HomeMy WebLinkAboutB14-0261 fireplace specs � � � �-I� �- ���� r ���
+ Isokern0 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 fireplaces, 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 firebox surfaces as specified 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 notification.
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 fire 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
�NtERrF,� Issued: February 2013
Revision: 006
u� INTERTEK TESTING SERVICES REPORT NO. 3159656MID-008
�7 0 2007 Earthcore Industries, L.L.C.
C � �� US
���ock H8�$
THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY
�
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THIS PAGE INTENTIONALLY LEFT BLANK
a
_ � TABLE OF CONTENTS
GeneralInformation ....................................................................................................................................... 4
IntendedUse Statement ...................................................................................................................................... 5
SafetyInstructions .............................................................................................................................................. 6-7
Warnock-Hersey Listing Label ........................................................................................................................... g
Assembled Firebox&Smoke Dome Dimensions-Isokern Standard Series....................................................... 9
ComponentList&Dimensions .......................................................................................................................... 10
Assembled Firebox&Smoke Dome Dimensions-Magnum Series................................................................... 11
ComponentList&Dimensions........................................................................................................................... 12
Required Clearance to Combustibles ................................................................................................................. 13
Rough Framing Dimensions&Corner Location Layout ................................................................................... 14
AssemblyInstructions ................................................................................................................................. 15-18
AccessModification ........................................................................................................................................... 19
FirebrickInstallation .......................................................................................................................................... 20
FlushWall Finish Detail ..................................................................................................................................... 21
Required Clearances(When sheathing protrudes beyond front of firebox) ....................................................... 22
Required Clearance to Combustible Framing .................................................................................................... 23
Flush Wall Fire Brick Finish Detail.................................................................................................................... 24
Interior Masonry Veneer Fireplace Finishes&Clearances................................................................... 25
Masonry Veneer Construction Details.................................................................................................. 26
Non Combustible Finished Facing Requirements&Clearance to Combustible Trim....................................... 27
ConcreteSupport ............................................................................................................................................... 28
DMChimney System ........................................................................................................................................ 29-39
GeneralInformation ............................................................................................................................ 29
Component List&Dimensions............................................................................................................. 30
ComponentWeights............................................................................................................................. 31
Installation ........................................................................................................................................... 32
LateralSupport .................................................................................................................................... 33
OffsetBlock ......................................................................................................................................... 34-36
BrickLedge Installation ....................................................................................................................... 37
BrickLedge Load Capacity .................................................................................................................. 38
Flashing&Crown Caps........................................................................................................................ 39
HeightRequirements ........................................................................................................................... 40
StructuralInformation .......................................................................................................................... 41
CommonChimney Terminations ......................................................................................................... 42
MetalFlue .......................................................................................................................................................... 43
SpecialtyApplications ....................................................................................................................................... 44-46
See-Thru Applications.......................................................................................................................... 45-46
Two Story Stacked Installations .......................................................................................................... 46
Fire-Lite Application.......................................................................................................................................... 47-52
Fire-Lite Application General Information.......................................................................................... 47
Fire-Lite Application-Required Clearance to Combustibles.............................................................. 48
Fire-Lite Application-Load Calculations........................................................................................... 49
Fire-Lite Application-Hearth Conditions........................................................................................... 50
FTF-l3 or Equivalent Chimney System............................................................................................................. 51-52
FTF-13 Installation Components........................................................................................................................ 53
FTF-13 Offset Elevation Chart........................................................................................................................... 54
FTF-13 Vertical Elevation Chart........................................................................................................................ 55
Summary............................................................................................................................................................. 56-57
RegistrationCard..................................................................................................................................................... 58
3
4 �
General Information
The Fireplaces referenced in this installation manual Important: Due to heat and weight issues, the fireplaces and
and DM chimney system are prefabricated, refractory DM chimney system installations require that the system be
modular fireplaces and a chimney system designed for field built upon a non-combustible concrete slab with no wood
assembly. The systems consist of interlocking precast parts underpinnings supported to footings with concrete or steel and
which are glued together with a masonry adhesive. designed to carry the total weight of the fireplace and chimney
The parts of the Fireplaces and DM chimney system system.
are precast using a proprietary mixture of volcanic pumice
aggregate and cement. It includes all the parts necessary for The Fire-Lite application of the fireplaces is designed
assembly of a complete firebox, smoke dome and chimney to be built upon a combustible floor system and wili also require
system. a design that will support the total weight ofthe Isokern firep(ace
Each precast fireplace component is designed for a and chimney system.The FTF-13 or equivalent chimney system
specific part of the fireplace such that only one means for only must be used with the Fire-Lite app(ication.Please refer to
assembly is possible. pages 46-51 for installation instructions.
The firebox and smoke dome are designed to be
fitted with a traditional cast iron, poker-style throat damper, Recommended minimum overall height for the
however alternate dampers are an option. Isokern fireplace and DM chimney system for an indoor
The fireplaces require a standard refractory fire application is 18'-0" when the chimney is straight and 21'-0"
brick liner be applied to the interior of the firebox.Fire brick when a chimney is offset. Maximum overall height is 82'- 0",
must be a minimum thickness of one and one-eighth inches however, heights above those listed below require additional
(1-1/8"). structural support.
Isokern Fireplaces are available in nine sizes,seven
of which are covered in this manual: Isokern Standard sizes: Maximum DM flue height without additional support needed:
thiriy-six (36), forty-two (42), and forty-six (46). Magnum
sizes: twenty-eight (28), thirty-six (36), forty-two (42) and Isokern Standard Series:
forty-eight(48).The Magnum is also available in two larger 36 54'-0"
sizes; information located online @ www.earthcore.co and 42 40'-0"
detailed in a separate installation manual. 46 41'-0"
All Isokern Standard units have a thirty-one and a
half inch (31-1/2") rough opening height and the Magnum Magnum Series:
units have a thirty-eight inch (38") rough opening height 28 50'-0"
before fire brick. The only parts which differ among the 36 54'-0"
available sizes are width and depth related pieces. The DM 42 40'-0"
chimney system is a dual module refractory chimney system. 48 41'-0"
The basic chimney consists of an outer casing block and an
inner liner. The chimney components are field assembled For heights above those listed above, consult a
using Earthcore(EC)Mortar to glue the components together. structural engineer for additional structural support for the
The DM chimney system also includes an offset DM chimney system.These heights do not reflect information
chimney block component, used to create 30° offsets to regarding metal flue. Any UL 103 or Class A metal flue can
the vertical run of the chimney. A brick ledge component be used on an Isokern fireplace. See metal flue manufacturers
is available, designed to support chimney top brick veneer installation instructions for information relating to height
finishes. Prefabricated masonry chimney termination caps requirements/restrictions.
are also available. For outdoor applications,there is no minimum height
The various fireplaces and the DM chimney requirement for the DM chimney flue system.Any UL 103 or
components will be described and illustrated in the following Class A metal flue can be used on an Isokern fireplace.See metal
pages. Close attention should be paid to each component flue manufacturers installation instructions for information
group's specifications and installation requirements as relating to height requirements/restrictions.
described in this manual.
4
r �
Intended Use Statement
Intended Product Use Statement: WARNING:
The Fireplaces and DM chimney system are intended This fireplace has not been tested for use with
to burn solid wood fuel,propane or natural gas. doors. To reduce the risk of fire or injury, do not install
doors. Operable doors are acceptable and if doors are
Note: required by the local authority having jurisdiction, doors
Installation of a gas pipe must comply with the Standard for must be kept in the fully open position when the fireplace
Decorative Gas Appliances for Installation in Vented Fireplaces, is in operation.
ANSI Z21.60.
This fireplace is not designed to sit directly on a Note: Do not scale drawings. Illustrations in this manual
combustible floor system.The Fire-Lite application listed in the are not to scale and are intended to show "typical"
back section of this manual is designed to sit on a combustible installations.
floor. See pages 46-51 for specific installation requirements. Nominal dimensions are given for design and
This fireplace is intended for use as a supplemental framing reference only,since actual installations may vary
heat source only and is not intended for heavy use as a primary due to job specific design preferences. Always maintain
heating system. the stated minimum clearances to combustible materials.
Overfiring, abusive burning or mistreatment will void Do not violate any specific installation requirements.
any claims (eg. burning construction debris or other highly The fireplaces and DM chimney system are tested
flammable material; tossing, kicking or otherwise forcing logs and listed by Warnock Hersey(Intertek Testing Service)-
into the firebox). ReportNo.3159656MID-008 andReportNo.315653MID-
Isokern fireplaces and the DM chimney system are 006-to UL 127,and UL 103HT-2006 respectively.
conventional indoor or outdoor fireplaces designed to appear Fireplace systems are also designed for
like traditional masonry fireplaces.Fireplaces and DM chimney installation in accordance with the National Fire Protection
system units are intended for installation in residential homes Association Standard for chimneys, fireplaces, vents and
and other buildings of conventional construction. Solid Fuel-Burning Appliances(NFPA 21 l).
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
fireplaces 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 finishing materials to the ������'�'r�
fireplace opening and hearth extension. �
Suitable standard residential, minimum four inch (4")
thick,2500 psi concrete foundations on properly compacted fill
can support installations up to thirty feet (30') overall height
(brick ledge installations not included) �
Each ofthese 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 fireplace �
and chimney installation must meet or exceed the specifications
and requirements in this manual and the prevailing local building
code.
Subsequent renovations, additions of cabinets and
storage spaces in the enclosure surrounding the fireplace are also
limited to the specifications in this manual and to the prevailing
local building code. ��
Earthcore is not responsible for other construction "
work around the fireplace unit.
Important:The top plate of the firebox 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
' s
Safety Instructions
1.Before starting the fireplace and DM chimney installation, 10. These fireplaces are not intended to heat an entire home
read these installation instructions carefully to be sure you or to be used as a primary heat source.They are designed to
understand them completely. Failure to follow them could ensure homeowner comfort by providing supplemental heat
cause fireplace malfunction resulting in serious injury or to the room.
property damage.
11. Always ensure that an adequate supply of replacement
2. Always check local building codes governing fireplaces air from the outside of the house is accessible to the fire
and fireplace installations. The Fireplace and DM chimney to support nor►nal combustion. Fireplaces consume large
installation must comply with all local, regional, state and volumes of air during the normal firing process.
national codes and regulations. In the event the home is tightly sealed and has
modern energy efficient features,the optional combustion air
3. Fireplaces and DM chimney systems are intended for use supply kits may not provide all the air required to support
in any application where a traditional masonry type fireplace combustion and the proper flow of combustion gases up the
would apply.The chimney system must always vent vertically chimney.
to the outside of the building. The manufacturer is not responsible for any smoking
or related problems that may result from the lack of adequate
4. Creosote and soot formation and the need for removal: air supply flowing into the house. It is the responsibility of
When wood is burned slowly, it produces tar and other the builder/contractor to ensure that adequate air supply has
organic vapors which combine with expelled moisture to been provided for the fireplace.
form creosote.The creosote vapors condense in the relatively
cool chimney flue of a slow burning fire.As a result,creosote 12. "Smoke free" operation is not warranted nor is the
residue accumulates on the flue lining. When ignited this manufacturer responsible for inadequate system draft caused
creosote makes an extremely hot fire. by mechanical systems, general construction conditions,
Because of creosote and soot buildup it is necessary inadequate chimney heights, adverse wind conditions or
to inspect and clean the fireplace and chimney prior to use any unusual environmental conditions or factors beyond the
and periodically during the heating season. Cleaning of the manufacturer's control.
fireplace and the chimney system should be done annually at It is acceptable to use mechanical draft systems, if
a minimum. In colder climates, chimney cleaning may need the venting companies do the engineering calculations and
to be done more often, periodically throughout the heating make the necessary recommendations for fan size and flue
season. vent diameter following the guidelines of NFPA 211/2006,
pg. 211-13. Installation of such systems must also follow
5. Befare servicing, allow the fireplace to cool. Always shut the mechanical drafting company's explicit installation and
off any electricity or gas to the fireplace while working on it. operation instructions.
6. Use only solid fuei or natural or LP gas log sets in this Caution: When used with the fireplace systems, all gas
unit. Do not use artificial waac based logs, chemical chimney log sets must be operated with the damper clamped in the
cleaners or flame colorants in this fireplace. fully open position. Only listed "vent free" log sets may be
operated with the damper in the closed position.
7. Never use gasoline, kerosene, gasoline-type lantern fuel,
charcoal lighter fluid, or similar liquids to start or "freshen 13. When in doubt about a component's usability - has
up"a fire in this fireplace.Keep all flammable liquids at a safe visible or suspected physical damage- consult your Isokern
distance from the fireplace. distributor or authorized Isokern representative for advice.
8.Always keep the flue damper open when heat is present in
the fireplace.
9. Do not use a product not specified for use with Isokern
fireplaces and the DM chimney system unless written
authorization is given by Earthcore. Failure to heed this
warning may cause a fire hazard and will void the Earthcore
warranty.
6
[ r
Safety Instructions - (cont.)
14. Modifications to fireplace 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 firebox are allowed with prior °
written approval and instructions from Earthcore Industries.
The installer indemnifies 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 modifications of the
fireplaces.
15. Keep all insulation, vapor barriers, "house wrap"
paper and other insulating type membranes and products,
including fiberglass, cellulose and other insulation,
(anything that carries an"R"rating)a minimum of three
inches (3") away from all firebox and chimney surfaces.
See exception.(Figure 34,Page 22)
Exception:
If insulation is used in walls surrounding the
fireplace, 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 fireplace sidewalls.
WARNING Do not pack required air spaces with insulation
or other materials.
16. Never leave children unattended when there is a fire
burning in the fireplace.
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 flu 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 fireplaces are in use.
7
i �
Warnock Hersey Listing Label
- Facsimile -
0
0
�
� � �S MODULAR REFRACTORY FIREPLACE 0 ivai�_21�
Intertek STANDARD: p 36" ❑42" O 4�" �MADE IN USA
� �MADE IN DENMARK
W/N 04895 WH- EARTHCORE
DO NOT REMOVE
OR COVER INDUSTRIES
THIS LABEL COMPLIES WITH APPLICABLE REQ.OF UL 127, ULC S610 JACKSONVILLE,
FL 32256
CLEARANCE TO COMBUSTIBLES:
UNITFRONTAND ISOKERN CHIMNEY =p��, DO NOT USE A FIREPLACE INSERT OR OTHER PRODUCTS
UNITSIDESAND REAR =1.5 in. (38mm) NOT SPECIFIED FOR USE WITH THIS PRODUCT.
COMBUSTIBLESHEATHINGABOVEOPENINGTOP =81n. (205mm) ��WARNING"THIS FIREPLACE HAS NOT BEEN TESTED FOR
SHEATHING ORTRIMTOOPENING SIDES =8 in. (205mm) USE WITH GLASS DOORS.TO REDUCE THE RISK OF FIRE OR
MAN7LEABOVEOPENING =14 in. (356mm) INJURY,DO NOT INSTALL GLASS DOORS.IF DOORS
OPENINGTOSIDEWALL =26in. (660mm) ARE USED,OPERATE FIREPLACE WITH DOORS FULLY OPEN.
HEARTH EXTENTION BEYOND FRON7 =20 in. (508mm) WHEN BURNING A DECORATIVE GAS APPLIANCE IN THE
HEARTH EXTENTION BEYOND SIDES =12 in. (305mm) FIREPLACE,LOCK THE DAMPER IN THE FULLY OPEN
COMBUSi1BLE FLOOR =4 in. (102mm) pOSIT10N.DO NOT OPERATE AN UNVENTED GAS LOG SET IN
INSULAiION FROM FIREBOX =3 in. (76mm) 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.
SEE INSTALLATION AND OPERATING INSTRUCTIONS FOR THIS MODEL AND ICC#ESR-2316,
LA.RR#25483,MEA#2490E.
CONTACT BUILDING OFFICIAL PRIOR TO INSTALLATION
FIGURE 1 -ISOKERN STANDARD SERIES
+��.
MODULAR REFRACTORY FIREPLACE /�,��,�
� MAGNUM:�28" ❑36" �41" �'�
,g � ❑4S° ❑BO° ❑�Z° �MADE IN USA �
wr��aua� COMPLIES WITH APPLICABLE REQ.OF UL 127,ULC 5610 �MADE IN DENMARK
y�j�.�� WM' EARTHCORE INDUSTRIES�LLC.
JACKSONVILLE,FL 32256
CLEARANCE TO COMBUSTIBLES: 28",36",42",48" 60"8 72"
UNIT FRONTAND ISOKERN CHIMNEY =0 in. =0 in.
UNIT SIDES AND REAR =1.5 in. (38mm) =1.5 in. (38 mm)
COMBUSTIBLE SHEATHING ABOVE OPENING TOP =8 in. (203mm) =24 in. (610 mm)
SHEATHING OR TRIM TO OPENING SIDES =6 in. (203mmj =9 in. (229 mm)
MANTLE ABOVE OPENING =14 in. (358mm) =38 in. (965 mm)
OPENING TO SIDEWALL =26 in. (660mm) =48 in. (1219 mm)
HEARTH EXTENTION BEYOND FRONT =20 in. (508mm) =33 in. (838 mm)
HEARTH EXTENTION BEYOND SIDES =12 in. (305mm) ='12 in. (305 mm)
COMBUSTIBLE FLOOR =4 in. (102mm) =N/A N/A
INSULATION FROM FIREBOX =3 in. (76mm) =3 in. (76 mm)
USE SOLID WOOD FUEL OR LISTED DECORATIVE GAS VENTED OR UNVEXTED APPLIANCE.AL50 FOR USE WITH LISTED LETAL CHIhNEY.
