Malm Fireplaces Zircon 30, Zircon 38, Lancer 76 Instruction Manual

Malm Fireplaces, Inc.Malm Fireplaces, Inc.

Malm Fireplaces, Inc.

Malm Fireplaces, Inc.Malm Fireplaces, Inc.

368 Yolanda Avenue

Santa Rosa, Ca 95404

[phone] - Fax: [phone]

Zircon 30

Tested to U/L Standard 737 & 1482

Assembly And Installation Instructions

LEAVE THESE INSTRUCTIONS WITH THE OWNER.

SAFETY NOTICE
If this fireplace is not properly installed, a house fire may result. To reduce the
risk of fire, follow the installation instructions. Contact local building or fire
officials about restrictions and installation inspection requirements in your
area.

This stove must be connected to (1) a chimney complying with the require­ments for Type HT chimneys in the Standard for Chimneys, Factory-Built,
Residential Type and Building Heating Appliance, UL 103, or (2) a code­approved masonry chimney with a flue liner.

Please read this entire manual before you install and use your new fireplace.
Failure to follow instructions may result in property damage, bodily injury, or
even death.

DO NOT INSTALL THIS UNIT IN A MOBILE HOME.

ASSEMBLY AND INSTALLATION INSTRUCTIONS

1. Carefully remove all components from the shipping cartons and inspect for damage. If any damage is noted contact
the shipping company or your dealer immediately. DO NOT INSTALL THIS UNIT IF DAMAGED OR MISSING
PARTS.

2. Protect the flooring near the intended place of installation with an old rug, blanket, or cardboard. Place the firebox
on this material.

3. Mix and install the Malmcrete hearth refractory as follows:
a. Obtain a sturdy water-tight mixing container such as a wheelbarrow or large wash tub, a bucket or can for

transporting the mixture, a cement trowel, and a source for clean mixing water. It is suggested that the

Malmcrete be mixed outside to avoid spillage or splatters in the dwelling.
b. Pour the dry Malmcrete mixture into the mixing container.
c. Use 1 quart water for each bag.
d. Add 1/2 to 3/4 of the water to the dry mix and mix thourghly. Add additional water in small increments, mixing

throughly between additions. Do not add more water than is necessary to get a somewhat dry mixture; to much

water in the mix may cause the refractory to crack excessively, and will reduce the strength of the refractory.

To test for proper water content, cut vertically into the mixture with the trowel, push the trowel sideways to open

a 3 inch deep by 2 inch wide cut in the mixture, then slide the trowel back up out of the cut. The cut should

stay open with very little "slumping" back into the cut. Next, run the trowel over the surface of the mixture with

the blade at a slight angle to the surface of the mixture, like spreading butter. The mixture should become

relatively smooth with few voids after 6 or 7 passes of the trowel using moderate pressure. Water should not

float to the top of the mixture.
e. Transfer the mixture to the hearth (floor) area inside the firebox, spreading the mixture out as it is added. Use

the trowel to spread the mix into the firebox area. Continue to add refractory until there is a minimum of 2 inches

thick over the entire hearth area. To measure the depth of the mix, place a piece of tape 2 inches from the pointed

end of a long nail. Insert the nail vertically through the mix every 6 inches (front to back and side to side) across

the hearth; the mix should come to a uniform height up the nail, at or slightly above the tape. Trowel in the nail

holes when completed.

f. Allow the mix to cure at least 48 hours. Additional curing time is necessary in cool temperatures. The longer

Malmcrete is allowed to cure before the first fire is lit, the stronger and more durable it will become.

g. Make the first 3 or 4 fires very small and of short duration to allow the refractory to adjust to the high temperature

of a fire.

Hearth Requirements

A floor protector is required to protect the floor in front of the fireplace opening from sparks. The floor protector must
be a minimum of 3/8 inch thick non-combustible material such as brick, concrete, slate, ceramic tile, or a listed floor
protection board such as Wonderboard or Homosote.

The floor protector must extend a minimum of 16 inches in front of the fireplace opening and 8 inches to either side of
the fireplace. The Zircon has been designed to provide floor protection allowing for flexible design of the hearth setting.

Clearance to Combustibles

The Zircon requires a clearance to combustible walls of 16" measured from the back of the unit. For locating the center
of the chimney the measurement is 22 1/2" from the backwall and 47" to the sidewall. See figure 1, page 3. For corner
installation the center of the chimney is 27". See figure 2, page 3.

Clearance to Non-combustibles

The Zircon clearance to a combustible wall may be reduced with proper wall protection. Accepted methods for wall
protection would allow reduction of the wall clearances. For appearance if desired a non-combustible wall covering can
placed on the wall. The covering should consist of a listed wall protection board installed to the manufacturer's
specifications. Approved protection boards at the time of this publication are Wonderboard, Dura Rock and Homosote.
A non-combustible material can then be placed over the wall protection board. With most of the protection boards the
clearance can be reduced to 8 inches from the original combustible wall. Be certain to check with your local building
officials and or fire inspector for accepted methods in your area. Refer to NFPA 211.

Page - 2

CLEARANCES

SIDEWALL AND BACKWALL INSTALLATION

Unit to Sidewall ----------------------------------- 32"
Unit to Backwall----------------------------------- 16"
Connector to Sidewall ---------------------- 43 1/2"
Center of Connector to Sidewall -------------- 47"
Connector to Backwall -------------------------- 18"
Center of connector to Backwall --------- 21 1/2"

!

#

46"

$

16"

"

CORNER INSTALLATION

Unit to Adjacent Wall ------------------------------ 16"
Connector to Adjacent Wall ----------------- 23 1/2"
Center of Connector to Adjacent Wall --------- 27"

Minimum Hearth Size -----------------46" x 30 1/2"

Hearth is not required to extend under the Zircon's base.

#

#

#

$

32"

#

8"

$

43 1/2"

$

!

16"

"

!

18"

"

#

Figure 1

Hearth dimensions shown are minimum requirements. It may be desired to exceede these minimum dimensions for
a more decorative installation. The hearth material must be 3/8" or thicker noncombustible material. It is not required
for the hearth material to extend under the base of the fireplace.

$

16"

30 1/2"

$

!

23 1/2"

"

Figure 2

!

16"

"

Page - 3