TOA Electronics BR-42 User Manual

INSTALLATION
INSTRUCTIONS

STANDARD SERIES

42" Wood Burning Fireplaces
P/N 700,026M REV. C 11/2003

MODELS

BR-42 BC-42
BRI-42 BCI-42
BR-42-2 BC-42-2

This installation manual will enable you to obtain a safe, efficient and
dependable installation of your fireplace system. Please read and under­stand these instructions before beginning your installation.

Do not alter or modify the fireplace or its components under any
circumstances. Any modification or alteration of the fireplace system,
including but not limited to the fireplace, chimney components and
accessories, may void the warranty, listings and approvals of this system
and could result in an unsafe and potentially dangerous installation.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

IMPORTANT! TO ASSURE PROPER ALIGNMENT OF GLASS DOORS:
INSTALL THIS FIREPLACE IN A SQUARE AND PLUMB CONDITION,
USING SHIMS AS NECESSARY AT SIDES AND/OR BOTTOM.

PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE.

WH Report No. J99025865B-231

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.

1

TABLE OF CONTENTS

Safety Rules .................................... page 2

Tools and Building Supplies ............ page 2

Precautions ..................................... page 3

Introduction ..................................... page 3

Clearances/Height Requirements..... page 3

Chimney System ............................. page 3

Assembly Outline............................. page 4

Location of Fireplace ....................... page 4

Assembly Steps ............................... page 5

Preinstallation Notes........................ page 5

Clearances ....................................... page 5

Installing the Fireplace ..................... page 5

Fireplace Specifications .................. page 6

Framing Specifications.................... page 7

Installing the Chimney System ........ page 8

30° Offset through Floor/Ceiling ...... page 9

Ten Foot Rule Summary .................. page 11

Multiple Terminations ...................... page 11

Chimney Component Calculations ... page 11

Special Offset Instructions............... page 12

Offset Calculations........................... page 12

Vertical Elevation Chart ................... page 12

Offset Elevation Chart ..................... page 13

Installing Offsets.............................. page 14

Optional Equipment Considerations. page 14

Forced Air Kits ................................. page 14

Combustion Air Kits ........................ page 15

Gas Line Connection........................ page 15

Vent Free Appliances ....................... page 15

Glass Doors ..................................... page 16

Cold Climate Insulation.................... page 16

Fireplace Finishes ............................ page 16

Mantels and Trim............................. page 16

Hearth Extensions/Wall Shields ....... page 16

Finish Requirements ........................ page 18

Installation Components .................. page 18

IMPORTANT: PLEASE READ AND
UNDERSTAND THESE RULES TO
FOLLOW FOR SAFETY.

1. Before starting your fireplace installation,

read these installation instructions carefully to
be sure you understand them completely and in
entirety. Failure to follow them could cause a
fireplace malfunction resulting in serious injury
and/or property damage.

2. Always check your local building codes. The
installation must comply with all local, regional,
state and national codes and regulations.

3. These fireplaces must be installed with
Security Chimneys FTF8 (8" inside diameter)
Chimney System only. These systems are in­tended for use in any application where a
traditional masonry type fireplace would ap­ply. The chimney system must always vent to
the outside of the building.

4. To ensure a safe fireplace system and to
prevent the build-up of soot and creosote,
inspect and clean the fireplace and chimney
prior to use and periodically during the heating
season.

5. Use solid fuel only. DO NOT use artificial
wax based logs, chemical chimney cleaners or
flame colorants in your fireplace.

6. DO NOT use charcoal or coal under any
circumstances.

7. NEVER use gasoline, gasoline-type lantern
fuel, kerosene, charcoal lighter fluid, or similar
liquids to start or “freshen up” a fire in this
fireplace. Keep any flammable liquids a safe
distance from the fireplace.

8. NEVER leave children unattended when
there is a fire burning in the fireplace.

9. Always keep flue damper open when heat is
present in the fireplace.

10. Before servicing, allow the fireplace to
cool. Always shut off any electricity or gas to
the fireplace while working on it. This will
prevent any possible electrical shock or burns.

