Isokern Standard 36, Standard 46, Standard 42, Magnum 28, Magnum 48 Installation, Operation, Maintenance And Owner's Manual
Isokern® Standard Fireplace
and
Magnum Fireplace
with Fire-Lite Application
and DM Chimney System
Installation, Operation, Maintenance and Owner’s Manual
Isokern Standard Models 36, 42 & 46
Magnum Models 28, 36, 42, & 48
A PRODUCT OF EARTHCORE
Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance instructions
for the Isokern Standard and Magnum Series replaces, DM chimney system, and Fire-Lite Application with
the FTF-13 Chimney 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 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 specied in this manual.
INSTALLER: Leave this manual with the appliance
CONSUMER: Retain this manual for future reference
Be Sure to Read Entire Manual Before Beginning Construction.
Contents of this manual may change without prior notication.
THESE FIREPLACES ARE 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
Issued: September 2012
Revision: 005
INTERTEK TESTING SERVICES REPORT NO. 3159656MID-008
© 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 ...........................................................................................................................
Assembled Firebox & Smoke Dome Dimensions -Isokern Standard Series .......................................................
Component List & Dimensions ..........................................................................................................................
Assembled Firebox & Smoke Dome Dimensions -Magnum Series ...................................................................
Component List & Dimensions ...........................................................................................................................
Required Clearance to Combustibles .................................................................................................................
Rough Framing Dimensions & Corner Location Layout ...................................................................................
Assembly Instructions .................................................................................................................................
Access Modication ...........................................................................................................................................
Firebrick Installation ..........................................................................................................................................
Flush Wall Finish Detail .....................................................................................................................................
Required Clearances (When sheathing protrudes beyond front of rebox) .......................................................
Required Clearance to Combustible Framing ....................................................................................................
Flush Wall Fire Brick Finish Detail ....................................................................................................................
Interior Masonry Veneer Fireplace Finishes & Clearances...................................................................
Masonry Veneer Construction Details ..................................................................................................
Non Combustible Finished Facing Requirements & Clearance to Combustible Trim .......................................
Concrete Support ...............................................................................................................................................
DM Chimney System ........................................................................................................................................
General Information ............................................................................................................................
Component List & Dimensions.............................................................................................................
Component Weights .............................................................................................................................
Installation ...........................................................................................................................................
Lateral Support ....................................................................................................................................
Offset Block .........................................................................................................................................
Brick Ledge Installation .......................................................................................................................
Brick Ledge Load Capacity ..................................................................................................................
Flashing & Crown Caps ........................................................................................................................
Height Requirements ...........................................................................................................................
Structural Information ..........................................................................................................................
Common Chimney Terminations .........................................................................................................
Metal Flue ..........................................................................................................................................................
Specialty Applications .......................................................................................................................................
See-Thru Applications ..........................................................................................................................
Two Story Stacked Installations ..........................................................................................................
Fire-Lite Application ..........................................................................................................................................
Fire-Lite Application General Information ..........................................................................................
Fire-Lite Application - Required Clearance to Combustibles ..............................................................
Fire-Lite Application - Load Calculations ...........................................................................................
Fire-Lite Application - Hearth Conditions ...........................................................................................
FTF-13 or Equivalent Chimney System .............................................................................................................
FTF-13 Installation Components ........................................................................................................................
FTF-13 Offset Elevation Chart ...........................................................................................................................
FTF-13 Vertical Elevation Chart ........................................................................................................................
Summary .............................................................................................................................................................
Registration Card .....................................................................................................................................................
3
4
5-6
7
8
9
10
11
12
13
14-17
18
19
20
21
22
23
24
25
26
27
28-39
28
29
30
31
32
33-35
36
37
38
39
40
41
42
43-45
43
44-45
46-51
46
47
48
49
50-51
52
53
54
55-56
57
3
General Information
The Fireplaces referenced in this installation manual
and DM chimney system are prefabricated, refractory
modular replaces and a chimney system designed for eld
assembly. The systems consist of interlocking precast parts
which are glued together with a masonry adhesive.
The parts of the Fireplaces and DM 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 precast replace component is designed for a
specic part of the replace such that only one means for
assembly is possible.
The rebox and smoke dome are designed to be
tted with a traditional cast iron, poker-style throat damper,
however alternate dampers are an option.
The replaces require a standard refractory re
brick liner be applied to the interior of the rebox. Fire brick
must be a minimum thickness of one and one-eighth inches
(1-1/8”).
Isokern Fireplaces are available in nine sizes, seven
of which are covered in this manual: Isokern Standard sizes:
thirty-six (36), forty-two (42), and forty-six (46). Magnum
sizes: twenty-eight (28), thirty-six (36), forty-two (42) and
forty-eight (48). The Magnum is also available in two larger
sizes; information located online @ www.earthcore.co and
detailed in a separate installation manual.
All Isokern Standard units have a thirty-one and a
half inch (31-1/2”) rough opening height and the Magnum
units have a thirty-eight inch (38”) rough opening height
before re brick. The only parts which differ among the
available sizes are width and depth related pieces. The DM
chimney system is a dual module refractory chimney system.
The basic chimney consists of an outer casing block and an
inner liner. The chimney components are eld assembled
using Earthcore (EC) Mortar to glue the components together.
The DM chimney system also includes an offset
chimney block component, used to create 30° offsets to
the vertical run of the chimney. A brick ledge component
is available, designed to support chimney top brick veneer
nishes. Prefabricated masonry chimney termination caps
are also available.
The various replaces and the DM chimney
components will be described and illustrated in the following
pages. Close attention should be paid to each component
group’s specications and installation requirements as
described in this manual.
Important: Due to heat and weight issues, the replaces and
DM chimney system 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 replace and chimney
system.
The Fire-Lite application of the replaces 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. Please refer to
pages 46-51 for installation instructions.
Recommended minimum overall height for the
Isokern replace and DM chimney system for an indoor
application is 18’-0” when the chimney is straight and 21’-0”
when a chimney is offset. Maximum overall height is 82’ - 0”,
however, heights above those listed below require additional
structural support.
Maximum DM ue height without additional support needed:
Isokern Standard Series:
36 54’-0”
42 40’-0”
46 41’-0”
Magnum Series:
28 50’-0”
36 54’-0”
42 40’-0”
48 41’-0”
For heights above those listed above, consult a
structural engineer for additional structural support for the
DM chimney system. These heights do not reect information
regarding metal ue. Any UL 103 or Class A metal ue can
be used on an Isokern replace. See metal ue manufacturers
installation instructions for information relating to height
requirements/restrictions.
For outdoor applications, there is no minimum height
requirement for the DM chimney ue system. Any UL 103 or
Class A metal ue can be used on an Isokern replace. See metal
ue manufacturers installation instructions for information
relating to height requirements/restrictions.
3
Intended Use Statement
Intended Product Use Statement:
The Fireplaces and DM chimney system 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 listed in the
back section of this manual is designed to sit on a combustible
oor. See pages 46-51 for specic installation requirements.
This replace is intended for use as a supplemental
heat source only and is not intended for heavy use as a primary
heating system.
Overring, 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).
Isokern replaces and the DM chimney system are
conventional indoor or outdoor replaces designed to appear
like traditional masonry replaces. Fireplaces and DM chimney
system units are intended for installation in residential homes
and other buildings of conventional construction.
WARNING:
This replace has not been tested for use with
doors. To reduce the risk of re or injury, do not install
doors. Operable doors are acceptable and if doors are
required by the local authority having jurisdiction, doors
must be kept in the fully open position when the replace
is in operation.
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 specic design preferences. Always maintain
the stated minimum clearances to combustible materials.
Do not violate any specic installation requirements.
The replaces and DM chimney system are tested
and listed by Warnock Hersey (Intertek Testing Service) -
Report No. 3159656MID-008 and Report No. 315653MID006 - to UL 127, and UL 103HT - 2006 respectively.
Fireplace 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).
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.
Suitable standard residential, minimum four inch (4”)
thick, 2500 psi concrete foundations on properly compacted ll
can support installations up to thirty feet (30’) overall height
(brick ledge installations not included)
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 specications
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 specications in this manual and to the prevailing
local building code.
Earthcore is not responsible for other construction
work around the replace unit.
Important: The top plate of the rebox is not meant to be used
as a structural support of any veneer. Please consult structural
engineer for structural support of any veneer bearing weight on
the Isokern top plate.
5
Safety Instructions
1. Before starting the replace and DM 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 Fireplace and DM chimney
installation must comply with all local, regional, state and
national codes and regulations.
3. Fireplaces and DM 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 more often, 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.
10. These replaces are not intended to heat an entire home
or to be used as a primary heat source. They are designed to
ensure homeowner comfort by providing supplemental heat
to the room.
11. Always ensure that an adequate supply of replacement
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 efcient 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 smoking
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.
It is acceptable to use mechanical draft systems, if
the venting companies do the engineering calculations and
make the necessary recommendations for fan size and ue
vent diameter following the guidelines of NFPA 211/2006,
pg. 211-13. Installation of such systems must also follow
the mechanical drafting company’s explicit installation and
operation instructions.
6. Use only solid fuel or natural or LP gas log sets in this
unit. Do not use articial 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 product not specied for use with Isokern
replaces and the DM chimney system unless written
authorization is given by Earthcore. Failure to heed this
warning may cause a re hazard and will void the Earthcore
warranty.
Caution: When used with the replace systems, all gas
log sets must be operated with the damper clamped in the
fully open position. 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
visible or suspected physical damage - consult your Isokern
distributor or authorized Isokern representative for advice.
6
Safety Instructions - (cont.)
14. Modications to replace components not mentioned in
this manual may void claims, listings and approvals and could
result in an unsafe and potentially dangerous installation.
Alterations to the rebox are allowed with prior
written approval and instructions from Earthcore Industries.
The installer indemnies 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 modications of the
replaces.
15. Keep all insulation, vapor barriers, “house wrap”
paper and other insulating type membranes and products,
including berglass, cellulose and other insulation,
(anything that carries an “R” rating) a minimum of three
inches (3”) away from all rebox and chimney surfaces.
See exception. (Figure 34, Page 22)
Exception:
If insulation is used in walls surrounding the
replace, insulation may be installed behind sheathing of
gypsom board, plywood, particle board or other material on
the side facing the Isokern. The facing material cannot be
within 1 1/2” to the replace sidewalls.
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.
7
Warnock Hersey Listing Label
CONTACT BUILDING OFFICIAL PRIOR TO INSTALLATION
ONLY UNVENTED GAS LOG SETS WHICH HAVE BEEN FOUND TO COMPLY WITH THE STANDARD FOR UNVENTED ROOM
HEATERS, ANSI/IAS/AGA Z21.11.2, ARE TO BE INSTALLED IN THIS FIREPLACE
SEE INSTALLATION AND OPERATING INSTRUCTIONS FOR THIS MODEL AND ICC # ESR-2316,
LA.RR # 25483, MEA #2490E.
DO NOT USE A FIREPLACE INSERT OR OTHER PRODUCTS NOT SPECIFIED FOR USE WITH THIS PRODUCT. “WARNING” THIS FIREPLACE HAS NOT BEEN TESTED FOR USE
WITH GLASS DOORS. TO REDUCE THE RISK OF FIRE OR INJURY, DO NOT INSTALL GLASS DOORS. IF DOORS ARE USED, OPERATE FIREPLACE WITH DOORS FULLY OPEN.
WHEN BURNING A DECORATIVE GAS APPLIANCE IN THE FIREPLACE, LOCK THE DAMPER TO THE FULLY OPEN POSITION. ONLY UNVENTED GAS LOG SETS WHICH HAVE
BEEN FOUND TO COMPLY WITH THE STANDARD FOR UNVENTED ROOM HEATERS, ANSI/IAS/AGA Z21.11.2, ARE TO BE INSTALLED IN THIS FIREPLACE. DO NOT OPERATE
AN UNVENTED GAS LOG SET IN THIS FIREPLACE WITH THE CHIMNEY REMOVED.
USE SOLID WOOD FUEL OR LISTED DECORATIVE GAS VENTED OR UNVENTED APPLIANCE. ALSO FOR USE WITH LISTED METAL CHIMNEY.
FIRE-LITE APPLICATION TO USE FTF13 OR EQUIVALENT CHIMNEY ONLY.
(38 mm)
(610 mm)
(229 mm)
(965 mm)
(1219 mm)
(838 mm)
(305 mm)
(305 mm)
N/A
(76 mm)
= 0 in.
= 1.5 in.
= 24 in.
= 9 in.
= 38 in.
= 48 in.
= 33 in.
= 33 in.
= 12 in.
= N/A
= 3 in.
(38mm)
(203mm)
(203mm)
(356mm)
(660mm)
(508mm)
(305mm)
(305mm)
(102mm)
(76mm)
= 0 in.
= 1.5 in.
= 8 in.
= 8 in.
= 14 in.
= 26 in.
= 20 in.
= 20 in.
= 12 in.
= 4 in.
= 3 in.
UNIT FRONT AND ISOKERN CHIMNEY
UNIT SIDES AND REAR
COMBUSTIBLE SHEATHING ABOVE OPENING TOP
SHEATHING OR TRIM TO OPENING SIDES
MANTLE ABOVE OPENING
OPENING TO SIDEWALL
HEA
HEARTH EXTENTION BEYOND FRONT
HEARTH EXTENTION BEYOND SIDES
COMBUSTIBLE FLOOR
INSULATION FROM FIREBOX
28”, 36”, 42”, 48” 60” & 72”
CLEARANCE TO COMBUSTIBLES:
JACKSONVILLE, FL 32256
EARTHCORE INDUSTRIES, LLC.
MADE IN USA
MADE IN DENMARK
COMPLIES WITH APPLICABLE REQ. OF UL 127, ULC S610
MAGNUM: 28” 36” 42” 48” 60” 72”
MODULAR REFRACTORY FIREPLACE
- Facsimile -
FIGURE 1 - ISOKERN STANDARD SERIES
Isokern Fireplace and Chimney Systems are tested and listed to UL standards: UL 127, ULC S610, and UL 103HT.
