DON-BAR ZERO CLEARANCE ZC Series Installation, Operation And Maintenance Manual

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Installation, Operation

and Maintenance Manual

LES FOYERS

DON-BAR

FIREPLACES

ZERO CLEARANCE

REV. 2016-01

FIREPLACES (ZC)

Les foyers DON-BAR Fireplaces, inc.

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

Phone: (418) 686-9114 - Fax: (418) 686-9117

Website: www.don-bar.com - Email: [email protected]

Page 2

LES FOYERS

DON-BAR

FIREPLACES

Installation, Operation,

and Maintenance Manual

The manual is divided into 5 parts:

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

PART 2: Security, Operation and Maintenance ...

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

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

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

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.

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

Page 3 Page 16 Page 22 Page 23 Page 25

REV. 2016-01

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PART 1: INSTALLATION

1. Warnings and cautions 9. Heating ducts installation (optional)

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

2. Typical interior installation

3. Typical exterior installation

4. Before beginning the installation

4.1 Choosing the best location

4.1.1 Chimney

4.1.2 Chimney minimum height

4.1.3 Minimum clearances from combustible materials

5. Factory-built chimney installation

5.1 Listed parts

5.2 Maximum allowed offsets

5.3 Radiation shield/firestop

5.4 Chimney weight

6. Anchor plate installation

6.1 Fixing the anchor plate

9.1 Heating an upper or lower floor

9.2 Heating a lower floor

9.3 Axial fan installation

9.4 Recommended ducts for heating

9.5 Heating an upper floor

9.6 Danger of overheating

10. Fireplace finishing

10.1 Metallic studs mandatories

10.2 Ventilated frame

10.3 Non combustible cement boards

10.4 Fixing the cement boards against the insulated case

10.5 Gypsum boards finish

11. Floor protection installation

11.1 Non-combustible floor protection

11.2 Removing the existing resilient flooring

12. Combustible mantel

12.1 Required clearances

13. Anti-smoke flap (optional)

13.1 Anti-smoke flap installation

14. Exterior air intake

14.1 Exterior air intake(optional)

7. Insert installation

7.1 Raised base

7.2 Insert positioning

7.3 Stainless steel liner installation

8. Factory-built chimney installation

8.1 Securing the anchor plate

8.2 Chimney lengths installation

8.3 Minimum chimney height above the roof

8.4 Flashing water tightness

8.5 Roof braces

8.6 Chimney top

REV. 2016-01

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PART 1: INSTALLATION

1. Warnings and Cautions

DO NOT OVERIFRE THE UNIT.

DO NOT OBSTRUCT SPACE UNDER FIREPLACE. CLEARANCES FROM COMBUSTIBLE MATERIALS CANNOT BE REDUCED.

BURN WOOD ONLY. DO NOT USE OTHER

FUELS.

DO NOT INSTALL IN A MOBILE HOME.

DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.

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

DO NOT ALTER THE AIR CONTROL.

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

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.

This unit is designed to receive only a Don-Bar Insert. No other insert model can be installed without ULC / UL approval.

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.

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.

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

Security, Operation and Maintenance.

1.6 Log holder prohibited: Do not install a log

holder in the hearth or elevate the fire in any way.

1.7 Listed factory-built chimneys: Your Don-Bar fireplace is designed to be installed with any 7” (174 mm) I.D. or 8” (200 mm) I.D. prefabricated chimney bearing the ULC-S629 (2100 degrees) label in Canada or the UL-103HT label in the USA.

REV. 2014-11

Page 2Page 3

Page 5

1. Typical interior installation

For an installation in a corner or inside an insulated exterior chasing see Pages 12 and 13

Round Top

Factory-built insulated chimney 2100 degrees

Flashing

2. Typical exterior installation

Round Top

Factory-built insulated chimney 2100 degrees

Storm collar

Flashing

Roof support

Radiation shield/firestop

Mandatory 2" air space (50 mm)

Optional warm air insulated duct to heat an upper floor

Chimney anchor plate

Don-Bar insulated case

Don-Bar insert

Protection for combustible floors

FIRST FLOOR

15 | 30 | 45 deg. Elbow

Must rest on a finished surface (masonry, Durok, wood, drywall)

BASEMENT

Protection for combustible floors

Wall support

Mandatory 2" (50 mm) air space across the legnth of the chimney

Offset support

15 | 30 | 45 deg. Elbow

Wall shield/firestop.

