Isokern EPA Qualified 36 C Owner's Manual

Isokern® EPA Qualied® Fireplace

Installation, Operation, Maintenance and Owner’s Manual

Model 36 C

A PRODUCT OF EARTHCORE INDUSTRIES, LLC.

Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance instruc-

tions for the Standard EPA qualied system. This manual must become the property of and be reviewed by

all current and future users of this product. It is the responsibility of the general contractor and the installer

of this product to ensure that the instructions in this manual are followed exactly and, further that any al­lowed gas log appliance used in this product be installed in strict accordance with NFPA 58, NFPA 54/
ANSI Z223.1 and the gas log manufacturer’s explicit installation, sizing and operation instructions. It is the
responsibility of the general contractor to provide adequate clearances from all rebox surfaces as specied

in this manual.

INSTALLER: Leave this manual with the appliance

CONSUMER: Retain this manual for future reference

Installation Date______________________________

NOTE: The Catalytic Combustor system should be replaced at a minimum in 3 years,
maximum of 5 years.

Be Sure to Read Entire Manual Before Beginning Construction.

Contents of this manual may change without prior notication.

THIS FIREPLACE IS DESIGNED for USE with

SOLID WOOD LOGS, PLUMBED PROPANE

(LP) or NATURAL GAS (NG), ONLY

WARNING: If the information in this manual is not followed exactly, a re or explosion may
result causing property damage, personal injury or loss of life.

SBCCI NO. 9626 NYC-MEA 241-90-E
ICC Report NO. ESR-2316 LA RR NO. 25483
IBC 2006, IRC 2006, IMC 2006 Issued: November, 2009
Revision: 002

INTERTEK TESTING SERVICES REPORT NO. 3159656MID-008

OMNI-TEST LABORATORIES REPORT NO. 257-F-06-3

© 2007 Earthcore Industries, L.L.C.

THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY

TABLE OF CONTENTS

General Information .......................................................................................................................................

Intended Use Statement ......................................................................................................................................

Safety Instructions ..............................................................................................................................................

Warnock-Hersey Listing Label and EPA Hangtag .............................................................................................

Assembled Firebox & Smoke Dome Dimensions ..............................................................................................

Component List & Dimensions ..........................................................................................................................

Required Clearance to Combustibles .................................................................................................................

Assembly Instructions 36 C .........................................................................................................................

Access Modication ..........................................................................................................................................

Firebrick Installation ..........................................................................................................................................

Summary .............................................................................................................................................................

Catalytic COmbustor Warranty............................................................................................................................

Fireplace Waranty.................................................................................................................................................

3
4
5
6

7

8
9
10-13
14
15
16-17
18
19

2

General Information

The Standard EPA qualied replace system is a
prefabricated, refractory modular replace and chimney system
designed for eld assembly. The system consists of interlocking
precast parts which are glued together with a masonry adhe­sive.
The parts of the Standard EPA qualied replace
system and DM 54 chimney system are precast using a pro­prietary mixture of volcanic pumice aggregate and cement.

It includes all the parts necessary for assembly of a complete

rebox, smoke dome and chimney system.
Each Standard EPA qualied replace component is
designed for a specic part of the replace such that only one

means for assembly is possible.

The EPA qualied model requires an in-line or

chimney top damper.

The Standard EPA qualied replace system requires
a Standard EPA qualied refractory re brick liner be applied to
the interior of the rebox. Fire brick must be a minimum thick­ness of one and one-eighth inch (1-1/8”).
The Standard EPA qualied replace system is avail­able in one size: thirty-six inch (36”). This unit has a thirty inch
(32”) rough opening height before re brick.
The DM 54 chimney system is a dual module refrac-

tory chimney system. The basic chimney consists of an outer

casing block and an inner liner with a fourteen inch (14”) di­ameter ue hole. The chimney components are eld assembled
using Earthcore Mortar to glue the components together.
The DM 54 chimney system also includes an offset
chimney block component, used to create offsets to the verti­cal run of the chimney. A brickledge component is available,
designed to support chimney top brick veneer nishes.
Prefabricated masonry chimney termination caps are also avail-

able.

The various Standard EPA qualied replace system
components will be described and illustrated in the follow-

ing pages. Close attention should be paid to each component
group’s specications and installation requirements as de­scribed in this manual.

Important: Due to heat and weight issues, the Standard EPA
qualied replace installations require that the system be built
upon a non-combustible concrete slab with no wood underpin­nings supported to footings with concrete or steel and designed
to carry the total weight of the Isokern replace and chimney

system.

The Fire-Lite application of the Standard EPA quali­ed replace replace is designed to be built upon a combusti­ble oor system and will also require a design that will support
the total weight of the Isokern replace and chimney system.
The FTF-13 or equivalent chimney system only must be used
with the Fire-Lite application.
Chimney system installations over 57’ - 0” will require

additional support.

3

Intended Use Statement

Intended Product Use Statement:

The Standard EPA qualied replace and DM 54
chimney systems are intended to burn solid wood fuel, propane

or natural gas.

Note:

Installation of a gas pipe must comply with the Stan­dard for Decorative Gas Appliances for Installation in Vented
Fireplaces, ANSI Z21.60.
This replace is not designed to sit directly on a com­bustible oor system. The Fire-Lite application is designed to
sit on a combustible oor. This replace is intended for use as
a supplemental heat source only and is not intended for heavy

use as a primary heating system.