FIRE�LITE APPLICATION TO USE FTFi�OR E�UIVALENT CHIMNEY ONIY.
DO NOT USE A FIREPLACE INSERT OROTHERPRODUCTS NOT SPECIFIED FOR USE WITH THIS PRODUCT."WpRNING"THIS FIREPLpCE HAS NOT BEEN TESTED FOR USE
YYI1H GLq55 DOORS.TO REDUCE THE RISK OF FIRE OR INJURY,DO NOT INSTALL GLASS DOORS.IF DOORS ARE USED,OPERqTE FIREVLACE YYffH DOORS FULLY OPEN.
WHEN BURNING A DECORATIVE GAS APP W1NCE IN THE FIREVLpCE,LOCK THE DAIRER TO THE FULLY OPEN POSI710N.ONLY UNVENTED GAS LOG SETS WNICH HAVE
9EEN FOUND TO COIRLY YYITH THE STANDARD FOR UNVENTED ROOM HEATERS,ANSIIIASIAGA ZT1.11.1,ARE TO BE INSTALLEO IN THIS FIREPIACE.UO NOT OPERAIE
AN UNVENTED GAS LOG SET IN iHIS FIREPLqCE YYITH THE CHIIMEY RENpVED.
SEE INSTALLATION ANO OPERATINO INSTRUCTIONS FOR THIS MOOEL AND ICC p ESR-2716,
LA.RR#2548�,MEA%Z190E.
ONLY UNVq1iED GAS LOG SETS WHICH NAVE BEEN FOUND TO COtRLY VNTH THE STANDARU FOR UNVEN7EU ROOM
HEATERS,ANSIIIASIA�A Z21.17.t,ARE TO BE INSTALLED IN THIS FIREPLACE
CONTACT BUILUING OFFICIAL PIiIOR TO INSTALLA710N
FIGURE 2-MAGNUM 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 affixed to each fireplace.Do not remove the listing label from the fireplace.
Prior to beginning installation,contact your local building official to determine the need to obtain a permit.
g
Assembled Firebox & Smoke Dome Dimensions
Isokern Standard Series 36, 42 & 46
� G
� �
M
� � �
�
N
14"
C TOP PLAN VIEW
D E
F �
J A
SIDE VIEW FRONT VIEW PLAN VIEW
MODEL A B C D E F G I J MINIMUM FRAMING WEIGHT
36 43" 25114" 63114" 31 112" 36118" 27114" 33" 20114" 5" (46"W)x(65"H)x(26 314"D) 1205 Ibs
� 42 49" 25114" 63114" 31 112" 43118" 33114" 33" 20114" 5" (52"W)x(65"H)x(26 314"D) 1325 Ibs
46 53" 25114" 63114" 31 112" 47118" 37114° 43" 20114" 5" (56"W)x(65"H)x(26 314"D) 1450 Ibs
TOP PLATE, MEDIUM TOP PLATE, LARGE
Part No. Model Qty Part No. Model Qty
77 36 1 81 46 1
77 42 1
25 1l4"
25 1/4" 10 314" 10 314"
33"
43"
�4 3l4"
�4 3/4"
9
v ,
Component List & Dimensions Isokern Standard Series 36, 42 & 46
� �
SIDE WALL �� �` '"�
Part Fireplace 25114"
25114" � No.: Model: Qty:
A 20 36 6 �
BASE PLATE 20 42 6
Par� Fireplace 20 46 6 10112"�
No.. Model: Qty: A
21 36 1 43"
22 42 1 49" 3„
23 46 1 53"
BACK WALL A
10112"�
SMOKE DOME-MEDIUM Part Fireplace
No.: Model: A: Qty:
Part Fireplace 25 36 26 314" 3
No.: Model: Qty: 4� 3$ 46 37114" 3 �
5
11 36 2 °
11 42 2
DAMPER SUPPORT-LEFT
Part Firepiace
43" 16"
No,: Model: Qty:
95� 36 1
95L 42 1
95L 46 1 "'' .��'
SMOKE DOME-LARGE DAMPER SUPPORT-RIGHT
Part Fireplace
Part Fireplace No.: Model: Qty:
No.: Model: Qty: � 95R 36 1
13 46 2 95R 42 1
95R 46 1
53"
16" A
3"
25114" �' DAMPER BEAM
TOP-SLOPING Par� Fireplace �8"
No.: Model; Qty: A
Part Fireplace 16" 68 36 2 43"
No.: Model: Qty: 69 42 2 49"
34 36 2 70 46 2 53"
34 42 2
34 46 2
10
,
Assembled Firebox & Smoke Dome Dimensions
Ma num Series 28, 36, 42 & 48
.. �
a
, �
0
+
2 314" N
14'
TOP PLAN VIEW
U
F
0
E � �
m
3"
�5,.� A
f' �
SIDE VIEW FRONT VIEW PLAN SECTION A-A
MODEL •q• ^g^ ^C" "D" ^E" "F" "G^ MINIMUM FRAMING: WEIGHT
28' 35112" 28" 60114" pg��° 31" 19 314" 22114" 39"W x 61 112"H x 29112"D 10401bs
36 q3• 28" 69 314" 38" 38 318" 27114" 33" 46"W x 71"H x 29112"D 1300 Ibs
42 49" 2$" 69 3/4" 38" 44112" 33114"" 33" 52"W x 71"H x 29112"D 1420 Ibs
48 53" 26" 69 314" 38" 481/2" 37114" 43" 56"W x 71"H x 29112"D 1600 Ibs
'Model 28 comes with three(3)sidewalls and some componenls must be Yeld cuY.
Firebox & Smoke Dome Components List
'L�Up 1og\q ,�5��a 1o,�a
� � �
�4 3/4" q3, �4 314"
�>i?.
TOP PLATE,SMALL ��,��p; 1��y�4 .
PART FIREPLACE QTY:
NO.: Model: TOP PLATE,LARGE
36 28 1 � PART FIREPLACE QTY:
NO.: Model:
�4 3/4" g1 48 1
313j4
TOP PLATE,MEDIUM
PART FIREPLACE QTY:
NO.: Model:
77 36 1
77 42 1
11
� w
Component List & Dimensions Magnum Series 28, 36, 42 & 48
ti�
�
.� BACK WALLS
h�F *Model 28 Only
Part Fireplace Qty: � �wa Field Cut Back Walls
� - I No.: Model: G: �
�C 65 28 Cut to 20" 3 ���,y
BASE PLATE � �' 65 36 26 3/4" 4 �
3, 66 42 32 1/4" 4 ��F � I
Part Fireplace Size Qty:� 67 48 37" 4 ��
No.: Model: A: c� 9�
91 28 Cut to 35 1/2" 1
92 42 49" 1 ��f �
93 48 53" 1 �` �
� � 9�
�� � 'Cut as shown in the field;
� � 9'r,
� mortar pieces together and
staggerjoints when stacking
� 18^ for installation.
� �
o�
� DAMPER SUPPORT(LEFT)
� Part Firepiace Qty:
� No.: Model:
SMOKE DOME \ � 94L 28 1
Part Fireplace Size Qty: .�, �� 94L 36 1
No.: Model: A: � , 94L 42 1
12 28 32 1/2" 2
� 8 94L 48 1
11 36 43" 2 �
11 42 43" 2 DAMPER SUPPORT(RIGHT)
13 48 53" 2
Part Fireplace Qty:
��.�,�_ No.: Model:
� 94R 28 1
��-��� � 94R 36 1
94R 42 1
94R 48 1
TOP-SLOPING '�e,
Part Fireplace Qty: DAMPER BEAMS
No.: Model: � Part Fireplace
34 28 2 No.: Model: A: Qty:
34 36 2 68 28 Cut to 35 1/2" 2
34 42 2 68 36 43" 2
34 46 2 'True Height When Installed 69 42 49" 2 �
70 48 53" 2
-v
�,� �\ Front of �
� a � Smokedome
y,� (above) REAR �
SIDE WALL � 8�
Part Fireplace Qty: �� �
No.: Model: �' � FRONT
90 28 6
90 36 8
90 42 8
90 48 8
12
r �
Required Clearance to Combustibles
The fireplaces and DM chimney systems are tested
and listed for installation with"clearance to combustibles"as
follows:
The Isokern Standard and Magnum Series firebox °
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) o"CLEARANCE
Note: "Combustibles" are defined as "normal construction
materials"and are considered to be: wood framing materials,
partic(e board, mill board, plywood sub-flooring, plywood
paneling and wood flooring.
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 firebox must be held 8" away from the sides of the
firebox opening and 8"above the top of the firebox 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 fiberglass, cellulose
and other insulation,(anything that carries an"R"rating) FIGURE 3
a minimum of three inches(3")away from all firebox and
chimney surfaces.
Exception:
If insulation is used in walls surrounding the fireplace,
insulation may be installed behind sheathing ofgypsom board,
plywood, particle board or other material on the side facing
the Isokern.The facing material cannot be within 1 1/2"to the
fireplace sidewalls.
Notes:
A. The fireplaces must sit upon a concrete support
slab designed to bear the total installed weight of the fireplace
and DM chimney system. These support slabs can have no
wood underpinnings.(Figure 4)
The fireplaces are rated for installation on a
combustible floor system when using the Fire-Lite application
only.See pages 46-51 for Fire-Lite installation instructions.
B.Concrete support slabs for fireplaces must provide
the noncombustible hearth extension substrate needed to
support the code required noncombustible hearth extension
finish materials.(Figure 4) M N 1 1/2"
C. All fireplaces shall have hearth extensions of
approved noncombustible material such as brick, tile, or
stone that is properly supported,with no combustible material ---,-Q----Q--a a---a-Q---•1
against the underside thereof. Wooden forms used during a �
the construction of hearths and hearth extensions must be
removed when the construction is complete.
D. If a raised fireplace floor and raised hearth
extension are referred, the raised underl m structure No Combustible
P Y� g Underpinnings
must be built of noncombustible material and must sit on
noncombustible substrate. FIGURE 4
13
. ,
Rough Framing Dimensions
Rough Framing Dimensions
Model Width Height Depth
A B C
Magnum
Model28 381/2" 611/2" 29.5"
Z Model36 46" 71" 29.5"
Z
°O o Mode142 52" 71" 29.5"
� Model48 56" 71" 29.5"
� Isokern Standard
Mode136 46" 65" 26 3/4"
Mode142 52" 65" 26 3/4"
Mode146 56" 65" 26 3/4"
C.
� ���M�� Notes:
1."B"includes the 3"thick base plate."B"is reduced by 3"if the base
FR�9tijF q plate is eliminated to create a"flush hearth".
O�AG
/ 2. "Raised hearth" requires additional rough opening height at "B"
equal to the height ofthe 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 ofthe Fireplaces.
Corner Location Layout
The following chart of dimensions is intended to aid in the positioning
of a fireplace in a corner condition where the DM chimney must turn 45°
degrees to align with overhead framing.
Ma num A B C D
Model28 331/2" 181/4" 24" 651/2"
Model 36 43" 16 3/4" 32" 78 3/4"
,
Mode142 49" 261/2" 36" 83"
i Mode148 53" 28 1/2" 39" 85 3/4"
Isokern Standard
O Mode136 43" 49" 35" 72"
� Model42 49" 52" 37" 75"
Model46 53" 54" 39" 79"
� a To turn flue 45°,first set one offset block on the firebox so that
the chimney offsets 3"toward the back of the firebox.(Figure 6)
Set a DM outer casing onto this offset block so that the outer
P casing is at 45°to the firebox 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.
Note: Support the third offset down to footings and at each third offset
FIGURE 6 block thereafter(see pages 33&34).
14
, �
Assembly Instructions
General lsokern Assembly Instructions:
Earthcore Mortar (a thin-set type masonry adhesive)
� is used to glue all Isokern components together during field
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 fitted
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
FIGURE 7 contact surface of the first component, some mortar should
squeeze out along the face of the entire joint as a sign of
EC� complete and proper sealing of the joint.
MORTAR 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 firebox and smoke dome assembly
requires approximately 30 pounds (dry measure) of Earthcore
mortar.
Broken Components:
Components broken into 2 or 3 pieces can be repaired
by using Earthcore mortar along the break line as the component
is set into place.Components broken into multiple small pieces
FIGURE 8 should be discarded and replaced.
Leveling and Aligning Components:
Be sure to assemble all Isokern components level and
flush 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
SHIM IF REQUIRED TO and align it with adjacent Isokern components. Be sure to re-
ACHIEVE CORRECT grout any and all gaps resulting from shim insertion to maintain
HEIGHT
components to full bearing.
Notes:
FIGURE 9 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
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. ec
MORTAR
BASE PLATE
Installation:
Step 1:Set the base plate in a full bed of Earthcore Mortar flat
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 FIGURE 10
floating it in a bed of Earthcore Mortar to full bearing against
the underlying noncombustible support surface.
Notes: If the design preference is for a "flush hearth" �
(fireplace floor flush with the room's floor), the base plate
can be omitted from the assembly and the firebox walls built
directly on the concrete support slab.The fire brick floor of the
firebox is then set directly to the concrete support slab. This
makes the fireplace finished fire brick floor 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(floor
of the fireplace elevated above the room's floor),then the base
plate can be set on a noncombustible platform that is built up FIGURE 11
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 fire brick floor in addition to the
height of the platform.
Whether a flush hearth is preferred or a raised hearth,
the combustible floor on front of the fireplace must be covered
with a noncombustible hearth extension set tight against the
fireplace front and extending at least 20 inches out from the
finished fireplace and at least 12 inches beyond the finished
sides of the fireplace 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.
FIGURE 12
Step 2: Set the first course of the firebox back wall and side
walls into place. �
It may be convenient to dry set the first course of
side wall and back wall into place on the Isokern base plate FIRST COURSE
and then to trace their position on the base plate with a pencil. sioewn��
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 first layer of Wall components can be set directly into
mortar already applied to the proper areas on the base plate. Ec
Be sure to put Earthcore Mortar on the contact surfaces of the MORTAR
vertical joints where the side wall and back wall components
connect.(Figure 13)
FIGURE 13
16
Assembly Instructions - (cont.)
� Note: At all component placement, be sure to mortar all
rwo couRSes component contact surfaces with Earthcore Mortar. Check for
BACKWALL complete sealing of each contact joint while assembly progresses.
EC
Mo Step 3: Continue assembly of the consecutive courses of the
firebox 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
FIGURE 14 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
FIRST DAMPER W�th the a roved mortar.
SUPPORTIN pP
PLACE
Step 4: When all of the firebox wall components are set, check
the top surface of the firebox 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.
O (Figure 9)
Any gap created under the wall components during the
Shim leveling process must be filled with mortar to full bearing
against the base plate.
Step 5: Make sure that the firebox assembly has been set level
and square.Adjust as required while the mortar is still wet.
Make a final inspection of all contact joints in the
FIGURE 15 firebox 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 fireplaces come with an eight inch(8")thick damper
CAST IRON beam assembly, a four piece component group that is to be
DAMPER assembled on top of the firebox sidewalls.
FRONT DAMPER The damper beam assembly consists of two long lintel
SUPPORT pieces and two short damper beam side pieces.
The damper side pieces are designed to sit on the firebox
side wall between the front lintel and the back lintel.Each of the
damper side pieces is designed specifically for its own side of the
unit. When properly set, each damper side piece fits flush with
the outside face of the firebox sidewall so that its interior bottom
edge aligns with the interior angle of the firebox side wall that it
sits on.(Figure IS)
The two long lintels are identical in shape, size and in
length,equal to the width of the fireplace model that they serve.
Properly placed,one lintel is to sit on top of the firebox back wall
and flush with it; the other lintel sits flush with the front of the
firebox,spanning the firebox opening.These components both sit
FIGURE 16 on their narrow base so that their beveled face points down and
into the firebox interior.(Figure 16)
Be sure to mortar all damper beam components to the
top surfaces of the firebox.
Mortar the contact surfaces of each damper side
component where it meets the front and back damper beam lintel
components.
17
Assembly Instructions - (cont.)
Step 7: With the damper beams assembled and mortared Make sure that the top plate is set so that the flue
together, set the cast iron throat damper (unless another hole is closer to the back wall of the smoke dome assembly.
damper type is being used) on top of the damper beam and Be sure to set the smoke dome top plate flush with
over the smoke chamber opening. The cast iron damper's the front, back and sides of the smoke dome assembly. All
operating plate should face toward the rear of the fireplace. contact surfaces must be properly sealed with the approved
(Figure 17)The flange at all four sides of the cast iron damper mortar.
should be supported by the damper beam's top surface.
Note:The completed smoke dome assembly should present
Before adjusting the cast iron damper to its final a stable and level surface for setting the flue components.
position proceed to Step 8. (Figure 19)
Note: A Damper is not required for exterior installations.
DAMPER
Step 8: Position the cast iron damper so that its front flange
is approximately one inch(1")away from the inside face of REAR
the front smoke dome component.(Figure 17) FRONT
Run a thin bead of mortar around the four sides of
the cast iron damper or tack the corners of the flange 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 flush with the back face of the back FIGURE 17
damper beam linteL(Figure 18)
Set the Isokern Standard front smoke dome �
component in mortar across the front damper beam and flush END�17°
with it. Set the Magnum front smoke dome component in
mortar accross the front damper beam and 2 -1/4 inches REAR
back from the front of the front damper beam lintel. This Damper Beam FRONT
placement should create a space of 17 inches(17")between
the front and rear smoke dome components.
