

6. Fan installation (optional)

6.1 Fan installation: There are three methods
for installing a fan to increase the heating power
of the insert:

1. Fan under the raised base (Drawing 5A):

This kit is shipped with a thermodisc and a
speed control switch. The kit comes complete
with an electrical plug ready to be connected
to a wall outlet. Just tilt the fan at the required
angle and slip it (with the thermodisc) under
the base. No securing required.

2. Side fans (Drawing 5B): This fan kit
includes a thermodisc and a speed control
switch ready to be plugged into any electrical
oulet. Just put the fans on each side of the
insert then adjust the tilt to the required angle.
Also insert the thermodisc inside the hearth.
No securing required.

5.3 Jointing the liner to the insert adaptor:

Secure the chimney liner to the insert adaptor

REV. 2014-11

Page 8

3. Basement fan (Drawing 5C): For
maximum ventilation power, it is possible to
use the existing ash shaft (if any) as an air
duct for a centrifugal fan installed in the
basement. In this case, it is important to
allow a minimum 1" (25 mm) air space under
the insert for the thermodisc wiring. The fan
is shipped with a thermodisc (to be installed
in the hearth, as indicated) and an acoustical
case designed to receive an optional exterior
air intake duct.

Electrical wiring of the axial fans
illustrated in Drawings 5A and 5B

Fan installation (fans are optional)

Fans under the raised base assembly

A

Raised base
(optional)

Axial fans (2)
(to slip under the base)

Speed control

Thermodisc
(to slip under
the base)

Side fans

B

Wire ready to be plugged
to a wall outlet

Axial fans

Thermodisc

Speed
control

120V Plug

Electrical wiring of the centrifugal
fan illustrated in Drawing 5C

Thermodisc

Centrifugal
fan

Ground

Speed
control

Thermodisc
(to slip into the
hearth)

Speed control

Basement fan

C

Thermodisc
(to place inside
the masonry
hearth)

Electrical
wire to slip
down into
the existing
ash shaft

Existing
ash trap

BASEMENT

Fix the fan plate
to the foundation
wall

Axial fans (2)
To place in the hearth
at each side of the insert

Wire ready to be plugged
to a wall outlet

Centrifugal fan
with speed control
to be plugged to any
electrical outlet

Exx terior
air intake
(optional)

Acoustical
case

120V Line

REV. 2014-11

DRAWING 5

Page 9

Frames and trims

7. Exterior air intake installation

Ventilated frame (2 louvres
on 3 sides

Ventilated frame (2 louvres
on 4 sides

Ventilated frame (2
louvres on 3 sides)
plus a flat frame on
3 sides

7.1 Exterior air intake: (Drawing 3C): The
exterior air intake is optional. Its installation
requires the drilling of a 4" (100 mm) diameter
hole in one of the walls of the existing masonry
hearth. For the air intake, use only a flexible
aluminum duct with a non-combustible insulated
jacket. WARNING: Do not use ducts made of

plastic materials, because the heat generated
by the insert will rapidly melt them. The air
intake duct should be extended to outside the
building. It is forbidden to leave an air intake
end in a garage, attic or any room with a
negative pressure.

7.2 Outside hood: Install an exterior hood fitted

with a screen. Seal the joint where the insulated
duct passes through the masonry wall, inside and
outside.

8. Finishing frames installation

8.1 Flat and ventilated frames (Drawing 6): To
install the flat and ventilated frames (three or four
sides) just slip them into place on the insert.
Many arrangements are possible (See Drawing 6
for all possible combinations). Please note that

a ventilated air space - 2" on top (50 mm) ­1/2" on each side (12 mm) is always required
if a finishing frame is not installed.

Ventilated frame (2
louvres on 4 sides)
plus a flat frame on
4 sides

NOTE: other models
available on request

DRAWING 6

REV. 2014-11

9. Floor protection installation

9.1 Non-combustible floor protection: A non­combustible protection must be placed in front of
the fireplace to protect the floor from fallling
embers. The floor protection must extend at least
18" (460 mm) in front of the insert door and 8"
(200 mm) on each side. Existing floor protection
should be modified as needed. IMPORTANT:
Under floor protection there should be no
combustible material to a depth of 8 "(200 mm)
measured from the bottom of the glass Drawing 8

.