The listing labels shown in Figures 1 and 2 above outline 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 those shown above is afxed to each replace. Do not remove the listing label from the replace.
Prior to beginning installation, contact your local building ofcial to determine the need to obtain a permit.
FIGURE 2 - MAGNUM SERIES
8
Assembled Firebox & Smoke Dome Dimensions
MODEL A B C D E F G I J MINIMUM FRAMING WEIGHT
36 43” 25 1/4” 63 1/4“ 31 1/2” 36 1/8“ 27 1/4” 33” 20 1/4” 5” (46”W)x(65”H)x(26 3/4”D) 1205 lbs
42 49” 25 1/4” 63 1/4“ 31 1/2” 43 1/8” 33 1/4“ 33” 20 1/4” 5” (52”W)x(65”H)x(26 3/4”D) 1325 lbs
46 53” 25 1/4” 63 1/4“ 31 1/2” 47 1/8“ 37 1/4“ 43” 20 1/4” 5” (56”W)x(65”H)x(26 3/4”D) 1450 lbs
TOP PLATE, MEDIUM
Part No. Model Qty
77 36 1
77 42 1
TOP PLATE, LARGE
Part No. Model Qty
81 46 1
25 1/4”
33”
4 3/4”
10 3/4”
10 3/4”
25 1/4”
4 3/4”
43”
J
C
33”
G
D
A
I
B
E
F
SIDE VIEW
FRONT VIEW
PLAN VIEW
TOP PLAN VIEW
25 1/4”"
14"
10 3/4”
Isokern Standard Series 36, 42 & 46
9
Component List & Dimensions Isokern Standard Series 36, 42 & 46
Part
No.:
22
23
Fireplace
Model:
42
46
Qty:
1
1
21 36 1
A
49”
53”
43”
BASE PLATE
Part
No.:
11
Fireplace
Model:
42
Qty:
2
11 36 2
SMOKE DOME - MEDIUM
Part
No.:
Fireplace
Model: Qty:
13 46 2
SMOKE DOME - LARGE
Part
No.:
34
Fireplace
Model:
42
Qty:
2
34 36 2
TOP-SLOPING
Part
No.:
20
20
Fireplace
Model:
42
46
Qty:
6
6
20 36 6
SIDE WALL
25 1/4”
10 1/2”
Part
No.:
28
31
Fireplace
Model:
42
46
Qty:
3
3
25 36 3
BACK WALL
10 1/2”
5”
Part
No.:
95L
95L
Fireplace
Model:
42
46
Qty:
1
1
95L 36 1
DAMPER SUPPORT - LEFT
Part
No.:
95R
95R
Fireplace
Model:
42
46
Qty:
1
1
95R 36 1
DAMPER SUPPORT - RIGHT
Part
No.:
69
70
Fireplace
Model:
42
46
Qty:
2
2
68 36 2
DAMPER BEAM
A
49”
53”
43”
A
8”
25 1/4”
16”
3”
53”
16”
4”
16”
43”
4”
3”
A
25 1/4”
A:
32 1/4”
37”
26 3/4”
A
10
TOP PLATE, LARGE
56"W x 71"H x 29 1/2"D
FIREPLACE
48
MINIMUM FRAMING:
46"W x 71"H x 29 1/2"D
52"W x 71"H x 29 1/2"D
TOP PLATE, MEDIUM
77
77
PART
NO.:
1 36
42 1
FIREPLACE
Model:
QTY:
81
PART
NO.: Model:
"C"
33”
43"
33”
48
36
42
MODEL
28”
53"
43"
49"
"A"
28"
28”
"B"
SIDE VIEW
48 1/2"
38 3/8"
44 1/2"
38”
38”
38”
"D"
"E"
FRONT VIEW
1
QTY:
PLAN SECTION A-A
TOP PLAN VIEW
E
B
F
28"
“F”
G
A
D
14"
4 3/4"
25 1/4"
32 3/4"
43"
25 1/4"
27 1/4"
AA
33 1/4”"
C
5"
2 3/4"
“G”
69 3/4"
69 3/4"
37 1/4"
69 3/4"
28 *
35 1/2"
28" 22 1/4"
31"
19 3/4"
39"W x 61 1/2”H x 29 1/2"D
60 1/4"
28 1/2”
WEIGHT
1040 lbs
1300 lbs
1420 lbs
1600 lbs
4 3/4"
* Model 28 comes with three (3) sidewalls and some components must be “field cut”.
3"
TOP PLATE, SMALL
36
PART
NO.:
1 28
FIREPLACE
Model:
QTY:
10 3/4"
4 3/4"
25 1/4"
22 1/2"
10 3/4”
10 3/4"
10 3/4"
Assembled Firebox & Smoke Dome Dimensions
Magnum Series 28, 36, 42 & 48
Firebox & Smoke Dome Components List
11
Component List & Dimensions Magnum Series 28, 36, 42 & 48
A
53”
A
A
2”
28”
9 ½”
9 ½”
28”
3”
16”
16”
4”
4”
8”
8”
5”
2 3/4”
25 ¼”
*16”
Front of
Smokedome
(above)
Part
No.:
91
92
93
Fireplace
Model:
36
42
48
Qty:
1
1
1
Part
No.:
90
90
90
Fireplace
Model:
36
42
48
Qty:
8
8
8
Part
No.:
65
66
67
Fireplace
Model:
36
42
48
Qty:
4
4
4
Part
No.:
94L
94L
94L
Fireplace
Model:
36
42
48
Qty:
1
1
1
TOP - SLOPING
BASE PLATE
SIDE WALL
DAMPER SUPPORT (LEFT)
DAMPER SUPPORT (RIGHT)
BACK WALLS
Part
No.:
34
34
34
Fireplace
Model:
36
42
46
Qty:
2
2
2
91 28 1
Size
A:
Cut to 35 1/2”
43”
49”
53”
Part
No.:
11
11
13
Fireplace
Model:
36
42
48
Qty:
2
2
2
SMOKE DOME
12 28 2
Size
A:
32 1/2”
43”
43”
53”
* True Height When Installed
34 28 2
90 28 6
9 ½”
G
5”
12”
* Model 28 Only
Field Cut Back Walls
65 28 3
G:
Cut to 20”
* Cut as shown in the field;
mortar pieces together and
stagger joints when stacking
for installation.
26 3/4”
32 1/4”
37”
9 ½”
G
5”
94L 28 1
Part
No.:
94R
94R
94R
Fireplace
Model:
36
42
48
Qty:
1
1
1
94R 28 1
Part
No.:
68
69
70
Fireplace
Model:
36
42
48
Qty:
2
2
2
DAMPER BEAMS
68 28 2
A:
Cut to 35 1/2”
43”
49”
53”
REAR
FRONT
12
0” CLEARANCE
20”
MIN.
1 1/2”
No Combustible
Underpinnings
1 1/2”
Required Clearance to Combustibles
The replaces and DM chimney systems are tested
and listed for installation with “clearance to combustibles” as
follows:
The Isokern Standard and Magnum Series rebox
side walls and back wall require 1-1/2” clearance. (Figures 3
& 4)
The smoke dome front wall requires 0” clearance.
All DM chimney components require 0” clearance to
combustibles. (Figure 3)
Note: “Combustibles” are dened 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.
Wherever insulation is used, the Fireplaces must
not be placed directly against it. Keep all insulation, vapor
barriers, “house wrap” paper and other insulating type
membranes and products, including berglass, cellulose
and other insulation, (anything that carries an “R” rating)
a minimum of three inches (3”) away from all rebox and
chimney surfaces.
FIGURE 3
Exception:
If insulation is used in walls surrounding the replace,
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing
the Isokern. The facing material cannot be within 1 1/2” to the
replace sidewalls.
Notes:
A. The replaces must sit upon a concrete support
slab designed to bear the total installed weight of the replace
and DM chimney system. These support slabs can have no
wood underpinnings. (Figure 4)
The replaces are rated for installation on a
combustible oor system when using the Fire-Lite application
only. See pages 46-51 for Fire-Lite installation instructions.
B. Concrete support slabs for replaces must provide
the noncombustible hearth extension substrate needed to
support the code required noncombustible hearth extension
nish materials. (Figure 4)
C. All replaces shall have hearth extensions of
approved noncombustible material such as brick, tile, or
stone that is properly supported, with no combustible material
against the underside thereof. Wooden forms used during
the construction of hearths and hearth extensions must 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 noncombustible material and must sit on
noncombustible substrate.
FIGURE 4
13
B
D
FRAMED OPENING
FRAMED OP'G.
C
MINIMUM
A
Rough Framing Dimensions
Rough Framing Dimensions
Model Width Height Depth
A B C
Magnum
Model 28 38 1/2” 61 1/2” 29.5”
Model 36 46” 71” 29.5”
Model 42 52” 71” 29.5”
Model 48 56” 71” 29.5”
Isokern Standard
Model 36 46” 65” 26 3/4”
Model 42 52” 65” 26 3/4”
Model 46 56” 65” 26 3/4”
Notes:
1. “B” includes the 3” thick base plate. “B” is reduced by 3” if the base
plate is eliminated to create a “ush hearth”.
2. “Raised hearth” requires additional rough opening height at “B”
equal to the height of the raised hearth detail.
3. Rough framing dimension for width “A” allows for the required
1-1/2” clearance at the sides of the Fireplaces.
FIGURE 5
4. Rough framing dimension for depth “C” allows for the required
1-1/2” clearance at the back of the Fireplaces.
Corner Location Layout
The following chart of dimensions is intended to aid in the positioning
of a replace in a corner condition where the DM chimney must turn 45°
degrees to align with overhead framing.
Magnum A B C D
Model 28 33 1/2” 18 1/4” 24” 65 1/2”
Model 36 43” 16 3/4” 32” 78 3/4”
Model 42 49” 26 1/2” 36” 83”
Model 48 53” 28 1/2” 39” 85 3/4”
C
A
Isokern Standard
Model 36 43” 49” 35” 72”
Model 42 49” 52” 37” 75”
Model 46 53” 54” 39” 79”
To turn ue 45°, rst set one offset block on the rebox so that
the chimney offsets 3” toward the back of the rebox. (Figure 6)
Set a DM outer casing onto this offset block so that the outer
casing is at 45° to the rebox and square to the overhead framing system.
Run the vertical DM chimney through the overhead framing.
More offset blocks can be used - if necessary to align with
overhead framing - before running the vertical DM chimney outer casing
and liner.
FIGURE 6
Note: Support the third offset down to footings and at each third offset
block thereafter (see pages 33 & 34).
14
ECI
MORTAR
SHIM IF REQUIRED TO
ACHIEVE CORRECT
HEIGHT
FIGURE 7
Assembly Instructions
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 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. (Figure 8)
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 30 pounds (dry measure) of Earthcore
mortar.
FIGURE 8
FIGURE 9
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. (Figure 9)
The shims can be inserted under a component to level
and align it with adjacent Isokern components. Be sure to regrout 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”.
15
FIRST COURSE
SIDEWALL
BASE PLATE
EC
MORTAR
EC
MORTAR
Assembly Instructions - (cont.)
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 mortar.
Installation:
Step 1: Set the base plate in a full bed of Earthcore Mortar at
on a proper concrete support foundation. (Figure 10). 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. (Figure 11)
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. (Figure 12)
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
platform 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. (Figure 13)
FIGURE 10
FIGURE 11
FIGURE 12
FIGURE 13
16
TWO COURSES
BACKWALL
EC
MORTAR
FIRST DAMPER
SUPPORT IN
PLACE
CAST IRON
DAMPER
FRONT DAMPER
SUPPORT
FIGURE 14
Assembly Instructions - (cont.)
Note: At all component placement, be sure to mortar all
component contact surfaces with Earthcore Mortar. Check for
complete sealing of each contact joint while assembly progresses.
Step 3: Continue assembly of the consecutive courses of the
rebox side wall and back wall. (Three courses for the Isokern
Standard Series, Four courses for the Magnum Series). 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. (Figure 14)
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.
(Figure 9)
Any gap created under the wall components during the
Shim leveling process must be lled with mortar to full bearing
against the base plate.
FIGURE 15
FIGURE 16
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: The replaces come with an eight inch (8”) thick damper
beam assembly, a four piece component group that is to be
assembled on top of the rebox sidewalls.
The damper beam assembly consists of two long lintel
pieces and two short damper beam side pieces.
The damper side pieces are designed to sit on the rebox
side wall between the front lintel and the back lintel. Each of the
damper side pieces is designed specically for its own side of the
unit. When properly set, each damper side piece ts ush with
the outside face of the rebox sidewall so that its interior bottom
edge aligns with the interior angle of the rebox side wall that it
sits on. (Figure 15)
The two long lintels are identical in shape, size and in
length, equal to the width of the replace model that they serve.
Properly placed, one lintel is to sit on top of the rebox back wall
and ush with it; the other lintel sits ush with the front of the
rebox, spanning the rebox opening. These components both sit
on their narrow base so that their beveled face points down and
into the rebox interior. (Figure 16)
Be sure to mortar all damper beam components to the
top surfaces of the rebox.
Mortar the contact surfaces of each damper side
component where it meets the front and back damper beam lintel
components.
17
DAMPER
1"
FRONT
REAR
REAR
FRONT
Damper Beam
END
END
17”
10 3/4”
NOTE: Magnum Series Shown for
Illustration only. Isokern Standard
Series Front Smoke Dome Will Sit
Flush With Front of Damper Beam
Assembly Instructions - (cont.)
Step 7: With the damper beams assembled and mortared
together, set the cast iron throat damper (unless another
damper type is being used) on top of the damper beam and
over the smoke chamber opening. The cast iron damper’s
operating plate should face toward the rear of the replace.
(Figure 17) The ange at all four sides of the cast iron damper
should be supported by the damper beam’s top surface.
Before adjusting the cast iron damper to its nal
position proceed to Step 8.
Note: A Damper is not required for exterior installations.