END
Step 9:Position the smoke dome's sloping sidewalls at each
end of the smoke dome components.(Figure 18)
The sloping sidewalls fit in between the front and
rear smoke dome components and also fit 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 NOTE:Magnum Series Shown for
will sit tight onto the flat top of the damper beam assembly. m�st�acion oniy.isokem sca�da�d
FIGURE 18 Series Front Smoke Dome Will Sit
Flush With Front of Damper Beam
Step 10:Make sure that all component contact surfaces have
been properly sealed with approved mortar.
10 314"
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 firebox.
FIGURE 19
18
,
Access Modification
Through-Wall Accesses:
Flex�uct ro Fireplace, 1. Combustion Air Inlet: Combustion air inlet kits though
(All Parts Noncombustibie) not required by Earthcore may help improve fireplace
operation in homes tightly sealed and with other ventilating
appliances installed (Figures 20 & 21). Check local codes
for combustion air inlet requirements.
Exterior
' Wall 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 fireplace combustion air kits typically
ExteriorAirVent consist of a sliding stainless steel access door affixed to a
With Dress Plate three inch(3")or four inch(4")diameter stainless steel sleeve
approximately twelve inches (12") long. An exterior vent
FIGURE 20 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 fitted into the finished fire brick
lining at the interior sidewall of the firebox.The twelve inch
� (12")long sleeve can be introduced into the firebox side wall
by core drilling an appropriately sized hole at the selected
firebox location.Keep the top of the access hole no more than
six inches (6") above the finished firebrick $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 firebox side wall and
must be connected to metal pipe(by others)- either flexible
or rigid-that leads to the source for outside combustion air,
as directly as possible from the fireplaces(Few to no bends)
Typical Placement of with a maximum length of sixty feet(60').
Gas or Electric Conduit
(See Detail Below) WARNING: Do not use combustible duct material. Avoid
SupplyAirVentilation installing a combustion air inlet where the opening could be
(If Required By Code) CAUTION: blocked by snow, bushes or other obstacles. Air inlet must
All access holes must be terminate a minimum of three feet below the chimney cap
grouted with mortar-after line
FIGURE 21 or conduit feed to seal any level.Air inlet ducts shall not terminate in attic spaces.
gaps or cracks around line
feed conduits 2. Gas Line Feed: For a fireplace 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
Fire Brick Side fireplace damper must be set in the fully open position.
Gas line for gas log sets used in the Isokern firebox can be
routed through the side wall of the firebox by drilling an
Gas or Electric appropriately sized hole using a masonry drill bit(Figure 21).
Conduit
NOTE:Fill Any Gaps
Around Conduit With Mortar 3. Electrical Line Feed can be routed through the firebox
side walls by drilling an appropriately sized hole using a
masonry drill bit(Figure 21). Be sure to follow the gas log
FIGURE 22 Appliance Manufacturer's explicit electrical line connection
instructions for vented masonry fireplace installations. Gas
line and electric line must be fed through separate access
holes.Be sure to fill any gaps around conduit with EC mortar.
(Figure 22)
19
Fire Brick Installation
Fire Brick Insta►tation:
The manufacturer requires that the fireplace fireboxes
be lined with a minimum one and one-eighth (1-1/8") thick
fire brick. Thicker fire brick may be used as an option. The
pattern for the fire brick lining is an owner option.Standard N
or S type brick mortar is suitable mortar for the fireplace.
Fire brick mortar needs to be suitable to both adhere Exp nsion
the fire brick to the inside of the firebox and to create the 1/2"Ga
finished face joints of the brick work. Based on a history of
field applications and experience, a suitable mortar would be
as follows:
FIGURE 23
Mix:
* 1 bucket masonry mortar(S or N type)
*5 ]bs 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 fire brick line a fireplace.
E pansi n
Installation Instructions: 1/2" ap
1. Wet mop the inside of the fireplace with a damp
sponge to remove dust and loose particles from the interior
before fire-bricking.
HINT:Dip each firebrick into water before applying. Fir Brick Floor
(Built irst)
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 fire brick.
3. Start the fire brick at the front edge of the floor FIGURE 24
of the Isokern firebox, proceeding inward toward the back.
Let the floor brick gap approximately 1/2" off the back wall
and side walls.This air space allows heat expansion of the fire
brick and is to be left empty of mortar.(Figure 23)
4.Next,apply fire brick to the back wall of the unit.
The back wall fire brick covers the 1/2"expansion gap left at
the brick floor along the back wall of the firebox.(Figure 25)
5. Set the side wall fire brick by starting at the front edge of
the unit's side wall and working inward toward the back wall
fire brick. The side wall fire brick, when completed, covers
the 1/2"expansion gaps where both the$oor fire brick and the
back wall fire brick were held ofFthe units side walls.(Figure No Gaps
24)
All required through-wall accesses(gas and electrical
line feeds and combustion air supply access holes) shou(d be Fire Brick Floor
drilied before the required fire brick lining is installed. and Back Wall
Earthcore makes no claims as to the performance (Built First)
offire brickorfire brick mortar(s).Itis typical for heat stress
cracks to appear in the fire brick in fireplaces.
FIGURE 25
20
Flush Wall Finish Detail
Framing Protrudes
Past Firebox Front
�
Magnum Series
Drywall Flush with
FIGURE 26 Firebox Front
FIGURE 28
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 firebox 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 firebox 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 ofthe smoke dome and
at the same time align flush 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 firebox opening top(Figure 26).
The Isokern Standard smoke dome front sits flush with the rough face of the firebox and damper beam. Eight inches (8") of
noncombustible facing material must span framing members for drywall to keep the rec�uired eight inches(8") above the firebox
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 firebox 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 firebox and damper beam.(Figure 28)
21
Required Clearances (when sheathing protrudes beyond front of firebox)
P��o� 1 1/2"MIN TO
Sheathing COMBUSTIBLE FRAMING
Noncombustible 8„ FINISHED OPENING 8„
Facing
FIGURE 29 MIN MIN
W D M STI E)
E IN
z
��
FIRE
BRICK
g�� 8„
MI 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 firebox, application of such combustible sheathing must assure that
the sheathing is held a minimum of eight inches(8")away from each side of the finished firebox opening and a minimum of eight
inches(8")above the top of the finished firebox opening.(Figure 29&30)
Do not build a combustible framed wall out in front of the firebox.
If sheathing and framing are to be installed across the front face of the firebox smoke dome,then the framing and sheathing
must be held a minimum of eight inches(8")above the top of the firebox opening.This means that framing and sheathing across the
smoke dome front must be kept at or above the damper beam.
22
Required Clearance to Combustible Framing
�Z
�� �MB�n�E Fireplaces are tested and listed for one and one-half
F'�"""� inch(1-1/2")clearance to combustible framing material at the
firebox sides and back.
lnstallation and use practices that are beyond the
"n� 'M�N control of the manufacturer* can result in situations where
MIN
clearance requirements (as determined through testing and
e — 8 as stated by the manufacturer) are not maintained due to
""" M'" construction subsequent to the installation of the Isokern
FIGURE 31 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 fire resulting in damage to property,
FACE OF personal injury or loss of life,do not pack or fill the required air
COMBUTIBLE�(- spaces with insulation or other material.No material is allowed
FRAMING \I
� in these areas.(Figures 31 &32)
*The manufacturer is not responsible for installation and use
'M,N' 'ti;,N� practices that are beyond the scope of the product as defined in
FACEOF the product listing and in the installation manual.
COMBU7IBLE
- --� FR4MING
The firebox backwall,side walls and the smoke dome
back require 1 1/2"clearance to combustibles.(Figure 33)
FIGURE 32 Keep all insulation,vapor barriers,"house wrap"
paper and other insulating type membranes and products,
"� including fiberglass, cellulose and other insulation,
(anything that carries an "R" rating) a minimum of three
inches(3")away from all firebox and chimney surfaces.See
exception.(Figure 34)
"� 'MiN Exception:
MIN
If insulation is used in walls surrounding the fireplace,
insulation may be installed behind sheathing of gypsom board,
� � plywood, particle board or other material on the side facing
FIGURE 33 the Isokern.The facing material cannot be within 1 1/2"to the
,,,r fireplace sidewalls.
MIN
When Fireplace installations are surrounded by walls
that are to be insulated,the walls must have enough clearance
3'minWhen InsulationBehindsheathing to the Isokern unit in order to maintain the three inch (3")
��pppR� with 1 il2"Clearence
��^s��� minimum clearance to insulation for unsupported insulation.
�+�r (Figure 34)
min
Never spray the Fireplaces with any type of sealer,
insulation or other material.
ir �Z. o
� Hearth Fxtension men 3
S
1 11Y
Do Not Place Sheathing
Wlthin the 1 112"Required
Clearence to Combustibles
NOT PERMITTED FIGURE 34
23
Flush Wall Fire Brick Finish Detail
Recommended Fire Brick Detail: When drywall is
the wall finish at the firebox face and flush with the rough
face of the firebox and damper beam, it is recommended
when installing the required fire brick lining to the interior
of the firebox, that the leading edge of the fire brick- at the
floor and at the side watls of the firebox-be set flush with the
�� �i2" rough firebox front.This will aid in the overall fit and finish
�� ��Z of the fireptaces front when the code required noncombustible
� finished facings are applied.
Drywall Flush With
Firebox Front This alignment of fire brick application as shown,
(Figure 35),allows the fire brick lining to be in the same plane
with the room's wall finish surface. With the fire brick set in
this fashion the noncombustible finish facing material can be
set tight against the leading edge(or,"room edge")of the fire
brick at the sides of the fireplace opening. At the same time
the finished facing material can lay flat against the room's
finished wali surface.
Important: Since there is no fire brick set along the top of
the firebox opening,when setting the noncombustible finished
facing material(code required and supplied by others)across
8� the top of the firebox opening there may be a gap between
Noncombustible Min
Facing Material the back of the noncombustible finish material and the rough
front face of the fireplace damper beam.
Be sure to check for and fill any such gap with
noncombustible Earthcore Mortar in conjunction with
placement of the code required noncombustible finish facing
material set across the top of the firebox opening.(Figure 36)
WARNING:Avoid false chimneys.
FIGURE 35 Important: Fai(ure to seal any gaps between the front face
of the damper beam and the back of the noncombustible
finished facing materiai 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 noncombustib(e
facing material at the top of the firebox opening and the rough
front of the fireplace damper beam. If left unfilled this gap
creates a"false chimney"which can draw smoke,heat and fire
out of the firebox into the space behind the noncombustible
finish facing and on up into overhead framed spaces causing
a fire hazard.
FILLANY GAPS
WITH EC MORTAR TO It is acceptable to apply noncombustible finish
AVOID FALSE CHIMNEYS facing to the front and below the firebox opening to create an
arched look, eta When doing so,make sure to check for and
fil( any such gap with noncombustible mortar in conjunction
with placement of the code required noncombustible finish
facing material.
, NOTE: You must still keep a minimum 8" from the firebox
opening to any combustible materials.
FIGURE 36
24
Interior Masonry Veneer Fireplace Finishes & Clearances
ooc�oo
00000
=----------------------- -------- --------o-------------- --; o0
OM ST LE � � � OOD
SH AT G , �� •., 0�
0 '��00
0� '� �0
Z ��`� �0
N- �� ��
�� ��
4 x 6 STEEL � MASONRY VENEER ��
"L"ANGLE
00
E O SO R ��
IR OX IT d ��
S EL" 'A N
MASON VENEE
0�
31/2" ��
2� ��
00
��
0
4 x 6 STEEL"L"
ALIG 4, ALIGN
2"
MIN
ISOKERN UNIT WIDTH DIM'N. BEARIN
EXTENT OF STEEL"L"
FIGURE 37
Stucco Finish Application:
Any finish can be applied to an Isokern fireplace however with each finish there are different application techniques which
can help with the longevity of your finish.When applying a stucco finish to the Isokern material, it is recommended that a scratch
coat is applied first 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 fireplace unit. Use 1 1/4"Tapcon screws to attach the lathe to the firebox using the minimum amount needed to secure
the wire lathe. A brown coat is applied next to create an even surface for the finish coat.The finish coat is applied last,creating the
decorative finish on the wall surface.
25
Masonry Veneer Construction Details
Brick,stone or other masonry veneer finished fronts to
fireplaces are possible. Special attention is required with regards
to:
(1)the placement of the proposed masonry veneer facing
COMBUSTIBLE and its interface with the fire brick lining,and
SHEATHING (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 fireplace unit behind the
veneer facing.
�., MIN.CLEARANCE Any proposed brick, stone or other masonry veneer
,,, facing must have sufficient foundation to support the full weight
� of the veneer work.This may require review by a local structural
�° � engineer prior to construction.
Z The veneer facing, when installed, must present a tight
4„ 2 seal with the leading edge-the room edge-of the fire brick lining
BEARING at the sides of the firebox opening.(Figure 39)
A steel "L" wili need to span the top of the finished
fireplace opening to carry the masonry veneer as it spans over the
BRICK firebox opening.(Figure 37)
VENEER
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
FIGURE 38 the steel"L"and the damper beam front.(Figure 39)
—AIR SPACE
Steel"L"or"angle"used to support masonry veneer
as it spans the firebox opening must, in all cases, have a two CoMBU IBLE
inch(2")minimum clearance to all combustible materials.The SHEATHI G
vertical leg of the steel "L" cannot exceed six inches (6") in MASON VENEER
height.
N
Note: Properly placed combustible sheathing is kept a
minimum of eight inches (8") away from the firebox 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 4x6STEE °�"
firebox must be moved to at least two inch(2")clearance to the
firebox sidewalls to maintain minimum two inch(2")clearance
to the steel"L"to avoid a potential fire hazard. MASONRY BEYOND
Moving frami�g members two inches(2")away from
the firebox side walls will maintain the minimum required two MORTAR OINT
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)
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 COMBUSTIBLE
material. Suitable hearth extension material for the fireplaces �Z�
shall be placed on the hearth extension's noncombustible MANTLE SHELF
substrate and must extend to at least twenty inches (20") in
front of the fireplace's finished opening and must extend to
at least twelve inches (12") beyond the sides of the finished �
fireplace opening.(Figure 41)
WARNING: The noncombustible hearth extension, by code,
must sit on noncombustible substrate which shall have no
wood underpinnings.
This means that of�grade wood floor systems shall be
constructed in such a way that all wood floor joists and 20" HEARTH
subflooring shall stop twenty inches(20")out from the front of EXTENSION
the firebox.(Figure 40)
Mantle and Mantle Shelf Clearances: Fireplaces are subject
to the same building code safety clearances to combustible e a
trim as with any radiant heat fireplace. �° �
All combustible trim shall be kept at least eight inches
(8")from the finished fireplace opening. COMBUSTIBLE
Combustible trim located along the sides of the FLOOR SYSTEM
fireplace opening, which project more than one and one-
half inches (1-1/2") from the face of the fireplace, shall have FIGURE 40
additional clearance from the eight inches (8") equal to the
projection. ADJOI N I N G
Combustible projecting mantles-up to twelve inches ROOM WALL
(12") of projection - shall not be placed less than fouteen
inches(14")from the top ofthe fireplace opening.Combustible
mantles which project more than twelve inches(12")from the
face of the fireplace, shall have additional clearance from the
fourteen inches(14")equal to the projection.
Note: The local authority having jurisdiction may require �, �
greater clearances for projecting combustible mantle shelves. _
�
Be sure to check local building codes regarding required O
clearances to projecting combustible mantles.
Adjoining Walls. Side walls and walls to rooms adjoining
fireplace installations cannot be closer than twenty-six inches
(26")to the finished fireplace opening.(Figure 41) HEARTH
EXTENSION
Note: "Clearance to Combustible Trim" are those distances
required to ensure that a fireplace mantle or facing will not 20�
catch fire. 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 �
N
of circumstances involving many variables.
These include paint or finish composition, previous
exposure to heat,methods and quality of construction,air flow
patterns,etc.Because of these variables,the manufacturer does FIGURE 41
not guarantee that heat warping or discoloration will never
occur.
27
Concrete Support
The Fireplaces are not rated for installation on a combustible
floor 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 fireplace installations may include
the following types:
1.Slab on grade:standard residential,minimum four inch(4")thick,2500
psi concrete foundation on properly compacted fill.This type foundation
can support Isokern installations up to thirty feet (30')* overall height
without additionai structural support. (brick ledge installations not
included)(Figure 42)
*Minimum height.See page 3 for specific models.
2. Slab-on-grade foundations, thickened and reinforced: for additional
——---- •--�—e� load carrying.(Figure 43)
FIGURE 42 3.Off-grade slab on foundation walls and footings
Projects with off-grade floor 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 fireplace unit. (Figure
44).Supports for off grade slabs must be concrete or steel and capable of
supporting the slab,Isokem unit and the chimney.
For multi-floor 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
--T---- .---<:--- �- 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.
FIGURE 43
Fireptace weights*and"foot print"areas:
The total fireplace 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: 13001bs.-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.
' *Totals are exclusive of any chimney components. See page 30 for
I I Isokern DM chimney component weights.
� a "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.
FIGURE 44 Note:Additional support slab area may be required at the side or back
of the fireplace 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.
0
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: lllustrations shown reflect"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 specific 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 fire
hazard and void the limited warranty.
Note: A firestop 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 fire 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 defined as "normal construction
materials"and are considered to be:framing materials,particle board,
mill board, drywall, plywood paneling, plywood sub flooring, and
wood flooring.