Anchor plate

Don-Bar insulated case

Rigide stainless liner 8" (200 mm)

Don-Bar Insert

Optional warm air insulated duct with axial fan to heat the basement

DRAWING 1A

REV. 2016-01

DESSIN NO 1B

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4. . Before beginning the installation

Typical interior installation

4.1 Choosing the best location: Before beginning the installation, make sure the spot you have in mind for the fireplace and the chimney meet the following requirements:

4.1.1 Chimney: Position the chimney to avoid, as much as possible, offsets, elbows and the cutting-out of structural elements. The weight of

the chimney must not rest on the insulated case. Allow at least 2" (50 mm) for air space

between the chimney and any combustible material including electrical cables, and plastic plumbing pipes. Never fill this air space with insulation. For example, if the chimney has an inside diameter of 8" (200 mm), by adding the required 2" (50 mm) air space, a 16" (410 mm) free continuous path is required to install the chimney. Do not connect this fireplace to a chimney that is connected to another heating device.

4.1.2 Chimney minimum height: 15 feet (4600 mm) for proper operation. This length is measured from the floor where the fireplace is installed to the top of the chimney.

4.1.3 Minimum clearances from combustible materials (See Page 13): The location of the

fireplace must meet the minimal specified clearances requirements from any combustible material, including furniture, drapes and other flammable objects. Note that Type X fireresistant gypsum board (Firecode) is considered combustible for fireplaces installations.

5. Factory-built chimney installation

5.1 Listed parts: Use only ULC or UL listed parts supplied by the chimney manufacturer when installing the chimney. The chimney must be installation in accordance with the manufacturer's instructions.

with warm air ducts on upper floor

Round top

Storm collar

Roof

Attic insulation

Note: Warm air ducts are optional for upper floor (wall or floor outlets)

Metal grilles

Radiant shield/ firestop

Joist

Metal duct 6" (150 mm) dia. (flexible or rigid) insulated 1" (25 mm), or B-Vent duct

Chimney anchor plate

DON-BAR insulated case

Rigid inox liner 8" dia. (200 mm)

DON-BAR insert

Protection for combustible floor

Factory-built insulated chimney 2100 degrees

Roof support

Flashing

Attic radiation shield/firestop

8” minimum (200 mm) from ceiling

8” minimum (200 mm) from floor

Joist

1” (25mm) min. clearance from joists or manufaturer’s instructions

Radiant shield/ firestop

warm

duct

s used

hea

uppe

r flo

ity

ris

e as

rtica

s po

Optional fan

t an

lly

air

hall

ible

REV. 2016-01

DRAWING 2

Page 5

Page 7

Jointing the chimney to the insulated case

Factory-built insulated chimney 2100 degrees

Chimney anchor plate

5.2 Maximum allowed offsets: Don't install more than 4 elbows in the chimney. Offsets cannot be more than 30 degrees from the vertical axis. The sum of all offsets (elbows) must never exceed the number 120. For example, maximum allowed offsets would include: two 30-degree offsets (4 elbows x 30 degrees =120) or an offset of 30 degrees plus another one of 15 degrees (2 elbows x 30 degrees + 2 elbows x 15 degrees =

90).

Raised base

Outside air intake: 4" (100 mm) flexible insulated duct

Don-Bar Insert

2 ventilated frames plus 1 flat ventilated frame, 4 sides

Do not connect the air intake to an attic or a garage or a room that can be under negative pressure.

Don-Bar insulated case

Rigid stainless chimney liner same dia. as the chimney

See details on Drawing 4

5.3 Radiation shield/firestop: Install a radiation shield/firestop every time the chimney passes through a combustible wall or ceiling.

5.4 Chimney weight: The weight of the chimney must be supported at regular intervals according to the manufacturer's instructions. The

weight of the chimney must never be supported by the Don-Bar insulated case. In

addition, offset supports must be installed above and as close as possible to each offset (elbow) in the chimney.

6. Anchor plate installation

6.1 Fixing the anchor plate to the insert: Bolt the anchor plate (Drawings 3 and 4) on the insert with the furnished bolts. Take care to insert a fiberglass sealing gasket between the anchor plate and the top of the insert to eliminate any smoke leak.

Raised base details

Thermodisc under the base

Speed control

DESSIN NO 3

DRAWING 3

REV. 2016-01

Axial fans (2) to insert under the base

Electric cable with 120 V plug

Page 6

Fan wiring

Thermodisc

Speed control

Axial

fans

120V Plug

Page 8

7. Insert installation

The insulated case with the insert

7.1 Raised base: The insert is installed on a 6.5" (165 mm) high raised base as indicated on Drawing 3. The raised base can be fitted with 2 optional fans. The raised base is factory installed. The insulated case must be fixed on the floor.