Step 8: Position the cast iron damper so that its front ange
is approximately one inch (1”) away from the inside face of
the front smoke dome component. (Figure 17)
Run a thin bead of mortar around the four sides of
the cast iron damper or tack the corners of the ange to avoid
movement of the damper as it gets opened and closed. Set
the rear smoke dome component across the damper beam
in a bed of mortar and ush with the back face of the back
damper beam lintel. (Figure 18)
Set the Isokern Standard front smoke dome
component in mortar across the front damper beam and ush
with it. Set the Magnum front smoke dome component in
mortar accross the front damper beam and 2 -1/4 inches
back from the front of the front damper beam lintel. This
placement should create a space of 17 inches (17”) between
the front and rear smoke dome components.
Step 9: Position the smoke dome’s sloping sidewalls at each
end of the smoke dome components. (Figure 18)
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. The smoke dome
sloping sidewalls have a beveled bottom edge so that they
will sit tight onto the at top of the damper beam assembly.
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.
(Figure 19)
FIGURE 17
FIGURE 18
Step 10: Make sure that all component contact surfaces have
been properly sealed with approved mortar.
Check smoke dome front and rear 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 11: Set the top plate into position on top of the smoke
dome wall assembly. (Figure 19)
One side of the top plate shows a thickened center.
This side is the bottom face.
The ue hole in the top plate is centered in the
smoke dome from side to side but is offset from front to back,
the center being 10 3/4” from the back of the rebox.
FIGURE 19
18
Flex Duct To Fireplace,
(All Parts Noncombustible)
Exterior
Wall
Exterior Air Vent
With Dress Plate
Typical Placement of
Gas or Electric Conduit
(See Detail Below)
Supply Air Ventilation
(If Required By Code)
CAUTION:
All access holes must be
grouted with mortar - after line
or conduit feed to seal any
gaps or cracks around line
feed conduits
Fire Brick Side
Gas or Electric
Conduit
NOTE: Fill Any Gaps
Around Conduit With Mortar
FIGURE 20
Access Modication
Through-Wall Accesses:
1. Combustion Air Inlet: Combustion air inlet kits though
not required by Earthcore may help improve replace
operation in homes tightly sealed and with other ventilating
appliances installed (Figures 20 & 21). 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. Local building codes prevail and
should be checked before installation.
Generic replace combustion air kits typically
consist of a sliding stainless steel access door afxed 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
by core drilling an appropriately sized hole at the selected
rebox location. Keep the top of the 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 side wall and
must be connected to metal pipe (by others) - either exible
or rigid - that leads to the source for outside combustion air,
as directly as possible from the replaces (Few to no bends)
with a maximum length of sixty feet (60’).
FIGURE 21
FIGURE 22
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 of the rebox by drilling an
appropriately sized hole using a masonry drill bit (Figure 21).
3. Electrical Line Feed can be routed through the rebox
side walls by drilling an appropriately sized hole using a
masonry drill bit (Figure 21). Be sure to follow the gas log
Appliance Manufacturer’s explicit electrical line connection
instructions for vented masonry replace installations. Gas
line and electric line must be fed through separate access
holes. Be sure to ll any gaps around conduit with EC mortar.
(Figure 22)
19
Fire Brick Installation
Fire Brick Installation:
The manufacturer requires that the replace reboxes
be lined with a minimum one and one-eighth (1-1/8”) thick
re brick. Thicker re brick may be used as an option. The
pattern for the re brick lining is an owner option. Standard N
or S type brick mortar is suitable mortar for the replace.
Fire brick mortar needs to be suitable to both adhere
the re brick to the inside of the rebox and to create the
nished face joints of the brick work. Based on a history of
eld applications and experience, a suitable mortar would be
as follows:
Mix:
* 1 bucket masonry mortar (S or N type)
* 5 lbs Earthcore mortar
* Six parts sand (1 1/2 bucket)
* One part Fire Clay (optional)
* Water to a sticky, toothpaste consistancy
These instructions may vary because of different
climates and conditions. The use of good masonry practices
for your area should also be considered. It takes about 25 lbs.
of mortar mix (dry measure) to re brick line a replace.
Installation Instructions:
1. Wet mop the inside of the replace with a damp
sponge to remove dust and loose particles from the interior
before re-bricking.
Expansion
1/2” Gap
FIGURE 23
Expansion
1/2” Gap
HINT: Dip each rebrick into water before applying.
2. Face joint dimensions of 1/4” to 3/8” in the brick
work is recommended and has the best appearance. Other face
joint dimensions are acceptable however smaller joints may
not leave room for heat expansion of re brick.
3. Start the re brick at the front edge of the oor
of the Isokern rebox, proceeding inward toward the back.
Let the oor brick gap approximately 1/2” off the back wall
and side walls. This air space allows heat expansion of the re
brick and is to be left empty of mortar. (Figure 23)
4. Next, apply re brick to the back wall of the unit.
The back wall re brick covers the 1/2” expansion gap left at
the brick oor along the back wall of the rebox. (Figure 25)
5. 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. The side wall re brick, when completed, covers
the 1/2” expansion gaps where both the oor re brick and the
back wall re brick were held off the units side walls. (Figure
24)
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.
Earthcore 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 brick in replaces.
Fire Brick Floor
(Built First)
FIGURE 24
No Gaps
Fire Brick Floor
and Back Wall
(Built First)
FIGURE 25
20
Magnum Series
Flush Wall Finish Detail
Framing Protrudes
Past Firebox Front
FIGURE 26
8” Minimum
Noncombustible
Facing Material
To Span Framing
Members
Isokern Standard
Series
FIGURE 27
Fireplaces are designed to be installed so that the rough front face of the rebox and damper beam project into the room approximately
one-half inch (1/2”) beyond the face of the rough framing members that create the room’s wall surface. The Magnum smoke dome
front sits two and three-fourths inches (2-3/4”) back from the rough face of the rebox and damper beam. This set back dimension
allows for one and one-half inch (1-1/2”) framing plus one-half inch (1/2”) thick wall board to pass in front of the smoke dome and
at the same time align ush with the room face of the Magnum damper beam. Set in this position, framing and wall board are kept
to the required eight inches (8”) above the rebox opening top (Figure 26).
Drywall Flush with
Firebox Front
FIGURE 28
The Isokern Standard smoke dome front sits ush with the rough face of the rebox and damper beam. Eight inches (8”) of
noncombustible facing material must span framing members for drywall to keep the required eight inches (8”) above the rebox
opening top; It is after this noncombustible material that framing members can be placed as shown above. Eight inches (8”) on each
side of the rebox opening is also required to be covered in noncombustible material. (Figure 27)
Important: Do not build a frame wall in front of the Magnum or Isokern Standard rebox and damper beam. (Figure 28)
21
Required Clearances (when sheathing protrudes beyond front of rebox)
FIGURE 29
Plywood
Sheathing
Noncombustible
Facing
1 1/2” MIN TO
COMBUSTIBLE FRAMING
8”
MIN
8”
MIN
FINISHED OPENING
WOOD (COMBUSTIBLE)
SHEATHING
8”
MIN
FIRE
BRICK
8”
MIN
8”
MIN
FIGURE 30
Combustible sheathing such as plywood and particle board may be used to cover the front face of the smoke dome and be
in direct contact with it. If sheathing protrudes in front of the rebox, application of such combustible sheathing must assure that
the sheathing is held a minimum of eight inches (8”) away from each side of the nished rebox opening and a minimum of eight
inches (8”) above the top of the nished rebox opening. (Figure 29 & 30)
Do not build a combustible framed wall out in front of the rebox.
If sheathing and framing are to be installed across the front face of the rebox smoke dome, then the framing and sheathing
must be held a minimum of eight inches (8”) above the top of the rebox opening. This means that framing and sheathing across the
smoke dome front must be kept at or above the damper beam.
22
1 1
/2"
MI
N.
1 1/2”
MIN
8”
MIN
1 1/2”
MIN
8”
MIN
Hearth Extension
20” min
12”
min
12”
min
Insulation Behind sheathing
with 1 1/2” Clearance
When Supported
3” min When
Unsupported
1 1/2”
min
1 1/2”
NOT PERMITTED
1 1/2”
MIN
Do Not Place Sheathing
WIthin the 1 1/2” Required
Clearance to Combustibles
COMBUSTIBLE
FRAMING
1 1/2”
MIN
1 1/2”
MIN
1 1/2”
MIN
FACE OF
COMBUTIBLE
FRAMING
1 1/2”
MIN
1 1/2”
MIN
FACE OF
COMBUTIBLE
FRAMING
8”
MIN
8”
MIN
FIGURE 31
FIGURE 32
Required Clearance to Combustible Framing
Fireplaces are tested and listed for one and one-half
inch (1-1/2”) clearance to combustible framing material at the
rebox sides and back.
Installation and use practices that are beyond the
control of the manufacturer* can result in situations where
clearance requirements (as determined through testing and
as stated by the manufacturer) are not maintained due to
construction subsequent to the installation of the Isokern
unit. It is the general contractor’s responsibility to assure that
listed clearances to combustible framing and to insulation
are maintained throughout the construction of the project
subsequent to the installation of the Isokern unit.
To avoid causing a re resulting in damage to property,
personal injury or loss of life, do not pack or ll the required air
spaces with insulation or other material. No material is allowed
in these areas. (Figures 31 & 32)
*The manufacturer is not responsible for installation and use
practices that are beyond the scope of the product as dened in
the product listing and in the installation manual.
The rebox backwall, side walls and the smoke dome
back require 1 1/2” clearance to combustibles. (Figure 33)
Keep all insulation, vapor barriers, “house wrap”
paper and other insulating type membranes and products,
including berglass, cellulose and other insulation,
(anything that carries an “R” rating) a minimum of three
inches (3”) away from all rebox and chimney surfaces. See
exception. (Figure 34)
FIGURE 33
FIGURE 34
Exception:
If insulation is used in walls surrounding the replace,
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing
the Isokern. The facing material cannot be within 1 1/2” to the
replace sidewalls.
When Fireplace installations are surrounded by walls
that are to be insulated, the walls must have enough clearance
to the Isokern unit in order to maintain the three inch (3”)
minimum clearance to insulation for unsupported insulation.
(Figure 34)
Never spray the Fireplaces with any type of sealer,
insulation or other material.
23
Flush Wall Fire Brick Finish Detail
Drywall Flush With
Firebox Front
Noncombustible
Facing Material
1 1/2”
1 1/2”
8”
Min
FILL ANY GAPS
WITH EC MORTAR TO
AVOID FA LSE CHIMNEYS
Recommended Fire Brick Detail: When drywall is
the wall nish at the rebox face and ush with the rough
face of the rebox and damper beam, it is recommended
when installing the required re brick lining to the interior
of the rebox, that the leading edge of the re brick - at the
oor and at the side walls of the rebox - be set ush with the
rough rebox front. This will aid in the overall t and nish
of the replaces front when the code required noncombustible
nished facings are applied.
This alignment of re brick application as shown,
(Figure 35), allows the re brick lining to be in the same plane
with the room’s wall nish surface. With the re brick set in
this fashion the noncombustible nish facing material can be
set tight against the leading edge (or, “room edge”) of the re
brick at the sides of the replace opening. At the same time
the nished facing material can lay at against the room’s
nished wall surface.
Important: Since there is no re brick set along the top of
the rebox opening, when setting the noncombustible nished
facing material (code required and supplied by others) across
the top of the rebox opening there may be a gap between
the back of the noncombustible nish material and the rough
front face of the replace damper beam.
Be sure to check for and ll any such gap with
noncombustible Earthcore Mortar in conjunction with
placement of the code required noncombustible nish facing
material set across the top of the rebox opening. (Figure 36)
FIGURE 35
WARNING: Avoid false chimneys.
Important: Failure to seal any gaps between the front face
of the damper beam and the back of the noncombustible
nished facing material will create what is known as a “false
chimney”. A “false chimney”, in this case, is the narrow gap
(mentioned above) between the back of the noncombustible
facing material at the top of the rebox opening and the rough
front of the replace damper beam. If left unlled this gap
creates a “false chimney” which can draw smoke, heat and re
out of the rebox into the space behind the noncombustible
nish facing and on up into overhead framed spaces causing
a re hazard.
It is acceptable to apply noncombustible nish
facing to the front and below the rebox opening to create
an arched look, etc. When doing so, make sure to check
for and ll any such gap with noncombustible Earthcore
Mortar in conjunction with placement of the code required
noncombustible nish facing material.
NOTE: You must still keep a minimum 8” from the rebox
opening to any combustible materials.
FIGURE 36
24
4"
6"
BEARING
4 x 6 STEEL “L”
ISOKERN UNIT WIDTH DIM'N.
EXTENT OF STEEL “L”
MASONRY VENEER
MASONRY VENEER
ALIGN
ALIGN
3 1/2"
COMBUSTIBLE
SHEATHING
END OF ISOKERN
FIREBOX UNIT and
STEEL “L” ALIGN
2"
MIN
4 x 6 STEEL
“L” ANGLE
2"
MIN
2"
MIN
Interior Masonry Veneer Fireplace Finishes & Clearances
FIGURE 37
Stucco Finish Application:
Any nish can be applied to an Isokern replace however with each nish there are different application techniques which
can help with the longevity of your nish. When applying a stucco nish to the Isokern material, it is recommended that a scratch
coat is applied rst to provide a strong base for the system. It is embedded in a wire lathe (not felt backed) which is screwed with
care to the replace unit. Use 1 1/4” Tapcon screws to attach the lathe to the rebox using the minimum amount needed to secure
the wire lathe. A brown coat is applied next to create an even surface for the nish coat. The nish coat is applied last, creating the
decorative nish on the wall surface.
25
COMBUSTIBLE
SHEATHING
MIN. CLEARANCE
2"6"
4" 2"
BEARING
FIGURE 38
Masonry Veneer Construction Details
Brick, stone or other masonry veneer nished fronts to
replaces are possible. Special attention is required with regards
to:
(1) the placement of the proposed masonry veneer facing
and its interface with the re brick lining, and
(2) the masonry veneer and clearance to combustible
framing and sheathing from any steel “L” support used in the
masonry veneer around the front of the replace unit behind the
veneer facing.