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 flue 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"
� 26 1/4" 26 1/4"
6"HIGH
INNER STARTER �6"
LINER
13/16"
16 1/2" 12"or 14" SMALL i
CROWN CAP 3"
�
12"
12"HIGH �
INNER LINER DM 54 37 1/2"
Note:DM 44 12"High Inner Liner will have a 6"or 8"Diameter Flue hole. 37 1/2°
21 1/2" 21 1/2"
�O� � �
�o� 13/16"
i
LARGE 3"
12 CROWN CAP
OUTER CASING
11"
21 1/2" 3��
.
31 1/2" 31 1/2"
0
�/ 6"
o O
25" �
OFFSET BLOCK � �3"
BRICK LEDGE
�3,�
r
OFFSET BLOCK
STACKED
30
DM Chimney: Component Weights
Isokern DM Chimney Weights:
Total installed Isokern DM chimney weight will vary
according to each specific installation. Total installed chimney
weight will be based on the overall height and the configuration 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,bricWstone SMALL
veneers,cement crown caps and chimney shrouds. CROWN CAP
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.
LARGE
*Construction of an offset block sequence will shift a portion, if CROWN CAP
not all of the chimney load off of the firebox 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 � o
offset sequence. (See pages 33-35) Consult a structural engineer
for specific,individual structural requirements. �
BRICK LEDGE
Notes:
Plan chimney configuration carefully before constructing
the required reinforced concrete support foundation for the
fireplaces.Be sure that enough structural masonry area is available
to support any offset chimney sequence included in the proposed
chimney design.(See Page 35)
Earthcore is not responsible for site specific structural INNER LINER
support details and load specifications for fireplaces and DM
chimney system installations. Consult local structural engineer O�O
for proper job-specific support structure design, sizing and load
bearing specifications. �o�
Unless otherwise noted,all floor drawings in this manual
are merely illustrations to indicate the presence of an underlying
noncombustible support structure to the fireplace installation.
OUTER CASING
OFFSET BLOCK
31
DM Chimney System: Installation Instructions
DM Chimney Alignment:
OO� Where the chimney run is to be a straight vertical run
the DM outer casing block sits directly onto the Isokern smoke
�o� dome lid.The DM outer casing block,properly set is intended
� OUTER CASING to be flush with the back face of the firebox smoke dome
assembly (Figures 48 and 49).
FIGURE 45 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).
12"HIGH This total set-back distance makes it possible for
INNER LINER a three and one-half inches (3-1/2") thick bearing header to
pass over the firebox smoke dome assembly and for the DM
FIGURE 46 chimney to run straight up the back side of the bearing header
(Figure 49).
6"HIGH STARTER
INNER LINER Installation of the DM chimney:
Begin straight DM chimney runs by setting a DM
FIGURE 47 10 3/4" � outer casing block in a bed of mortar on top of the smoke dome
- o lid with the outer casing block centered on the lid from side to
� side and flush with the back of the smoke dome lid.
3 3/4^ � Be sure that the outer casing block aligns with the flue
° hole in the smoke dome lid.
Next set the DM inner liner's six inch(6")tall starter
piece (Figure 47) inside the first outer casing block. The
"factory" version of the six inch (6") tall inner liner starter
piece has a female end and a flat end.Set this inner liner starter
with the flat end down. Set the downward end into Earthcore
FIGURE 48 Mortar so that it is fully sealed to the smoke dome lid.
WARNING: Do not mortar the air space between the inner
�o� liners and the outer casing blocks.
��� 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.
Magnum Fireplace Shown For Illustration Purposes Only After setting the DM inner liner starter piece, apply
FIGURE 49 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 fit 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 flue is attained. Mortar all outer casing blocks
together and mortar all inner liners together.Do not mortar or
fill 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 FIGURE 50
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 o
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 flue 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,
parailel 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: Afirestop 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 fire to
get to the attia FIGURE 51
33
�
DM Chimney System: Offset Block
DM Offset Chimney Block:
� 3,� For vertical DM chimney to bypass overhead obstructions,
i<� the Isokern offset ch�mney 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-five inches(25")long.The
fourteen inch hole passes through the block at thirty(30°)degrees.An
offset chimney block can be set as the first$ue component on top of
�o� the fireplace smoke dome.
When building offset sequences it is necessary to support
FIGURE 52 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"),a(lowing the flue to rise at an angle of thirty
(30°)degrees off of vertical. (Figure 52)
When building offset sequences check the interior flue
alignment as each offset block is set to avoid creating overhanging
ledges on the inside of the flue. Such internal overhangs will inhibit
flue drafting.
Eact�offset block is to be set ful(y in a bed of Earthcare 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 fireboac/smoke dome
assembly. Offset blocks can also be set in a spiraling rotation, thus
FIGURE 53 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.
Offsets to the Left or Right:
When offsetting chimneys to the left or right of the firebox 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 firebox 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 five-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 biock sequences that clear the side
wall of the firebox below,it is allowable to support the first offset
block that ctears the the firebox side wall and then to proceed with
FIGURE 54 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 flush 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 first DM outer casing block flush
to the back end of this offset block.This will leave a distance of
6-3/4"from the face of the firebox smoke dome assembly to the
face of the DM outer casing block. This allows for the smoke
FtGURE 55 dome to sit flush 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",nominal8"CMU plus 1-1/2"
furring strip - first 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
__1� building with more offset chimney blocks.(Figure 56)
Offset block Support Foundations:
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 fireplace and DM chimney systems carefully
before foundations are laid to assure that proper footings are
available to support Isokern offset blocks chimney run.
FIGURE 56 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 firebox/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
� � firebox/smoke dome assembly as though starting a straight
"'s"'----'� 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
FIGURE 57 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
.-.1-;- offset sequence will require.
35
DM Chimney System: Offset Block (cont.)
MEASURE
TRAVEL
When establishing the "far face" of the overhead IDISTANCE
obstruction,be sure that the DM chimney blocks can run straight 1
to chimney termination without further overhead obstruction .
(Figure 59) OVERHEAD
Be sure that there is sufficient space beyond the "far OBSTRUCTION
face"of the overhead obstruction to accept the DM chimney's
outer casing dimension of 21 1/2". Support all offset sequences PLUMBLINE
down to bearing as discussed on previous pages.
Notes:
A)Always support the last offset biock 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. FIGURE 58
C) Be sure the foundation under all support columns
is made of concrete or steel and designed to support the loads
applied to it. T�a`vE�
DISTANC
D)Check with local codes and a structural engineer to �
confirm loading and foundation requirements.
E) Maximum horizontal distance of offset is six feet
(6')and represents twenty-four offset biocks in seyuence.
F)By code the maximum angle of offset for a chimney �
system is 30°off of vertical.
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. FIGURE 59
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 3
reinforcing rods and subsequent grouting.(Figure 60&61) 1,��ti ��i�,
The brick ledge is intended for use in chimneys that 3
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 O O
ledge must not be cut or altered in any way.
0 3�
BRICK LEDGE
FIGURE 60
36
DM Chimney System: Brick Ledge Installation
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 flat contact surface for the
brick ledge.Temporarily leave out the inner liner that fits this outer
casing block.
Set the Isokern brick ledge onto the flat 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
Brick Ledge 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').
Consult local structural engineer for proper job-specific
support structure design,sizing and load bearing specifications.
� 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 fill the holes with grout. Suitabie 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 firebox/smoke dome assembly include the placement of a 4"
by 4" by 3/8" minimum steel angle across the firebox opening.
(See page 40 for "Structural Informatiod' for details regarding
FIGURE 61 specification and placement of steel angles in fireplaces.)
37
DM Chimney System: Brick Ledge Load Capacity
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 finished height of
any chimney varies based upon site-specific conditions (eg.
elevation of roof line, roof pitch, distance of the chimney from
the ridge,etc.).
ISOKERN
It is relatively simple to calculate the total physical load BRICK LEDGE
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 specific and based on
local variables such as wind speed zone,exposure classification,
eave height and roof pitch of the structure, as well as height of
chimney mass exposed to wind.
I 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 specific
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.
-'a-----'-'-'- '-'a'-'--e--e--'e'-'-'�--
FIGURE 62
38
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-proofing details and
� the placement of flashings.
A typical flashing detail would be to field fabricate an
Y aluminum or galvanized sheet metal flashing, approximately
thirty-two inches(32")square with a twenty inch(20")square hole
in it,to serve as an inner$ashing.(Figure 63)
INNER Place the inner flashing on the first DM outer casing block
FLASHING that fully clears the roof line.Keep the flashing to about a one-half
FIGURE 63 inch(1/2") lap onto the top of the outer casing block.The twenty
inch (20") square hole in the flashing should fit 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 flashing
is set into a horizontal joint in the veneer at a level above all
other roof deck flashings, chimney-to-roof flashings and counter
� flashings. Weep holes should open to the outer face of the veneer
at vertical mortar joints located at the level of the inner flashing.
(Figure 64)
Where moisture may develop between the DM outer
casing and the chimney veneer,inner flashings 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
FIGURE 64 not require the installation of the Isokern brick ledge. The small
crown cap is also suitable where DM chimneys are to receive
a stucco finish. Other chimney terminations are possible with
DM chimneys. Check local codes for use of custom chimney
terminations and decorative shrouds.
SMALL DM Large Crown Cap(Figure 66)
CROWN CAP The DM large crown cap is a prefabricated cement
weather cap for masonry veneer chimneys. The large crown cap
FIGURE 65 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
LARGE crown cap over the inner liner and onto the top of the last outer
CROWN CAP casing in the stack.
FIGURE 66 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
LESS THAN 10'-0" Chimney Height Requirement:
The required minimum chimney height above the roof
and adjacent walls and buildings is specified by all major building
codes and is summed up in what is known as"the 2 foot in 10 foot
ROOF RIDGE rule":
WORK POINT ° z
N IM E � (1) If the horizontal distance from the roof ridge to the opening
CRICKET r, of the chimney is less than 10',the top of the chimney must be at
least 2'above the roof ridge.(Figure 67)
SECTION
THRU ROOF (2) If the horizontal distance from the opening of the chimney
to the roof ridge is more than 10'then a chimney height"work
i point"is established on the roof surface 10'horizontally from the
FIGURE 67 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)
10'-0"
A simple example of this would be if the roof is flat
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)
WORK
POINT N Z Note: The "2 foot in 10 foot rule" is necessary in the interest
IMN � of fire safety but does not ensure smoke-free operation of the
o fireplace. Trees, buildings, adjoining roof lines, adverse wind
SECTION CRICKET "' conditions, etc. may require a taller chimney for the fireplace to
THRU ROOF draft properly.
Chase Enclosures: DM chimneys can be enclosed within a
wood framed chase at zero clearance to wood framing members.
FIGURE 68 Chase enclosures need to be built to local wind load reGuirements
and shall be structurally independent of the Isokern chimney.As
with all chimney installations, avoid overhead obstructions such
Z as trees,power lines,etc.
�
° 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 instal(ed
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 fire hazard and void
the limited warranty.Do not pack insulation around the fireplace
or chimney.Do not insulate the chase cavity with blown or loose-
fill type insulation materials.
Chase Top Flashings:
Non-combustible, weather tight chase flashing 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 flashing for
FIGURE 69 positive weather seal.Chase flashings may be supplied by others.
40
Structural Information
The firebox/smoke dome assembly has a load capacity
that allows for the fireplace 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 CAST IRON DAMPER
offsets)and are exclusive of the brick ledge. (IF USED)
Important: DM chimneys taller than the listed maximum FRONT DAMPER
heights require a steel angle (minimum of 4" x 4" x 3/8") be SUPPORT
set across the firebox opening when assembling the unit as a
structural lintel. Consult a structural engineer to design proper
structural support.
This steel angle shall span the firebox opening,bearing
fully on the front 4 inches of the firebox 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 STEELANGLE
above is also required in all fireplace installations where the
4x4x318 MIN
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 Top Piate
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.
STEELANGLE
Wind Load Calculations: Using the required Earthcore 4x4x3/8 MIN
Mortar to install the DM chimney system,the maximum height
above the roof line of a one story residence with an exposure
classification C without additional structural support is:
90 MPH 26'-0"
100 MPH 24'-0"
110 MPH 21'-8"
l20 MPH 19'-8"
130 MPH 18'-0"
140 MPH 17'-6"
146 MPH 16'-8"
150 MPH 16'-4"
Far two story residences,please call the Technical Department
at: 800-642-2920. FIGURE 70
Important: The top plate of the firebox 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
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 flow of smoke and
gasses out the top of the flue opening. Figure 71 depicts some common
chimney terminations.
LARGE Check with local building codes to establish the need for
CROWN CAP chimney caps and spark arrestors or for any limitations to their design
and use.
SMALL
CROWN CAP
I
FIGURE 71
42
..� x�n wwa. rwnr- --°� rirwwrwr�sawirt � . . ..... ,:n.=. .. .. �.� ."",•RN14•:.�"... .
��.
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 fireplaces, 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 flue design can be from the following
types:
METAL
FLUE 1.Non-insulated completely thermal siphoning,double-wall,air-
cooled 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).
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 fireplaces.
Note:
The selected, approved chimney manufacturer must
provide the masonry anchor plate designed to fit their flue system.
(Figure 73)
FIGURE 72
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 fireplaces.
ANCHOR
PLATE
Maximum height of a metal flue system is not required
FIGURE 73 as all the load can be taken offthe firebox.
o Refer to metal Hue manufacturer for number of offsets,
approved chimney shrouds, clearance to combustibles and any
irvswoo� information specific to that flue system. Earthcore does not
BLANKET
manufacture these components and defers to manufacturers
instructions.
�
SMOKE DOME
TOP PLATE
43
� � ,r� . ,
,
,,� ,
Specialty Applications - See-Thru
The See-Thru application of the fireplace is built with
a fireplace 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- vERTICA�S��E
sided fireplace this type of fireplace can be difficult to get to FACE INSIDE FIREBOX
reach and to maintain proper dra8ing. (aoTH S�oES)
Constructing a See-Thru Unit: STEEL
ANGLE
1)Set the base plate in place. �
Notes: If the design preference is for a"flush hearth"(fireplace
floor flush with the room's floor),the base plate can be omitted STEELANGLE
from the assembly and the firebox walls built directly on the 4 x 4 x 3/8 MIN
concrete support slab as long as there are no combustible
underpinnings underneath the concrete slab.
Whether a flush hearth is preferred or a raised hearth,
the combustible floor on front of the fireplace must be covered NOTCH FOR STEEL
with a noncombustible hearth extension set tight against both FRONT� ANGLE PLACEMENT
open sides of the firepiace and extending at least 20 inches out viEw (BOTH SIDES)
from the fireplace opening and at least 12 inches beyond the
finished sides of the fireplace opening.
2)The firebox back wall components are not used.The
firebox side walls are set,reversed from their normal position, FIGURE 74 VERTICAL
FACE IN
their flared faces set to the outside of the firebox.(Figure 74)
The firebox side walls must sit a fu113"on the front&
rear of the base plate.Since the side wall components flair 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 > >�2"
rear of the unit.(Figure 76)
OVERHANG
3) Once the side wall assembly is complete it is
necessary to place a steel angle minimum 4"x 4"x 3/8"across FIGURE 75
each face of the two sided opening before building the smoke
dome assembly. Notch the ends of each sidewall equal to the 1 1/2° ���2°
thickness of the steel as shown. Each end of the steel angles MIN* HEARTH MW,
EXTENSION �
must bear fully at least 3"onto the side wall assembly.(Figure � MINIMUMS
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 fireplace is built by placing one long � ,
damper beam on top of the firebox back wall and flush with � ;
it;the other long damper beam sits flush with the front of the
� ---------------- �
Isokern Standard firebox,spanning the firebox opening. � A �
These components both sit on their narrow base so that
their beveled face points down and into the firebox interior. B
5)The damper plate end pieces are designed to sit on
the firebox 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 firebox. This wi(t allow the fire FIGURE 76
brick to align flush 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 MODEL A B
the flue or a bottom mount damper is installed to the inside of
the top plate. 28 351/2" 451/2"
36 43" 53"
42 49" 59"
46148 53" 63"
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 fireplace 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 sufficient width in order to accommodate the o
width of the upper fireplace plus the width of the by-passing
chimney system rising from the lower unit.(Figure 77)
Dimensions for each fireplace 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 fireplace 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 fireplace 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 firebox in the °
upper location there are minimum required floor-to-floor height
dimensions. (See chart,page 45-Dimension"F")
The minimum floor-to-floor height required for an
installation is determined by calculating the total horizontal
distance the lower flue must travel to the left or right for it to
bypass to one side of the upper fireplace.(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 fireplace and the lower fireplace sit on the
same centerline then the required floor-to-floor dimension is at a
ma�cimum(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 fireplace will increase
the minimum floor-to-floor 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.)
The following chart gives important dimensions needed
when laying out two story stacked fireplace units.Chart dimensions �
I
assume that both the upper and lower fireplace units sit on the same I
centerline.
I
i
Note: Widths of both Isokern Standard and Magnum fireplaces �
are the same. Only the depth of the firebox and the height of the j
finished opening differ. i
Upper/Lower A B C D E F !
I
36/36 43 51 30 81 70 ]42
36/42 43 51 33 84 70 142 �
I
36/48 43 51 35 86 70 142
42/36 49 54 33 87 70 148 !