Page 10

Non-combustible floor protection

Non-combustible
floor

1

8

"

(

(

4

f

6

r

o

0

m

g

m

l

th

a

s

m

)

e

s

d

o

o

r

)

mm)

00

2

(

8"

DESSIN NO 7

Floor protection may consist of:

.1 Stone tiles or slabs (marble, granite, slate,
etc.) or ceramic at least 3/8" (8 mm) thick,
secured in place;

.2 Concrete or terra-cotta brick, secured in
place;

.3 For temporary floor protection, a sheet of
metal of at least 0.015" (0,38 mm) thickness
or a non-combustible composite cement
board (Durok type) of at least 3/8" (10 mm)
thickness may be used.

protection

10. Combustible mantel

10.1 Required clearances: See Drawing 8 for
the required minimum clearances if a combustible
fireplace mantel is to be installed. The mantel
must be located at least 18" (460 mm) above the
insert door and the jambs must be spaced at least
8" (200 mm) from the door as. Its horizontal
projection must follow a 45-degree angle as
indicated.

Required clearance for a combustible
fireplace mantel

)

m

m

0

0

2

(

"

8

Non­combustible
materials

8

"

(

2

m

i

n

im

0

0

m

m

)

um

8

"

(

2

0

0

m

i

n

i

m

u

Combustible
shelf

45 deg.

"

8

1

m

m

0

6

4

(

mum

i

n

i

m

Glass bottom

Combustible
mantel

m

m

)

m

IMPORTANT

Combustible
materials are not
allowed below 18"
(460 mm) above
the door of the
insert. Beyond that

)

height, the
width of the
combustible
shelf must follow a
clearance line
of 45 degrees,
as indicated.

"

18

)

mm

0

6

4

(

um

m

ni

i

m

REV. 2014-11

8”

Minimum clearance of 8 "(200 mm) from combustible
materials including those under the floor protection
measured from the bottom of the glass

DRAWING 8

Page 11

11. Anti-smoke flap

opened. For installation details, see Drawing 27.

11.1 Anti-smoke flap (optional): This part is
used when the flue draught is not sufficient or
when there is a negative pressure in the house.
The anti-smoke flap will prevent the smoke from
spilling into the room when the insert door is

Framing a large-sized hearth

Metal studs
IMPORTANT: Allow
for thermal expansion.
Cut all the studs 1/8"
(3 mm) shorter than
necessary

Don't secure the
insert to the studs.
Provide a 1"
(25 mm) free
space between
the metal framing
and the insert.

The insert must
always be
removable.

12. Installation in a large-sized
hearth

12.1 Non-combustible materials (Drawing 9 :

Use only 100% non-combustible materials to
reduce the area of an over large hearth. When in
doubt, don't hesitate to contact Don-Bar.

12.2 Metal framing: Use only metal studs to

frame the hearth. Allow for thermal expansion by

cutting all studs 1/8" (3 mm) shorter than
necessary.

12.3 Insert must be removable: The insert must

always be easily removable from the hearth.
Provide a 2" (50 mm) free space between all
metal studs and the ventilated finishing frame. Do
not secure metal studs to the insert or to its
finishing frame.

12.4 Non-combustible finishing materials

(Drawing 9): Use only 100% non-combustible
composite cement boards (Durok or equivalent).
Fill the joints or cover the boards with ceramic
tile.

DRAWING 9

REV. 2014-11

100% non-combustible
composite cement
board (Durok or
equivalent). Finish
by filling joints or
recover with ceramic
tiles, at choice.

Ventilated frame

Non-combustible
floor protection
(See Drawing 7
for minimum
dimensions)

Page 12

13. Lateral clearances

13.1 Minimum clearances to lateral walls:

Follow the indications of Drawing 10 when the
insert is installed near a combustible wall..

Minimum lateral clearances

masonry

24" (610 mm) min.

Note: Measures are took on the insert door

ry

n

maso

combustible wall

min

)

0 mm

1

" (6

4

2

combustible wall

.

DRAWING 10

REV. 2014-11

Page 13

Don-Bar
Insert

6" or 7" dia. int.
(150 or 175 mm)

No scale

Pyramidal adaptor
for the 98 Series and the
See-Through models
(option)

8"
(203 mm)

D

J

6"
(150 mm)

10,5"

1

0

,5

"

(26

7

m

m)

(267 mm)

C

i

6’ or 7’ I.D.
(150 or 175 mm)

i

O

D

J

M

P

6 " (154 mm)

6" or 7" I.D..
(150 or 175 mm)

1-1/16" (28 mm)

98-78
98-87

NOT IN SCALE

1" (25 mm)

3-1/8" (79 mm)

C

i

Flat frame 4 sides

Note: All frames can also be made-to-measure.