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

12. Always ensure an that adequate supply of
replacement combustion air from the outside
of the house is accessible to the fire to support
normal combustion. Fireplaces consume large
volumes of air during the normal combustion
process. In the event the home is tightly sealed
with modern energy efficient features, the op­tional combustion air kit may not provide all
the air required to support combustion.

The manufacturer is not responsible for any
smoking or related problems that may result
from the lack of adequate combustion air. It is
the responsibility of the builder/contractor to
ensure that adequate combustion air has been
provided for the fireplace.

13. DO NOT use a fireplace insert or any other
products not specified herein by the manufac­turer for use with this fireplace. All gas log sets
must be operated with the damper clamped
open, including unlisted “vent free” log sets.
Listed “vent-free” log sets may be operated
with the damper closed.

14. "Smoke free” operation is not warranteed
nor are we responsible for inadequate system
draft caused by mechanical systems, general
construction conditions, inadequate chimney
heights, adverse wind conditions and/or un­usual environmental factors or conditions be­yond our control.

15. Never, under any circumstances, install a
fireplace, chimney component or any acces­sories, that has visible or suspected physical
damage as a result of handling or transporta­tion. These items should be inspected by your
distributor or qualified factory representative
to ensure safe condition. When in doubt, con­sult your distributor.

16. For additional safety considerations and
complete operating instructions, refer to the
Care and Operation Manual provided with the
fireplace.

TOOLS AND BUILDING SUPPLIES
NORMALLY REQUIRED

Tools should Include:

Phillips screwdriver
Hammer
Saw and/or sabersaw
Level
Measuring tape
Plumb line
Electric drill and bits
Pliers
Square

Building supplies:

Framing materials
Wall finishing materials
Caulking materials (noncombustible)
Fireplace surround and hearth
extension materials (noncombustible)

2

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.

PRECAUTIONS

Note: These fireplace systems are not difficult

to install. However, in the interest of safety, it
is recommended that the installer be a quali­fied or certified “tradesman” familiar with com­monly accepted fireplace installation and safety
techniques as well as prevailing local codes.

The most important areas of concern dealing
with the installation of factory-built fireplaces
are clearances to combustible materials, proper
assembly of component parts, height of the
chimney system, the proper use of accesso­ries supplied by the manufacturer and the
techniques employed in using finishing mate­rials applied to the wall surrounding the fire­place, hearth extensions and wall shields. Each
of these topics will be covered in thorough
detail throughout this manual. Please give
each your special attention as you progress
with your installation.

INTRODUCTION
General Information

These fireplaces are conventional radiant heat
fireplaces with standard bar grates, optional
outside combustion air kits and optional deco­rative glass doors.

TYPICAL INSTALLATION

Chimney and

Termination

Outside
Combustion
Air Kit
(Optional)

The "C" models are designed as heat circulating
fireplaces and may be fitted with accessory
fans.

The BRI and BCI models are fully insulated for
installation in colder climates.

WARNING: MODELS THAT HAVE THE
"-2" SUFFIX HAVE NOT BEEN TESTED
WITH AN UNVENTED GAS LOG SET. TO
REDUCE RISK OF FIRE OR INJURY, DO
NOT INSTALL AN UNVENTED GAS LOG
SET INTO THIS FIREPLACE.

Note: Illustrations shown reflect “typical” in-

stallations with nominal dimensions and are
for design and framing reference only. Actual
installations may vary due to individual design
preferences. However, always maintain mini­mum clearances to combustible materials and
do not violate any specific installation require­ments.

These fireplaces have been tested and listed by
Warnock Hersey (Report No. J99025865B-231)
to U.L. standard 127. These units are intended
for installation in residential homes and other
buildings of conventional construction includ­ing commercial, not in mobile homes.

These fireplaces have been tested for installa­tion in Canada to ULC-S610. For installations

in Canada, the chimney clearance to com­bustibles must be 2 inches and the Cold
Climat Kit must be installed.

These fireplace systems are designed for in­stallation in accordance with the National Fire
Protection Standard for chimneys, fireplaces
and solid fuel burning appliances; NFPA 211
and in accordance with codes such as the
BOCA Basic/National Codes, the Standard Me­chanical Code and the Uniform Building Codes.