42/42 49 54 33 87 70 148 j
42/48 49 54 35 89 70 148
48/36 53 56 35 91 70 149 �
48/42 53 56 35 91 70 149 i A
48/48 53 56 35 91 70 149 j
Chart Dimension Description: (Figure 78) �',-- --------b�_._._____-_�_
"A"is the outside width dimension of the Fireplace model chosen I
for the upper unit. �
i
"B" dimension represents distance (taken in the direction of the j
chimney offset) from the centerline of the lower fireplace to the � I I
I
outside face of the eight inch(8")thick bearing wall underpinning I i i
the upper unit's floor system. ! I
"C" dimension is the distance (taken away from the direction of j I
the chimney offset) from the centerline of the lower or the upper � �
fireplace, whichever is the larger plus eight inches (8") to the j` �
outside of the eight inch(8")thick bearing wall for the upper unit's � I "
support slab. �
"D" is the outside-to-outside dimension of the two eight inch(8") I j I
thick bearing walls underpinning the upper uniYs support slab."D" !
is also the width of the upper unit"s support slab and includes the I I I
additional space for the width of the DM chimney as it bypasses the �
I j j W
upper unit."D"is also the sum of"B"plus"C".
"E" is the height of the Fireplaces chosen for the lower unit and � I I
includes the Isokem three inch thick base plate. p_ �
"F" is the dimension from the top of the support slab of the lower � I I
unit to the top of the floor of the upper unit. �
—e—�—
��---'-�------------��--J------�-af
Notes: � B � C �
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. D I
In the interest of clarity the drawings on page 44 and 45 � I
(Figures 77&78)of the offset chimney sequence do not show the _,1___� _r_�,_
offset block support columns as required for offset seyuences. See
pages 33&34 for complete offset support instructions.
Consult local structural engineer for support slab load FIGURE 78
calculations.
46
Fire-Lite Application - General Information
General Information:
The Fire-Lite is an application of the Isokern Standard
and Magnum fireplaces designed, tested and listed with the
ability to be installed on a combustible floor system.The design
and installation reyuire that the system use Class A metal flue,
or equivalent.The Fire-Lite assembled unit must sit on a raised,
noncombustible piatform allowing a minimum 4" air space
between the Isokern base plate and the combustible floor.
Many of the requirements for the Fire-Lite such as fire �
brick installation,safety precautions and installation instructions
for the Isokern Standard and Magnum fireplaces 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 specific to the Fire-Lite system.
Intended Use Statement:
The Fire-Lite fireplace is designed to sit on a
combustible floor system and is intended to burn solid wood
fuel,propane or natural gas.The fireplace 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 specific �
design preferences. Always maintain the stated minimum � °0
clearances to combustible materials.Do not violate any specific 0
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 fireplace systems are also designed for
installation in accordance with the National Fire Protection
Association Standard for chimneys,fireplaces, 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 flue manufacturer's
explicit installation instructions.
Safety Instructions:
Because the Fire-Lite is an application of the Magnum
or Isokern Standard Series fireplaces,the safety instructions are
listed on pages 5 & 6 of this manual. Please refer to them and FIGURE 79
read them carefully before installing your Fire-Lite system.
47
Fire-Lite Application - Required Clearance To Combustibles
y
The Fire-Lite is tested and listed for installation with 2"min.�-I I��I I�2°min.
II I I
"clearance to combustibles"SS fOI�OWS: FTF 13
Metal Chimney
(or equivalent) o
1)Four inches(4")clearance to the combustible floor. ze�o aeara�ce
1%:"min.to
2) Zero inch (0") clearance at the Isokern smoke dome front wall Combustible
(FigU1'e 77�. Framing
3)One and one half inches(1-1/2")clearance at the Isokern firebox
back walls and side walls.
4)Two inches(2")minimum air space to combustibles at all FTF- F"e-uie sta"d
Hearth Extension Supporl with (4"min)
13 metal chimney components'OUtOT�ay01'. Noncombustible Material.
20"min
Important: "Combustibles" are defined as "normal construction m���2 O
materials" and are considered to be: wood framing materials,
particle board,mill board,plywood sub-flooring,plywood paneling
and wood flooring. Sheathing materials, such as plywood, particle Combustible
board and drywall may cover the smoke dome front at zero inch Floor System
(0") clearance. All combustible sheathing materials must be held 'Height based on the use of 1 1/4"fire-brick and a 1/4"mortar bed.
eight inches (8") away from the sides of the firebox opening and This height may vary based on lhe firebrick used.
eight inches(8")above the top of the firebox opening.
FIGURE 80
The firebox backwall,side walls and the smoke dome back 1'/:"min.
require 1 1/2"clearance.(Figures 80&81)
3"min When
Unsupported 1 1/2"min
Keep all insulation, vapor barriers, "house wra " a er and When Supported•
p P P Plus width of backing
other insulating type membranes and products, including
��/2� Noncombuslible N
fiberglass,cellulose and other insulation,(anything that carries Min �2" Meanh Exlension °
an "R" rating) a minimum of three inches (3") away from all min m� _
firebox and chimney surfaces.
��i2• FIGURE 81
Exception: If insulation is used in walls surrounding the fireplace, ��
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing the
Isokern.(Figure 81) CombustiblesMust
Have 1 1/2""min
The sheathing material holding back the insulation cannot be Clearance
closer than 1 1/2"to the firepiace sidewalls,backwall or chimney
system.(Figure 83)
When Fireplace installations are surrounded by walls CORRECT
that are to be insulated, the walls must have enough clearance to
the Isokern unit in order to maintain the three inch(3") minimum ���2�
clearance to insulation for unsupported insulation.Never spray the FIGURE 82
Fireplace or chimney system with any type of sealer,insulation
or other material.
Combustibles Must Have 1 1/2""min
NOtes: Clearance.
The Fire-Lite Application is designed,tested and approved DO NOT ENCROACH ON
for installation at a minimum of four inches(4")above combustible CLEARANCE WITH COMBUSTIBLES!
floor systems per the installation specifications given in this manual.
All portions of the combustible floor system under the
Fire-Lite stand are to be covered with minimum 1/2"thick ceramic INCORRECT
fiber inswool or equivalent rated to 2100 degrees Fahrenheit(Figure
79�' FIGURE 83
All Fire-Lite Series result in the finished fire brick floor
of the firebox being at least eight inches (8 1/2")* above the
combustible floor system(Figure 80).
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 floor area.
The following weights and sizes can be used to
calculate Fire-Lite loading. Consult with local structural
engineer for proper sizing of structural floar frame members for
specific 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: 14201bs.- 42 SFP: 1325 lbs.
c.Model 48 MFP: 1600 lbs.- 46 SFP: 1450 lbs.
2.Damper,fire brick and mortar:450-500 Ibs.
3.Raised platform:40 lbs.
4.Fireplace finished facing:approx.200 lbs.
(dependant on facing used)
5.Weight of inetal flue: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. � �
0
The$oor area for each model is as follows: ' �
�
Magnum:
Model 28 FP @ 35.5"x 28"= 6.90 sq.ft.
Mode136 FP @ 43"x 28"= 8.36 sq.ft.
Model 42 FP @ 49"x 28"= 9.52 sq.ft.
Mode148 FP @ 53"x 28"= 10.3 sq.ft.
Isokern Standard:
Model 36 FP @ 43"x 25.25"=7.54 sq.8.
Mode142 FP @ 49"x 25.25"=8.59 sq.ft.
Mode148 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 specific site's proposed
floor.
The load estimates given above for items are estimates
only and may not accurately define total loads related to the
completed fireplace due to material choices that are at owner
option. Consult your local structural engineer for proper floor
system design,sizing and specifications.
Isokern is not responsible for structural floor support
details for the Fire-Lite fireplace. Unless otherwise noted all
floor framing drawings in this manual are merely illustrations to FIGURE 84
indicate the presence of an underlying floor system.
Magnum Series Shown for Illustration Purposes Only
49
. �
Fire-Lite Application - Hearth Conditions
�25P�
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. o0
1'/:'min.
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
Fire-Lite Stand
raised platform. a•o�e•Ha�9n�s
Metal safet stri Available
y p-a metal angle is attached to the Fire- No��omb�s��bie
Lite stand when shipped. This angle is to be removed before 14GA.Metal Joists
20"Hearth Substrate @ 12"O.C.with a 3"Dia.
installation,turned over and re-attached to the metal stand so that �— Hole forAir Dissipation
8'/:"MIN O
the 2"lip faces forward of the metal stands.This creates a metal
safety strip and can be adjusted to ensure your metal stand, set
on top of the inswool will be level.The safety strip must extend
out from the front of the raised platform at least two inches 2" Combustible
(Figure 85). � � Floor System
Insboard oi Inswool Cut and
Flashing Bar and Placed Belween
The exposed combustible $oor underneath the SafetyStrip se�e°"S
noncombustible raised platform must be completely covered
with Inswool ceramic fiber insulation (Figure 84). The Inswool � o
is dry laid to the$oor within the block perimeter. o
The ceramic fiber 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., F�GURE 85
Pittsburgh, PA 15219, ph. 412-562-6200: "Insboard 2100" or
equivalent.)
Fire Brick Installation: Follow instructions on page 19 of this
manual.
Recessed Fire-Lite:
If the design preference is for a flush hearth Fire-Lite
application (floor of the fireplace at the same level the room's
floor),with advanced planning,the metal stand can be lowered,
set and attached to the joist system.(Figure 86)
NOTE: For seismic anchorage design and instructions of the "°"�"'"���'�"�rth
E�ter�ai0n Required 1 1YY 1 1R' 7 12'
PO'min
flush hearth application,please contact the Technical Department
at 1-800-642-2920. � o� � o "�o �`o''o 0
-� �
When calculating flush hearth height be sure to allow 5�„�„��„E.��„�„
N51h NonmmbuetidB Ma�enal �ure Fire{he Fbor Frsming
for the four or eight inch(4"or 8")metal stand,three inch(3") S�^^T T�,�a ByO11,,,,
SIDE VIEW FRONT NEW
thick base plate plus the one and one half inch(1-1/2")thick fire
brick floor.
Nob:Field VerifieE Dimemiona Slwultl MakeNbxarKe In HeaM
Whether a flush hearth is preferred or a raised hearth� EdansbnsinFrony20�JanESkea(72'ea.�FromFireplace0qining.
Nso Firepke SiOes aM Rear,7 7lY Cleereza b Cdnbus�idBs
the combustible floor in front of the fireplace must be covered Fbave�rtyo��,�,: Fbavxrtyo�meos�e:
with a noncombustible hearth extension set tight against the "'�"""'�"B8 '��5""�`°5°'�°:
ze SSL4'Wx091/7D 36 sevaw.asa�a•o �2• I-
fireplace front and extending at least 20 inches out from the � sevrw.aevro<2 savaw�asya•o " HBerthExiMSion
42 651/2'YYxd91YY0 48 681/0^NMd63�4'D m� ReQUired p�
finished fireplace and at least 12 inches beyond the finished sides ^� ��n,�•<9„�•0
of the fireplace opening. °��"`«�'S'�'°�a'E���«,SO°°�S���a��„��.
Use Me�al FIUB Only.
For all "Fire-Lite" construction, it is necessary to use PW+��+
the base plate.Be sure to secure the Fire-Lite metal stand to the FIGURE 86
floor framing system, then mortar the base plate to the metal
stand for stability.
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 flue or metal flue
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 FTF-
13 chimney system. If "equal" metal chimney systems are
used, follow the metal flue 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 21l and in
accordance with codes such as BOCA Basic/National codes, the
Standard Mechanical Code and the Uniform Building Codes.
Note: Illustrations shown reflect "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 specific
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 fire 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 fire hazard.
The FTF-13 chimney's fire stop spacer and roof flashing
(not chase flashings)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,
flooring,and drywall.
Chimney Height Requirements:
Refer to flue manufacturer for chimney height
requirements and recommendations.
Revised:2013-02-13
FIGURE 87
51
m
v . . �
� f'��� � 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 flue attaches to the smoke dome's top
plate by use of the AP-ISO masonry anchor plate. The Anchor
Plate is fitted with an octagonal base plate to affix 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 flue(Figure 89).
Step 1. Lay a twenty-four inch (24") square, half inch (1/2")
thick(minimum)piece of ceramic fiber 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 FIGURE 88
temperature blanket and align the blanket on the flue hole in the
top plate(Figure 89).
UL 103 or
Step 2.Fit the AP-ISO Anchor Plate assembly onto the Inswool so Class A
that the inner flue sleeve projecting out the bottom of the anchor
plate is inserted through the high temperature blanket and into the Anchor Plate
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 Inswool
through holes provided in the anchor plate into the top plate. Do O Blanket
not over torque masonry screws into the Isokern material.(Figure
90)
Chimney Terminations: �
FTF-13 chimney pipe requires a termination component
� to be instalied at or near the top of the chimney chase flashing.
The FTF-I3-CTD Round Termination is the
recommended termination.(See page 52)
Installation:
Step 1.Hold the FTF-I3-CTD over top of last chimney section.
Step 2.Center inner slip section in inner flue pipe and slip down.
Step 3. Center outer locking section over outer flue pipe. Push FIGURE 89
down until locking tabs are firmly engaged.
Step 4.Pull up slightly on CTD to ensure locking joint has firmly
engaged.
UL 103 or
Class A
Note: It is recommended that all exterior exposed metal chimney
components-such as terminations,flashings,and flue-be painted Anchor
with a premium quality,high temperature,rust preventative paint Top Plate Plate
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 Inswool
conditions. Consult the paint manufacturer's instructions for Blanket
proper preparation and application. ❑��
Chimney Height Requirements:
Refer to page 39 of this manual.
FIGURE 90
52
, . .