Overring, abusive burning or mistreatment will void

any claims (eg. burning construction debris or other highly

ammable material; tossing, kicking or otherwise forcing logs
into the rebox).
Standard EPA qualied replace and DM 54 chimney
systems are conventional indoor or outdoor replaces designed
to appear like traditional masonry replaces. Standard EPA
qualied replace and DM 54 chimney system units are in-

tended for installation in residential homes and other buildings

of conventional construction.

Note: The local authority having code jurisdiction should be

consulted before installation to determine the need to obtain a
permit.

Important areas of concern with the installation of
these replaces are: construction of proper load bearing foun­dation and concrete support slab; code required hearth exten­sion substrates and supports; proper assembly of components;
clearance to combustible materials; height of chimney; and,
techniques employed in applying nishing materials to the
replace opening and hearth extension.
Each of these important topics will be covered in
detail throughout this manual. Installation personnel must give

special attention to each topic as the installation progresses.

All work performed on, near and adjoining the
replace and chimney installation must meet or exceed the
specications and requirements in this manual and the
prevailing local building code.
Subsequent renovations, additions of cabinets and
storage spaces in the enclosure surrounding the replace are
also limited to the specications in this manual and to the
prevailing local building code.
Isokern is not responsible for other construction work
around the replace unit.

WARNING:

This replace has not been tested for use with glass
doors. To reduce the risk of re or injury, do not install glass

doors.

Some jursdictions require the use of glass doors.
If glass doors are used, operate replace with doors in the
fully open position.

Note: Do not scale drawings. Illustrations in this manual are
not to scale and are intended to show “typical” installations.
Nominal dimensions are given for design and
framing reference only, since actual installations may vary
due to job specic design preferences. Always maintain the

stated minimum clearances to combustible materials. Do

not violate any specic installation requirements.
The Standard EPA qualied replace and DM 54

chimney system is tested and listed by Warnock Hersey (In-

tertek Testing Service) - Report No. 315965MID-008 and
Report No.315986MID-006 - to UL 127, and UL 103HT

- 2006. The EPA qualifying emissions tests were conducted
by OMNI-Test Laboratories Report No.: 257-F-06-3.
Standard EPA qualied replace systems are also
designed for installation in accordance with the National
Fire Protection Association Standard for chimneys, replac­es, vents and Solid Fuel-Burning Appliances (NFPA 211).
Standard EPA qualied replaces are not listed for use with

replace inserts.

4

Safety Instructions

1. Before starting the Standard EPA qualied replace and DM
54 chimney installation, read these installation instructions
carefully to be sure you understand them completely. Failure to
follow them could cause replace malfunction resulting in serious

injury or property damage.

2. Always check local building codes governing replaces and
replace installations. The Standard EPA qualied replace and
DM chimney installation must comply with all local, regional,

state and national codes and regulations.

3. Standard EPA qualied replace and DM 54 chimney sys­tems are intended for use in any application where a traditional
masonry type replace would apply. The chimney system must
always vent vertically to the outside of the building.

4. Creosote and soot formation and the need for removal: When
wood is burned slowly, it produces tar and other organic vapors
which combine with expelled moisture to form creosote. The
creosote vapors condense in the relatively cool chimney ue of
a slow burning re. As a result, creosote residue accumulates on
the ue lining. When ignited this creosote makes an extremely
hot re.

Because of creosote and soot buildup it is necessary to

inspect and clean the replace and chimney prior to use and peri­odically during the heating season. Cleaning of the replace and

the chimney system should be done annually at a minimum. In
colder climates, chimney cleaning may need to be done periodi­cally throughout the heating season.

5. Before servicing, allow the replace to cool. Always shut off
any electricity or gas to the replace while working on it.

6. Use only solid fuel or natural or LP gas log sets in this unit. Do
not use articial wax based logs, chemical chimney cleaners or
ame colorants in this replace.

7. Never use gasoline, kerosene, gasoline-type lantern fuel,
charcoal lighter uid, or similar liquids to start or “freshen up” a
re in this replace. Keep all ammable liquids at a safe distance
from the replace.

8. Always keep the ue damper open when heat is present in the
replace.

9. Do not use a replace insert or any other product not speci­ed for use with the Standard EPA qualied replace and DM 54
chimney systems unless written authorization is given by Isokern.
Failure to heed this warning may cause a re hazard and will void
the Isokern warranty.

10. This replace is not intended to heat an entire home or to be
used as a primary heat source. It is designed to ensure homeown­er comfort by providing supplemental heat to the room.

11. Always ensure that an adequate supply of replacement com­bustion air from the outside of the house is accessible to the re
to support normal combustion. Fireplaces consume large volumes
of air during the normal ring process.
In the event the home is tightly sealed and has modern
energy efcient features, the optional combustion air supply kits
may not provide all the air required to support combustion and
the proper ow of combustion gases up the chimney.

The manufacturer is not responsible for any smok
ing or related problems that may result from the lack of

adequate air supply owing into the house. It is the respon­sibility of the builder/contractor to ensure that adequate air
supply has been provided for the replace.

12. “Smoke free” operation is not warranted nor is the

manufacturer responsible for inadequate system draft caused
by mechanical systems, general construction conditions,

inadequate chimney heights, adverse wind conditions or
any unusual environmental conditions or factors beyond the
manufacturer’s control.

Caution: When used with the Standard EPA qualied
replace system, all gas log sets must be operated with the

damper clamped in the fully open position. This includes

unlisted “vent free” log sets. Only listed “vent free” log sets
may be operated with the damper in the closed position.

13. When in doubt about a component’s usability - has vis-
ible or suspected physical damage - consult your Isokern

distributor or authorized Isokern representative for advice.