7.2 Insert positioning: Slip the insert on the raised base into the insulated case and adjust the alignment.

7.3 Stainless steel liner installation: Secure to the anchor plate bolted on the top of the insert a rigid stainless chimney liner of the same diameter as the chimney. The height of the liner must be 1/4" (6 mm) below the insulated case top. Secure the liner to the anchor plate with 3 stainless steel screws as indicated in Drawing 4.

Securing the anchor plate and the liner to the insert

Rigid stainless chimney liner

same dia. as the chimney

with a length 1/4"

(6 mm) lower than the top

of the insulated case.

Anchor plate

and the chimney assembly

DRAWING 5

8. Factory-built chimney installation

8.1 Securing the anchor plate for the factorybuilt chimney: Use a standard factory-built

chimney anchor plate for securing the chimney to the insulated case. Screw the anchor plate to the insulated case top with 4 metal screws. Join the anchor plate to the stainless rigid liner already secured to the insert. The male end of the anchor plate must slip into the stainless rigid liner for the condensation water to drip and stay inside the liner.

Bolt for securing the adaptor to the insert from inside

DRAWING 4

REV. 2016-01

Stainless screws

(minimum 3,

equally

spaced)

Fiberglass

stove gasket

1/2" (6 mm)

8.2 Chimney lengths installation: Continue with the installation of the chimney by positioning lengths with the male end up. The attic insulation must never be in contact with the chimney. Allow at least 2" (50 mm) for air space between the chimney and any combustible material.

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Chimney minimum height above the roof

10 feet (3 m) Radius

2 feet min (610 mm) min.

3 fe e

t (1

m )

m i

DRAWING 6

8.3 Minimum chimney height above the roof: (Drawing 6): Extend the chimney at least 3

feet (1 m) above the roof or 2 feet (610 mm) above any construction element within 10 feet (3 m) of the chimney.

Warning: Lateral roof braces need to

n .

be installed when the unsupported chimney height above the roof is more than 6 feet (2 m).

9. Heating ducts installation (Optional)

9.1 Heating an upper or lower floor

(Drawings 7 and 8): Your Don-Bar Zero Clearance Fireplace is designed to permit the heating of another floor - upper or lower. For this reason, openings have been provided into the sides of the insulated case to allow for the installation of insulated heating ducts of 6" I.D. (150 mm).

9.2 Heating a lower floor: The heating of a basement requires the installation an insulated duct with an axial fan. The insulated duct can run inside or outside the insulated case (Drawings 7 and 8).

Installation alternatives for the optional warm air ducts

Lower floor heating duct (at right, left or behind the insulated case)

Duct for heating by gravity an upper floor (at right, left or both, on the top of the insulated case.)

Outside air intake, 4" (100 mm) I.D. (optional) with a sliding mecanism (left or right). Use only a flexible aluminium duct with a non combustible vapour barrier.

8.4 Flashing water tightness: Install a metal roof flashing with a storm collar where the chimney pass meets the roof. Seal the joint between the chimney and the storm collar and the

joint between the roofing and the flashing.

8.5 Roof braces: Any chimney that extends more than 6 feet (2 m) above the roof needs to be laterally strengthened with a pair of telescopic

roof braces.

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

REV. 2016-01

Lower floor heating duct (preinstalled duct - left or right)

Axial fans, 105, 245 or 438 cfm (to slip and secure inside the duct)

Heating ducts must be made of metal, 6" (150 mm) I.D., with a 1" (25 mm) fiberglass insulating jacket finished with an aluminized covering.

DRAWING 7

Page 8

Page 10

9. Heating ducts installation

10. Fireplace finishing

(Optional) Cont'd

9.3 Axial fan installation: The axial fan for basement heating must be installed near the basement ceiling at the end of the heating duct. The easiest way to secure the fan in place is to insert it into the heating duct and use a t-wrap around the duct to tighten the fan.

9.4 Recommended ducts for heating: Use only non combustible ducts of 6" (150 mm) I.D. insulated with a fiberglass layer and a flexible protective covering. (total: 8" / 200 mm O.D.) Don't use ducts that have an inner side made of combustible plastics.