Any proposed brick, stone or other masonry veneer
facing must have sufcient foundation to support the full weight
of the veneer work. This may require review by a local structural
engineer prior to construction.
MIN. CLEARANCE
BRICK
VENEER
The veneer facing, when installed, must present a tight
seal with the leading edge - the room edge - of the re brick lining
at the sides of the rebox opening. (Figure 39)
A steel “L” will need to span the top of the nished
replace opening to carry the masonry veneer as it spans over the
rebox opening. (Figure 37)
By code requirement this steel “L” must have a minimum
four inch (4”) end bearing. This bearing surface area shall be
provided in the veneer work. (Figure 39) It is important that the
steel “L” is set tight against the damper beam front and set in a
mud joint to avoid creating a “false chimney” between the back of
the steel “L” and the damper beam front. (Figure 39)
Steel “L” or “angle” used to support masonry veneer
as it spans the rebox opening must, in all cases, have a two
inch (2”) minimum clearance to all combustible materials. The
vertical leg of the steel “L” cannot exceed six inches (6”) in
height.
Note: Properly placed combustible sheathing is kept a
minimum of eight inches (8”) away from the rebox opening
sides and top.
Important: Combustible framing members, normally set at
one and one-half inch (1-1/2”) clearance to the sides of the
rebox must be moved to at least two inch (2”) clearance to the
rebox sidewalls to maintain minimum two inch (2”) clearance
to the steel “L” to avoid a potential re hazard.
Moving framing members two inches (2”) away from
the rebox side walls will maintain the minimum required two
inch (2”) clearance from the steel “L” and, at the same time
allow full four inch (4”) end bearing required for the steel “L”.
(Figure 38)
AIR SPACE
COMBUSTIBLE
SHEATHING
MASONRY VENEER
2"6"
4x6 STEEL “L”
MASONRY BEYOND
MORTAR JOINT
FIGURE 39
26
Non-combustible Finished Facing Requirements &
Clearance to Combustible Trim
Hearth Extensions:
All Fireplaces shall have hearth extensions of brick,
concrete, stone, tile or other code approved noncombustible
material. Suitable hearth extension material for the replaces
shall be placed on the hearth extension’s noncombustible
substrate and must extend to at least twenty inches (20”) in
front of the replace’s nished opening and must extend to
at least twelve inches (12”) beyond the sides of the nished
replace opening. (Figure 41)
WARNING: The noncombustible hearth extension, by code,
must sit on noncombustible substrate which shall have no
wood underpinnings.
This means that off-grade wood oor systems shall be
constructed in such a way that all wood oor joists and
subooring shall stop twenty inches (20”) out from the front of
the rebox. (Figure 40)
Mantle and Mantle Shelf Clearances: Fireplaces are subject
to the same building code safety clearances to combustible
trim as with any radiant heat replace.
All combustible trim shall be kept at least eight inches
(8”) from the nished replace opening.
Combustible trim located along the sides of the
replace opening, which project more than one and onehalf inches (1-1/2”) from the face of the replace, shall have
additional clearance from the eight inches (8”) equal to the
projection.
Combustible projecting mantles - up to twelve inches
(12”) of projection - shall not be placed less than fouteen
inches (14”) from the top of the replace opening. Combustible
mantles which project more than twelve inches (12”) from the
face of the replace, shall have additional clearance from the
fourteen inches (14”) equal to the projection.
COMBUSTIBLE
MANTLE SHELF
20” HEARTH
EXTENSION
FIGURE 40
12"
14”
8”
COMBUSTIBLE
FLOOR SYSTEM
ADJOINING
ROOM WALL
Note: The local authority having jurisdiction may require
greater clearances for projecting combustible mantle shelves.
Be sure to check local building codes regarding required
clearances to projecting combustible mantles.
Adjoining Walls. Side walls and walls to rooms adjoining
replace installations cannot be closer than twenty-six inches
(26”) to the nished replace opening. (Figure 41)
Note: “Clearance to Combustible Trim” are those distances
required to ensure that a replace mantle or facing will not
catch re. In most cases the distances should also be adequate
to prevent any discoloration or warping due to heat. However
each installation presents a unique and completely different set
of circumstances involving many variables.
These include paint or nish composition, previous
exposure to heat, methods and quality of construction, air ow
patterns, etc. Because of these variables, the manufacturer does
not guarantee that heat warping or discoloration will never
occur.
FIGURE 41
27
26"
HEARTH
EXTENSION
4"8"
20"
12”
Concrete Support
The Fireplaces are not rated for installation on a combustible
oor system unless used in the Fire-Lite application. Fireplaces must be
built upon a concrete support slab with no wood underpinnings. Proper
reinforced concrete support slab for replace installations may include
the following types:
1. Slab on grade: standard residential, minimum four inch (4”) thick, 2500
psi concrete foundation on properly compacted ll. This type foundation
can support Isokern installations up to thirty feet (30’)* overall height
without additional structural support. (brick ledge installations not
included) (Figure 42)
* Minimum height. See page 3 for specic models.
2. Slab-on-grade foundations, thickened and reinforced: for additional
load carrying. (Figure 43)
FIGURE 42
FIGURE 43
3. Off-grade slab on foundation walls and footings
Projects with off-grade oor systems as well as upper story
installations require this type of support. When building off-grade
support slabs the code required hearth extension substrate should be
built as a continuation of the support slab for the replace unit. (Figure
44). Supports for off grade slabs must be concrete or steel and capable of
supporting the slab, Isokern unit and the chimney.
For multi-oor and back-to-back installations proper weight
computation on an individual basis is required. Consult a local structural
engineer for load bearing requirements.
Important: Foundations and footings must meet local code and be
approved by the local building authority. For any foundation design
and load requirements check with a local structural engineer. It is the
responsibility of the General contractor to insure adequate foundations.
Fireplace weights* and “foot print” areas:
The total replace weight and footprint for each model listed below
includes: Fireplace pumice components only:
A. Model Magnum 28: 1040 lbs. - 35.5” x 28” = 6.90 sf.
B. Model Magnum 36: 1300 lbs. - 43” x 28” = 8.36 sf.
C. Model Magnum 42: 1420 lbs. - 49” x 28” = 9.52 sf.
D. Model Magnum 48: 1600 lbs. - 53” x 28” = 10.3 sf.
A. Isokern Standard 36 - 1205 lbs. - 43” x 25 25” = 7.54 sq. ft.
B. Isokern Standard 42 - 1325 lbs. - 49” x 25.25” = 8.59 sq. ft.
C. Isokern Standard 46 - 1450 lbs. - 53” x 25.25” = 9.29 sq. ft.
FIGURE 44
*Totals are exclusive of any chimney components. See page 30 for
Isokern DM chimney component weights.
“Footprint” areas listed above are base plate dimensions
for each model and are exclusive of manufacturer’s required hearth
extension areas. See page 26 for hearth extension dimensions.
Note: Additional support slab area may be required at the side or back
of the replace unit to provide bearing for structural supports to a DM
offset chimney sequence. (See pages 33-35 for offset chimney support
requirements.)
28
DM Chimney System: General Information
The DM chimney system is a dual module, refractory masonry
chimney system. It is composed of two precast, mating components,
the outer casing block and an inner liner.
General Information:
This chimney system is designed for installation in accordance
with the National Fire Protection Standard for Chimneys and Solid
Fuel-Burning Appliances, NFPA 211 and in accordance with codes
such as ICC, BOCA Basic/National Codes, the standard Mechanical
Code and the Uniform Building Code.
Note: Illustrations shown reect “typical” installations with nominal
dimensions and are for design and framing reference only. Always
maintain minimum required clearances to combustible materials and
do not violate any specic installation requirements.
Required DM Chimney Clearance:
The DM chimney system, rated UL 103HT, is listed for zero
clearance to normal construction materials.
The DM chimney system may be enclosed in a wood chimney
chase at zero clearance to wood framing members.
WARNING: Keep all insulation minimum of three inches (3”)
away from all DM chimney components. If insulation is used in
walls surrounding the chimney, insulation may be installed behind
sheathing of gypsom board, plywood, particle board or other material
on the side facing the Isokern material. The facing material cannot be
within 1 1/2” to the chimney outer casing. Failure to use manufacture’s
provided parts or variations in techniques and construction materials
or practices other than those described in this manual may create a re
hazard and void the limited warranty.
Note: A restop is required wherever a chimney passes between one
zone of a building to another. Ex: When the chimney passes through
the ceiling into the attic area, there must be a sealed area around the
chimney so there isn’t a chaseway for a re to get to the attic.
When lateral support is required for DM chimneys, the
framing members will be in contact with the DM chimney system.
Important: “Combustibles” are dened as “normal construction
materials” and are considered to be: framing materials, particle board,
mill board, drywall, plywood paneling, plywood sub ooring, and
wood ooring.
Mechanical Vent Systems:
It is acceptable to use mechanical draft systems, if the venting
companies do the engineering calculations and make the necessary
recommendations for fan size and ue vent diameter following
the guidelines of NFPA 211/2006, pg. 211-13. Installation of such
systems must also follow the mechanical drafting company’s explicit
installation and operation instructions.
29
DM Chimney Component List & Dimensions
16 1/2” 14”
6” HIGH
INNER STARTER
LINER
16 1/2”
12” HIGH
INNER LINER DM 54
Note: DM 44 12” High Inner Liner will have a 6” or 8” Diameter Flue hole.
21 1/2” 21 1/2”
6”
12” or 14”
12”
12”
26 1/4”
SMALL
CROWN CAP
37 1/2”
LARGE
CROWN CAP
26 1/4”
13/16”
3”
37 1/2”
13/16”
3”
OUTER CASING
21 1/2”
25”
OFFSET BLOCK
OFFSET BLOCK
STACKED
11”
3”
6”
3”
31 1/2”
BRICK LEDGE
31 1/2”
3”
30
DM Chimney: Component Weights
Isokern DM Chimney Weights:
Total installed Isokern DM chimney weight will vary
according to each specic installation. Total installed chimney
weight will be based on the overall height and the conguration of
the chimney system.
Chimneys may be straight vertical stacks of DM outer
casing and inner liner but may also include the use of offset
chimney blocks, brick ledges, chimney reinforcement, brick/stone
veneers, cement crown caps and chimney shrouds.
The DM chimney component weights are as follows:
Small crown cap: 80 lb.
Large crown cap: 100 lb.
Brick ledge: 110 lb.
14” diameter inner liner: 45 lb.
Outer casing block: 90 lb.
Offset block*: 84 lb.
*Construction of an offset block sequence will shift a portion, if
not all of the chimney load off of the rebox and smoke dome.
Additional reinforced concrete footing and slab area may need to
be provided adjacent to or as a continuation of the primary support
slab area for bearing the steel or masonry support required for an
offset sequence. (See pages 33-35) Consult a structural engineer
for specic, individual structural requirements.
Notes:
Plan chimney conguration carefully before constructing
the required reinforced concrete support foundation for the
replaces. Be sure that enough structural masonry area is available
to support any offset chimney sequence included in the proposed
chimney design. (See Page 35)
SMALL
CROWN CAP
LARGE
CROWN CAP
BRICK LEDGE
Earthcore is not responsible for site specic structural
support details and load specications for replaces and DM
chimney system installations. Consult local structural engineer
for proper job-specic support structure design, sizing and load
bearing specications.
Unless otherwise noted, all oor drawings in this manual
are merely illustrations to indicate the presence of an underlying
noncombustible support structure to the replace installation.
INNER LINER
OUTER CASING
OFFSET BLOCK
31
10 3/4”
OUTER CASING
12” HIGH
INNER LINER
6”HIGH STARTER
INNER LINER
3 3/4”
Magnum Fireplace Shown For Illustration Purposes Only
FIGURE 45
FIGURE 46
FIGURE 47
FIGURE 48
DM Chimney System: Installation Instructions
DM Chimney Alignment:
Where the chimney run is to be a straight vertical run
the DM outer casing block sits directly onto the Isokern smoke
dome lid. The DM outer casing block, properly set is intended
to be ush with the back face of the rebox smoke dome
assembly (Figures 48 and 49 ).
Set in this way the DM outer casing block will sit
three and three fourths inches (3-3/4”) back from the front face
of the smoke dome. (Figure 48).
This total set-back distance makes it possible for
a three and one-half inches (3-1/2”) thick bearing header to
pass over the rebox smoke dome assembly and for the DM
chimney to run straight up the back side of the bearing header
(Figure 49).
Installation of the DM chimney:
Begin straight DM chimney runs by setting a DM
outer casing block in a bed of mortar on top of the smoke dome
lid with the outer casing block centered on the lid from side to
side and ush with the back of the smoke dome lid.
Be sure that the outer casing block aligns with the ue
hole in the smoke dome lid.
Next set the DM inner liner’s six inch (6”) tall starter
piece (Figure 47) inside the rst outer casing block. The
“factory” version of the six inch (6”) tall inner liner starter
piece has a female end and a at end. Set this inner liner starter
with the at end down. Set the downward end into Earthcore
Mortar so that it is fully sealed to the smoke dome lid.
WARNING: Do not mortar the air space between the inner
liners and the outer casing blocks.
FIGURE 49
Starting with the six inch (6”) tall inner liner starter
piece creates six inch (6”) staggered horizontal joints between
the inner liner and the outer casing block.
Both the outer casing block and the inner liner
components have tongue and groove type detailing on each
end to assure alignment and interlock of the pieces as they are
stacked and glued together.
Notes: If the “factory” inner liner starter piece is broken or
otherwise unavailable then a full twelve inch (12”) tall inner
liner piece can be cut to six inches (6”) in height to make an
inner liner starter piece.
DM chimney inner liners can be stacked with either
the male or the female end up. In either case start the inner
liner stack with a six inch (6”) starter piece.