69-52 69-61 69-69 69-80 69-90 80-60 80-69 80-80 98-78 98-87

24”

I

17-3/8”

J

19-3/4”

C

13”

D

19-1/4”

M

17-1/4”

O

14-1/4”

P

REV. 2014-11

610
441
502
330
489
438
362
mm

24”
21”
19-3/4”
13”
19-1/4”
17-1/4”
14-1/4”

610
533
502
330
489
438
362
mm

24”
24”
19-3/4”
19-3/4”
19-1/4”
17-1/4”
14-1/4”

610
533
502
502
489
438
362
mm

24”
28-1/4”
19-3/4”
19-3/4”
19-1/4”
17-1/4”
14-1/4”

Flat frame 3 sides

610

24”

718

32-1/4”

502

19-3/4”

502

24”

489

19-1/4”

438

17-1/4”

362

14-1/4”

mm

Optional Frames

610
819
502
610
489
438
362
mm

28-1/4”
20-3/8”
24”
16”
21-1/4”
17-1/4”
16-1/4”

718
518
610
406
540
438
413
mm

28-1/4”
24”
24”
16”
21-1/4”
17-1/4”
16-1/4”

Page 14

Ventilated frame 3 sides
or 4 sides

718
610
610
406
540
438
413
mm

28-1/4”
28-1/4”
24”
19-3/4”
21-1/4”
17-1/4”
16-1/4”

718
718
610
502
540
438
413
mm

33-1/2”
25-3/4”
29-1/4”
21-1/4”
21-1/4”
21-1/8”
16-1/4”

See-through inserts also
available

2

8

"

(

7

1

0

m

(

o

r

m

a

d

e

to

851

33-1/2”

654

29-3/4”

743

29-1/4”

540

21-1/4”

540

21-1/4”

537

21-1/8”

413

16-1/4”

mm

m

)

m

e

851
756
743
540
540
537
413
mm

a

s

u

r

e

)

PART 2: SECURITY, OPERATION AND MAINTENANCE

1. General operation 7. Glass firescreen maintenance

1.1 Combustion control 7.1 Glass maintenance

1.2 Air intake control 7.2 Replacing a glass pane

1.3 Smoke outlet control 7.3 Door gaskets

1.4 Danger of burns

8. BBQ installation

2. Precautions before lighting your
first fire

2.1 Adequate air supply

2.2 Preventing smoke returns 9.1 Creosote build-up and removing

3. Firewood

3.1 Allowed fuels

3.2 Forbidden fuels

3.3 Recommended wood species 9.1 Firescreen

3.4 Green wood

4. The fire

4.1 Opening the high efficiency HE smoke damper

4.2 Open fires

4.3 Controlled combustion fires

4.4 How to start a fire

4.5 Firescreen is mandatory with open fires

4.6 Preventing overfiring

4.7 Forbidden flammable liquids

4.8 Smoke release during the first fire

4.9 Caution: Very hot!

4.10 Gloves and poker

4.11 Smoke detector

8.1 BBQ grill installation

9. Chimney maintenance

9.2 Inspection and regular maintenance

9.3 Soot build-up removal

10. Firescreen

11. Anti-smoke flap

9.1 Anti-smoke flap installation

13. Humidity and condensation

13.1 Excessive humidity and condensation

5. Ashes

5.1 Ashes removal

5.2 Metallic container

5.2 Natural fertilizer

6. Fireplace maintenance and protection

6.1 Finish maintenance

6.2 Repainting

6.3 Fireplace storing before installation

REV. 2014-11

Page 15

PART 2: OPERATION AND MAINTENANCE

1. General operation

1.1 Combustion control: Two valves are used
to control combustion. The first one (Drawing

20), controls the air intake in the combustion
chamber. The second one control the smoke outlet
(Drawing 21). These two valves are controlled by
the same removable handle.

1.2 Air intake control (Drawing 20): The sliding
valve controlling the air intake is located above
the insert glass door. A special multi-purpose
removable handle is provided to open or close it.
Pull the handle to admit more air into the
combustion chamber. Push the handle to reduce
the air intake. In practice, the best position for
the valve will vary according to three factors: fire
intensity, chimney draught and wood humidity.
As a general rule, a fire will last longer if less air
is admitted in the combustion chamber. If a hot
and blazing fire is wanted, then open the air
intake fully.

1.3 Smoke outlet control: This sliding valve is a
part the of the high efficiency HE deflector
system (Drawing 22). It is located in the middle
of the insert just above the air intake control
(Drawing 21). Use the multi-purpose handle to
operate it. Close it to increase the combustion
efficiency by reburning the gases contained in the
smoke. Open fully when opening the door,
starting a fire or when using a firescreen or the
BBQ grill.