9.5 Heating an upper floor (Drawings 2, 7, 8): The heating of an upper space shall be done by gravity only, without a fan, by using the outlets provided on the top of the insulated case. For the best results, the duct must be installed in a vertical position without offsets that could reduce the airflow. The duct can be secured on the top of the insulated case using one of the pre punched holes, on the left or on the right, at choice. The outlet grille at the end of the duct must be made of metal and designed to allow a non restricted airflow.

9.6

Danger of overheating: Never install the

heating ducts horizontally or downward because they will overheat and can cause a fire

(Drawing 8).

10.1 Metallic studs mandatories: Use only metallic studs for the framing around the fireplace.

Don-Bar insulated case framing

IMPORTANT: The Durok must rest and be secured directly

Gypsum board or plywood or particle board mandatory behind the insulated case

Chimney 2100 degrees

against the front of the insulated case (without any air space)

Metal studs mandatory

Non combustible board 1/2" (12 mm) (Durok)

Durok 18" (460 mm) minimum

Ventilated frame

Durok 8" (203 mm) minimum

Danger of overheating

Overheating here

Never use the outlets on the top of the insulated case for heating down or horizontally, and this, even with a fan.

DRAWING 8

REV. 2016-01

Page 9

Gypsum board 1/2" (12 mm)

DRAWING 9

Metal band of 5" (130 mm) width to slip 2.5" (65 mm) under the insulated case to protect against the infiltration of embers

18"

mm)

Protection for combustible floors

r t

m) wid

las

(

Page 11

10. Fireplace finishing

Cont'd

consist of:

10.2 Ventilated frame: Prior to framing, install temporarily the ventilated frame around the insert in order to facilitate the taking of the measurements. Leave a 1/8" (3 mm) air space between the ventilated frame and the framing to accommodate metal expansion.

10.3 Non combustible cement boards (Durok or Unifix): The finishing around the ventilated

frame shall be done with non combustible cement boards only, Durox, Unifix or equal. These boards shall not contain wood fibre particles (Drawing

9). The non combustible finishing shall extend at least 8" (200 mm) on each sides of the ventilated frame, at least 18" (460 mm) over and 3" (75 mm) below at floor. The joints can be finished like ordinarily gypsum boards joints or alternatively, covered with ceramic tiles, marble, granit.

10.4

insulated case: Above the fireplace door, the

cement boards shall be screwed directly against the insulated case (no air space) to prevent warm air from seeping between the box and finishing.

Fixing cement boards against the

.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 or Unifix type) of at least 3/8" (10 mm) thickness may be used.

11.2 Removing the existing resilient flooring:

Prior to installing the floor protection, remove any existing resilient flooring. (carpet, etc.)

12. Combustible mantel

12.1 Required clearances: See Drawing 12 for the required minimum clearances if a combustible fireplace mantel is to be installed.

13. Anti-smoke flap

10.5 Gypsum

of the parts to be protected by incombustible cement boards indicated in 10.3, the framing of the fireplace can be covered with gypsum boards. Finish the joints as usual.

board finish: With the exception

11. Floor protection installation

11.1 Non combustible floor protection: When the fireplace is installed on a combustible floor, a non-combustible protection must be placed under and in front of the fireplace to protect the floor from falling embers (Drawing 9). A metal strip of

5" wide (115 mm) must be inserted half and half under the insulated case and under the floor

protection. In addition, the joints of the floor protection shall be perfectly fitted or filled with grout. The floor protection must extend at least 18" (460 mm) in front of the fireplace door and 8" (200 mm) on each side. Floor protection may

13.1 Anti-smoke flap (optional): For installation details, see Drawing 27.

14. 7. Exterior air intake (optional)

14.1 Outside air intake (Drawing 7) IMPORTANT: The air intake must take air directly from the outside and not be connected to an attic or a garage or another interior space under negative pressure.

REV. 2016-01

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Page 12

Corner installation

Clearances from combustible materials

Combustible wall

Series 69

56-11/16" (1440)

46-1/16" (1170)

35-1/2" (902)

82-1/8" (2086)

20-1/4" (514)

28-5/8" (727)

58-1/16" (1475)

40-1/16" (1018)

50-1/4" (1276) 80-1/8" (2035)

" (457

There are 3 choices for framing: Small footprint framing

Angle framing

Wall to wall framing

Series 80

62-7/16" (1586) 50-9/16" (1284) 38-11/16" (983) 87-15/16" (2234) 21-7/16" (545) 30-5/16" (770) 62-3/16" (1580) 44-3/16" (1122) 54-3/4" (1391) 88-5/16" (2243)

18" (460 mm)

)

Non combustible cement board (Durok type). 8" (200 mm) wide, on each side of the ventilated frame and 18" (460 mm) over the frame

(Drawing 9)

DANGER OF FIRE

Series 90/98

66-3/8" (1686) 54-7/16" (1383) 42-9/16" (1081) 91-13/16" (2332) 23-3/8" (594) 33-1/16" (840) 64-15/16" (1649) 46-15/16" (1192) 60-3/16" (1529) 93-7/8" (2384)

Never fill (stuff) with insulation the empty spaces around the insulated case and around the insert. Moreover, non-mineral insulation (foams, cellulose, cotton, etc.) needs a minimum 12" (300 mm) clearance from the fireplace and the insulated case.