After setting the DM inner liner starter piece, apply
mortar to the top of the starter liner. Continue the straight
chimney run by placing a full height inner liner onto the six
inch (6”) starter liner. The top of this full height inner liner
will sit 6” above the top of the outer casing block that was
previously set.
32
DM Chimney System: Lateral Support
This six inch (6”) offset between joints of the inner
liner stack and the joints of the outer casing stack continues to
the top of the chimney run.
Continue the straight vertical DM chimney by setting
an outer casing block onto the mortared top surface of the
preceding outer casing. The grooves on the bottom end of the
upper outer casing block t onto the tongues on the top of the
lower outer casing block. This assures proper alignment of the
two components.
Next place a full height inner liner onto the mortared
top end of the previously set inner liner. Proceed this alternate
stacking of outer casing blocks and inner liners until the desired
height of the ue is attained. Mortar all outer casing blocks
together and mortar all inner liners together. Do not mortar or
ll the space between the outer casing and the inner liner.
Lateral Support for DM Chimneys:
Though not required, it is recommended that where
the DM chimney is built up along an exterior wall the vertical
chimney system can be connected to the structural wall system
at a minimum of four foot (4’) intervals. This connection can
be made using 18 gauge strap ties (Simpson Strong Tie CS coil
strap, or equivalent).
Starting on one side of the DM chimney, at four foot
(4’) intervals up the structural wall adjoining the chimney,
connect one 18 gauage strap tie to the structural wall with
two, three inch (3”) #8 (minimum) wood screws or masonry
anchors, as appropriate.
Next fold the strap around the three exposed sides of
the outer casing. Connect the strap to each of the three outer
casing faces with two, one and one-half inch (1-1/2”) long
masonry anchors, such as “Tapcon” or “Titen” screws. Fasten
the strap back to the structural wall with two three inch (3”)
# 8 (minimum) wood screws or masonry screws, as appropriate.
(Figure 50)
Where DM chimneys are built up from the interior
walls the DM chimney outer casing block is to be laterally
braced at ceiling and roof penetrations.
Pressure treated two inch (2”) by four inch (4”)
blocks, set at each side of the ue between the trusses or rafters
and fastened to the pre-engineered roof trusses or rafters with
two 16d common nails at each end, provides lateral support,
parallel with the framing. Additionally, a two inch (2”) by four
inch (4”) by six feet (6’) minimum pressure treated member
(“rat run”) installed on each side of and butted up to the outer
casing block will provide lateral support perpendicular to the
direction of the truss or rafter framing system.
Fasten the perpendicular member with two 16d
common nails to each intersecting truss or rafter. The
perpendicular bracing should be installed on the top side the
ceiling level framing as well as on the bottom side of the rafters.
(Figure 51)
Note: A restop is required wherever a chimney passes between
one zone of a building to another. Ex: When the chimney passes
through the ceiling into the attic area, there must be a sealed
area around the chimney so there isn’t a chaseway for a re to
get to the attic.
FIGURE 50
FIGURE 51
33
3”
FIGURE 52
DM Chimney System: Offset Block
DM Offset Chimney Block:
For vertical DM chimney to bypass overhead obstructions,
the Isokern offset chimney block is used. Offset blocks are six inch
(6”) thick, single module chimney components, measuring twenty-one
and one-half inch (21-1/2”) wide by twenty-ve inches (25”) long. The
fourteen inch hole passes through the block at thirty (30°) degrees. An
offset chimney block can be set as the rst ue component on top of
the replace smoke dome.
FIGURE 53
When building offset sequences it is necessary to support
the third offset block in the sequence and every third offset block
thereafter. When using only one or two offset blocks no additional
support is required.
Offset sequences are best when built as low as possible in the
chimney run to maximize performance. Do not make support columns
of brick, stone or wood. All support columns must bear onto proper
noncombustible foundations.
Isokern Offset Chimney Block Installation:
Isokern offset chimney blocks are stacked in a stair step
fashion with each successive block overhanging the previous offset
block by three inches (3”), allowing the ue to rise at an angle of thirty
(30°) degrees off of vertical. (Figure 52)
When building offset sequences check the interior ue
alignment as each offset block is set to avoid creating overhanging
ledges on the inside of the ue. Such internal overhangs will inhibit
ue drafting.
Each offset block is to be set fully in a bed of Earthcore Mortar,
completely sealing each offset block to the underlying component.
Offset chimney block sequences can be built to shift the
chimney run to the left, right or to the rear of the rebox/smoke dome
assembly. Offset blocks can also be set in a spiraling rotation, thus
moving the chimney to a point that is diagonally away from its starting
point.
Offset blocks require a 1 1/2” clearance to combustible
framing.
FIGURE 54
Offsets to the Left or Right:
When offsetting chimneys to the left or right of the rebox it
is not possible to build a support column directly under the third offset
block. To create proper support, construct a support column against
the rebox from bearing up to the level of the smoke dome. Bridge
from the column over to bearing on the smoke dome with two pieces
of four inch (4”) by four inch (4”) by ve-eighths inch (5/8”) steel
angle. On the steel angles build a masonry or steel support column up
to the underside of the third offset block in the sequence. (Figure 53)
Note: For offset chimney block sequences that clear the side
wall of the rebox below, it is allowable to support the rst offset
block that clears the the rebox side wall and then to proceed with
supports at each third offset block thereafter. (Figure 54)
34
DM Chimney System: Offset Block (cont.)
With straight chimneys the front of the DM outer
casing block sits approximately three and three-quarters inch
(3- 3/4”) back from the front of the smoke dome. This allows
for a nominal 4” thick wall to be ush with the room side face
of smoke dome assembly while the DM chimney passes up the
backside of the wall.
For a nominal 2” by 6” wall thickness the chimney can
be offset 3” rearward. Set the rst DM outer casing block ush
to the back end of this offset block. This will leave a distance of
6-3/4” from the face of the rebox smoke dome assembly to the
face of the DM outer casing block. This allows for the smoke
FIGURE 55
dome to sit ush with the inside face of the 2” by 6” wall and the
straight chimney to run up the outside of the wall. (Figure 55).
For a wall thickness of 9”, nominal 8” CMU plus 1-1/2”
furring strip - rst set two offset chimney blocks in sequence,
rearward. This leaves a distance of 9-3/4” from the front face of
the smoke dome to the front face of the DM outer casing once
the outer casing block is set in position. (Figure 57)
Greater offset distances can be accomplished by
building with more offset chimney blocks. (Figure 56)
Offset block Support Foundations:
FIGURE 56
FIGURE 57
It is required that every third Isokern offset chimney
block in the sequence be supported down to footings via concrete
block or steel support columns.
Plan replace and DM chimney systems carefully
before foundations are laid to assure that proper footings are
available to support Isokern offset blocks chimney run.
Calculate Offset Distance:
To calculate the distance of Isokern offset chimney travel in a
straight line to the right, left or to the rear of the rebox/smoke
dome assembly, proceed as follows:
Refer to Figure 58: temporarily dry set a DM outer
casing block in its proper location on top of the completed
rebox/smoke dome assembly as though starting a straight
chimney.
If the offset sequence is to move to the left then, starting
from the right side of the temporary DM outer casing measure
left ward to the far face of the overhead obstruction that needs to
be bypassed by the vertical chimney run.
For accurate measuring drop a plumb line down from
the far face of overhead obstruction to the level of the top of
the smoke dome assembly. Measure from the far side of the
temporary DM outer casing to the plumb line.
This measurement, taken in inches and divided by
three (three inches of horizontal travel per offset block) gives
the total number of offset blocks needed to accomplish the
required travel distance.
To calculate the height that the offset block
sequence will require, take the total number of offset blocks
needed to accomplish the travel distance (described above)
multiplied by 6”. This number is the height (inches) that the
offset sequence will require.
35
PLUMBLINEPLUMBLINE
MEASURE
TRAVEL
DISTANCE
OVERHEAD
OBSTRUCTION
TRAVEL
DISTANCE
31 1/2”
BRICK LEDGE
31 1/2”
3”
DM Chimney System: Offset Block (cont.)
When establishing the “far face” of the overhead
obstruction, be sure that the DM chimney blocks can run straight
to chimney termination without further overhead obstruction .
(Figure 59)
Be sure that there is sufcient space beyond the “far
face” of the overhead obstruction to accept the DM chimney’s
outer casing dimension of 21 1/2”. Support all offset sequences
down to bearing as discussed on previous pages.
Notes:
A) Always support the last offset block in a sequence
for full support of the DM chimney where it returns to vertical.
Support columns often carry the majority of the total load of the
vertical chimney that is set onto the last offset block.
B) The total chimney weight above the last offset
block will be the total weight of the vertical chimney plus any
additional allowable loads such as the Isokern brick ledge, its
related brick or stone veneers, and any crown caps, or other
chimney terminations.
C) Be sure the foundation under all support columns
is made of concrete or steel and designed to support the loads
applied to it.
D) Check with local codes and a structural engineer to
conrm loading and foundation requirements.
E) Maximum horizontal distance of offset is six feet
(6’) and represents twenty-four offset blocks in sequence.
F) By code the maximum angle of offset for a chimney
system is 30° off of vertical.
FIGURE 58
DM Brick Ledge:
The DM brick ledge is a 3” thick, 31-1/2” square, steel
reinforced, concrete and pumice slab (Figure 60).
The Brick ledge provides a 5” ledge at all four sides
of the outer casing block and is designed to support masonry
veneers to DM chimneys starting below the rafters and
continuing to termination. (Figure 61)
The component is cast with an octagonal hole in its
center so that the DM octagonal inner liner can pass through it.
The brick ledge has four 2-1/2” holes through it that
align with the hole in each of the four corners of the DM outer
casing block. These four holes are provided for reinforcement
of the chimney stack by the insertion of #4, minimum, steel
reinforcing rods and subsequent grouting. (Figure 60 & 61)
The brick ledge is intended for use in chimneys that
rise through the roof only where all four sides of the chimney
are bounded by the roof.
WARNING: To maintain structural performance the DM brick
ledge must not be cut or altered in any way.
FIGURE 59
FIGURE 60
36
DM Chimney System: Brick Ledge Installation
Brick Ledge
DM Brick Ledge Installation:
Use of the brick ledge will require a roof framing rough
opening of at least 34” in width. The required opening dimension
along the length of the rafter, where the chimney is to penetrate the
roof line, will increase above 34” relative to the pitch of the roof.
As the DM outer casing and inner liner assembly
approaches the roof penetration set an outer casing block to a level
as close to the the low side of the roof framing as possible. (Figure
62)
The alignment tongues on the top of this outer casing
block must be ground off to leave a at contact surface for the
brick ledge. Temporarily leave out the inner liner that ts this outer
casing block.
Set the Isokern brick ledge onto the at top surface of the
outer casing in a full bed of Earthcore Mortar. Be sure to align the
four 2-1/2” holes in the brick ledge with the matching holes in the
outer casing block below it. Return to setting the next inner liner
in the sequence. This inner liner comes up from below and passes
through the octagonal hole in the brick ledge. The liner’s top end
will be approximately 3” above the top surface of the brick ledge.
Set the next outer casing block onto the top of the brick ledge in a
bed of Earthcore Mortar.
Insert one piece of #4 (minimum) steel reinforcing rod into
each of the four 2-1/2” holes in the brick ledge. The reinforcement
rods must start from a depth of at least 18” below the bottom of the
brick ledge, (In some cases, a minimum recommendation could be
5’).
FIGURE 61
Consult local structural engineer for proper job-specic
support structure design, sizing and load bearing specications.
If short lengths of steel rods are used be sure to properly
lap and wire tie all splices in the rebar. As the reinforcing
progresses, completely ll the holes with grout. Suitable grout can
be a pourable mixture of Portland cement and sand or Portland
cement, sand and pea gravel. The rebar must be fully embedded in
grout.
Leave enough of the #4 steel reinforcing rod exposed
above the brick ledge so that as the stacking of outer casing
blocks continues to termination the reinforcing rods and grout can
continue through the stack. Reinforcing shall continue to chimney
termination.
All DM chimneys that include the brick ledge must be
reinforced as described above.
CAUTION: When using the Isokern brick ledge it is required that
the rebox/smoke dome assembly include the placement of a 4”
by 4” by 3/8” minimum steel angle across the rebox opening.
(See page 40 for “Structural Information” for details regarding
specication and placement of steel angles in replaces.)
37
DM Chimney System: Brick Ledge Load Capacity
ISOKERN
BRICK LEDGE
Lateral Support for Isokern Brick ledge Chimneys:
Once the DM chimney and brick ledge are assembled
and after the intended masonry veneer has been installed on the
brick ledge, be sure to brace the chimney following the guidelines
on page 32 of this manual for Lateral Support of DM chimneys.
Load Capacity for Brick Ledge:
The sources of load delivered into the Isokern brick
ledge are:
(1) the total physical load of brick, stone or other
masonry veneer on the brick ledge, and
(2) loading due to the force of wind delivered against
the exposed height of the chimney mass.
The required height of any chimney is governed by
applicable local building codes. The overall nished height of
any chimney varies based upon site-specic conditions (eg.
elevation of roof line, roof pitch, distance of the chimney from
the ridge, etc.).
It is relatively simple to calculate the total physical load
on the brick ledge resulting from the physical weight of applied
veneers built to code height, however calculation values for load
to the brick ledge due to wind are site specic and based on
local variables such as wind speed zone, exposure classication,
eave height and roof pitch of the structure, as well as height of
chimney mass exposed to wind.
The total of physical load and load due to wind must not
exceed ninety four hundred (9400) pounds.
Notes:
Calculation of wind load requires the services of a local
structural engineer who can evaluate wind load for the specic
structure and site in question.
Do not subject the brick ledge to unequal loading when
applying veneers. Build veneers equally on all four sides of the
brick ledge.
FIGURE 62
38
INNER
FLASHING
SMALL
CROWN CAP
LARGE
CROWN CAP
FIGURE 63
FIGURE 64
DM Chimney System: Flashing & Crown Caps
Brick ledge Veneer Finish and Flashing Details:
When applying brick, stone or other masonry veneer
to the Isokern brick ledge standard good building practices for
masonry veneer work should govern weather-proong details and
the placement of ashings.