1.4 DANGER OF BURNS: Danger of burns by

the excessive heat if the handle is left in place
when using the device. Always remove the
handle and store out of reach of children.

Using the removable handle to
control the air intake

d

e

s

o

l

c

n

e

p

o

Use the handle to
adjust the air
intake

DRAWING 20

Using the handle to control the
sliding smoke deflector

IMPORTANT: Always
open this key before
opening the door or
lighting a fire

o

l

c

d

se

en

p

o

REV. 2014-11

Use the handle to
control the damper

DRAWING 21

Page 16

Using the handle to control the
HE sliding smoke deflector

Open fully the smoke damper
to start a fire, when opening the
door or when making
an open fire with the firescreen

Close the smoke damper
for a long-lasting high efficiency
fire (close the door first).

d

e

s

o

l

c

supply to maintain the combustion. If the room is
under a negative pressure, if the house is too
airtight, or if a ventilation device is in operation it
may be necessary to open a door or a window to
compensate.

2.2 Preventing smoke returns: Your fireplace

is designed to operate without smoke returns
during normal operating conditions and when
installed according to the instructions outlined in
the manual. However, some conditions out of our
control can create smoke returns. Don-Bar
Fireplaces cannot guarantee the absence of smoke
returns but if this phenomenon occurs special
attention should be given to the following
situations: mechanical ventilators in operation
(kitchen hood, dryer, air heating system, air
exchanger), drafts, room or house negative
pressure, inadequate chimney height, exterior
structures harmful to the chimney draft or capable
of causing smoke returns, an indoor moisture
level that is too high and causes ice build-up in
the flue and reduces chimney draft, too many
elbows in the chimney, crushed outside air intake

n

e

p

o

duct, strong winds, etc.

Use the handle to
control the damper

DRAWING 22

2. Precautions before lighting
your first fire

2.1 Adequate air supply: A wood fire requires
plenty of air. Always be sure there is enough air

REV. 2014-11

3. Firewood

3.1 Allowed fuels: Your fireplace is designed to

burn wood only. To start a fire, use only
newspaper and small pieces of firewood.

3.2 Forbidden fuels: Anthracite, melamine,

pressure treated or painted wood, wood particle
boards and other composite materials. These
materials reach very high temperatures and
release corrosive gases, which may irreparably
damage your installation and void the warranty.

Page 17

3.3 Recommended wood species: For an
efficient and economical operation, use only dry
hardwood such as maple, oak, wild cherry, birch,
etc. The use of dry hardwood reduces creosote
formation. Avoid softwoods, coniferous and
green woods. These produce a lot of creosote.

3.4 Green wood: If your firewood is too green,
place it in a well ventilated space, sheltered from
rain, as long as necessary to allow it to dry. Dry
wood is easy to identify: it is cracked at the ends
and much lighter because it contains less water.

the air intake control must be fully open. Always
use a firescreen with an open fire. Note that the
air intake control is inoperative when the door is
open.

4.3 Controlled combustion fires: First, follow

the instructions at 4.2 for open fires. Later,
following the formation of embers, the flame will
be less intense, the chimney flue warmer and you
will be able to close gradually the sliding smoke
damper. You will also be able to close gradually
the air intake control to increase the heating
power of the fire.

Using the handle to open the door

DANGER OF BURNS
Never leave the handle on the
door during a fire.

Turn the handle
to lock or unlock
the door

4.4 How to start a fire: To light a good fire,

begin by placing 4 or 5 newspaper balls in the
fireplace. Next, place 5 to 8 small pieces of dry
firewood over the newspaper. Then add 2 or 3
small-sized logs. Light the newspaper in 4 or 5
spots. When the small firewood begins to burn,
add 1 or 2 medium-sized logs.

4.5 Firescreen is mandatory when the insert is

used with an open door: In order to prevent

dangerous spark discharges and falling embers,
always use a firescreen (supplied separately - not
shipped with the insert) when making an open
fire.

4.6 Preventing overfiring: Don't overload your

fireplace. Don't make fast and hot fires (such as
those using only paper, cardboard or small wood).
These fires can generate very high temperatures
that may damage your chimney if they last longer
than 2 minutes.

DRAWING 23

4. The fire

4.1 Opening the HE smoke sliding damper:

Before lighting a fire, completely open the smoke
sliding damper. Use the provided handle as
indicated in Drawings 21.