FTF-13 Installation Components
O
Round Termination Fire Stop Spacer(30° Offset)
O
Fire Stop Spacer
Offset Return Package (30°)
Chimney Flue Section
Combination Offset
Return Elbow
Stabilizer
bD
Anchor Plate
Locking Band
53
� a l
FTF-13 Offset Elevation Chart
A B FTF-13-ES30 Number of FTF-13
Offset Height Offset/Return FTF-13-S4 Chimney Section
Inches Inches Elbow Set Stabilizer 12" 18" 36"
4 15 3/4 1 0 0 0 0
9 24 1/2 1 0 1 0 0
12 29 3/4 1 0 0 1 0
141/4 331/2 1 0 2 0 0
17 1/4 38 1/2 1 0 1 1 0
20 1/4 43 3/4 1 0 0 2 0
21 45 1/4 1 0 0 0 1
22 1/4 47 1/2 1 0 2 1 0
251/4 521/2 1 0 1 2 0
26 1/4 54 1/4 1 0 1 0 1
28 1/4 57 3/4 1 0 0 3 0
29 1/4 59 1/4 1 0 0 1 1
311/4 63 1 0 2 0 1
21 1/2 65 1 0 4 1 0
34 1/4 68 1/4 1 0 1 1 1
36 1/4 71 3/4 1 0 3 0 1
371/4 731/4 1 0 0 2 1
38 1/4 75 1 0 0 0 2
39 1/4 77 1 0 2 1 1
411/2 801/2 1 0 1 4 0
� 43 1/4 83 3/4 1 0 1 0 2
44 1/2 85 3/4 1 0 3 1 1
451/4 871/2 1 0 0 3 1
46 1/4 89 1 0 0 1 2
48 1/4 91 1/2 1 0 2 0 2
49 1/2 94 1/2 1 0 1 5 0
51 1/4 97 3/4 1 0 1 1 2
54 1/4 103 1 0 0 2 2
55 1/4 104 1/2 1 0 0 0 3
56 1/2 106 1/2 1 0 2 1 2
591/2 1113/4 1 0 1 2 2
61 3/4 116 1 1 1 0 3
64 3/4 121 1/4 1 1 0 1 3
67 124 3/4 1 1 2 0 3
69 127 3/4 1 1 1 3 2
70 130 1 1 1 1 3
73 135 1/4 1 1 0 2 3
75 138 3/4 1 1 2 1 3
79 145 1/2 1 1 1 0 4
80 1/4 147 1/2 1 1 3 1 3
$2 150 3/4 1 1 0 1 4
87 159 1/2 1 1 1 1 4
54
FTF-13 Vertical Elevation Chart
Height of No. of FTF-13 Height of No. of FTF-13 Height of No. of FTF-13
Chimney Only Chimney Lengths Chimney Only Chimney Lengths Chimney Only Chimney Lengths
Inches Feet Inches 12" 18" 36" Inches Feet Inches 12" 18" 36" Inches Feet Inches 12" 18" 36"
11 0 11 1 0 0 308 1/2 25 8 1/2 0 0 9 608 1/4 50 8 1/4 1 1 17
�� � 5 0 1 0 318 3/4 26 8 3/4 � 0 9 1 1 4 51 4 1 4 0 0 18
21 3/4 � 9 1/4 2 0 0 324 3/4 27 3/4 0 1 9 626 1/4 52 2 1!4 1 0 18
27 1/4 � 9 1/4 2 0 0 328 3/4 2� 4 3/4 2 0 9 632 1/4 52 8 1/4 0 1 18
636 1/2 53 1/2 2 0 18
33 1/4 2 9 1/4 0 2 0 334 3/4 27 10 3/4 1 1 9 642 1/2 53 6 1/2 1 1 18
35 2 11 0 0 1 342 3/4 28 6 3/4 0 0 10 650 1/4 54 2 1/2 0 0 19
37 1/4 3 1 1/4 2 1 0 352 3/4 29 4 3/4 1 0 10 660 1/2 55 1/2 1 0 19
43 1/4 3 7 1/4 1 2 0 358 3/4 29 10 3/4 0 1 10 666 1/2 55 6 1/2 0 1 19
51 1/4 4 3 1/4 0 1 1 363 30 3 2 0 10 670 3/4 55 10 3/4 2 0 19
55 1/4 4 7 1/4 2 0 1 369 30 g 1 1 10 676 3/4 56 4 3/4 1 1 19
61 1/4 5 1 1/4 1 1 1 376 3/4 31 4 3/4 0 0 11 684 1/2 57 1/2 0 0 20
67 1/4 5 7 1/4 0 2 1 387 32 3 1 0 11 694 3/4 5� 10 3/4 1 0 20
69 1/4 5 9 1/4 0 0 2 393 32 9 0 1 11 700 3/4 58 4 3/4 0 1 20
79 1/4 6 7 1/4 1 0 2 397 1/4 33 1 1/4 2 0 11 705 58 9 2 0 20
85 1/4 7 1 1/4 0 1 2 403 1/4 33 7 1/4 1 1 11 711 59 3 1 1 20
89 1/2 � 5 1/2 2 0 2 411 34 3 0 0 12 718 3/4 59 10 3/4 0 0 21
95 1/4 � 11 1/2 1 1 2 421 1/4 35 1 1/4 1 0 12 729 60 g 1 0 21
103 1/4 8 7 1/4 0 0 3 427 1/4 35 7 1/4 0 1 12 735 61 3 0 1 21
1131/2 9 51/2 1 0 3 4311/2 36 111/2 2 0 12 739 61 7 2 0 21
119 1/2 9 11 1/2 0 1 3 437 1/2 36 5 1/2 1 1 12 745 62 1 1 1 21
123 3/4 10 3 3/4 2 0 3 445 1/4 37 1 1/4 0 0 13 753 62 g 0 0 22
129 1/3 10 9 3/4 1 1 3 445 1/2 3� 11 1/2 1 0 13 763 63 7 1 0 22
137 1/2 11 5 1/2 0 0 4 461 1/2 3$ 5 1/2 0 1 13 769 64 1 0 1 22
147 3/4 �2 3 3/4 1 0 4 465 1/2 38 9 1/2 2 0 13 773 1/4 64 5 1/4 2 � 22
471 1/2 39 3 1/2 1 1 13
153 3/4 �2 9 3/4 0 1 4 479 1/2 39 11 1/2 0 0 14 779 1/4 64 11 1/4 1 1 22
158 13 2 2 0 4 7g7 65 7 0 0 23
164 13 g 1 1 4 489 1/2 40 g 1/2 1 0 14 797 1/4 66 5 1/4 1 0 23
171 3/4 14 3 3/4 0 0 5 495 1/2 41 3 1/2 0 1 14 803 1/4 66 11 1/4 0 1 23
�82 �5 2 1 0 5 499 3/4 41 7 3/4 2 0 14
�gg 15 g 0 1 5 505 3/4 42 1 3/4 1 1 14 807 1/2 6� 3 1/2 2 0 23
192 16 0 2 0 5 813 1/2 67 9 1/2 1 1 23
513 1/2 42 9 1/2 0 0 15 821 1/4 68 5 1/4 0 0 24
�gg 16 6 1 1 5 523 3/4 43 7 3/4 1 0 15 831 1/2 69 3 1/2 1 0 24
206 17 2 0 0 6 529 3/4 44 1 3/4 0 1 15
215 3/4 �� 11 3/4 1 0 6 534 44 g 2 0 15 837 1/2 69 g 1/2 0 1 24
222 18 6 0 1 6 8413/4 7� 13/4 2 0 24
540 45 0 1 1 15 847 3/4 �� 7 3/4 1 1 24
226 1/4 �$ 10 1/4 2 0 6 547 3/4 45 7 3/4 0 0 16 855 1/2 71 3 1/2 0 0 25
232 1/4 �9 4 1/4 1 1 6 558 46 6 1 0 16
240 2� 0 0 0 7 564 47 0 0 1 16 865 3/4 72 1 3/4 1 0 25
250 1/4 20 10 1/4 � � 7 871 3/4 �2 6 3/4 0 1 25
568 1/4 47 4 1/4 2 0 16 875 3/4 72 11 3/4 � � 25
256 1/4 2� 4 1/4 0 1 7 574 1/4 4� 10 1/4 1 1 16 881 3/4 �3 5 3/4
260 1/2 2� 8 1/2 2 0 7 582 48 6 0 0 17
266 1/2 22 2 1/2 1 1 7 592 1/4 49 4 1/4 1 0 17 889 3/4 74 1 3/4 0 0 26
274 1!4 22 10 1/4 � � 8 899 3/4 74 11 3/4 1 0 26
598 1/4 49 10 1/4 0 1 17 905 3/4 75 5 3/4 0 1 26
2841/2 23 81/2 1 0 8 6021/4 50 21/4 2 0 17 910 75 10 2 0 26
290 1/2 24 2 1/2 0 1 8 916 76 4 1 1 26
294 3/4 24 6 3/4 2 0 8 924 77 0 0 0 27
300 3/4 25 3/4 1 1 8
55
Summary
1. WARNING: Fireplace and chimney systems will only draft After these first five or six small fires of short duration,
properly when they are installed according to the instructions, normal use of the fireplace can proceed. For normal use the
in an appropriate location and with the proper chimney maacimum recommended fuel load is twelve to sixteen pounds
height. Installing the fireplace according to the manufacturers of dry firewood at a time. This fuel load is considered to be
instructions, choosing an appropriate location, and choosing an approximately three to five cured hardwood logs of about three
appropriate chimney height are the responsibility of the designer inches (3") to six inches (6") in diameter. As the fire burns
and the building contractor. down,refueling should be only one or two logs added at a time.
Tightly insulated and sealed homes, two story interior
spaces and high vaulted ceilings can cause negative air pressures Important: Do not burn construction debris or trash of any
within the house which can impair drafting performance. HVAC kind in the firep(ace.
return air ducts near the fireplace opening will adversely affect It is not uncommon for construction debris and refuse
the fireplace drafting performance. to be burned in a firepiace by site personnel on a project that is
It is the responsibility of the designer, the building under construction,this activity must be avoided.
contractor and their mechanical contractor to determine that It is the responsibility of the building contractor
the building's internal air pressures are conducive to positive to insure that the required dry-in period is met and that the
fireplace drafting. required lighting sequence is performed by the owner or by the
Avoid placing any fireplace in an area near tall trees, owner's agent.
tall buildings, or high land masses. These structures can reduce
ambient air flow pressure as well as produce down dra8s,either 3. Log grates are required for burning solid fuel in the
of which can impair fireplace drafting performance. Tsokern fireplace. Grates al(ow for easy air flow up through
Earthcore Industries L.L.C. does not warrant drafting the burning logs thus creating a more complete and efficient
and is not responsible for it. burning of the fuel.
2.Fireplace Curing Instructions: 4.How to Build a Fire:
It is critical that the refractory elements in the Isokern First set the fireplace damper in the full open position.
firebox and smoke dome components be dry before firing of the Begin laying the fire by placing several pieces of wadded up
unit. Moisture left in the Isokern components from exposure paper directly on the log grate. Place kindling(small splits of
during storage and shipping, as well as moisture from the dry pine or other dry softwood) on top of the paper, enough
installation phase,must be eliminated before the unit is put to its to loosely cover the paper. Next arrange several small, dry
intended use. hardwood or softwood logs or log splits on top of the kindling
The first step in reducing the ambient moisture is to be layer.
sure that the completed firepiace rest in a dried-in setting for a Finaliy, arrange two or three larger hardwood logs
minimum of 28 days after construction of the unit is complete. (oak,hickory,etc.)or log splits on top of the stack. Ignite the
The next step in curing the fireplace is to be sure that the paper at the bottom of the stack.The burning paper will ignite
first five or six fires are of short duration. the kindling which will,in turn,set the remaining fuel on fire.
The first fire of the unit can take place once the minimum Be sure to stack all firewood in such a way that it will
twenty-eight day drying period has passed. This fire should be settle into the log grate as the paper and kindling layers are
especially short. burned away. Additional logs can be set onto the fire as each
Start the first fire slowly with a small amount of paper fueling burns down.
and kindling (small dry wood splits or twigs) and a maximum Ideally,fuel logs should be of a hardwood species that
load of four to six pounds of dry firewood, estimated to be no have been air dried for one year or longer. Use of cured or
more than two or three logs each of about three inches (3") to uncured pine logs and uncured hardwood logs for fuel should
four inches(4")diameter. be avoided. Pine logs and uncured hardwood logs will tend
The first fire shouid burn for no more than thiriy to sixty to smolder and burn at relatively low temperatures producing
minutes and then allowed to go out. Do not refuei the fireplace high levels of soot and creosote.
during the first lighting.
Acoolingoffperiodoftwenty-fourhours,ataminimum, Important: Do not throw, toss,jam, kick or otherwise force
shouid follow the first fire. logs into the fireplace.
The second fire should be the same as the first fire.
Atwenty-four hour cooling offperiod must be observed
following second lighting.
After first and second fire,continue use of the unit with
three or four small fires of short duration (sixty minutes or so)
and small fuel loads.
56
� . .
Summary
WARNING: Never use gasoline, gasoline type lantern fuel, 8. Inspection and Cleaning:
kerosene,charcoal lighter fluid or other similar liquids to start At least twice a year in warm climates or monthly
or"freshen up"the fire in this or any fireplace. during the heating season in colder climates, thoroughly
inspect the fireplace and chimney system. Chimneys must be
WARNING: If processed solid fuel firelogs are used, do not installed so that access is provided for inspection and cleaning.
poke or stir the logs while they are burning.Use only firelogs The chimney should be inspected monthly during the heating
that have been evaluated for the application in fireplace and season.
refer to firelog warnings and caution markings on packaging Inspect the entire flue from the top down for
prior to use. obstructions such as birds'nests,leaves,etc.Such obstructions
must be removed.
5.Avoid over-firing.Some examples of over-firing are: Check spark arrestor screens for clear flow of smoke
a. Burning of scrap lumber,construction debris,pine every two to four weeks during the heating season.Inspect the
branches and brush or cardboard boxes; flue periodically during the heating season for the presence of
b. Burning small diameter twigs, branches or any soot and creosote build up.If creosote or soot has accumulated,
other small sized combustible materia►s in quantities which it should be removed to reduce the risk of chimney fire.
exceed the volume of the normal log fire; Have your chimney cleaned by a professional
c. Use of artificial wax base logs, trash or other chimney sweep if you have doubts about your ability to do it.
chemicals or chemically treated combustibles. Use a plastic,wood or steel brush to clean the chimney. Scrub
the spark arrestor/chimney cap with a wire brush.Remove any
WARNING: Over-firing can permanently damage this chimney cap for flue cleaning from the top. Open the damper
fireplace system. in the firebox for cleaning access from below.
Clean the inner portion of the flue by using a flexible
6.Fireplace Doors and Screens: handled chimney cleaning brush.
This fireplace has not been tested for use with doors. For straight run flue the proper size brush can be
To reduce the risk of fire or injury, do not install doors. pulled up through the flue from the firebox with the damper
Operable doors are acceptable and if doors are required by the open.
local authority having jurisdiction, then doors must be kept If the chimney has an offset chimney section, brush
in the fully open position when the fireplace is in operation. cleaning from the chimney top down to the offsetheturn and
Isokern does not limit the use of fireplace screens. then from the firebox up to the offset section is the proper
method.
In either case, cover the fireplace opening with a
7.Disposal of Ashes: damp sheet (sealed to the opening with masking tape) before
It is recommended that the firebox be cleaned of brush cleaning.Do not remove sheet until the soot has settled.
excessive ashes before each use. It is necessary to remove It is advised to vacuum loosened soot.Do not sweep loosened
ashes from the open front of the fireplace.To do so,proceed in soot as sweeping will disperse soot into the air and about the
the following manner: room.
Allow the fire to go out and the ashes to cool for at
least six to eight hours. WARNING: Do not use chemical fireplace and chimney
After the cooling period, carefully pick up the ashes cleaners that are poured on a hot fire.These can be dangerous
from the firebox with a small, metal fireplace shovel or other and generally work only on the flue section nearest the fire,
metal scoop and place them in a metal container with a tight leaving the rest of the flue unaffected.
fitting lid.
If possible do not sweep the ashes as this will stir 9.Exterior Maintenance:
them into the air and disperse them into the room. Annually,at a minimum,check all metal flashings and
The closed container of ashes should be placed on weather seals around the exterior chimney where it penetrates
a noncombustible floor or on the ground, well away from all the roof surface;inspect any chimney top spark arrestors,metal
combustible materials, pending final disposaL lf the ashes are cowlings and weather hoods to make sure they are secure and
disposed of by burial in soil or otherwise locally dispersed, weather tight.
they should be retained in the closed container until all cinders Seal any cracks or gaps in chimney-to-roof flashings
have thoroughly cooled. 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
I
� Please tear out along dashed lines and send to:
I Earthcore Industries
� Attn:Technical Dept.
� 6899 Phillips Industrial Blvd.
� Jacksonville, FL. 32256
� Or register your Isokern online at: www.earthcore.co
I
� WARRANTY CARD
I Purchased From:
� Date of Purchase:
�
I Name:
� Address:
�
� City, State&Zip:
� Phone No:
�
I 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
I 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:
I Phone Number
I
58
^ r ♦ ♦
Notes
��
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.
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,.
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s9
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• a
"°�` �s ,.� y t
m
_ ��s
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v.� , z�,. taf' � , ,' �.. x° �.?e `� , �' c��:� � mr*e' �,
Ae�_ `°�
�e � � �
„ 4� ° �
„— 4,,�t � t��„a� • ��` �� � "�r,.4��� �� ��
��° � ,���
.t�`�r
��,..
-�� �9 ttrrttn�� & � isrlttimPr
����� �,�.
�.�����
�,,,�-,�" <� ��'-�
�.�Q'�������,��.2'�.�s� ,��:�`�.
�: x< '��� �
�°";_ ' ' 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.
i�5; ��` ��"�
��,�:� � 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,F1RE BRICK ��`° '��� �
OR ACCESSORIES.THIS WARRANTY DOES NOT COVER DRAFTING,SMOKING OR PUFFING OF THE �
'��"'`� '�� FIREPLACE SYSTEM.Factors be ond the manufacturer s control affect fire lace draftino
��,9: .' y � t�„�
� smokin and uffin and ISOKERN cannot guarantee these aspects of perfo mance. b ��� `W'��
��° g, P g�
��x 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 � ���
��;,� re�istered mail,within thi �� �",�;
� �� b rty(30)days following the discovery of the defect within the lifetime warranty period. ��.°�
���� I'he notice shall contain(1)the date of purchase;(2)place of purchase;(3)address of installation;(4)name,ad- � '
.,�,a��, � dress and phone number of the owner;and(5)a brief description of the defect. �`�`�,��.��
*���� ��
���,� �,;�,�
s� � 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 �������
� ���a � which the fireplace or chimney system has been installed or to persons or property therein arising out of the use, �'� �� �
� .��
����= misuse,or insta(lation 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. '� �a�`'
��� ,
�„,�. �'��'`.�:
�` m k ��
� � �i.
,.��� ���� This warranty is null and void when the fireplace or chimney systems are not installed pwsuant to the ` °
��,���� �� installation instructions provided by ISOKERN or local building codes have not been followed completely. '��� .
�"�:°�` ,��
°����� '�.g�
This warranty applies only to those fireplace 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. � `�
�.fi,,,� `x#���
� �� �`'�;,�;
ISOKERN HEREBY DISCLAIMS ALL GUARANTEES AND WARRANTIES,EXPRESS OR IMPLIED,BE-
'�"`°-�� YOND THE WARRANTIES SET FORTH HEREIN. �
�w�+ e ,�
���,�
.�.��
��*�� .'�,*��
`� � � '����
���� � ear e re ���
��� ,������.
��" .,.. „��:
� w ryrt��
� ��
����Q ; ��
"���"��"� � 6899 PHILIPS INDUSTRIAL BLVD.•JACKSONVILLE,FLORIDA 32256 ;�����
�,� ,,
� TEL(904)363-3417•TOLL 1 (800)642-2920•FAX(904)363-3408 "e.o�
m�, -,�, ���^� , �� � � p�
,�"�w`� a tt',��`�'�-' � ,"��r� ", �� , � '° =�„a$� y�y � > ����,�'„ E"F, �� , � «,�� ;. �'� ,�
,.�,., �"2"' .''� �q w� �s�e s-` �.�� ��, .�v 'a«'t' � ��� , +�'��` �:�� "�,�°�.nY ,�'�.
.�"_ ,,s� � �� � "� � ` �� ,a* " 'm � �
� .• � , _� ��
; ��-s "� ,� � �`x?�:��� x%* a e'6,° �ip y � ti�.�•_ ;�4"i ��:,`'.
� , >� �4`� �`� �
� � x� �
,� ;„ �
� � �'����� �w��. ` �� , ,��„
List of Cleaner Fireplaces � Burn Wise � US EPA Page 1 of 2
http://www.epa.gov/bu rnwise/fireplacel ist.htm I
�� ���nr�.�.�t���._�..,.
Burn Wise
Partners - �,�����;ek
Program Participation -
List of Cleaner Fireplaces & Retrofit Devices S�bs��;be,oe��nW,se
• List of Phase 2 Qualified Fireplaces
• List of Phase 2 Qualified Fireplace Retrofit Devices
Phase 2 Qualified Fireplaces•
Manufacturer 'Model Name and Number Type Emission Rate�'� Fuel Type
Flamma L�C Caminetti Montegrappa LIGHTO6 CD Low mass 0.59 grams/kg Stick Wood
Industrial Chimney Company,Inc. Rumford Renaissance 1500 CD Low mass 0.68 grams/kg Stick Wood
Industrial Chimney Company,Inc. Renaissance Rumford 1000 CD Low mass 0.94 grams/kg Stick Wood
Wolf Steel Ltd NZ8000 Low mass 2.2 grams/kg Stick Wood
'Pacific Energy Fireplace Products,Ltd. TCW 120 CD Low mass 2.4 grams/kg StiGc Wood
.... .___
Earthcore Industries,LLC Standard Series 36C Masonry 2.9 grams/kg Stick Wood
Stove Builder lntemational Inc. FP-1 LM Low mass 2.9 grams/kg Stick Wood
Industrial Chimney Company,Inc. Renaissance Rumford 1000 Low mass 3.0 grams/kg Stick Wood
Wolf Steel Ltd 'NZ7000 Low mass 3.1 grams/kg Stick Wood
Industrial Chimney Company,Inc. Renaissance Rumford 1000 H Low mass 3.4 gramslkg Stick Wood
Industrial Chimney Company,Ina Rumford Renaissance 1500 Low mass 3.4 grams/kg Stick Wood
�.