WARNING: FAILURE TO USE MANUFAC­TURE PROVIDED PARTS, VARIATIONS
IN TECHNIQUES AND CONSTRUCTION
MATERIALS OR PRACTICES OTHER THAN
THOSE DESCRIBED IN THIS MANUAL
MAY CREATE A FIRE HAZARD AND VOID
THE LIMITED WARRANTY.

When complete these fireplace systems con­sists of five basic “sub-systems”:

1. The Fireplace

2. The Chimney and Termination

3. The Optional Glass Doors

4. The Optional Combustion Air Kits

5. Optional Cold Climate Kit (Mandatory in

Canada).

CLEARANCES AND HEIGHT
REQUIREMENTS

The fireplace may be placed on or near normal
construction materials*. The combustion air
kit, firestop spacer and roof flashing (not chase
flashings) may be placed directly on or against
normal construction materials.* The chimney

and fireplace outer wrapper require a mini­mum 1"** air space to combustibles. A com-

bustible mantle may be installed 12" above the
opening of the fireplace as per NFPA 211,
Section 7-2.3.3 (1992). In Canada, the mini­mum is 18" above the fireplace opening.

The minimum installed height of the completed
fireplace system is 15' 0". The maximum height
is 60' 0".

The fireplace and 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 fire hazard.

For questions, please call your distributor or
the manufacturer. Special restrictions apply to
the front and facing of the fireplace and nearby
walls (See pages 16, 17 and 18 ).

CHIMNEY SYSTEM

These fireplaces are designed and code listed
for use with Security Chimneys FTF8 chimney
System only. Always use Security Chimneys
FTF8 chimney components with these fire­places. Do not modify or alter these compo­nents as this may cause a potential serious
hazard and void the Warranty.

*Construction Materials:

• framing materials • paneling

• particle board • flooring

• millboard • dry wall

• plywood • etc.

Radiant Model Shown

Figure 1

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.

**Note: 2" clearance to combustibles around
chimney components required in Canada.

3

Insulate Joists

Wall
Covering

Black Portion Of Frame

Not To Be Covered With

Combustible Materials

Safe

Zone

45°

12”

12”

Door

Opening

1”

Same As Ceiling

Draft Stops

Chimney Height

The total height of your completed fireplace
system from the surface the fireplace rests on
to the chimney top must not exceed 60' and
must also meet minimum height requirements.
Refer to the minimum system height chart.

Minimum System Height

LOCATION OF FIREPLACE

Carefully select the proper location for heat
circulation, aesthetics, chimney obstructions
and clearance to side wall(s). With proper pre­planning, a slight adjustment of a few inches
can save considerable time and expense later
during construction and assembly.

Firestop

CTDT
Termination

Note: Non­Combustible
Chase
Flashing
Must Be
Used To
Cover
Chase
Opening

Optional
Insulation
In Outside
Walls Of
Chase

8'

Level

Solid
Continuous
Surface

Outside
Insulation
(Thermal Barrier)

Base

Figure 2

WARNING: IF INSULATION IS USED, THE
FIREPLACE MUST NOT BE PLACED DI­RECTLY AGAINST IT. INSULATION OR
VAPOR BARRIERS, IF USED, MUST FIRST
BE COVERED WITH GYPSUM BOARD,
PLYWOOD, PARTICLE BOARD OR OTHER
MATERIAL TO ASSURE INSULATION AND
VAPOR BARRIERS REMAIN IN PLACE.

Security's FTF8 Pipe

Vertical Installation 15' 0"

One Offsets 15' 0"

Two Offsets 25' 0"

Chase Enclosure

A chase is a vertical box-like structure con­structed to surround the fireplace and chimney.
Refer to

Figure 2

for a typical chase configura­tion. As with all chimney installations, avoid
overhead obstructions such as trees, power
lines, etc. A chase should be constructed and
insulated just like any outside wall. In a cold
climate, we recommend the base of the chase
should also be insulated between the solid
continuous floor beneath the fireplace and the
chase bottom. Chase insulation in a cold cli­mate installation is not required for safety.