4.2 Open fires: The smoke sliding damper and

REV. 2014-11

Page 18

4.7 Forbidden flammable liquids: Never use
flammable liquids or accelerators such as gas,
lamp oil, kerosene, BBQ starters, or other
flammable substances to start or stir up a fire.
Always keep these products away from the fire
when using the fireplace.

4.8 Smoke release during the first fire: It is
possible that, while making your first fire, the
fireplace releases smoke for about 20 minutes.
This smoke release is normal and is usually
caused by the "baking" of the fireplace paint
finish. Open a window and the smoke will
disappear by itself in a few minutes. Caution:
This smoke can trigger a smoke detector causing
a false alarm!

4.9 Caution: Very hot! Your fireplace can
become very hot. Be careful when coming close
to it. Keep clothes, furniture, drapes, pets and
young children away from the fireplace.

potash, phosphorus, and ideal for acidic soils.

6. Fireplace maintenance and
protection

6.1 Finish maintenance: Your fireplace is
covered and protected by a special high­temperature paint finish. Normal maintenance
requires only a simple dusting using a dry and
soft duster or a feather duster. Avoid splashing
liquids on the fireplace.

6.2 Repainting: If, over time, it becomes
necessary to freshen up the fireplace finish, you
can spray directly on the old finish a coat of
"Stove Bright" high temperature stove paint. The
standard color used by Don-Bar is Metallic Black
no 6309.

4.10 Gloves and poker: In order to operate the
fireplace safely, always keep a poker on hand.
Heat resistant gloves are also recommended and
can be very useful when you have to handle hot
parts during an emergency.

4.11 Smoke detector: For your safety install a
smoke and carbon monoxyde detector in the room
where the fireplace is installed.

5. Ashes

5.1 Ashes removal: Your fireplace must be
emptied regularly. Always keep a bed of ashes of
about 1" (25 mm) in the fireplace to protect the
hearth bottom. Do not use a log grate.

5.2 Metallic container: To collect ashes, use a
metal container with an airtight lid.. Dispose of
them on the ground, outside, away from any
combustible material. If you plan to bury ashes
or dispose of them another way, keep them in an
airtight container until completely cooled.

6.3 Fireplace storing before installation: To
prevent rusting, always store the fireplace and its
components in a dry space.

7. Glass firescreen maintenance

7.1 Glass maintenance: To clean the glass,
begin with a duster and, preferably, a stove glass
cleaner. These aerosol glass cleaners are sold by
stove and fireplace dealers. They are specially
formulated to dissolve creosote without damaging
the glass. Then, to get a sparkling surface, finish
with a clean duster and a domestic glass cleaner
such as Windex. Warning: Wait until the glass
has completely cooled before attempting to clean
it. Never use an abrasive cleaner on the glass.

7.2 Replacing a glass pane: If a glass pane
shatter, replaced it with a 5 mm ceramic glass
pane of the same dimensions.

5.3 Natural fertilizer: Ashes are useful as
natural plant fertilizer. They are rich in lime,

REV. 2014-11

Page 19

back of the fireplace (Drawing 25).

Glass Pane Replacement

5 mm ceramic glass

Securing strips
and screws

DRAWING 24

Insert door

1/2" (12 mm)
U-shaped gasket

9. Chimney maintenance

9.1 Creosote build-up and removing: When
wood burns slowly, tar and organic vapors are
released. These combustion by-products combine
with moisture to form creosote. When creosote
vapor comes in contact with a relatively cold
surface, such as a chimney flue during a slow
burning fire, it condensates. As a result, creosote
residues build up inside the chimney. When this
creosote deposit catches fire, the chimney can
reach dangerously high temperatures.

9.2 Inspection and regular maintenance: The
chimney must be inspected regularly during the
heating season in order to determine whether is
creosote build-up. In order to avoid chimney
fires, the chimney must be cleaned if the creosote
build-up reaches a 1/8" (3 mm) thickness.

The ceramic replacement glass (pyroceram) can
usually be ordered from a local glazier or ordered
directly from Don-Bar Fireplaces. (Note: the
glass panes are not warrantied against breaking).

Warning: Never replace a broken door glass
with an ordinary or tempered glass: it will
shatter and may cause serious injuries.

7.3 Door gaskets: The gasket ensuring the door

airtightness must be changed periodically.

Replace it with a similar fiberglass 3/8" (10 mm)

round stove gasket. To replace the gasket around

the glass, use a U-shaped 1/2" (12 mm) fiberglass

stove gasket.