14. Modication to STANDARD components not men­tioned in this manual may void claims, listings and approv-

als and could result in an unsafe and potentially dangerous
installation.

Alterations to the STANDARD rebox are allowed
with prior written approval and instructions from Earthcore
Industries, LLC. The installer indemnies the manufacturer
of all claims and under no circumstances will manufacturer
be liable for consequential, incidental, indirect, punitive or
other damages of any kind or nature, whether foreseeable or
not, based on any claim by any party as to the modications
of the Isokern replaces.

15. Wherever insulation is used, the Standard EPA quali­ed replace must not be placed directly against it. Keep all
insulation or vapor barriers a minimum of three inches (3”)
away from all replace and chimney components.
It is recommended that insulation and vapor barriers, if
used, rst be covered with gypsum board, plywood, particle
board or other material to assure that insulation and vapor

barriers remain in place.

WARNING: Do not pack required air spaces with

insulation or other materials.

16. Never leave children unattended when there is a re
burning in the replace.

17. Burning some fuels (such as charcoal) can be hazard­ous due to the possibility of producing carbon monoxide,
a colorless, odorless gas. Early signs of carbon monoxide
poisoning resemble u symptoms, including headaches,
dizziness or nausea. Over exposure to carbon monoxide

can lead to illness and death. It is strongly recommended to

install smoke and carbon monoxide alarm / detector devices
wherever replaces are in use.

-

5

Warnock Hersey Listing Label

MANUFACTURER: EARTHCORE INDUSTRIES, LLC

MODEL NO: Series 36 C

PARTICLE EMISSIONS: 2.93 GRAMS/KG OF WOOD BURNED

For proper operation, catalyst must be replaced every 3 to 5 years.

FIREPLACE

SMOKE EMISSIONS RANGE

Higher Emissions

Lower Emissions

0

12.0

THIS MODEL

EPA PHASE 2 EMISSIONS LEVEL

2.93 5.1

Better

Worse

U.S. Environmental Protection Agency

Wood-burning Fireplace Program

Phase 2 Qualified models are cleaner and pollute less than those models that
have not met this emissions level. Exposure to smoke has been associated with
respiratory illness and other health problems. Models that have lower smoke
emissions may reduce your risk.

PHASE 2 QUALIFIED

For more information go to www.epa.gov/burnwise

Fireplaces with lower emissions produce less smoke when installed and operated properly.

* EPA has determined, based on testing by an accredited independent laboratory and a certification
of conformity by a nationally recognized certification body, that this model qualifies at the Phase 2
emissions level for U.S. EPA's Voluntary Fireplace Program.

- Facsimile -

EPA Yellow Qualifying Hangtag

Isokern Fireplace and Chimney Systems are tested and listed to UL standards: UL 127, ULC S610, and UL 103HT.
The listing label shown above outlines the listed clearances to combustibles and indicates that the units are
suitable for use with solid fuel or listed gas appliances. Refer to the manufacturer’s installation manual for detailed description of
clearances to combustibles and all other installation information. A metal listing label similar to that shown above is afxed to each
Standard EPA qualied replace. Do not remove the listing label from the Standard EPA qualied replace replace.
In addition, an EPA qualifying label will be afxed to the Catalytic Combustor system. Keep this label in a safe place if needed for
permits or building inspection. Prior to beginning installation, contact your local building ofcial to determine the need to obtain a

permit.

6

Assembled Firebox & Smoke Dome Dimensions 36 C

Side View

Front View

Plan View

Catalyst

A

E

F

E

G

H

C

D

B

Model A B C D E F G

H I

Minimum Framing Weight

36” C

43”

25 1/4” 71 1/4” 31 1/2 ” 36 1/8” 27 1/4” 21 1/2”

20 1/4” 5“

44” W x 72” H x 27” D 1500 lbs.

I

Catalytic Combustor system Operation

The proper use of a wood burning replace equipped with the Catalytic Combustor system will signicantly
reduce the emissions that it produces. Simple fuel considerations with regard to moisture content, size, and quality of
fuel will help control the production of wood smoke and ultimately improve the performance of the Catalytic Combustor
system and replace efciency. With proper care, the Catalytic Combustor system will provide years of fuel savings and
lowered emissions. By following some simple guidelines, you will ensure maximum performance and longevity.

The smoke that is usually seen coming out of a chimney is essentially a combination of unburned fuel (carbon

and hydrogen) and moisture in the form of water vapor. The Catalytic Combustor system is a technology that provides
secondary combustion for the wood burning process.
Avoid the use of treated, painted and laminated wood. Never incinerate garbage or other foreign materials. Do
not use articial logs, colored newspaper or petroleum based re starters. Avoid wood with high salt content. All of these
materials may contain compounds which can shorten the life of the catalyst. Wet or unseasoned wood may lower catalytic
temperatures and result in inefcient operation.
The Catalytic Combustor system is designed to function at optimum efciency when the replace is burning
clean, dry cordwood as replace fuel. A simple visual inspection of the chimney during the wood burning process will

determine catalytic performance.

NOTE: Chimney smoke may be visible during the rst 8-10 minutes of replace operation when the re is rst started
and also during the nal 8-10 minutes of operation when the re in the replace is going out. Otherwise, the catalytic

system will eliminate approximately 90% of the visible chimney smoke typically produced by a wood burning replace.