18" (460 mm)

Floor protection: Shall exceed the width of the door plus 8" (200 mm) on each side

Door clearance: 48" (1220 mm) minimum from any furniture combustible material

C o m

b u sti

b l

e w a

DRAWING 10

Clearances for the installation of a combustible mantel

Combustible mantel

Incombustible materials

DRAWING 12

REV. 2016-01

)

(

DRAWING 11

Combustible mantel or shelf

)

IMPORTANT Combustible

material ARE NOT allowed at less than 18 "(460 mm) over the fireplace door. Beyond this height, the width of any combustible shelf shall follow a 45-degree line, as indicated.

45 deg.

18"

mm)

460

(

)

(

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Page 13

Insulated exterior chasing - Construction details

DANGER OF FIRE

Insulated exterior chasing

with a non covered chimney

Never fill (stuff) with insulation the empty spaces around the insulated case and around the insert.

Insulated exterior chasing

for a covered chimney

roof support

round top

wall bracket

roof support

23" min. (585 mm)

fiberglass insulation

MANDATORY:

plywood, particle or gypsum boards

fiberglass insulation

free

space

17" min.

(430 mm)

round top

2100 chimney 7" or 8" I.D. (180 ou 200 mm)

Maximum

slope for

flashing

radiation shield/firestop

gypsum board on metal studs

Durok 18 " (460 mm)

floor protection 18" (460 mm)

storm collar

chimney flashing

metal flashing

offset to center the chimney

2100 chimney 7" or 8" I.D. (180 or 200 mm)

wall bracket

roof support

84" (2135 mm) min.

radiation shield/firestop

fiberglass insulation

MANDATORY:

plywood, particle or gypsum boards

fiberglass insulation

free

space

17" min.

(430 mm)

roof flashing

gypsum board on metal studs

Durok 18 " (460 mm)

floor protection 18" (460 mm)

84" (2135 mm) min.

air barrier

Free depth

See table

Drawing 14

DRAWING 13

REV. 2016-01

vapour barrier (sealed with the vapour barrier of the wall)

Page 12

air barrier

Free depth

See table

Drawing 14

vapour barrier (sealed with the vapour barrier of the wall)

Page 14

Insulated exterior chasing - dimensions

DANGER OF FIRE

Never fill (stuff) with insulation

Free interior dimensions

of the insulated

exterior chasing

the empty spaces around the insulated case and around the insert. Moreover, non-mineral insulation (foams, cellulose, cotton, etc.) needs a clearance from the fireplace and the insulated case of 12" minimum (300 mm) .

MANDATORY: metal studs

Non combustible

protection

Non combustible cement board 1/2" (12 mm) (Durok)

Durok 18" (460 mm) minimum

Exterior wall thickness (*)

Minimum free depth

Minimim free width

Minimum free height

58" (1470 mm) min.

For the chasing depth:

See the table below

(180 mm)

27"

(685 mm)

(200 mm)

28"

(710 mm)

84" (2135 mm) min.

Gypsum board 1/2" (12 mm)

imu

Free depth of the exterior insulated chasing

(varies according to the exterior wall thinkness)

(230 mm)

29"

(740 mm)

10"

(255 mm)

30"

(760 mm)

58"

(1470 mm)

84"

(2135 mm)

11"

(280 mm)

31"

(790 mm)

12"

(305 mm)

32"

(810 mm)

13"

(330 mm)

32"

(810 mm)

(460

14"

(355 mm)

32"

(810 mm)

Durok 8" (200 mm) minimum

Non combustible floor protection: (Shall exceed the width of the door plus 8" (200 mm)

8" (203 mm) minimum

on each side

* The exterior wall inludes everything from the exterior finish to the interior finish.

In case of doubt, please call Don-Bar.