8. BBQ grill installation

8.1 BBQ grill installation: First, adjust the
height of the metal bar supplied with the grill to
support it at front. The BBQ grill is set in place
by simply inserting the central long rod into one
of the holes provided on the hearth plate at the

BBQ grill installation

Adjust the height
of the support bar

DRAWING 25

Insert the central long bar
into one of the holes
provided on the back
hearth plate

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Page 20

9.3 Soot build-up on the HE smoke sliding
deflector (Drawing 26): During the chimney

cleaning, be sure to remove any creosote or soot
build-up over the HE smoke deflector. The build­up of soot on the deflector can prevent the flow of
smoke.

Cleaning of the HE smoke deflector

To prevent soot build-up the
smoke deflector must be
cleaned at regular intervals

Cleaning sequence

10. Firescreen installation

10.1 Firescreen: The optional firescreen is
simply put in place in the front of the insert. Just
tilt it a little and slip it into the opening.
Integrated clips will keep it in place.

11. Anti-smoke flap

11.1 Anti-smoke flap installation (optional):

See details on Drawing 27.

12. Humidity and condensation

12.1 Excessive humidity and condensation: In
winter, high humidity levels inside the house can
cause chimney problems such as condensation,
and ice build-up eventually dripping into the
fireplace. In extreme cases, the condensation
water can even infiltrate the chimney insulation.
To avoid these problems, it is necessary to
maintain a 30-35% humidity level inside the
house.

Unscrew the rod that control

1

the sliding damper. Access the nut
from inside the fireplace.

Unscrew the 4 bolts that

2

hold the smoke deflector.

Take out the deflector. Tilt it down

3

to unhook it from its bracket
on the back of the fireplace.

DRAWING 26

Anti-smoke flap installation
(optional)

Slip the pins at the ends
of the flap into the
predrilled holes on each
side of the insert

1

2

3

REV. 2014-11

Install this way

The anti-smoke flap comes down automatically when opening
the door. It raises when the door is closed.

DRAWING 27

Page 21

Screw the small plate
retaining the arm into
the predrilled holes
on the door frame

PART 3: REPLACEMENT PARTS LIST

To order a part:

1) Check the replacement part required

2) Specify the year of the fireplace installation _________________

69-61

3) Fax this list with your coordinates to 418-686-9117

HE Combustion System

Sliding damper
Deflector (without the sliding damper)
Rod and plate assembly for the sliding damper
Chimney adaptor

Standard Parts

Sliding plate for air intake control
Hearth plate
Anti-smoke flap

Insert door including glass retaining bars
Ceramic glass, 5 mm
Glass retaining bars only (2 short, 2 long)
Glass pane gasket
Door gasket

69-52

69-69

69-80

80-60

69-90

80-69

80-80

98-87

98-78

Tilted fan assembly (2) to slip under the raised base
Side fan assembly (1)
Centrifugal fan
Insulated box for the centrifugal fan
Thermodisc
Speed control

Levelling plate complete with levelling bolts
Raised triangular base

Metal firescreen

BBQ grill
BBQ gril support rod

Ventilated frame (3 sides)
Ventilated frame (4 sides)

Fireplace handle (to operate the fireplace)

Sliding damper assembly for the exterior air intake

REV. 2014-11

Page 22

PART 4: CHIMNEY FIRES

DIRECTIVES IN CASE OF A CHIMNEY FIRE

How to detect a chimney fire

- Odour: Smell of smoke in the air.

- Sight: The colour of the pipe change. Flames at

the top of the chimney on the roof.

- Hearing: Abnormal rumbling.

How to avoid chimney fires

- Burn only dry firewood.

- Clean the chimney at least once a year before the
heating season or after burning 4 or 5 cords of
firewood.

- Don’t let creosote built-up in the chimney.

- Don’t burn coniferous, construction wastes,
or materials containing glues, paints, or other
chemicals.

- Always have a fire extinguisher on hand.

What to do

- Immediately alert the occupants of the building about
the potential danger.

- Call your local fire department or 911.

Cut all the sources of air that can feed the

-

fire (windows, air intakes, doors, etc...)

- Evacuate the house.

- Following a chimney fire, don't reuse your fireplace
until a professional has inspected it. A chimney fire
can overheat the chimney components, wrap it
inside, curve, crack or dislocate certain components.

- Do all the recommendations of the professional
and replace any part that is damaged or judged
unsafe.

What NOT to do

Do not throw water on the fire.

-

Do not block the top of the chimney

- .