A typical ashing detail would be to eld fabricate an
aluminum or galvanized sheet metal ashing, approximately
thirty-two inches (32”) square with a twenty inch (20”) square hole
in it, to serve as an inner ashing. (Figure 63)
Place the inner ashing on the rst DM outer casing block
that fully clears the roof line. Keep the ashing to about a one-half
inch (1/2”) lap onto the top of the outer casing block. The twenty
inch (20”) square hole in the ashing should t to the outside of
the alignment grooves on top of the DM outer casing. Continue the
DM chimney up to the required termination height.
Once the masonry veneer is in progress the inner ashing
is set into a horizontal joint in the veneer at a level above all
other roof deck ashings, chimney-to-roof ashings and counter
ashings. Weep holes should open to the outer face of the veneer
at vertical mortar joints located at the level of the inner ashing.
(Figure 64)
Where moisture may develop between the DM outer
casing and the chimney veneer, inner ashings as described above
will help to divert such moisture to exterior face of the veneer
by way of the weep holes and thereby keep such moisture from
working its way down between the veneer acing and the DM outer
casing and into the interior of the structure below.
DM Small Crown Cap (Figure 65)
The DM small crown cap is a prefabricated cement
weather cap that measures 26- 1/2” square and 3” thick. The small
crown cap is designed and installed the same as the large crown
cap.
The small crown cap is intended for use where DM
chimneys are to receive thin veneers and cultured stone that do
not require the installation of the Isokern brick ledge. The small
crown cap is also suitable where DM chimneys are to receive
a stucco nish. Other chimney terminations are possible with
DM chimneys. Check local codes for use of custom chimney
terminations and decorative shrouds.
FIGURE 65
FIGURE 66
DM Large Crown Cap (Figure 66)
The DM large crown cap is a prefabricated cement
weather cap for masonry veneer chimneys. The large crown cap
measures 37-1/2” square and is 3” thick at its center.
The component has an octagonal hole at its center so that
the top inner liner of the DM chimney stack can pass through it.
The crown cap then sits on the top most DM outer casing block.
To set the large crown cap the last inner liner should be at
least 3” above the last outer casing block in the chimney stack.
Mortar the top of the last outer casing block. Set the large
crown cap over the inner liner and onto the top of the last outer
casing in the stack.
Caulk or mortar the joint between the octagonal liner and
the crown cap where the liner comes through the top surface of the
large crown cap.
39
DM Chimney System: Height Requirements
10’-0”
LESS THAN 10’-0”
CRICKET
3’-0” MIN
ROOF RIDGE
WORK POINT
SECTION
THRU ROOF
CHIMNEY
2’-0”
WORK
POINT
CRICKET
CHIMNEY
3’-0” MIN
SECTION
THRU ROOF
2’-0”
3’-0” MIN
Chimney Height Requirement:
The required minimum chimney height above the roof
and adjacent walls and buildings is specied by all major building
codes and is summed up in what is known as “the 2 foot in 10 foot
rule”:
FIGURE 67
FIGURE 68
(1) If the horizontal distance from the roof ridge to the opening
of the chimney is less than 10’, the top of the chimney must be at
least 2’ above the roof ridge. (Figure 67)
(2) If the horizontal distance from the opening of the chimney
to the roof ridge is more than 10’ then a chimney height “work
point” is established on the roof surface 10’ horizontally from the
opening of the chimney. The top of the chimney must be at least
2’ above this work point. (Figure 68)
(3) In all cases, the chimney cannot be less than 3’ above the roof
at the edge of the chimney. (Figure 67 & 68)
A simple example of this would be if the roof is at
then the chimney would need to be at least 3’ above the roof
surface. Or, if the chimney penetrates the roof at the ridge then
the chimney must be at least 3’ above the ridge. (Figure 69)
Note: The “2 foot in 10 foot rule” is necessary in the interest
of re safety but does not ensure smoke-free operation of the
replace. Trees, buildings, adjoining roof lines, adverse wind
conditions, etc. may require a taller chimney for the replace to
draft properly.
Chase Enclosures: DM chimneys can be enclosed within a
wood framed chase at zero clearance to wood framing members.
Chase enclosures need to be built to local wind load requirements
and shall be structurally independent of the Isokern chimney. As
with all chimney installations, avoid overhead obstructions such
as trees, power lines, etc.
FIGURE 69
WARNING: Keep all insulation minimum of three inches (3”)
away from all DM chimney components. If insulation is used
in walls surrounding the chimney, insulation may be installed
behind sheathing of gypsom board, plywood, particle board or
other material on the side facing the Isokern material. The facing
material cannot be within 1 1/2” to the chimney outer casing.
Failure to use manufacture’s provided parts or variations in
techniques and construction materials or practices other than
those described in this manual may create a re hazard and void
the limited warranty. Do not pack insulation around the replace
or chimney. Do not insulate the chase cavity with blown or loose-
ll type insulation materials.
Chase Top Flashings:
Non-combustible, weather tight chase ashing must be
used to cover the top of the chimney chase. Be sure to seal the
joint where the DM liner passes through the chase top ashing for
positive weather seal. Chase ashings may be supplied by others.
40
STEEL ANGLE
4x4x3/8 MIN
FRONT DAMPER
SUPPORT
CAST IRON DAMPER
(IF USED)
STEEL ANGLE
4x4x3/8 MIN
Top Plate
Structural Information
The rebox/smoke dome assembly has a load capacity
that allows for the replace system to carry a limited amount of
straight, vertical DM chimney sections. The load capacity for
each model, stated as maximum DM chimney heights without
additional structural support, are listed on page 3.
These chimney heights are for straight chimneys (no
offsets) and are exclusive of the brick ledge.
Important: DM chimneys taller than the listed maximum
heights require a steel angle (minimum of 4” x 4” x 3/8”) be
set across the rebox opening when assembling the unit as a
structural lintel. Consult a structural engineer to design proper
structural support.
This steel angle shall span the rebox opening, bearing
fully on the front 4 inches of the rebox side wall components.
The vertical leg of the angle steel lintel should turn up and sit in
front of the damper plate component. (Figure 70)
Important: The application of the steel angle as described
above is also required in all replace installations where the
brick ledge is used.
This required steel lintel placement is in addition to
the reinforcing required for DM chimneys with brick ledge as
described on pages 36 and 37.
Important: For DM chimneys with both offsets and a brick
ledge it is important to fully support the last offset block where
the chimney returns to vertical. This is required in order to
provide complete vertical support for the brick ledge and its
related loads.
Important: When placing steel angles or any other steel support
members into the Fireplaces structure maintain a 2” minimum
air space around steel members for clearance to combustible
members and combustible surfaces.
Wind Load Calculations: Using the required Earthcore
Mortar to install the DM chimney system, the maximum height
above the roof line of a one story residence with an exposure
classication C without additional structural support is:
90 MPH 26’-0”
100 MPH 24’-0”
110 MPH 21’-8”
120 MPH 19’-8”
130 MPH 18’-0”
140 MPH 17’-6”
146 MPH 16’-8”
150 MPH 16’-4”
For two story residences, please call the Technical Department
at: 800-642-2920.
FIGURE 70
Important: The top plate of the rebox is not meant to be
used as a structural support of any veneer. Consult a structural
engineer for structural support of any veneer bearing weight on
the Isokern top plate for additional structural support.
41
LARGE
CROWN CAP
SMALL
CROWN CAP
Common Chimney Terminations
Two chimney terminations are offered by Isokern, the DM
large crown cap and the DM small crown caps. These are cement crown
caps designed to provide a weather cap to the DM chimney system.
Their design is typical of the cement caps found on traditional masonry
chimneys.
Due to owner preference and architectural design criteria other
chimney terminations can be used alone or in conjunction with the
crown caps. Special design caps may be designed and constructed by
others and must be fashioned so as not to restrict the ow of smoke and
gasses out the top of the ue opening. Figure 71 depicts some common
chimney terminations.
Check with local building codes to establish the need for
chimney caps and spark arrestors or for any limitations to their design
and use.
FIGURE 71
42
METAL
FLUE
Metal Flue
Fireplaces are tested and listed for use with factory-built
metal, Class “A” (solid fuel) chimneys as an option. Any Class
“A” or UL 103 listed metal chimney system is accetable for use
on any Isokern system. (Figure 72)
Metal Flue Types:
The selected factory-built metal chimney for use with
the replaces, at a minimum, must be listed by a recognized
agency for solid fuel and as tested to UL 103, for continuous use
of one thousand degrees (1000°) Fahrenheit and intermittent use
of seventeen hundred degrees (1700°) Fahrenheit.
The factory-built metal ue design can be from the following
types:
1. Non-insulated completely thermal siphoning, double-wall, aircooled solid fuel rated chimneys listed to UL 103, ULC S629.
2. Double-wall with solid-pack insulation.
3. A combination of double-wall, solid-pack insulation and air
space (triple-wall).
FIGURE 72
FIGURE 73
ANCHOR
PLATE
INSWOOL
BLANKET
4. Triple-wall air space solid fuel chimney.
5. Listed chimney liners conforming with the seventeen hundred
degree (1700°) Fahrenheit requirements of UL 1777 or ULCS635
or ULC640 may also be used with Isokern replaces.
Note:
The selected, approved chimney manufacturer must
provide the masonry anchor plate designed to t their ue system.
(Figure 73)
All chimneys and chimney liners must be installed in
accordance with the manufacturer’s installation instructions and
under the terms of their listing for use with open faced replaces.
Maximum height of a metal ue system is not required
as all the load can be taken off the rebox.
Refer to metal ue manufacturer for number of offsets,
approved chimney shrouds, clearance to combustibles and any
information specic to that ue system. Earthcore does not
manufacture these components and defers to manufacturers
instructions.
SMOKE DOME
TOP PLATE
43
A
B
STEEL ANGLE
4 x 4 x 3/8 MIN
VERTICAL SIDE
FACE INSIDE FIREBOX
(BOTH SIDES)
NOTCH FOR STEEL
ANGLE PLACEMENT
(BOTH SIDES)
FRONT
VIEW
STEEL
ANGLE
MODEL A B
28 35 1/2” 45 1/2“
36 43” 53”
42 49” 59”
46/48 53” 63”
1 1/2”
MIN *
1 1/2”
MIN *
HEARTH
EXTENSION
MINIMUMS
VERTICAL
FACE IN
1 1/2”
OVERHANG
The See-Thru application of the replace is built with
a replace kit, omitting the back walls. To support the smoke
dome and chimney, steel angle is required to be installed as
described. Note that due to the large opening area of a two-
sided replace this type of replace can be difcult to get to
reach and to maintain proper drafting.
Constructing a See -Thru Unit:
1) Set the base plate in place.
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 as long as there are no combustible
underpinnings underneath the concrete slab.
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 both
open sides of the replace and extending at least 20 inches out
from the replace opening and at least 12 inches beyond the
nished sides of the replace opening.
2) The rebox back wall components are not used. The
rebox side walls are set, reversed from their normal position,
their ared faces set to the outside of the rebox. (Figure 74)
The rebox side walls must sit a full 3” on the front &
rear of the base plate. Since the side wall components air from
3” at the narrow front end to 8” on the wide rear end, the side
walls will overhang the base plate by approximately 5” at the
rear of the unit. (Figure 76)
3) Once the side wall assembly is complete it is
necessary to place a steel angle minimum 4”x 4”x 3/8” across
each face of the two sided opening before building the smoke
dome assembly. Notch the ends of each sidewall equal to the
thickness of the steel as shown. Each end of the steel angles
must bear fully at least 3” onto the side wall assembly. (Figure
74)
4) Since there is no back wall assembly and no side
wall ledge for placement of a cast iron throat damper, the smoke
dome for the See-Thru replace is built by placing one long
damper beam on top of the rebox back wall and ush with
it; the other long damper beam sits ush with the front of the
Isokern Standard rebox, spanning the rebox opening.
These components both sit on their narrow base so that
their beveled face points down and into the rebox interior.
5) The damper plate end pieces are designed to sit on
the rebox side wall between the front and back long damper
beams. Place the vertical face of each piece 1-1/2” to the inside
of the inside sidewall of the rebox. This will allow the re
brick to align ush with the damper end pieces. (Figure 75)
6) Once the smoke dome assembly is built and the DM
chimney is installed, a chimney top damper is set at the top of
the ue or a bottom mount damper is installed to the inside of
the top plate.
Specialty Applications - See-Thru
FIGURE 74
FIGURE 75
FIGURE 76
44
Specialty Applications - Two Story Stacked Installations
General Information:
To install one Fireplace and DM chimney system above
one another, as in a two story stacked installation, both the upper
and lower replace installations require a structurally designed
support down to footings designed by a structural engineer.
Frequently in two story stacked installations the lower
unit is supported by a slab-on-grade, whereas the upper unit is a
typical off-grade support. The off-grade slab for the upper unit
must be built with sufcient width in order to accommodate the
width of the upper replace plus the width of the by-passing
chimney system rising from the lower unit. (Figure 77)
Dimensions for each replace unit can be found on the
website at: www.earthcore.co.
The slab for the lower unit will need to be built with
enough width to provide support for the lower replace unit
plus the bearing surface for the support columns needed to carry
the offset chimney sequence of the lower system. (Figure 77)
Floor-to-Floor Height Considerations:
In order for the lower replace installation to have
enough overhead height clearance for its chimney to rise at a
thirty degree (30°) angle of offset (maximum angle of offset as
allowed by code) and bypass to one side of the rebox in the
upper location there are minimum required oor-to-oor height
dimensions. (See chart, page 45 - Dimension “F”)
The minimum oor-to-oor height required for an
installation is determined by calculating the total horizontal
distance the lower ue must travel to the left or right for it to
bypass to one side of the upper replace. (see calculating offsets
on pages 34 & 35)
The total amount of horizontal chimney offset travel
distance will be determined by two factors:
1. The width dimension of the upper unit; and
2.The horizontal distance between centerlines of the
proposed upper and lower units.