7

Component List & Dimensions 36 C

Base Plate
Part No. Model Qty
No.
21 36 1

Model A
36 43”

Smoke Dome - Small

Part No. Model Qty
No.
12 36 2

Smoke Dome - Medium

Part No. Model Qty
No.
11 46 2

Side Wall
Part No. Model Qty
No.
20 36 6

Back Walls
Part No. Model Qty
No.
25 36 3

Model A
36 26 3/4”

Smoke Dome - Sidewall

Part No. Model Qty
No.
34 36 4

A

25 1/2”

3”

4”

16”

32 1/2”

4”

16”

43”

10 5/8”

25 1/4”

10 5/8”

5”

A

25 1/4”

16”

3”

Catalytic Filter
Part No. Model Qty
No.
CCB-S 36 1

Isokern reserves the right to make changes at any time, without notice in design, materials and specications and also to
discontinue styles and products. Please call [phone] for an Isokern dealer near you.

8

Required Clearance to Combustibles

B

A

B

B

D

D

D

C

Non-Combustible

Floor System

(non-insulation)

Hearth Extension

(non-combustible)

The Standard EPA qualied replace replace and DM 54 chimney system is tested and listed for installation with “clear­ance to combustibles” as follows:

A: Four inch (4”) clearance to the combustible oor;
B: One and one-half inches (1 1/2”) clearance at the Isokern rebox and smoke dome sides and front ;
C: One and one half inches (1-1/2”) clearance at the Isokern rebox and smoke dome back wall ;
D: Zero inch (0”) Clearance to the DM chimney system. Contact metal pipe manufacturer for specic clearance

information

CAUTION: Maintain three inches (3”) clearance to insulation and vapor barriers from all rebox, smoke dome ue components.

Note: “Combustibles” are dened as “normal construction materials” and are considered to be: wood framing materials, particle

board, mill board, plywood sub-ooring, plywood paneling and wood ooring.
Sheathing materials, such as plywood, particle board and drywall may cover the smoke dome front at 0” clearance.
All combustible sheathing materials that protrude beyond front of rebox must be held 8” away from the sides of the re­box opening and 8” above the top of the rebox opening. Drywall must be cut 2” back from the rebox opening sides and 8” above

the top of the opening.

Notes:

A. The Standard EPA qualied replace replace is rated for installation on a combustible oor system when using the
Fire-Lite application only.
The Standard EPA qualied replace must sit upon a concrete support slab designed to bear the total installed weight of
the replace and DM 54 chimney system. These support slabs can have no wood underpinnings.
B. Concrete support slabs for the Standard EPA qualied replace must provide the noncombustible hearth extension
substrate needed to support the code required noncombustible hearth extension nish materials.
C. All Standard EPA qualied replaces shall have hearth extensions of approved noncombustible material such as brick,
tile, or stone that is properly supported and with no combustible material against the underside thereof. Wooden forms used during
the construction of hearths and hearth extensions shall be removed when the construction is complete.
D. If a raised replace oor and raised hearth extension are preferred, the raised underlying structure must be built of non-

combustible material and must sit on noncombustible substrate.

9

Assembly Instructions - 36 C

Earthcore Mortar

Shim if required
to acheive
correct height

General Isokern Assembly Instructions:

Earthcore Mortar (a thin-set type masonry adhesive) is
used to glue all Isokern components together during eld assembly
of the unit. The mortar is supplied dry, in either 15 pound or 50

pound pails.

Earthcore mortar is mixed with clean water to a smooth,
workable texture (without lumps or dry pockets) of a “toothpaste”
consistency. This mixture is suitable for application onto Isokern
components by using a masonry grout bag supplied with the unit.
Attention should be paid that the mortar mixture is not too
thin or runny, as this will not allow the mortar to reach its maximum

bonding strength.

Earthcore mortar is squeezed from a grout bag onto the
contact surfaces of the Isokern components as they are tted

together.

It is important that a 1/2” bead of mortar on all the compo­nents’ contact surfaces is applied at about 1/2” in from all edges of

the contact surface of the component.

When setting the next component onto the mortared con­tact surface of the rst component, some mortar should squeeze out

along the face of the entire joint as a sign of complete and proper
sealing of the joint.

On broader contact surfaces it is advisable to apply several
additional 1/2” beads of the Earthcore Mortar to the area to assure

proper sealing of the joint.

Properly mortared rebox and smoke dome assembly re­quires approximately 25 pounds (dry measure) of Earthcore mortar.

Broken Components:

Components broken into 2 or 3 pieces can be repaired by

using Earthcore mortar along the break line as the component is set
into place. Components broken into multiple small pieces should be
discarded and replaced.

Leveling and Aligning Components:

Be sure to assemble all Isokern components level and ush
with adjoining components.

Earthcore mortar is not intended to create a mortar joint

of any thickness for leveling purposes. Therefore, leveling and

alignment adjustments are made by the use of small plastic shims

supplied with the unit.
The shims can be inserted under a component to level and
align it with adjacent Isokern components. Be sure to re-grout any

and all gaps resulting from shim insertion to maintain components
to full bearing.

Notes:

1. Do not mix Earthcore mortar with spirits or anti-freeze agents.

2. The maximum recommended mortar joint thickness at Isokern
components is 1/4”.

3. Earthcore mortar can be troweled over the face of a joint where
it has squeezed out while setting components. It is not intended that
the exposed faces of the Isokern components be completely covered
with the mortar.

10

Assembly Instructions - 36 C

Raised hearth

for wood or

concrete installs

Flush Hearth

on Concrete

Foundations Only

Earthcore
Mortar

Installation:

Step 1: Set the Standard EPA qualied replace base plate in a
full bed of Earthcore Mortar at on a proper concrete support
foundation. Do not set the base plate so that it is in span. Level
the base plate by oating it in a bed of Earthcore Mortar to full

bearing against the underlying noncombustible support surface.