REV. 2014-11

Page 22

LES FOYERS

DON-BAR

FIREPLACES

1. The first 5 years: If, during this 5­year period, and in the course of a normal
use, a component part of the fireplace
becomes defective due to a material or
workmanship defect, this part will be
replaced or, at our discretion, repaired
free of charge. The following parts are
excluded from this warranty:

1.1 Hearth back plate, smoke
deflector, HE deflector system,
grate, ash drawer/tray, wood
basket, fireguard, refractories,
metal fire screen, BBQ grill,
electric fan blower: Being subject

to high temperatures, these parts
may have to be replaced from time to
time; this is regarded as normal
maintenance. However, all the
original parts shipped with the
fireplace are warranted against
material or workmanship defects for
1 year following the date of
purchase.

1.2 Chimney: Since the chimney
and its components are not
manufactured by Don-Bar, please
refer to the warranty of the chimney
manufacturer for any claim about it.

1.3 Fireplace paint finish: The
fireplace is painted with a high
temperature paint that needs to be
freshen up from time to time.
However, the original finish applied
to the fireplace is warranted for 1
year following the date of purchase.
The warranty is limited to the supply
of the paint required for repainting
the fireplace.

25 YEAR LIMITED WARRANTY

1.4 Gaskets: Fireplace gaskets are 8. The duration of the warranty on any

warranted for 90 days following the part that is the object of a claim must
date of purchase. never exceed the total duration of the

original warranty of the part shipped with

2. 20-Year Replacement Plan: After the fireplace.
the expiration of the first 5 years, and for
an additional 20 years period following 9. Draft and smoke returns: All Don-
the date of purchase, we will ship (at the Bar fireplaces are designed and tested to
exception of transport expenses and operate with a positive draft, without
parts described in the articles 1.1, 1.2, smoke returns, when installed according

1.3 and 1.4) any defective part for a price to the manu fact urer's inst ructions.
not exceeding 50% of its retail price. Smoke returns caused by environmental

factors (negative pressure, lack of air,

3. These warranties shall never be turbulence, etc.) are not covered by the
interpreted as covering workmanship on present warranty.
site. Don-Bar takes no responsibility for
damages to the building following the
repair or the replacement of any part
covered by the warranty.

4. No representative, employee or agent
of Don-Bar is authorized to change or
extend the present warranty.

5. The warranty is valid only if the
installation, the operation, and the
maintenance of the fireplace have been
done in accordance with the fireplace
manufacturer written instructions.

6. Don-Bar takes no responsibility for any
damage to the fireplace, the chimney or
the building if fireplace repairs done by
third parties are executed with non
original parts.

7. Any part that is the object of a claim in
accordance with the present warranty
must by returned to the shop (transport
prepaid) with a proof of purchase. All
returns must be approved by the
manufacturer before shipping.

10. The warranty does not cover:

10.1 Broken glass

10.2 Damages caused by a
chimney fire;

10.3 Shipping damages not
reported on delivery;

10.4 Faulty installation;

10.5 Damages caused by
abnormal or abusive use.

10.6

altered or containing substituted
components or when the
instructions for installation,
operation or maintenance have not
been followed.

11. Caution: Improper operation or lack
of maintenance can endanger your
safety.

12. Send any communication or claim to
the following address:

Foyers Don-Bar Fireplaces, inc.

741, St-Vallier Ouest, Québec,
(Quebec) Canada G6V 3N9
Phone: [phone]
Fax: [phone]
Website: www.don-bar.com
Email: [e-mail]

Any fireplace modified,

REV. 2014-11

Page 24

APPENDIX 1 - REQUIREMENTS

FOR EXISTING FIREPLACES

Before installing a Don-Bar insert the owner must ensure that its existing

masonry fireplace meets the requirements of CSA A405 (excerpts below). Failing this, the

required modifications must be executed by a licensed contractor.

5.3.6 Hearth and Hearth Extensions

5.3.6.1 Hearth Extension and Fire Chamber Depth

The distance from the back wall of the fire chamber to the front
edge of the hearth extension shall be not less than 28 in. (700 mm),
and the hearth extension shall extend not less than 16 in. (400 mm)
in front of the fireplace opening.

5.3.6.2

Where the hearth floor is elevated at least 6 in. (150 mm) above the hearth
extension, the width of the hearth extension shall be increased by:

(A) 2 in. (50 mm) for an elevation of between 6 in. (150 mm) and

12 in. (300 mm); and

(B) an additional 1 in. ( 25 mm) for every 2 in. (50 mm) in elevation

above 12 in. (300 mm)

5.3.6.3
All hearth extensions shall extend not less than 8 in. (200 mm) beyond

each side of the fire chamber.