ASSEMBLY OUTLINE
Before You Start

Check your inventory list to be sure you have all
the necessary parts supplied in good usable
condition. Check also for any concealed damage.

Check the operation of the damper. The damper
is controlled through the use of a control lever
located within the firebox opening at the top
center in front of the firebox lintel (
The control lever snaps into place at either
extreme of its range of motion. When locked
in position all the way to the right, the damper
is open. When locked in position all the way to
the left, the damper is closed.

Figure 3

Hearth

Hearth

Optional
Outside Chase

Figure 4

Carefully consider the position of the fireplace
opening with respect to the location of adja­cent or nearby stairwells, bath or kitchen ex­haust fans and/or return air registers for forced
air furnaces/air conditioners that could cause
a smoking fireplace condition if the house is
tightly insulated.

When locating the fireplace, consideration must
be given to combustibles and final finishing.
See

Figure 5

and confine the final location of

combustible finish materials to the "Safe Zone".

DO NOT permanently place furniture or other
items such as decorative pillows within 60" of
the fireplace front face.

).

WARNING: DO NOT PACK OR FILL RE­QUIRED AIR SPACES WITH INSULATION
OR OTHER MATERIAL. NO MATERIAL IS
ALLOWED IN THESE AREAS.

Note: Do not insulate the chase cavity with

blown or fill type insulation materials.

Note: Local codes may not require firestopping
at the ceiling levels for outside chase installa­tions. However, it is recommended for safety
and the reduction of heat loss.

4

Damper
Closed

Damper

Lintel

Combustion
Air Actuator

Figure 3

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.

Open

Figure 5

ASSEMBLY STEPS

Note: The following steps represent the normal

sequence of installation. Each installation is
unique, however, and might require a different
sequence.

1. Position firebox prior to framing or into
prepared framing.

2. Install the chimney system.

3. Connect house wiring to the fireplace for

later attachment of optional blower.

4. Install optional outside combustion air kit.

5. Plumb gas line if a decorative gas appliance

will be used. (Gas connections should only be
performed by an experienced, licensed/certi­fied tradesman.)

6. Complete the installation, finish wall mate­rial, surround and hearth extension to your
individual taste.

7. Assemble and attach optional glass door
assembly.

1. Estimate the total weight of the fireplace
system including chimney and surround ma­terials such as brick, stone, etc., to be in­stalled. Shipping weights for the fireplace
may be found on page 18.

2. Measure the square footage of the floor
space to be occupied by the system, surrounds
and hearth extensions.

3. Note the floor construction, i.e. 2 x 6’s, 2 x 8’s
or 2 x 10’s, single or double joists, type and
thickness of floor boards.

4. Use this information and consult your local
building code to determine if you need addi­tional support.

CAUTION: DO NOT BLOCK THE HEAT-CIRCU­LATING AIR INLET AND OUTLET PORTS ON
CIRCULATING MODELS. DOING SO MAY RE­SULT IN A POTENTIAL FIRE HAZARD.

If you plan to raise the fireplace and hearth
extension, build the platform assembly then
position fireplace and hearth extension on top.
Secure the platform to the floor to prevent
possible shifting.

Top Spacer

Maintain
1" (25 mm)
Air Space
At Back
And Sides

Hearth

1" (25 mm) Space

Metal Safety Strip Floor

Note: Hearth extensions must not interfere with
circulating grillwork

Extension

Figure 6

Maintain
1" (25 mm)
Air Space
At Back
And Sides

Study the three dimensional illustration (

ure 1

) to get a general idea of each element of

Fig-

your fireplace system.

PRE-INSTALLATION NOTES

The fireplace may be installed directly on a
combustible floor or raised on a platform of an
appropriate height. Do not place fireplace on
carpeting, vinyl or other soft floor coverings. It
may, however, be placed on flat wood, ply­wood, particle board or other hard surfaces.
Be sure fireplace rests on a solid continuous
floor or platform with appropriate framing for
support and so that no cold air can enter the
room from under the fireplace.

The fireplace may be positioned and then the
framing built around it, or the framing may be
constructed and the fireplace positioned into
the opening.