Notes: If the design preference is for a “ush hearth” (replace
oor ush with the room’s oor), the base plate can be omitted
from the assembly and the rebox walls built directly on the
concrete support slab. The re brick oor of the rebox is then
set directly to the concrete support slab. This makes the replace
nished re brick oor approximately one and one-half inches
(1-1/2”) above the top of the concrete support slab.
If the design preference is for a raised hearth (oor of
the replace elevated above the room’s oor), then the base plate

can be set on a noncombustible platform that is built up to the
desired raised hearth height on the concrete support slab.

When calculating raised hearth height be sure to allow
for the three inch (3”) thick base plate plus the one and one half
inch (1-1/2”) thick re brick oor in addition to the height of the
platform. Whether a ush hearth is preferred or a raised hearth,
the combustible oor on front of the replace must be covered
with a noncombustible hearth extension set tight against the re­place front and extending at least 20 inches out from the nished
replace and at least 12 inches beyond the nished sides of the

replace opening.
For all “raised hearth” construction where concrete

blocks are used to create the raised platform, it is necessary to
use the base plate. Be sure to mortar the concrete block plat-

form together. CMU used for base plate support should be rated
ASTM 90.

Step 2: Set the rst course of the rebox back wall and side
walls into place.
It may be convenient to dry set the rst course of side
wall and back wall into place on the Isokern base plate and then
to trace their position on the base plate with a pencil.
After outlining the dry set pieces, remove them and
apply Earthcore Mortar to the areas traced on the base plate
where the side walls and back wall are to sit. By doing this, the
rst layer of wall components can be set directly into mortar

already applied to the proper areas on the base plate.

Be sure to put Earthcore Mortar on the contact surfaces
of the vertical joints where the side wall and back wall

components connect.

11

Assembly Instructions - 36 C

Earthcore
Mortar

Earthcore Mortar

First Course
Back Wall

Top Course
Back Wall

Earthcore Mortar

Step 3: Continue assembly of the second, third and fourth
courses of the rebox side wall and back wall. Apply mortar to
the top of each layer of wall components, set the next course
above into place. Be sure to mortar all vertical joints of the side
wall to back wall connection when setting each component to

its mate.

Look for some mortar to squeeze out along the joints

of all contact surfaces as a sign that the joint is thoroughly

sealed with the approved mortar.

Step 4: When all of the rebox wall components are set, check
the top surface of the rebox for level.
If necessary, adjust the top surface of the box assembly for level
by inserting a shim between the lowest wall component and the

top surface of the base plate.

Any gap created under the wall components during the
Shim leveling process must be lled with mortar to full bearing

against the base plate.

Step 5: Make sure that the rebox assembly has been set level
and square. Adjust as required while the mortar is still wet.
Make a nal inspection of all contact joints in the re­box assembly to be sure they are properly sealed. Fill any and
all gaps in the assembly, as necessary, with the approved mortar.

Step 6: Take the Catalytic assembly out of the box and verify all
components are in tact and Yellow EPA hangtag is attached to
the lter. The Catalytic kit should contain a Catalytic
Combustor, 6” diameter ue pipe (24” tall) and two (2) metal

angle support brackets.

Step 7: Insert support brackets so that the largest angled portion

slides into the side wall cavity toard the rear of the rebox. The
smaller angles should be facing upward toward the inside of the
rebox.

Step 8: Center the Catalytic Combustor in the rebox and rest
it on top of the support brackets making sure that the lter is
equally settled on the brackets. The lter should be set toward
the rear of the rebox.

Step 9: Attach the twenty four inch (24”) ue pipe on the appro­priate tting making sure there are no obstructions above it.

Step 10: Set the back smoke dome component across the rear
side walls in a bed of mortar and ush with the back face of the
back wall.

Set the front smoke dome component in mortar across

the front side walls ush with the front of the sidewalls.

Step 11: Position the smoke dome’s sloping sidewalls at each

end of the smoke dome components.

The sloping sidewalls t in between the front and rear
smoke dome components and also t into the haunches at the
ends of the front and rear smoke dome components. Mortar all

contact surfaces thoroughly.

12

Assembly Instructions - 36 C

Note: The smoke dome sloping sidewalls have a bev­eled bottom edge so that they will sit tight onto the at
top of the side walls.

Step 12: Make sure that all component contact surfaces
have been properly sealed with approved mortar.
Check smoke dome front and back walls to see
that they are plumb, level and in alignment with mating

components.
Check alignment of the smoke dome sloping

sidewall components to see that they are fully seated.

Step 13: Set the smoke dome top plate into position on
top of the smoke dome wall assembly.
One side of the smoke dome top plate shows a

thickened center. This side is the bottom face of the top
plate.

The fourteen inch (14”) diameter ue hole in

the top plate is centered in the smoke dome from side to
side but is offset from front to back.

Make sure that the top plate is set so that the
ue hole is closer to the back wall of the smoke dome

assembly.

Be sure to set the smoke dome top plate ush
with the front, back and sides of the smoke dome assem­bly. All contact surfaces must be properly sealed with the
approved mortar.

Note: The completed smoke dome assembly should

present a stable and level surface for setting the ue

components.

13

FIGURE 22

Firebrick
side

Gas or electric
line

NOTE: Fill any gaps around
line with Earthcore Mortar

Flex duct to fireplace
firebox (all parts non-combustible)

Exterior wall

Exterior air vent
with dress plate

Supply air ventilation

(if required by code)

T

ypical placement of

gas or electric line

(see detail below)

NOTE: Gas lines and combustion
air ventilation placement can be reversed.
This page used for illustration of systems
only.