Lennox HeaRh Products. Solana Low mass 3.9 grams/kg Stick Wood
Stove Builder Intemational Ina Antoinette FP-7 LM Low mass 4.0 grams/kg Stick Wood
Srove Builder Intemational Ina Frontenac FP-11 Low mass 4.2 grams/kg Stick Wood
Whitacre Greer MFR-100 Series Masonry 4.3 grams/kg Stick Wood
_
FMI Products,LLC GCAT42�°� Low mass 4.4 grams/kg Stick Wood
FMI Products,LLC GCAT50�z� Low mass 4.4 grems/kg Stick Wood
_.�______ __W
Earthcore Industries,LLC Isokern Magnum 86072 Masonry 4.6 grams/kg Stick Wood
FMI Produds,LLC CCAT36�3� Low mass 4.8 grams/kg Stick Wood
EaAhcore Industries,LLC 'Isokem Standard Series 42C Masonry 4.8 grams/kg Stick Wood
__ __ �. �� � ___
EaRhcore Industries,LLC Isokern Standard Series 46C Masonry 4.8 grams/kg Stick Wood
Earthcore Industries,LLC Isokern Magnum 36 Masonry 4.8 grams/kg Stick Wood
EaAhcore Industries,LLC Isokern Magnum 42 Masonry 4.8 grams/kg Stick Wood
_.._____ _ ____�___
Earthcore Industries,LLC Isokern Magnum 48 Masonry 4.8 grams/kg Stick Wood
���Units reflecl grams ot particulate emitted per kilogram of wood bumed.
�2�Qualified GCAT50 firebox available in flreplace series VGCAT50,GMCAT50,VGMCAT50,JCAT50,VJCAT50,WCMCAT50,JMCAT50,and VJMCAT50.
�3�Qualified CCAT36 firebox available in fireplace series VCCAT36,SCAT36,and VSCAT36.
�'�Qualified GCAT42 firebox available in fireplace series VGCAT42,GMCAT42,VGMCAT42,JCAT42,VJCAT42,WCMCAT42,JMCAT42,and VJMCAT42. '
`The wood-buming appliances that are"qualified"under the EPA's Voluntary Fireplace Program are not"certitied"per EPA's Wood Heater New Source Performance
Standard.Contact your state or local air qualitv aaencv for clarification on the rype of wood-burning appliances,if any,that may legally be installed in your area.
Phase 2 Qualified Fireplace Retrofit Devices*
Manufacturer Model Name Type Emission Rate��� Percent Reduction�z� Fuel Type
Earth's Flame Hybrid Clean BumTM System Retrofil Device 3.4 grams/kg 72%�3� wood/gas
FMI Products,LLC Pure FireT""Catalytic Control Retrofit Device 4.8 grams/kg 60%�^� stick wood
System
Healthy Hearth,LLC Integrate Catalytic Control 'Retrofit Device 4.8 gramslkg�5� 60°k�5� stick wood '
System I
http://www.epa.gov/burnwise/fireplacelist.html 8/6/2014
�
List of Cleaner Fireplaces � Burn Wise � US EPA Page 2 of 2
���Units reflect grams of paAiculate matter emitted per kilogram of wood bumed
�2�Percent reduction in emissions compared to an existing fireplace that emits 12 grams/kg
�3�As tested on the Heatilator E36 fireplace,results may vary for other fireplace models
�^>As tested on the Craftsman 36 fireplace,results may vary for other fireplaces
�5�Equivalent to FMI Products Pure Fire Catalytic Control System
'The wood-burning appliances that are"qualified"under the EPA's Voluntary Fireplace Program are not"certified"per EPA's Wood Heater New Source Performance
Slandard.Contact your state or local air aualiN aaencv for Garification on the type of wood-burning appliances,if any,that may legally be installed in your area.
� Last updated on T�hurday.July 1Z 201A �
http://www.epa.gov/burnwise/fireplacelist.html 8/6/2014
. ,Stt� . � . .
J�ytit��t���
�m UNiTED STATES ENVtRONMENi'AL PROTECTION AGENCY
o ��\��'�` w
��` ,� RESEARCH TRIANGLE PARK, NC 27711
�n Ir� � •
� 1��
��'4t AflCJ��'�
December 21, 2012
OFFIGE UF
AIR(]UALITY PtANNINU
AND STANDARUS
Mr. Carl R. Spadaro
Earthcore Industries, LLC
6899 Phillips Industrial Blvd.
Jacksonville, FL 32256
Dear Mr. Spadara
We are pleased to acknowledge that the Earthcore Isokern Standard 42C and 46C
and Magnum 36, 42, and 48 models are Phase 2 qualified under the EPA Wood-Burning
Fireplace Program. Thus, you may use the qualifying labels and hangtags in accordance
with the Partnership Agreement Guidelines. Information regarding these five qualified
fireplace models will be posted on the EPA Burn Wise website:
http://www.epa.qov/burnwise/fireplacelist.html
This acknowledgement is based on our review of the information Earthcore
Industries submitted to EPA in the document entitled "Wood-burning Fireplace Emissions
Calculation Report," dated July 2012. Based on our review of the material in this report,
EPA is qualifying these fireplaces at an emissions level of 4.8 grams of fine particles pe�
kilogram of wood burned (g/kg). This emission level is below the Phase 2 qualifying
emission level of 5.1 g/kg.
Thank you for your participation in Phase 2 of EPA's Wood-Burning Fireplace
Program and your interest in improving air quality. We recommend that EPA Phase 2
qualified cleaner fireplace models be considered over other fireplaces for reducing wood ,
smoke pollution.
We will provide you in a separate e-mail a template for use in generating the
Phase 2 qualified hangtag for each of these fireplace models. If you have any questions, "
p(ease do not hesitate to contact me at (919) 541-5383.
Sincerely,
�(,�a�„'If�•'�rt�t�..
Thomas N. Braverman
EPA Wood-Burning Fireplace Program Liaison
Innovative Programs and Outreach Group
�
�
Intemet Addrass(URL)• http:/(www.epa.gov
RecycledlRecyclable•Prinled wflh Vegetable Oil Based Inks un Recycled Paper(Mlnlmum 25%Postconsumer}
Isokern0 EPA Qualified0 Fireplace
Installation, Operation, Maintenance and Owner's Manual
Model 36 C
A PRODUCT OF EARTHCORE INDUSTRIES, LLC.
Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance instruc-
tions for the Standard EPA qualified system. This manual must become the property of and be reviewed by
all current and future users of this product. It is the responsibility of the general contractor and the installer
of this product to ensure that the instructions in this manual are followed exactly and, further that any al-
lowed 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. lt is the
responsibility of the general contractor to provide adequate clearances from all firebox surfaces as specified
in this manual.
INSTALLER: Leave this manual with the appliance
CONSUMER: Retain this manual for future reference
Installation Date
NOTE: The Catalytic Combustor system should be replaced at a minimum in 3 years,
maximum of 5 years.
Be Sure to Read Entire Manual Before Beginning Construction.
Contents of this manual may change without prior notification.
THIS FIREPLACE IS DESIGNED for USE with
SOLID WOOD LOGS, PLUMBED PROPANE
(LP) or NATURAL GAS (NG), ONLY
WARNING: If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
SBCCI NO. 9626 NYC-MEA 241-90-E
ICC Report NO. ESR-2316 LA RR NO. 25483
IBC 2006, IRC 2006, IMC 2006 Issued: February, 2010
Revision: 003
INTERTEK TESTING SERVICES REPORT NO. 3159656M1D-008
OMN1-TEST LABORATORIES REPORT NO. 257-F-06-3
`N'(ERTFk
lested& ,/� $earbalua
� Lisied llY # aEUyun U�A
��M �O 2007 Earthcore Industries, L.L.C.
C !y 0� uS Ohdh11•iesl Labvraturies,lnc.
���ock Ne�s Rupvrk�iv.2�7 F U5�5
THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY
TABLE OF CONTENTS �
GeneralInformation ....................................................................................................................................... 3
IntendedUse Statement ...................................................................................................................................... q
SafetyInstructions .............................................................................................................................................. 5
Warnock-Hersey Listing Label and EPA Hangtag............................................................................................. 6
Assembled Firebox& Smoke Dome Dimensions ............................................................................
.................. 7
Component List&Dimensions .......................................................................................................................... g
RequiredClearance to Combustibles ................................................................................................................. q
AssemblyInstructions 36 C .........................................................................................................................
Access Modification 10-13
......................................................................................................
.................................... 14
Firebrick Instaliation .......................................................................................................................................... 15
Summary.............................................................................................................................................
................ 16-17
Catalytic Combustor Warranty............................................................................................................................ 18
FireplaceWaranty................................................................................................................................................. 19
2
General Information
The Standard EPA qualified fireplace system is a
prefabricated,refractory modular fireplace and chimney system
designed for field assembly.The system consists of interlocking
precast parts which are glued together with a masonry adhe-
0
sive.
The parts of the Standard EPA qualified fireplace
system and DM 54 chimney system are precast using a pro-
prietary mixture of volcanic pumice aggregate and cement.
It includes all the parts necessary for assembly of a complete
firebox,smoke dome and chimney system.
Each Standard EPA qualified fireplace component is
designed for a specific part of the fireplace such that only one
means for assembly is possible.
The EPA qualified model requires an in-line or
chimney top damper.
The Standard EPA qualified fireplace system requires
a Standard EPA qualified refractory fire brick liner be applied to
the interior of the firebox.Fire brick must be a minimum thick-
ness of one and one-eighth inch(1-1/8").
The Standard EPA qualified fireplace system is avail-
able in one size:thirty-six inch(36").This unit has a thirty inch
(32")rough opening height before fire brick.
The DM 54 chimney system is a dual module refrac-
tory chimney system.The basic chimney consists of an outer
casing block and an inner liner with a fourteen inch(14")di-
ameter flue hole.The chimney components are field assembled
using Earthcore Mortar to glue the components together.
The DM 54 chimney system also includes an offset
chimney block component,used to create offsets to the verti-
cal run of the chimney.A brickledge component is available,
designed to support chimney top brick veneer finishes.
Prefabricated masonry chimney termination caps are also avail-
able.
The various Standard EPA qualified fireplace system
components will be described and illustrated in the follow-
ing pages.Close attention should be paid to each component
group's specifications and installation requirements as de-
scribed in this manual.
Important:Due to heat and weight issues,the Standard EPA
qualified fireplace installations require that the system be built
upon a non-combustible concrete slab with no wood underpin-
nings supported to footings with concrete or steel and designed
to carry the total weight of the lsokern fireplace and chimney
system.
The Fire-Lite application of the Standard EPA quali-
fied fireplace fireplace is designed to be built upon a combusti-
ble floor system and will also require a design that will support
the total weight of the lsokern fireplace and chimney system.
The FTF-13 or equivalent chimney system only must be used
with the Fire-Lite application.
Chimney system installations over ST-0"will require
additional support.
3
Intended Use Statement �
Intended Product Use Statement:
The Standard EPA qualified fireplace and DM 54 Note: Do not scale drawings. Illustrations in this manual are
chimney systems are intended to burn solid wood fuel not to scale and are intended to show"typicaP'installations.
,propane Nominal dimensions are given for design and
or natural gas.
Note: framing reference only,since actual installations may vary
Instailation of a gas pipe must comply with the Stan- due to job specific design preferences.Always maintain the
dard for Decorative Gas Appliances for Installation in Vented stated minimum clearances to combustible materials.Do
Fireplaces,ANSI Z21.60. not violate any specific installation requirements.
This fireplace is not designed to sit directly on a com- The Standard EPA qualified fireplace and DM 54
bustible floor system.The Fire-Lite application is designed to chimney system is tested and listed by Warnock Hersey(In-
sit on a combustible floor. This fireplace is intended for use as tertek Testing Service)-Report No.�15965MID-008 and
a supplemental heat source only and is not intended for heavy Report No.315986M1D-006-to UL 127,and UL 103HT
use as a primary heating system. -2006.The EPA qualifying emissions tests were conducted
Overfiring,abusive burning or mistreatment will void by OMNI-Test Laboratories Report No.:257-F-06-3.
any claims(eg.burning construction debris or other highly Standard EPA qualified fireplace systems are also
$ammable material;tossing,kicking or otherwise forcing logs designed for installation in accordance with the National
into the firebox). Fire Protection Association Standard for chimneys,fireplac-
Standard EPA qualified fireplace and DM 54 chimney es,vents and Solid Fuel-Burning Appliances(NFPA 211).
systems are conventional indoor or outdoor fireplaces designed Standard EPA qualified fireplaces are not listed for use with
to appear(ike traditional masonry fireplaces. Standard EPA fireplace inserts.
qualified fireplace and DM 54 chimney system units are in-
tended for installation in residential homes and other buildings
of conventional construction,
Note: The local authority having code jurisdiction should be
consulted before installation to determine the need to obtain a
permit.
Important areas of concern with the installation of
these fireplaces are: construction of proper load bearing foun-
dation and concrete support slab;code reyuired hearth exten-
sion substrates and supports;proper assembly of components;
clearance to combustible materials;height of chimney;and,
techniques employed in applying finishing materials to the
fireplace opening and hearth extension.
Each of these important topics will be covered in
detail throughout this manual. Installation personnel must give
special attention to each topic as the installation progresses.
All work performed on,near and adjoining the
fireplace and chimney installation must meet or exceed the �
specifications and reyuirements in this manual and the
prevailing local building code.
Subseyuent renovations,additions of cabinets and
storage spaces in the enclosure surrounding the fireplace are
also limited to the specifications in this manual and to the
prevailing local building code.
Isokern is not responsible for other construction work
around the fireplace unit.
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.
Some jursdictions require the use of glass doors. `
If glass doors are used,operate fireplace with doors in the
fully open position.
4
Safe Instructions
The manufacturer is not responsible for any smok-
1.Before starting the Standard EPA qualified fireplace and DM ing or related problems that may result from the lack of
54 chimney installation,read these installation instructions adequate air supply$owing into the house. It is the respon-
carefully to be sure you understand them completely.Failure to sibility of the builder/contractor to ensure that adequate air
follow them could cause fireplace malfunction resulting in serious supply has been provided for the fireplace.
injury or property damage. 12."Smoke free"operation is not warranted nor is the
2.Always check local building codes governing fireplaces and manufacturer responsible for inadequate system draft caused
fireplace installations.The Standard EPA qualified fireplace and by mechanical systems,general construction conditions,
DM chimney installation must comply with all local,regional, inadequate chimney heights,adverse wind conditions or
state and national codes and regulations. any unusual environmental conditions or factors beyond the
3. Standard EPA qualified fireplace and DM 54 chimney sys- manufacturer's control.
tems are intended for use in any application where a traditional
masonry type fireplace would apply.The chimney system must Caution:When used with the Standard EPA qualified
always vent vertically to the outside of the building. fireplace system,all gas log sets must be operated with the
4.Creosote and soot formation and the need for removal:When damper clamped in the fully open position.This includes
wood is burned slowly, it produces tar and other organic vapors unlisted"vent free"log sets.Only listed"vent free"log sets
which combine with expelled moisture to form creosote.The may be operated with the damper in the closed position.
creosote vapors condense in the relatively cool chimney flue of
a slow burning fire.As a result,creosote residue accumulates on 13.When in doubt about a component's usability-has vis-
the flue lining.When ignited this creosote makes an extremely ible or suspected physical damage-consult your Isokern
hot fire. distributor or authorized Isokern representative for advice.
Because of creosote and soot buildup it is necessary to 14.Modification to STANDARD components not men-
inspect and clean the fireplace and chimney prior to use and peri- tioned in this manual may void claims,listings and approv-
odically during the heating season.Cleaning of the fireplace and als and could result in an unsafe and potentially dangerous
the chimney system should be done annually at a minimum.In �nstallation.
colder climates,chimney cleaning may need to be done periodi- Alterations to the STANDARD firebox are allowed
cally throughout the heating season. with prior written approval and instructions from Earthcore
5.Before servicing,allow the fireplace to cooL Always shut off lr►dustries,LLC.The installer indemnifies the manufacturer
any electricity or gas to the fireplace while working on it. of all claims and under no circumstances will manufacturer
6.Use only solid fuel or natural or LP gas log sets in this unit.Do be liable for consequential,incidental,indirect,punitive or
not use artificial wax based logs,chemical chimney cleaners or other damages of any kind or nature,whether foreseeable or
Hame colorants in this fireplace. not,based on any claim by any party as to the modifications
7.Never use gasoline,kerosene,gasoline-type lantern fuel, of the Isokern fireplaces.
charcoal lighter fluid,or similar liquids to start or"freshen up"a 15.Wherever insulation is used,the Standard EPA quali-
fire in this fireplace.Keep all flammable liquids at a safe distance fied fireplace must not be placed directly against it.Keep all
from the fireplace. insulation or vapor barriers a minimum of three inches(3")
8.Always keep the flue damper open when heat is present in the away from all fireplace and chimney components.
fireplace. It is recommended that insulation and vapor barriers,if
9.Do not use a firepiace insert or any other product not speci- used,first be covered with gypsum board,plywood,particle
fied for use with the Standard EPA qualified fireplace and DM 54 board or other material to assure that insulation and vapor
chimney systems unless written authorization is given by Isokern. barriers remain in place.