Usually, no special floor support is needed for
the fireplace, however, to be certain:

CLEARANCES

Minimum clearance to combustibles for the
appliance is as follows: sides and back - 1" (25
mm), floor - 0" (0 mm), adjacent wall - 12" (305
mm), ceiling - 37 ¹⁄₂" (953 mm).

INSTALLING THE FIREPLACE

Step 1. Slide the fireplace into prepared fram-

ing or position fireplace in its final position and
frame later.

The fireplace may not be recessed into a com­bustible floor. Maintain the floor to hearth clear­ance established by the fireplace lower front
face.

Step 2. Insert the provided metal safety strips,
beneath the fireplace as illustrated (

and 8

). The safety strips should overlap ¹⁄₂" for

continual coverage of the floor.

Note: Safety strips are not required when fire­place rests on a noncombustible surface.

Figures 6, 7

Hearth

1" (25 mm) Space

Metal Safety Strip Floor

Note: Hearth extensions must not interfere with
circulating grillwork

Platform

Extension

Figure 7

Note: Install the hearth extension only as illus-

trated.

The safety strips should extend from front of
the fireplace at least 1 ¹⁄₂" and should extend to
be at least flush with the sides. In the event a
wooden support is used to elevate the fireplace
above the floor, a “Z” type safety strip should be
fabricated and used to protect the front surface
of the wood support as well as the floor beneath
the hearth extension (

Figures 8 and 9

). The
safety strips should be tacked down to prevent
possible movement.

Note: The “Z” type safety strip is not supplied.

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.

5

1 ¹⁄₂"

Figure 8

Metal Safety Strips

FIREPLACE SPECIFICATIONS

8 ³⁄₈"

(213 mm)

22 ⁵⁄₁₆"

(566 mm)

12 ¹⁄₂"

(318 mm)

41"

(1041 mm)

2"

(51 mm)

13 ⁷⁄₁₆"

(341 mm)

7 ³⁄₁₆"

(183 mm)

43"

(1092 mm)

Blocking

Metal Safety Strips

Figure 9

Step 3. Refer to fireplace drawings and specifi-

cations on pages 6 and 7 for framing dimensions
and details. Frame appliance enclosure as illus­trated in

Figures 11 through 14

on page 8.

IMPORTANT: UNDER NO CIRCUMSTANCES
CAN THE FIREPLACE TOP SPACERS (

10

) BE REMOVED OR MODIFIED, NOR MAY

FIGURE

YOU NOTCH THE HEADER TO FIT AROUND OR
BE INSTALLED LOWER THAN THE SPACERS.
THE HEADER MAY BE IN DIRECT CONTACT
WITH THE TOP SPACERS BUT MAY NOT BE
SUPPORTED BY THEM.

Note: The framed depth, 20

⁵⁄₈

" (524 mm) from
a framed wall, must always be measured from
a finished surface. If a wall covering such as
drywall is to be attached to the rear wall, then
the 20

⁵⁄₈

" (524 mm) must be measured from
the drywall surface. It is important that this
dimension be exact.

If the appliance is to be elevated above floor
level, a solid continuous platform must be
constructed.

The header may rest on the top metal spacers,
but must not be notched to fit around them.

Consult all local codes.

Gas Line

Access

Fireplace

Top Spacer

1"

(25 mm)

21 ¹⁄₄"

(540 mm)

Left Side

8 ³⁄₁₆"

(208 mm)

(1143 mm)

(1092 mm)

38"

(965 mm)

(1194 mm)

45"

Front

43"

(802 mm)

(318 mm)

47"

Top View

Combustion

Air Inlet

19"

(483 mm)

31 ⁹⁄₁₆"

12 ¹⁄₂"

45"

(1143 mm)

Gas Line

Access

Right Side

(540 mm)

Fireplace Top Spacer

9 ⁷⁄₈"

(251 mm)

10"

(254 mm)

Junction
Box

21 ¹⁄₄"

21 ¹⁄₄"

(540 mm)

43"

(1092 mm)

Figure 10

6

NOTE: DIAGRAMS & ILLUSTRATIONS NOT TO SCALE.