Assembly Instructions - Access Modication

Through-Wall Accesses:

1. Combustion Air Inlet: Combustion air inlet kits though not required
by Isokern may help improve replace operation in homes tightly sealed
and with other ventilating appliances installed. Check local codes for

combustion air inlet requirements.
The following is a general representation of a generic com­bustion air kit and not a requirement of Earthcore Industries, LLC.
Local building codes prevail and should be checked before
installation.

Generic replace combustion air kits typically consist of a
sliding stainless steel access door afxed to a three inch (3”) or four inch
(4”) diameter stainless steel sleeve approximately twelve inches (12”)
long. An exterior vent with dress plate, weather hood and rodent preven­tion screen of a maximum one-quarter inch (1/4”) wire mesh completes
the kit. (Figure 20)
The access door is tted into the nished re brick lining at
the interior sidewall of the rebox. The twelve inch (12”) long sleeve
can be introduced into the rebox side wall or back wall by core drilling
an appropriately sized hole at the selected rebox location. Keep the
top of the four inch (4”) diameter access hole no more than six inches
(6”) above the nished rebrick oor. The hole size should allow for a
one-quarter inch (1/4”) mortar joint around the air access sleeve for heat
expansion.
The sleeve passes through the rebox wall and must
be connected to metal pipe (by other) - either exible or rigid - that leads

to the source for outside combustion air, as directly as possible from the

Standard EPA qualied replace (Few to no bends) with a maximum
length of sixty feet (60’).

WARNING: Do not use combustible duct material. Avoid installing
a combustion air inlet where the opening could be blocked by snow,

bushes or other obstacles. Air inlet must terminate a minimum of three

feet below the chimney cap level. Air inlet ducts shall not terminate in

attic spaces.

2. Gas Line Feed: For a replace having the provision for installation of
a gas pipe, the provision is intended only for connection to a decorative

gas appliance.

CAUTION: When using the decorative appliance, the replace damper

must be set in the fully open position.

Gas line for gas log sets used in the Isokern rebox can be
routed through the side wall, back wall or oor of the rebox by drilling
an appropriately sized hole using a masonry drill bit.

3. Electrical Line Feed can be routed through the rebox back wall, side
walls or oor by drilling an appropriately sized hole using a masonry
drill bit. Be sure to follow the gas log appliance manufacturer’s explicit
electrical line connection instructions for vented replace installations.
Gas line and electric line must be fed through separate access

holes.

CAUTION: All access holes must be grouted with mortar – after line or

conduit feed - to seal any gaps or cracks around line feed conduits.

14

Fire Brick Installation:

Expansion
Gap
(Both Sides)

Firebrick Floor
and Backwall
(Built First)

Firebrick Floor
and Backwall
(Built First)

The manufacturer requires that the Standard EPA

qualied rebox be lined with a minimum one and one-eighth
(1-1/8”) thick rated re brick. The pattern for the re brick lin­ing is an owner option. Standard N-Type brick mortar is a suit­able re brick mortar for the Standard EPA qualied replace
and good masonry practices should be followed.
All required through-wall accesses (gas and electrical
line feeds and combustion air supply access holes) should be
drilled before the required re brick lining is installed.
It takes a total of about ve gallons of N-Type brick
mortar mix (dry measure) to re brick line a replace.
Face joints of one quarter inch (1/4”) to three-eights
inch (3/8”) give a good appearance to the nished brickwork
however, this is just a suggestion and other face joint

dimensions are also acceptable.

Step 1. Wet mop the inside of the Standard EPA qualied
replace with a damp sponge to remove dust and loose
particles from the interior before installing re brick.

Assembly Instructions - Fire Brick Installation

Step 2. Start the re brick at the front edge of the oor of the
Isokern rebox, proceeding inward toward the back.

HINT: Dip each rebrick into water before applying.

Step 3. Next, apply re brick to the back wall of the unit start­ing at the bottom of the back wall and working upward to the
top of the back wall.

Step 4. Finally, set the side wall re brick by starting at the
front edge of the unit’s side wall and working inward toward
the back wall re brick.

Isokern makes no claims as to the performance
of re brick or re brick mortar(s). It is typical for heat
stress cracks to appear in the re bricks in wood burning
replaces.

15

Summary

1. WARNING:

Fireplace and chimney systems will only draught prop­erly when they are installed according to the instructions, in an
appropriate location and with the proper chimney height. Install­ing the replace according to the instructions, choosing an ap-

propriate location, and choosing an appropriate chimney height
are the responsibility of the designer and the building contractor.

Tightly insulated and sealed homes, two story interior
spaces and high vaulted ceilings can cause negative air pressures
within the house which can impair drafting performance. HVAC
return air ducts near the replace opening will adversely affect
the replace drafting performance.

It is the responsibility of the designer, the building
contractor and their mechanical contractor to determine that the
building’s internal air pressures are conducive to positive re­place drafting.

Avoid placing any replace in an area near tall trees, tall

buildings, or high land masses. These structures can reduce am-

bient air ow pressure as well as produce down draughts, either
of which can impair replace drafting performance.
Earthcore Industries L.L.C. does not warrant drafting

and is not responsible for it.

2. Standard EPA qualied replace and Fire-Lite Fireplace
Curing Instructions:

It is critical that the Isokern masonry elements in the

rebox and smoke dome assembly be dry before ring of the
unit. Moisture left in the components from exposure during stor­age and shipping, as well as moisture from the installation phase,

must be eliminated before the unit is put to its intended use.