5.3.6.4

The hearth and hearth extension shall be supported on not less than a 4 in.
(100 mm) thick reinforced concrete slab. For cantilevered, raised hearth
extensions, this slab may taper to not less than 2 in. (50 mm) at the front
edge and ends except as provided in Clause 5.3.6.5.

5.3.6.5

,

.

MINIMUM DIMENSIONS FOR THE
HEARTH EXTENSION

16”

8”

8”

If the hearth
is elevated
between 6”
and 12” *

18”

* If the hearth is elevated more than
12” see Article 5.3.6.2. B)

PROTECTION OF THE VERTICAL
SURFACE UNDER THE HEARTH

(A) When a fireplace opening is raised 8 in. (200 mm) or more from a
combustible floor, the hearth extension or pad may be placed on the
combustible floor and shall be not less than 2 in. (50 mm) thick when made
of a single unjointed unit of artificial or natural stone, or of reinforced
concrete.

(B) When thin material less than 1 in. (25 mm) thick (ie, tile or slate) is

,

used a bedding of steel mesh reinforced grout or concrete shall be

provided. The composite thickness shall be not less than 2 in. (50 mm)

(C) Jointed units of tile, slate or other noncombustible material more than

1 in. (25 mm) thick may be installed in conformance with Item (B) or shall

be placed over a continuous layer of sheet metal with a thickness of not

less than 0.5 mm.

(D) Mastic or grout used to place tile, slate or other thin masonry units
shall be noncombustible.

REV. 2014-11

Page 25

If the hearth
is elevated
protect the
vertical surface
under the hearth
as specified
in theArticle

5.3.6.7

.

Note: The CSA A405 Standard governs the
construction of masonry fireplaces and
contains several other articles.

APPENDIX 1 (Con’t)

(E) ln the area for which a hearth extension is required (see Clause 5.3.6.3), the
joint between the wall face below the hearth and the hearth extension shall be
provided with a firestop of sheet metal.

5.3.6.6
A vertical face below a fireplace opening shall be of noncombustible material, shall
extend to the top of the hearth extension, and shall extend at least 8 in. (200
mm) on each side.

5.3.6.7
When tile veneer is used (25 mm or less) on the vertical face below a fireplace
opening, it shall

(A) be backed with a sound, dry, rigid plane surface consisting of masonry,
reinforced concrete, or cement plaster on metal lathe; and

(B) be applied to its noncombustible backing by means of full embedding in
Type M mortar or other approved means with ail joints filled.

5.3.9 Clearance of Combustible Material

5.3.9.1
Combustible material shall not be placed on or near the face of a fireplace within 6 in.
(150 mm) of the fireplace opening, except that where the combustible material
projects more than 1-1/2 in. (38 mm) from the face of the fireplace above the opening,
such material shall be placed at least 12 in. (300 mm) above the top of the opening.
Material below the opening shall conform to Clause 5.3.6.

REQUIREMENTS FOR THE HEARTH
EXTENSION

Standard
hearth

Cantilevered
reinforced
concrete slab of 4”
tapered to 2” min.

2”

16”

Elevated
hearth of
8” min.

2” min. Reinforced
concrete slab

Choice no1:

8” min

4”

5.3.9.2
Metal exposed to the heated interior of a fireplace, such as the damper control
mechanism or a built-in glass door, shall have at least a 2 in. (50 mm) clearance from
any combustible material on the face of the fireplace where such metal penetrates
through the face of the fireplace.

5.3.9.3
When a fireplace is equipped with heat circulating outlet ducts above the fireplace
opening, the distance from such a duct or metal duct grill to the combustible material
above shall beat least 12 in. (300 mm) where the combustible material projects more
th an 1-1/2in. (38 mm) from the face. Where the combustible material projects less
than 1-1/2 in. (38 mm), the distance between the combustible material and the duct
shatl be not less than 6 in. (150 mm).

CLEARANCE FROM COMBUSTIBLE MATERIALS

Flush fireplace:

6” clearance between
the hearth and a
combustible material

Fireplace with a 1-1/2”
projecting shelf (or more):

6” clearance on each side and
12” clearance at the top

Flush heating grill

6” clearance

6”

18”

Choice no 2:

Grouted ceramic tile or
stone, 1” thick min,
over a metal sheet of

0.5 mm

18”

Heating grill recessed
1-1/2” behind the surface

12” clearance

Metal
fire shield

8” min

Metal
fire shield

Min. 6” of
noncombustible

REV. 2014-11

12”

Min 12”
&

min. 6” of

noncombustible

Page 26