Example:
If the upper replace and the lower replace sit on the
same centerline then the required oor-to-oor dimension is at a
maximum (See Figure 78 and chart, page 45 dimension, column
“F”.)
For every 3” of horizontal distance separating the
centerlines of the upper and lower units the overall height of the
offset sequence is reduced by one offset block or by 6”.
Notes:
A raised hearth at the lower replace will increase
the minimum oor-to-oor height requirement by the height
dimension of the raised hearth.
In the interest of clarity the drawing on pages 44 and
45, (Figures 77 & 78) of the offset chimney sequence does not
show the offset block support columns as required for offset
sequences and as described on pages 33 & 34 of this manual.
FIGURE 77
45
Specialty Applications - Two Story Stacked Installations (cont.)
D
B
C
E
F
A
The following chart gives important dimensions needed
when laying out two story stacked replace units. Chart dimensions
assume that both the upper and lower replace units sit on the same
centerline.
Note: Widths of both Isokern Standard and Magnum replaces
are the same. Only the depth of the rebox and the height of the
nished opening differ.
Upper/Lower A B C D E F
36/36 43 51 30 81 70 142
36/42 43 51 33 84 70 142
36/48 43 51 35 86 70 142
42/36 49 54 33 87 70 148
42/42 49 54 33 87 70 148
42/48 49 54 35 89 70 148
48/36 53 56 35 91 70 149
48/42 53 56 35 91 70 149
48/48 53 56 35 91 70 149
Chart Dimension Description: (Figure 78)
“A” is the outside width dimension of the Fireplace model chosen
for the upper unit.
“B” dimension represents distance (taken in the direction of the
chimney offset) from the centerline of the lower replace to the
outside face of the eight inch (8”) thick bearing wall underpinning
the upper unit’s oor system.
“C” dimension is the distance (taken away from the direction of
the chimney offset) from the centerline of the lower or the upper
replace, whichever is the larger plus eight inches (8”) to the
outside of the eight inch (8”) thick bearing wall for the upper unit’s
support slab.
“D” is the outside-to-outside dimension of the two eight inch (8”)
thick bearing walls underpinning the upper unit’s support slab. “D”
is also the width of the upper unit”s support slab and includes the
additional space for the width of the DM chimney as it bypasses the
upper unit. “D” is also the sum of “B” plus “C”.
“E” is the height of the Fireplaces chosen for the lower unit and
includes the Isokern three inch thick base plate.
“F” is the dimension from the top of the support slab of the lower
unit to the top of the oor of the upper unit.
Notes:
If raised hearths are planned for the lower unit then “F”
dimension will increase by the height of the raised hearth at the
lower unit.
In the interest of clarity the drawings on page 44 and 45
(Figures 77 & 78) of the offset chimney sequence do not show the
offset block support columns as required for offset sequences. See
pages 33 & 34 for complete offset support instructions.
Consult local structural engineer for support slab load
calculations.
FIGURE 78
46
Fire-Lite Application - General Information
General Information:
The Fire-Lite is an application of the Isokern Standard
and Magnum replaces designed, tested and listed with the
ability to be installed on a combustible oor system. The design
and installation require that the system use Class A metal ue,
or equivalent. The Fire-Lite assembled unit must sit on a raised,
noncombustible platform allowing a minimum 4” air space
between the Isokern base plate and the combustible oor.
Many of the requirements for the Fire-Lite such as re
brick installation, safety precautions and installation instructions
for the Isokern Standard and Magnum replaces will apply and
are referred to in previous pages of this manual. Refer to those
instructions for additional information.
The following pages will refer to installation
requirements specic to the Fire-Lite system.
Intended Use Statement:
The Fire-Lite replace is designed to sit on a
combustible oor system and is intended to burn solid wood
fuel, propane or natural gas. The replace is intended for use as
a supplemental heat source only and is not intended for heavy
use as a primary heating system.
Notes:
The local authority having code jurisdiction should be
consulted before installation to determine the need to obtain a
permit. Refer to page 4 of this manual for areas of concern.
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 specic
design preferences. Always maintain the stated minimum
clearances to combustible materials. Do not violate any specic
installation requirements.
The Fire-Lite has been tested and listed by Warnock
Hersey (Report Nos. J20004277-231 and 632-912500) to UL
127-1999. These units are intended for installation in residential
homes, and other buildings of conventional construction.
Fire-Lite 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).
Though any Class A or UL 103 metal chimney can be
installed with a Fire-Lite, the following installation instructions
refer to the FTF-13 chimney system. If an equivalent metal
chimney system is used, follow the metal ue manufacturer’s
explicit installation instructions.
Safety Instructions:
Because the Fire-Lite is an application of the Magnum
or Isokern Standard Series replaces, the safety instructions are
listed on pages 5 & 6 of this manual. Please refer to them and
read them carefully before installing your Fire-Lite system.
FIGURE 79
47
FTF 13
Metal Chimney
(or equivalent)
2” min. 2” min.
1 ½” min. to
Combustible
Framing
Fire-Lite Stand
(4” min)
Combustible
Floor System
1 ½” min.
Noncombustible
Hearth Extension
Zero Clearance
20” min
Hearth Extension Support with
Noncombustible Material.
*8 1/2”
min
20” min
3” min When
Unsupported
1 1/2”
Min
12”
min
12”
min
1 1/2” min
When Supported*
Plus width of backing
Combustibles Must
Have 1 1/2”” min
Clearance
Combustibles Must Have 1 1/2”” min
Clearance.
DO NOT ENCROACH ON
CLEARANCE WITH COMBUSTIBLES!
1 1/2”
1 1/2”
CORRECT
INCORRECT
* Height based on the use of 1 1/4” fire-brick and a 1/4” mortar bed.
This height may vary based on the firebrick used.
The Fire-Lite is tested and listed for installation with
“clearance to combustibles” as follows:
1) Four inches (4”) clearance to the combustible oor.
2) Zero inch (0”) clearance at the Isokern smoke dome front wall
(Figure 77).
3) One and one half inches (1-1/2”) clearance at the Isokern rebox
back walls and side walls.
4) Two inches (2”) minimum air space to combustibles at all FTF-
13 metal chimney components’ outer layer.
Important: “Combustibles” are dened 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 zero inch
(0”) clearance. All combustible sheathing materials must be held
eight inches (8”) away from the sides of the rebox opening and
eight inches (8”) above the top of the rebox opening.
The rebox backwall, side walls and the smoke dome back
require 1 1/2” clearance. (Figures 80 & 81)
Fire-Lite Application - Required Clearance To Combustibles
FIGURE 80
Keep all insulation, vapor barriers, “house wrap” paper and
other insulating type membranes and products, including
berglass, cellulose and other insulation, (anything that carries
an “R” rating) a minimum of three inches (3”) away from all
rebox and chimney surfaces.
Exception: If insulation is used in walls surrounding the replace,
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing the
Isokern. (Figure 81)
The sheathing material holding back the insulation cannot be
closer than 1 1/2” to the replace sidewalls, backwall or chimney
system. (Figure 83)
When Fireplace installations are surrounded by walls
that are to be insulated, the walls must have enough clearance to
the Isokern unit in order to maintain the three inch (3”) minimum
clearance to insulation for unsupported insulation. Never spray the
Fireplace or chimney system with any type of sealer, insulation
or other material.
Notes:
The Fire-Lite Application is designed, tested and approved
for installation at a minimum of four inches (4”) above combustible
oor systems per the installation specications given in this manual.
Any portion of the combustible oor system left exposed
under the base plate is to be covered with minimum 1” thick
ceramic ber insulation board or equivalent rated to 2100 degrees
Fahrenheit (Figure 79).
All Fire-Lite Series result in the nished re brick oor
of the rebox being at least eight inches (8 1/2”)* above the
combustible oor system (Figure 80).
FIGURE 81
FIGURE 82
FIGURE 83
48
Fire-Lite Application - Load Calculations
Floor framing for a Fire-Lite installation will need to
be designed and built to accept substantial dead loads spread
over a relatively small oor area.
The following weights and sizes can be used to
calculate Fire-Lite loading. Consult with local structural
engineer for proper sizing of structural oor frame members for
specic installations.
Load Calculations:
Total dead load amounts include (but are not necessarily
limited to) the following items and their corresponding weight
estimates listed below:
1. Fire-Lite unit model weights:
MFP = Magnum Series - SFP = Isokern Standard Series
a. Model 36 MFP: 1300 lbs. - 36 SFP: 1205 lbs.
b. Model 42 MFP: 1420 lbs. - 42 SFP: 1325 lbs.
c. Model 48 MFP: 1600 lbs. - 46 SFP: 1450 lbs.
2. Damper, re brick and mortar: 450 - 500 lbs.
3. Raised platform: 40 lbs.
4. Fireplace nished facing: approx. 200 lbs.
(dependant on facing used)
5. Weight of metal ue: negligible
By adding the weight of the appropriate Fire-Lite
Model listed in #1 above to the allowance given for each item in
2 through 5, above, the total weight of the Fire-Lite Series can
be estimated.
The oor area for each model is as follows:
Magnum:
Model 28 FP @ 35.5” x 28” = 6.90 sq.ft.
Model 36 FP @ 43” x 28” = 8.36 sq.ft.
Model 42 FP @ 49” x 28” = 9.52 sq.ft.
Model 48 FP @ 53” x 28” = 10.3 sq.ft.
Isokern Standard:
Model 36 FP @ 43” x 25.25” = 7.54 sq.ft.
Model 42 FP @ 49” x 25.25” = 8.59 sq.ft.
Model 48 FP @ 53” x 25.25” = 9.29 sq.ft.
Notes:
These dead load totals are in addition to the live load
and other dead load requirements for the specic site’s proposed
oor.
The load estimates given above for items are estimates
only and may not accurately dene total loads related to the
completed replace due to material choices that are at owner
option. Consult your local structural engineer for proper oor
system design, sizing and specications.
Isokern is not responsible for structural oor support
details for the Fire-Lite replace. Unless otherwise noted all
oor framing drawings in this manual are merely illustrations to
indicate the presence of an underlying oor system.
FIGURE 84
Magnum Series Shown for Illustration Purposes Only
49
1 ½” min.
25 ¼”
Fire-Lite Stand
4” or 8” Heights
Available
Combustible
Floor System
14GA. Metal Joists
@ 12” O.C. with a 3” Dia.
Hole for Air Dissipation
Noncombustible
20” Hearth Substrate
Air Dissipation
26 Gauge Metal
Safety Strip
8 ½”
MIN
Insboard or Inswool Cut and
Placed Between
Sections
Fire-Lite Application - Hearth Conditions
Noncombustible Hearth
Extension Required
20” min
Support Hearth Extension
With Noncombustible Material
Secure Fire-Lite
Stand To Trusses
Floor Framing
By Others
1 1/2”
min
1 1/2”
min
1 1/2”
min
SIDE VIEW
FRONT VIEW
PLAN VIEW
Hearth Extension
Required
12”
min
20”
min
Field Verify Dimensions:
Magnum Series:
28 55 3/4”W x 49 1/2”D
36 58 1/2”W x 49 1/2”D
42 65 1/2”W x 49 1/2”D
48 69 1/2”W x 49 1/2”D
Field Verify Dimensions:
Isokern Standard Series:
36 58 1/4”W x 46 3/4”D
42 64 1/4”W x 46 3/4”D
48 68 1/4”W x 46 3/4”D
Note: Field Verified Dimensions Should Make Allowance for Hearth
Extensions in Front (20”) and Sides (12” ea.) From Fireplace Opeining.
Also Fireplce Sides and Rear, 1 1/2” Clearance to Combustibles
** Consult Local Structural Engineer for Specific Structural Suppot.
Use Metal Flue Only.
The noncombustible raised platform must be set with a
minimum one and one half inch (1-1/2") clearance to the wall to
the sides and directly behind the Fire-Lite assembly.
Raised Platform:
Nominal four inch (4") metal base. (Figure 85). Set the
Fire-Lite base plate in a mortar bed on to the non-combustible
raised platform.
Metal safety strip - a generic 26 ga., four inch (4”) wide
galvanized metal strip - must be inserted to approximately two
inch (2”) beneath the platform at the front of the noncombustible
raised platform. The safety strips must extend out from the
front of the raised platform at least two inches (2”) and must
extend to at least two inches (2”) beyond the ends of the raised
platform. Any overlaps in the length of the safety strips should
be a minimum of two inches (2”) for continual coverage of the
combustible oor at the front of the replace (Figure 85).
The exposed combustible oor within the perimeter
formed by the noncombustible raised platform must be
completely covered with Inswool or Insboard ceramic ber
insulation (Figure 84). The Inswool or Insboard is dry laid to the
oor within the block perimeter.
The ceramic ber must have a thermal conductivity
rating equal to or greater than 0.4 Btu-in/hrsq. ft-degree
Fahrenheit. (Reference: Harbison-Walker, 600 Grant St.,
Pittsburgh, PA 15219, ph. 412-562-6200: “Insboard 2100” or
equivalent.)
FIGURE 85
Fire Brick Installation: Follow instructions on page 19 of this
manual.
Recessed Fire-Lite:
If the design preference is for a ush hearth Fire-Lite
application (oor of the replace at the same level the room’s
oor), with advanced planning, the metal stand can be lowered,
set and attached to the joist system. (Figure 86)
When calculating ush hearth height be sure to allow
for the four or eight inch (4” or 8”) metal stand, three inch (3”)
thick base plate plus the one and one half inch (1-1/2”) thick re
brick oor.
Whether a ush hearth is preferred or a raised hearth,
the combustible oor in 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 “Fire-Lite” construction, it is necessary to use
the base plate. Be sure to secure the Fire-Lite metal stand to the
oor framing system, then mortar the base plate to the metal
stand for stability.
*For seismic anchorage design and instructions of the iush
hearth application, please contact the Technical Department at
1-800-642-2920.
FIGURE 86
50
FTF-13 or Equivalent Chimney System
The Fire-Lite is designed, tested and listed for use with
UL 103 or Class A metal chimney system, or equal.