The rst step in reducing the ambient moisture is to be
sure that the completed replace rest totally in a dried-in setting
for a minimum of 28 days after construction of the unit is com-

plete.

The next step in curing the replace is to be sure that
the rst ve or six res are of short duration.
The rst re of the unit can take place once the mini­mum twenty-eight day drying period has passed. This re should

be especially short.

Start the rst re slowly with a small amount of paper
and kindling (small dry wood splits or twigs) and a maximum
load of four to six pounds of dry rewood, estimated to be no
more than two or three logs each of about three inches (3”) to
four inches (4”) diameter.
The rst re should burn for no more than thirty to sixty
minutes and then allowed to go out. Do not refuel the replace
during the rst lighting.
A cooling off period of twenty-four hours, at a mini­mum, should follow the rst re.
The second re should be the same as the rst re.
The second re should burn for no more than thirty to
sixty minutes and allowed to go out. Do not refuel the replace

during the second lighting.

A twenty-four hour cooling off period must be
observed following second lighting.
After rst and second re, continue use of the unit with three
or four small res of short duration (sixty minutes or so) and

small fuel load.

After these rst ve or six small res of short dura­tion normal use of the replace can proceed. For normal use
the maximum recommended fuel load is twelve to sixteen
pounds of dry rewood at a time. This fuel load is consid­ered to be approximately three to ve cured hardwood logs
of about three inches (3”) to six inches (6”) in diameter. As
the re burns down, refueling should be only one or two logs

added at a time.

Important: Do not burn construction debris or trash of any

kind in the Fire-Lite replace.

Whereas it is not uncommon for construction debris

and refuse to be burned in a replace by site personnel on
a project that is under construction, this activity must be
avoided.

It is the responsibility of the building contractor
to insure that the required dry-in period is met and that the

required lighting sequence is performed by the owner or by
the owner’s agent.

3. Log grates are required for burning solid fuel in the
Isokern replace. Grates allow for easy air ow up through

the burning logs thus creating a more complete and efcient

burning of the fuel.

4. How to Build a Fire:

First set the replace damper in the full open posi­tion. Begin laying the re by placing several pieces of wad-

ded up paper directly on the log grate. Place kindling (small

splits of dry pine or other dry softwood) on top of the paper,
enough to loosely cover the paper. Next arrange several
small, dry hardwood or softwood logs or log splits on top of

the kindling layer.

Finally, arrange two or three larger hardwood logs
(oak, hickory, etc.) or log splits on top of the stack.

Ignite the paper at the bottom of the stack. The burning

paper will ignite the kindling which will, in turn, set the
remaining fuel on re.
Be sure to stack all rewood in such a way that it
will settle into the log grate as the paper and kindling layers
are burned away. Additional logs can be set onto the re as
each fueling burns down.
Ideally, fuel logs should be of a hardwood species
that have been air dried for one year or longer. Use of cured
or uncured pine logs and uncured hardwood logs for fuel
should be avoided. Pine logs and uncured hardwood logs
will tend to smolder and burn at relatively low temperatures
producing high levels of soot and creosote.

Important: Do not throw, toss, jam, kick or otherwise force

logs into the replace.

16

WARNING:

Never use gasoline, gasoline type lantern fuel, kero­sene, charcoal lighter uid or other similar liquids to start or
“freshen up” the re in this replace or in any replace.

WARNING:

If processed solid fuel relogs are used: Do not poke
or stir the logs while they are burning. Use only relogs that
have been evaluated for the application in replace and refer
to relog warnings and caution markings on packaging prior

to use.

5. Avoid over-ring this replace. Some examples of over­ring are:

a. Burning of scrap lumber, construction debris, pine branches

and brush or cardboard boxes;
b. Burning small diameter twigs, branches or any
other small sized combustible materials in quantities which

exceed the volume of the normal log re;
c. Use of articial wax base logs, trash or other chemicals or

chemically treated combustibles.

WARNING: Over-ring can permanently damage this
replace system.

6. Fireplace Doors and Screens:

This replace has not been tested for use with doors.
To reduce the risk of re or injury, do not install doors. If
doors are required by the local authority having jurisdiction
then doors must be kept in the fully open position when the
replace is in operation. Isokern does not limit the use of
replace screens.

7. Disposal of Ashes:

It is recommended that the rebox be cleaned of ex­cessive ashes before each use. It is necessary to remove ashes
from the open front of the replace. To do so, proceed in the
following manner:
Allow the re to go out and the ashes to cool for at
least six to eight hours.

After the cooling period carefully pick up the ashes

from the rebox with a small, metal replace shovel or other
metal scoop and place them in a metal container with a tight
tting lid.
If possible do not sweep the ashes as this will stir

them into the air and disperse them into the room.
The closed container of ashes should be placed on

a noncombustible oor or on the ground, well away from all
combustible materials, pending nal disposal. If the ashes are
disposed of by burial in soil or otherwise locally dispersed,

they should be retained in the closed container until all cin-

ders have thoroughly cooled.

8. Inspection and Cleaning:

At least twice a year in warm climates or monthly

during the heating season in colder climates, thoroughly

inspect the Fire-Lite replace and chimney system.

Summary

Chimneys must be installed so that access is provided for

inspection and cleaning. The chimney should be inspected
monthly during the heating season.