DRAWING 14

REV. 2016-01

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Page 15

Fireplace insert

7" or 8" I.D. (175 or 200 mm)

Not to scale

7" or 8" I.D. (175 or 200 mm)

NOT TO SCALE

7" or 8" I.D.

(175 or 200 mm)

1" (25 mm)

1-1/16" (28 mm)

6 " (154 mm)

Flat frame 4 sides Flat frame 3 sides

Note: Flat and ventilated frames can be also made to measures.

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

24”

I J C D

610

17-3/8”

441

19-3/4”

502

13”

330

19-1/4”

489

17-1/4”

438

14-1/4”

362 mm

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

610

24”

533

24”

502

19-3/4”

330

19-3/4”

489

19-1/4”

438

17-1/4”

362

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”

610

24”

718

32-1/4”

502

19-3/4”

502

24”

489

19-1/4”

438

17-1/4”

362

14-1/4”

Optional frames

610

28-1/4”

819

20-3/8”

502

24”

610

16”

489

21-1/4”

438

17-1/4”

362

16-1/4”

718

28-1/4”

518

24”

610

24”

406

16”

540

21-1/4”

438

17-1/4”

413

16-1/4”

718

28-1/4”

610

28-1/4”

610

24”

406

19-3/4”

540

21-1/4”

438

17-1/4”

413

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”

Ventilated frame 3 sides or 4 sides

851

33-1/2”

851

756

29-3/4”

654

743

29-1/4”

743

540

21-1/4”

540

21-1/4”

540

537

21-1/8”

537

413

16-1/4”

413 mm

3-1/8" (79 mm)

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Page 16

Don-Bar Insulated Case

Not to scale

11 1/2”

Optional: 2 axial fans of 5" (125 mm) under the raised base

finishing cover joint

ventilated frame

9" (230 mm)

Ø 6”

TYP.2

Ø 9”

13 1/16”

Ø 6”

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

591

23-1/4”

1448

57”

946

37-1/4”

746

29-3/8”

695

27-3/8”

762

30”

651

23-5/8”

*Q and *S - spacers included

23-1/4” 57” 37-1/4” 25-3/4” 31” 30” 27-1/4”

591

23-1/4”

1448

57”

946

37-1/4”

654

22-3/4”

787

34”

762

30”

692

30-1/4”

591

23-1/4”

1448

57”

946

37-1/4”

578

18-1/2”

864

38-1/4”

762

30”

768

34-1/2”

591

23-1/4”

1448

57”

946

37-1/4”

470

14-1/2”

972

42-1/4”

762

30”

876

38-1/2”

591

25-1/4”

1448

57”

946

42- 1/2”

368

26-1/2”

1073

30-3/8”

762

34-1/4”

978

26-5/8”

641

25-1/4”

1448

57”

1080

42- 1/2”

673

22-3/4”

772

34”

870

34-1/4”

676

30-1/4”

641

25-1/4”

1448

57”

1080

42- 1/2”

578

18-3/4”

864

38-1/4”

870

34-1/4”

768

34-1/2”

641 1448 1080 476 972 870 876 mm

25-1/8” 57” 48-1/4” 21” 35-3/4” 39-1/2” 32”

638

25-1/8”

1448

57”

1226

48-1/4”

533

17-1/4”

908

39-3/4”

1003

39-1/2”

813

36”

638 1448 1226 438 1010 1003 914 mm

Ø 4”

11 1/2”

5 1/16”

10 7/8”

7”

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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

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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 to start 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

Use the handle to adjust the air intake

DRAWING 20

Using the handle to control the HE sliding smoke deflector

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

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Use the handle to control the damper

DRAWING 21

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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).

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

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

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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.

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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 Drawing 21.

4.2 Open fires: The smoke sliding damper and

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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. A log grate is not recommended.

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,

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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 rod 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 rod

DRAWING 25

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

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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. In addition, the sooth accumulation

over the HE plate reduces the efficiency of the secondary combustion because ash insulates and lowers the temperature of the secondary combustion chamber; the HE plate could

overheat and damage over time.

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

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

Unscrew the 4 bolts that

hold the smoke deflector.

Take out the deflector. Tilt it down

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

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Install this way

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

DRAWING 27

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

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PART 3: REPLACEMENT PARTS LIST

To order a part:

1) Check the replacement part required

2) Specify the year of the fireplace installation _________________

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 (rear) Herath plate (left) Hearth plate (right) 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

69-61

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

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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

- .

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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 facturer '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: 418-686-9114 Fax: 418-686-9117 Website: www.don-bar.com Email: [email protected]

Any fireplace modified,

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