Do not modify or alter metal ue or metal ue
components as this could result in an unsafe and potentially
dangerous installation that may cause a serious hazard and void
the listings, approvals and the limited warranty of the system.
The following installation instructions refer to FTF13 chimney system. If “equal” metal chimney systems are
used, follow the metal ue manufacturer’s explicit installation
instructions.
General Information:
This chimney system is designed for installation in
accordance with the National Fire Protection Standard for
chimneys and solid fuel burning appliances, NFPA 211 and in
accordance with codes such as BOCA Basic/National codes, the
Standard Mechanical Code and the Uniform Building Codes.
Note: Illustrations shown reect “typical” installations with
nominal dimensions and are for design and framing reference
only. Actual installations may vary due to individual design
preferences. However, always maintain minimum required
clearances to combustible materials and do not violate any specic
installation requirements.
WARNING: Failure to use manufacture’s provided parts,
variations in techniques and construction materials or practices
other than those described in this or the manufacturers manual
may create a re hazard and void the limited warranty.
Chimney Clearance Requirements:
The FTF-13 chimney’s outer layer requires a minimum
two inch (2”) air space to combustibles.
The chimney system must be enclosed when installed in
or passing through a living area where combustibles or people
may come in contact with it. This is important to prevent possible
personal injury or re hazard.
The FTF-13 chimney’s re stop spacer and roof ashing
(not chase ashings) may be placed directly on or against normal
construction materials.
Note: “Normal construction materials” are considered to be:
framing materials, particle board, mill board, plywood, paneling,
ooring, and drywall.
Chimney Height Requirements:
Refer to ue manufacturer for chimney height
requirements and recommendations.
FIGURE 87
51
FTF-13 or Equivalent Chimney System (cont.)
Installation of the FTF-13 Metal Chimney System for the
Isokern Fire-Lite:
Transition from the Isokern to the FTF-13 Metal Chimney
System:
The FTF-13 metal ue attaches to the smoke dome’s top
plate by use of the AP-ISO masonry anchor plate. The Anchor
Plate is tted with an octagonal base plate to afx it to the smoke
dome’s top plate. The anchor plate also has starter rings for both
the inner and the outer sleeves of the metal ue (Figure 89).
Step 1. Lay a twenty-four inch (24”) square, half inch (1/2”)
thick (minimum) piece of ceramic ber high temperature blanket
(“Inswool” Ceramic Fiber HP Blanket, rated for temperatures
up to 2400 degrees F., or equal.) on the top of the top plate. Cut
a hole approximately 11” in diameter in the center of the high
temperature blanket and align the blanket on the ue hole in the
top plate (Figure 89).
Step 2. Fit the AP-ISO Anchor Plate assembly onto the Inswool so
that the inner ue sleeve projecting out the bottom of the anchor
plate is inserted through the high temperature blanket and into the
hole in the top plate. The high temperature blanket is held between
the anchor plate and the top plate as a gasket (Figure 89). Attach
Anchor Plate to the top plate with masonry attachment screws
through holes provided in the anchor plate into the top plate. Do
not over torque masonry screws into the Isokern material. (Figure
90)
FIGURE 88
UL 103 or
Class A
Anchor Plate
Inswool
Blanket
Chimney Terminations:
FTF-13 chimney pipe requires a termination component
to be installed at or near the top of the chimney chase ashing.
The FTF-13-CTD Round Termination is the
recommended termination. (See page 52)
Installation:
Step 1. Hold the FTF-13-CTD over top of last chimney section.
Step 2. Center inner slip section in inner ue pipe and slip down.
Step 3. Center outer locking section over outer ue pipe. Push
down until locking tabs are rmly engaged.
Step 4. Pull up slightly on CTD to ensure locking joint has rmly
engaged.
Note: It is recommended that all exterior exposed metal chimney
components - such as terminations, ashings, and ue - be painted
with a premium quality, high temperature, rust preventative paint
designed for metal. This is especially important when installations
are made in abnormally adverse or corrosive environments such as
near lakes and oceans or, in areas with consistently high humidity
conditions. Consult the paint manufacturer’s instructions for
proper preparation and application.
Chimney Height Requirements:
FIGURE 89
UL 103 or
Class A
Top Plate
Anchor
Plate
Inswool
Blanket
Refer to page 39 of this manual.
FIGURE 90
52
FTF-13 Installation Components
Round Termination
Fire Stop Spacer
Chimney Flue Section
Fire Stop Spacer (30° Offset)
Offset Return Package (30°)
Stabilizer
Locking Band
Combination Offset
Return Elbow
Anchor Plate
53
FTF-13 Offset Elevation Chart
A
Offset
Inches
B
Height
Inches
FTF-13-ES30
Offset/Return
Elbow Set
FTF-13-S4
Stabilizer
Number of FTF-13
Chimney Section
12”
18” 36”
4
9
12
14 1/4
17 1/4
20 1/4
21
22 1/4
25 1/4
26 1/4
28 1/4
29 1/4
31 1/4
21 1/2
34 1/4
36 1/4
37 1/4
38 1/4
39 1/4
41 1/2
43 1/4
44 1/2
45 1/4
46 1/4
48 1/4
49 1/2
51 1/4
54 1/4
55 1/4
56 1/2
59 1/2
61 3/4
64 3/4
67
69
70
73
75
79
80 1/4
82
87
15 3/4
24 1/2
29 3/4
33 1/2
38 1/2
43 3/4
45 1/4
47 1/2
52 1/2
54 1/4
57 3/4
59 1/4
63
65
68 1/4
71 3/4
73 1/4
75
77
80 1/2
83 3/4
85 3/4
87 1/2
89
91 1/2
94 1/2
97 3/4
103
104 1/2
106 1/2
111 3/4
116
121 1/4
124 3/4
127 3/4
130
135 1/4
138 3/4
145 1/2
147 1/2
150 3/4
159 1/2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
0
1
0
2
1
0
0
2
1
1
0
0
2
4
1
3
0
0
2
1
1
3
0
0
2
1
1
0
0
2
1
1
0
2
1
1
0
2
1
3
0
1
0
0
1
0
1
2
0
1
2
0
3
1
0
1
1
0
2
0
1
4
0
1
3
1
0
5
1
2
0
1
2
0
1
0
3
1
2
1
0
1
1
1
0
0
0
0
0
0
1
0
0
1
0
1
1
0
1
1
1
2
1
0
2
1
1
2
2
0
2
2
3
2
2
3
3
3
2
3
3
3
4
3
4
4
54
FTF-13 Vertical Elevation Chart
Height of
Chimney Only
No. of FTF-13
Chimney Lengths
12”
18” 36”
11
17
21 3/4
27 1/4
33 1/4
35
37 1/4
43 1/4
51 1/4
55 1/4
61 1/4
67 1/4
69 1/4
79 1/4
85 1/4
89 1/2
95 1/4
103 1/4
113 1/2
119 1/2
123 3/4
129 1/3
137 1/2
147 3/4
153 3/4
158
164
171 3/4
182
188
192
198
206
215 3/4
222
226 1/4
232 1/4
240
250 1/4
256 1/4
260 1/2
266 1/2
274 1/4
284 1/2
290 1/2
294 3/4
300 3/4
Height of
Chimney Only
No. of FTF-13
Chimney Lengths
Height of
Chimney Only
No. of FTF-13
Chimney Lengths
Inches Feet Inches
12”
18” 36”
Inches Feet Inches
12”
18” 36”
Inches Feet Inches
0
1
1
1
2
2
3
3
4
4
5
5
5
6
7
7
7
8
9
9
10
10
11
12
12
13
13
14
15
15
16
16
17
17
18
18
19
20
20
21
21
22
22
23
24
24
25
11
5
9 1/4
9 1/4
9 1/4
11
1 1/4
7 1/4
3 1/4
7 1/4
1 1/4
7 1/4
9 1/4
7 1/4
1 1/4
5 1/2
11 1/2
7 1/4
5 1/2
11 1/2
3 3/4
9 3/4
5 1/2
3 3/4
9 3/4
2
8
3 3/4
2
8
0
6
2
11 3/4
6
10 1/4
4 1/4
0
10 1/4
4 1/4
8 1/2
2 1/2
10 1/4
8 1/2
2 1/2
6 3/4
3/4
1
0
2
2
0
0
2
1
0
2
1
0
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
0
2
0
1
2
1
0
1
2
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
0
0
0
1
0
0
1
1
1
1
2
2
2
2
2
3
3
3
3
3
4
4
4
4
4
5
5
5
5
5
6
6
6
6
6
7
7
7
7
7
8
8
8
8
8
308 1/2
318 3/4
324 3/4
328 3/4
334 3/4
342 3/4
352 3/4
358 3/4
363
369
376 3/4
387
393
397 1/4
403 1/4
411
421 1/4
427 1/4
431 1/2
437 1/2
445 1/4
445 1/2
461 1/2
465 1/2
471 1/2
479 1/2
489 1/2
495 1/2
499 3/4
505 3/4
513 1/2
523 3/4
529 3/4
534
540
547 3/4
558
564
568 1/4
574 1/4
582
592 1/4
598 1/4
602 1/4
25
26
27
27
27
28
29
29
30
30
31
32
32
33
33
34
35
35
36
36
37
37
38
38
39
39
40
41
41
42
42
43
44
44
45
45
46
47
47
47
48
49
49
50
8 1/2
8 3/4
3/4
4 3/4
10 3/4
6 3/4
4 3/4
10 3/4
3
9
4 3/4
3
9
1 1/4
7 1/4
3
1 1/4
7 1/4
11 1/2
5 1/2
1 1/4
11 1/2
5 1/2
9 1/2
3 1/2
11 1/2
9 1/2
3 1/2
7 3/4
1 3/4
9 1/2
7 3/4
1 3/4
6
0
7 3/4
6
0
4 1/4
10 1/4
6
4 1/4
10 1/4
2 1/4
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
9
9
9
9
9
10
10
10
10
10
11
11
11
11
11
12
12
12
12
12
13
13
13
13
13
14
14
14
14
14
15
15
15
15
15
16
16
16
16
16
17
17
17
17
608 1/4
616 1/4
626 1/4
632 1/4
636 1/2
642 1/2
650 1/4
660 1/2
666 1/2
670 3/4
676 3/4
684 1/2
694 3/4
700 3/4
705
711
718 3/4
729
735
739
745
753
763
769
773 1/4
779 1/4
787
797 1/4
803 1/4
807 1/2
813 1/2
821 1/4
831 1/2
837 1/2
841 3/4
847 3/4
855 1/2
865 3/4
871 3/4
875 3/4
881 3/4
889 3/4
899 3/4
905 3/4
910
916
924
50
51
52
52
53
53
54
55
55
55
56
57
57
58
58
59
59
60
61
61
62
62
63
64
64
64
65
66
66
67
67
68
69
69
70
70
71
72
72
72
73
74
74
75
75
76
77
8 1/4
4 1/4
2 1/4
8 1/4
1/2
6 1/2
2 1/2
1/2
6 1/2
10 3/4
4 3/4
1/2
10 3/4
4 3/4
9
3
10 3/4
9
3
7
1
9
7
1
5 1/4
11 1/4
7
5 1/4
11 1/4
3 1/2
9 1/2
5 1/4
3 1/2
9 1/2
1 3/4
7 3/4
3 1/2
1 3/4
6 3/4
11 3/4
5 3/4
1 3/4
11 3/4
5 3/4
10
4
0
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
2
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
0
1
0
1
0
17
18
18
18
18
18
19
19
19
19
19
20
20
20
20
20
21
21
21
21
21
22
22
22
22
22
23
23
23
23
23
24
24
24
24
24
25
25
25
25
25
26
26
26
26
26
27
55
Summary
1. WARNING: Fireplace and chimney systems will only draft
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 manufacturers
instructions, choosing an appropriate 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
ambient air ow pressure as well as produce down drafts, either
of which can impair replace drafting performance.
Earthcore Industries L.L.C. does not warrant drafting
and is not responsible for it.
2. Fireplace Curing Instructions:
It is critical that the refractory elements in the Isokern
rebox and smoke dome components be dry before ring of the
unit. Moisture left in the Isokern 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 in a dried-in setting for a
minimum of 28 days after construction of the unit is complete.
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.
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 loads.
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 replace.
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 efcient
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 wadded 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.
56
Summary
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 or 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. 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 articial 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.
Operable doors are acceptable and 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 cinders
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 replace and chimney system. 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.
57
Registration Card
Please tear out along dashed lines and send to:
Earthcore Industries
Attn: Technical Dept.
6899 Phillips Industrial Blvd.
Jacksonville, FL. 32256
Or register your Isokern online at: www.earthcore.co
WARRANTY CARD
Purchased From:
Date of Purchase: _______________________________________________________
Name: _______________________________________________________
Address: _______________________________________________________
City, State & Zip: _______________________________________________________
Phone No: _______________________________________________________
Gas Log Burner Size: (Circle One) 24” 30” Other__________
Fireplace Series/Size: Magnum _____ Isokern Standard _____ IBV ______ Vent-Free _____
Green Tech _____ ISO’ven _______ Fire-Lite Stand? (Circle One) Yes No
Gas Control Valve Type: (Circle One) Remote Control Safety Pilot
Gas Type: (Circle One) Natural Gas Propane
Buyer:
Date of Installation: (Completed) ________________________________________________
Name: _______________________________________________________
Address: _______________________________________________________
City, State & Zip: _______________________________________________________
Phone No: _______________________________________________________
Fireplace Serial Number: (Located on Rating Plate Inside Fireplace) ___________________
Installed By: _______________________________________________________
Address: _______________________________________________________
Phone Number _______________________________________________________
58
Notes
59
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 pufng, 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, BE-
YOND THE WARRANTIES SET FORTH HEREIN.
6899 PHILIPS INDUSTRIAL BLVD. • JACKSONVILLE, FLORIDA 32256
TEL (904) 363-3417 • TOLL 1 (800) 642-2920 • FAX (904) 363-3408
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