Inspect the entire ue from the top down for obstruc­tions such as birds’ nests, leaves, etc. Such obstructions must
be removed.
Check spark arrestor screens for clear ow of smoke
every two to four weeks during the heating season.
Inspect the ue periodically during the heating season for the

presence of soot and creosote build up. If creosote or soot

has accumulated, it should be removed to reduce the risk of
chimney re.
Have your chimney cleaned by a professional chim­ney sweep if you have doubts about your ability to do it.
Use a plastic, wood or steel brush to clean the chimney.
Scrub the spark arrestor/chimney cap with a wire brush.
Remove any chimney cap for ue cleaning from the
top. Open the damper in the rebox for cleaning access from
below.
Clean the inner portion of the ue by using a exible

handled chimney cleaning brush.

For straight run ue the proper size brush can be
pulled up through the ue from the rebox with the damper

open.
If the chimney has an offset chimney section, brush

cleaning from the chimney top down to the offset/return and
then from the rebox up to the offset section is the proper

method.

In either case, cover the replace opening with a
damp sheet (sealed to the opening with masking tape) before
brush cleaning. Do not remove sheet until the soot has settled.
It is advised to vacuum loosened soot. Do not sweep loosened
soot as sweeping will disperse soot into the air and about the

room.

WARNING: Do not use chemical replace and chimney
cleaners that are poured on a hot re. These can be dangerous
and generally work only on the ue section nearest the
re, leaving the rest of the ue unaffected.

9. Exterior Maintenance:

Annually, at a minimum, check all metal ashings
and weather seals around the exterior chimney where it
penetrates the roof surface; inspect any chimney top spark
arrestors, metal cowlings and weather hoods to make sure they
are secure and weather tight.
Seal any cracks or gaps in chimney-to-roof ashings
to prevent possible roof and chimney chase leaks.

Inspect any cement chimney cap or clay chimney pot

terminations to make sure they are not diverting water into the

structure. Seal any suspected cracks or gaps in these masonry
components.

17

Catalytic Combustor Warranty

Clear Skies warranty obligations for the HearthCAT Emissions Control System are limited to the
terms set forth below: Clear Skies Unlimited, Inc. (“Clear Skies”) warrants to the consumer who purchases
a new solid fuel burning replace containing a HearthCAT Emission Control System as a new component,
to replace the catalyst at no charge should it cease to function within three years from the date of purchase.
The HearthCAT Catalytic Component is designed to perform efciently for three years of replace
operation. ONLY recommended fuels should be burned. Follow the fueling directions in manufacturers
operating manual. For warranty purposes, proof of replace or HearthCAT™ purchase is required. Labor
for removal and/or re-installation of the catalytic component is not the responsibility of the manufacturer.

This warranty applies only to CS-100 Series HearthCAT™ catalytic components manufactured by Clear
Skies Unlimited Inc. For replacement of a Clear Skies catalytic combustor under the conditions of this
warranty, please contact the manufacturer @ www.clearskiesunlimited.com

NEITHER CLEAR SKIES UNLIMITED INC. NOR THE DEALER WHO SELLS THE HEARTHCAT™
EMISSION CONTROL SYSTEM IS RESPONSIBLE FOR INDIRECT, INCIDENTAL, SPECIAL,
PUNITIVE OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE IMPROPER USE OF THIS
PRODUCT OR THE CONTINUED USE OF THIS PRODUCT BEYOUND THE REQUIRED
REPLACEMENT PERIOD.

18

Warranty & Disclaimer

Isokern FIreplace

ISOKERN offers a lifetime warranty for all Isokern components, to be free from defects in materials that
negatively affect system performance from the date of purchase, subject to the terms and conditions of this
limited warranty.

This warranty covers only the above stated components, and NO WARRANTY, EXPRESS OR IMPLIED,
EXTENDS TO ANY OF THE HARDWARE, FOOTING, VENTS, DUCTING, METAL FLUES, FIRE
BRICK OR ACCESSORIES. THIS WARRANTY DOES NOT COVER DRAFTING, SMOKING OR
PUFFING OF THE FIREPLACE SYSTEM. Factors beyond the manufacturer's control affect replace

drafting,

smoking, and pufng, and ISOKERN cannot guarantee these aspects of performance.

If a component is found to be defective under the terms of this warranty the party to whom this warranty is
extended shall, notify ISOKERN, 6899 Philips Industrial Blvd, Jacksonville, Florida 32256, in writing, by
registered mail, within thirty (30) days following the discovery of the defect within the lifetime warranty
period. The notice shall contain (1) the date of purchase; (2) place of purchase; (3) address of installation;
(4) name, address and phone number of the owner; and (5) a brief description of the defect.

ISOKERN, or any division thereof, is not responsible for any labor costs or indirect costs incurred for the
replacement of defective components.

ISOKERN is not responsible for misuse or mishandling of components. Nothing in this warranty makes
ISOKERN, or any division thereof, liable in any respect for any injury or damage to the building or struc­ture in which the replace or chimney system has been installed or to persons or property therein arising out
of the use, misuse, or installation of properly manufactured ISOKERN product.

ISOKERN, OR ANY DIVISION THEREOF, SHALL NOT BE HELD LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES OR EXPENSES ARISING OUT OF THE USE OF THE
FIREPLACES OR CHIMNEY SYSTEMS. ALL SUCH DAMAGES AND EXPENSES ARE HEREBY
EXCLUDED.

This warranty is null and void when the replace or chimney systems are not installed pursuant to the
installation instructions provided by ISOKERN or local building codes have not been followed completely.

This warranty applies only to those replace and chimney systems installed in the continental United States,
Alaska, and Canada. If any part of this warranty is found to be unenforceable, the remaining parts shall

remain in force and effect.

ISOKERN HEREBY DISCLAIMS ALL GUARANTEES AND WARRANTIES, EXPRESS OR IMPLIED,
BEYOND THE WARRANTIES SET FORTH HEREIN.