Failure to heed this warning may cause a fire hazard and will void
the Isokern warranty. WARNING: Do not pack required air spaces with
10.This fireplace is not intended to heat an entire home or to be insulation or other materials.
used as a primary heat source.It is designed to ensure homeown-
er comfort by providing supplemental heat to the room. 16.Never leave children unattended when there is a fire
11.Always ensure that an adequate supply of replacement com- burning in the fireplace.
bustion air from the outside of the house is accessible to the fire 17.Burning some fuels(such as charcoal)can be hazard-
to support normal combustion.Fireplaces consume large volumes ous due to the possibility of producing carbon monoxide,
of air during the normal firing process. a colorless,odorless gas.Early signs of carbon monoxide
ln the event the home is tightly sealed and has modern poisoning resemble flu symptoms, including headaches,
energy efficient features,the optional combustion air supply kits dizziness or nausea.Over exposure to carbon monoxide
may not provide all the air required to support combustion and can lead to illness and death.It is strongly recommended to
the proper flow of combustion gases up the chimney. install smoke and carbon monoxide alarm/detector devices
wherever fireplaces are in use.
5
_
Warnock Hersey Listing Label �
- Facsimile -
r.�.• t��1f3UtAft REFR�IIC"fqRY FI��PtAC� !Q���,�-
��� �
'� ':,,,,...;^� STAHDARDr C136" CJ 42" �3 d6" 3,�..a�1..u�,
W/N C5Alt4$ �;—�,MIM[SB f!t bEh1AWkK
�c"�N'r°v� �"' -� �rr�o�e
n�ia ue�t �imusr��s
COMRLIE8 YYPik4 APPLiGABLE R�Q.OF UL 127,UlC 8i10 JkGM480NVYl.l.E,
�a�
CIEARANCE TD COAAStJ9Ti8LE$: b0 NOT USE A FIREPLACE lNSE(tT QR OTH�R PROCIUC7S
t»si�Otrr,wD i�+7�tet catr�raEr ��!^ �pT SPECIFIEQ�4R USE WiTH T}I►S PaOaUCT.
t�eT SiDESAfi�t FFitR �4.3 Mr, (:�b+nn)
c4t�usna¢�s�rr�,tecn+�fypEN�iUp .a�r, �2�„mk "WARNIN6"THIS FIREPLACE HAS NOT B€EN TESTED�QR
SHFATHItd(i 4R TR�M TO pi>BN1N6 SILIES =l4ir�. (2pSmm} USE Wll'H GLAS$DQ4RS�TQ liEDt}CE TFiE R1SiC 4F FIRE QR
tA�4N1'tE�&flv�opEwtkfl =tt xe �35&nm� INJURY,04 NOT iFtSTAI.L GLASS OOpR�.IF DODR$
or+�r+�3 tQ g�Ey+�i:4 •29 v+ e66d+im} ARE U9EQ.dPERATE FIitEPLACE WfTH DDOR$Fl1LlY ClPEH.
�r��T����`�a F�i °2Q k� SSa9mm) WHEN HURNIt�G A DECORATIVE GAS AFP�fANCE IN TME
��H��Y����N���� "42�' ��0�^"'"> FIREPIACE,i.00K fiHE dAI�qPER iM THE FtlLIY OPEN
Cr�Mt�VSnpi 6�g,p�t .4 n. {raamm} p��TlON.pp NOT i?F�ERA7E AN UNY€NTEO 6AS LQG S�7'IN
�usutnria+tvrt4►t��t� _�� �T�+"'^1 THISFlFtEPLACEWYfHTHECHIMNEYREA�10VE0.
IlSf SaW YV04"1D fC�I.OR t�TED DECQRAkTNE WS YENtED OR INIVEIiTED APPLIAIICE,AL90 fdR USE WiiH L�iED I�TJVR CMq1iM�Y;
SE�INSTAL.LATfOPI AN6 OPERATING IAIS1`itUCT10NS FOR Tt11S MQD�I AkIO ICC#E3Ti-231B,
lA.itR M25�#83,MEA�2490E.
CONTACT 8UM.0�OFFiCIAI.PN90R TO ikStALUTiWI
EPA Yellow Qualifying Hangtag
O
��� � ���..�����
U.S.Environmental Protection Agency
Wood-burning Fireplace Program
Phase 2 QualiFleO models are cleaner and pollute less Man ihose models ihat
have not met this emissbns level.Exposure ro srtqke has bren associatetl with
respiratory illness and other healih problems.Models tha[have bwer smdce
emisswns may reduce your risk.
For more information go to www.epa.gov/bumwise
FIREPLACE
SMOKE EMISSIONS RANGE
Lawer Emissions Higher Emissions
� 12.0
293 5.'I EvnvHnsezeuisswHS�eve�
T01ffi P9�PP�6
F�no�.u•wxn iow.r em�.,b�s o��.b...moxe»n.n in.ten.e a�a uw�.�ee pmwM.
MIINUFRCiURER: FJIRTXCORE IfiDUSTRIES,LLC
MODEL NO: SMes 36 C
PARiICLE EMI5520N5: ].93 GRI1M5/KG OF WOOD BURNED
ro�qopn oper�tlary oblyN mu[be rcpYmp evey]to S yea�v
'EiA has de[ermir N,baseG m testirg by an acaMitM iMependent laboratory aM a certifimWn
W mnlamty M a natbulh�9nize0 art�mtion botlY.Uut[Ms motlel Walifi at Ue Phase 2
mxssons kvd lor U.S.EPA's W uMary Freplace Rogram.
Isokern Fireplace and Chimney Systems are tested and listed to UL standards: UL 127,ULC S610,and UL 103HT.
The listing label shown above outlines the listed clearances to combustibles and indicates that the units are
suitable for use with solid fuel or listed gas appliances.Refer to the manufacturer's installation manual for detailed description of
clearances to combustibles and all other installation information.A metal listing label similar to that shown above is affixed to each
Standard EPA qualified fireplace.Do not remove the listing label from the Standard EPA qualified fireplace fireplace.
In addition,an EPA yualifying label will be affixed to the Catalytic Combustor system.Keep this label in a safe place if needed for
permits or building inspection.Prior to beginning installation,contact your local building official to determine the need to obtain a
permit.
6
Assembled Firebox & Smoke Dome Dimensions 36 C
� G
� Catalyst
�
� E � � "I
� F H
�
� � � �— A � � E �
Side View Front View Plan View
Model A B C D E F G H I Minimum Framing Weight
36" C 43" 25 1/4" 71 1/4" 31 1/2"36 1/8" 27 1/4" 21 1/2" 20 1/4" 5" 44"W x 72"H x 26 3/4"D 1500 Ibs.
Catalytic Combustor system Operation
The proper use of a wood burning fireplace equipped with the Catalytic Combustor system will significantly
reduce the emissions that it produces. Simple fuel considerations with regard to moisture content,size,and quality of
fuel will help control the production of wood smoke and ultimately improve the performance of the Catalytic Combustor
system and fireplace efficiency. With proper care,the Catalytic Combustor system will provide years of fuel savings and
lowered emissions.By following some simple guidelines,you will ensure maximum performance and longevity.
The smoke that is usually seen coming out of a chimney is essentially a combination of unburned fuel(carbon
and hydrogen)and moisture in the form of water vapor. The Catalytic Combustor system is a technology that provides
secondary combustion for the wood burning process.
Avoid the use of treated,painted and laminated wood.Never incinerate garbage or other foreign materials.Do
not use artificial logs,colored newspaper or petroleum based fire starters.Avoid wood with high salt content.All of these
materials may contain compounds which can shorten the life of the catalyst.Wet or unseasoned wood may lower catalytic
temperatures and result in inefficient operation.
The Catalytic Combustor system is designed to function at optimum efficiency when the fireplace is burning
clean,dry cordwood as fireplace fuel.A simple visual inspection of the chimney during the wood burning process will
determine catalytic performance.
NOTE:Chimney smoke may be visible during the first 8-10 minutes of fireplace operation when the fire is first started
and also during the final 8-10 minutes of operation when the fire in the fireplace is going out.Otherwise,the catalytic
system will eliminate approximately 90%of the visible chimney smoke typically produced by a wood burning fireplace.
7
Component List & Dimensions 36 C
Base Plate
Part No. Model Qty Side Wall
No. Part No. Model Qty
21 36 1 / No. 251/4"
25��Z, 20 36 6 �
� A
Model A
36 43" 10 5/8" L
Back Walls
�3. Part No. Model Qty
No.
25 36 3
105/8"� q
SmokeDome-Small Model A
36 26 3/4"
Part No. Model Qry 4•
No. � �
12 36 2 ' S"
Catalytic Filter
32��2� 16� PartNo. Model Qty
No.
CCB-S 36 1
Smoke Dome-Medium
Part No. Model Qty 4�
No.
it 46 2
43°
16" Catalytic Filter Brackets(2)
Smoke Dome-Sidewall 3"
251/4" � Top Plate Small
Part No. Model Qty Part No. Model Qty
No. No.
36 36"W 1 �" o"
34 36 4 16" ti
�
�
` �a
���,
�..'
Isokern reserves the right to make changes at any time,without notice in design,materials and specifications and also to
discontinue styles and products. Please call(800)642-2920 for an Isokern dealer near you.
8
' Required Clearance to Combustibles
� The Standard EPA qualified fireplace fireplace and DM 54 chimney system is tested and listed for installation with"clear-
ance to combustibles"as follows:
A:Four inch(4")clearance to the combustible floor;
B:One and one-half inches(1 1/2")clearance at the Isokern firebox and smoke dome sides and front;
C:One and one half inches(1-1/2")clearance at the Isokern firebox and smoke dome back wall ;
D:Zero inch(0")Clearance to the DM chimney system.Contact metal pipe manufacturer for specific clearance
information
CAUTION:Maintain three inches(3")clearance to insulation and vapor barriers from all firebox,smoke dome flue components.
Note:"Combustibles"are defined as"normal construction materials"and are considered to be:wood framing materials,particle
board,mill board,plywood sub-flooring,plywood paneling and wood flooring.
Sheathing materials,such as plywood,particle board and drywall may cover the smoke dome front at 0"dearance.
All combustible sheathing materials that protrude beyond front of firebox must be held 8"away from the sides of the fire-
box opening and 8"above the top of the firebox opening.Drywall must be cut 2"back from the firebox opening sides and 8"above
the top of the opening.
Notes:
A.The Standard EPA qualified fireplace fireplace is rated for installation on a combustible floor system when using the
Fire-Lite application only.
The Standard EPA qualified fireplace must sit upon a concrete support slab designed to bear the total installed weight of
the fireplace and DM 54 chimney system. These support slabs can have no wood underpinnings.
B.Concrete support slabs for the Standard EPA qualified fireplace must provide the noncombustible hearth extension
substrate needed to support the code required noncombustible hearth extension finish materials.
C.All Standard EPA qualified fireplaces shall have hearth extensions of approved noncombustible material such as brick,
tile,or stone that is properly supported and with no combustible material against the underside thereo£Wooden forms used during
the construction of hearths and hearth extensions shall be removed when the construction is complete.
D.lf a raised fireplace floor and raised hearth extension are preferred,the raised underlying structure must be built of non-
combustible material and must sit on noncombustible substrate.
I I p I I
� � � � � I
B
B C
B
Hearth Extension
(non-combustible)
A
Non-Combustible
Floor System
(non-insulation)
9
Assembly Instructions - 36 C
General Isokern Assembly Instructions:
Earthcore Mortar(a thin-set type masonry adhesive)is
used to glue all Isokern components together during field assembly
of the unit.The mortar is supp(ied dry,in either 15 pound or 50
pound pails.
Earthcore mortar is mixed with clean water to a smooth,
workable texture(without lumps or dry pockets)of a"toothpaste"
Earthcore Mortar
rF� 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 fitted
together.
It is important that a 1/2"bead of mortar on all the compo-
nents'contact surfaces is applied at about 1/2"in from all edges of
the contact surface of the component.
When setting the next component onto the mortared con-
tact surface of the first 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 i/2"beads of the Earthcore Mortar to the area to assure
O proper sealing of the joint.
Properly mortared firebox and smoke dome assembly re-
quires approximately 25 pounds(dry measure)of Earthcore mortar.
Broken Components:
Components broken into 2 or 3 pieces can be repaired by
shim if required using Earthcore mortar along the break line as the component is set
to acheive into place.Components broken into multiple small pieces should be
correct height discarded and replaced.
Leveling and Aligning Components:
Be sure to assemble all Isokern components level and flush
with adjoining components.
Earthcore mortar is not intended to create a mortar joint
of any thickness for leveling purposes.Therefore,leveling and
alignment adjustments are made by the use of small plastic shims
supplied with the unit.
The shims can be inserted under a component to level and
align it with adjacent Isokern components.Be sure to re-grout any
and all gaps resulting from shim insertion to maintain components
to full bearing.
Notes:
1.Do not mix Earthcore mortar with spirits or anti-freeze agents.
2.The maximum recommended mortar joint thickness at Isokern
components is 1/4".
3.Earthcore mortar can be troweled over the face of a joint where
it has squeezed out while setting components.It is not intended that
the exposed faces of the Isokern components be compietely covered
with the mortar.
10
Assembly Instructions - 36 C
� Installation:
,� Earthcore Step 1: Set the Standard EPA qualified fireplace base plate in a
� � ,�
Mortar full bed of Earthcore Mortar flat on a proper concrete support
; � � foundation.Do not set the base plate so that it is in span.Levei
' � `'� ' � � the base plate by$oating it in a bed of Earthcore Mortar to full
� � � bearing against the underlying noncombustible support surface.
� �
�-'�� i� , Note: The bottom of the sidewall has a slightly smaller opening
�� � ' than does the top(meaning when the sidewalls are made—the
�
' � board side of the sidewall has about a 1/8"narrower opening
; , than does the top.If the fireplace is stacked where the top
' sidewall is placed upside down the clip will have a slight
~ interference when attempting to instalL lf this occurs,scrape
away an area about 1.5"wide by the 1/8".
Note: If the design preference is for a"flush hearth"(fireplace
� floor flush with the room's floor),the base plate can be omitted
from the assembly and the firebox walls built directly on the
concrete support slab.The fire brick floor of the firebox is then
set directly to the concrete support slab.This makes the fireplace
finished fire brick floor approximately one and one-half inches
(1-1/2")above the top ofthe concrete support slab.
If the design preference is for a raised hearth(floor of
the fireplace elevated above the room's floor),then the base plate
can be set on a noncombustible platform that is built up to the
desired raised hearth height on the concrete support slab.
When calculating raised hearth height be sure to allow
for the three inch(3")thick base plate plus the one and one half
inch(1-1/2")thick fire brick floor in addition to the height of the
Flush Hearth platform.Whether a flush hearth is preferred or a raised hearth,
on concrete the combustible floor on front of the fireplace must be covered
Foundations Only
with a noncombustible hearth extension set tight against the fire-
place front and extending at least 20 inches out from the finished
� fireplace and at least 12 inches beyond the finished sides of the
fireplace opening.
For all"raised hearth"construction where concrete
blocks are used to create the raised platform,it is necessary to
use the base plate.Be sure to mortar the concrete block plat-
form together.CNIU used for base plate support should be rated
ASTM 90.
Raised hearth
for wood or
co�crete installs
11
.
Assembly Instructions - 36 C
Step 2: Set the first course of the firebox back wall and side
walls into place.
� It may be convenient to dry set the first course of side
wall and back wall into place on the Isokern base plate and then
��
Earthcore to trace their position on the base plate with a pencil.
' �;� nnortar After outlining the dry set pieces,remove them and
� ; ,��'� apply Earthcore Mortar to the areas traced on the base plate
� 'w����% � � where the side walls and back wall are to sit.By doing this,the
, � � first 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
��; �� i � of the vertical joints where the side wall and back wall
�` � components connect.
�
� ��
,�
� Step 3: Continue assembly of the second,third and fourth
�'�" courses of the firebox side wall and back wall.Apply mortar to
the top of each layer of wall components,set the next course
above into place.Be sure to mortar all vertical joints ofthe side
wall to back wall connection when setting each component to
its mate.
First Course Look for some mortar to squeeze out along the joints
Backwa�l of all contact surfaces as a sign that the joint is thoroughly
Earthcore nnorcar sealed with the approved mortar.
Step 4: When all of the firebox wall components are set,check
� the top surface of the firebox 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
� ��r top surface of the base plate.
�_.�
� �,,� Any gap created under the wall components during the
Shim leveling process must be filled with mortar to fu(I bearing
against the base plate.
Step 5:Make sure that the firebox assembly has been set level
and square.Adjust as required while the mortar is still wet.
Make a final inspection of all contact joints in the fire-
box assembly to be sure they are properly sealed.Fil(any and
all gaps in the assembly,as necessary,with the approved mortar.
Top Course Step 6:Take the Catalytic assembly out of the box and verify al(
Back Wall components are in tact and Yellow EPA hangtag is attached to
Othe combustor. The Catalytic kit should contain a Catalytic
Combustor,and two(2)metal angle support brackets.
Note: Remove hangtag from combustor and place in a
secure,permanent location.Retention of this hangtag by the
Earthcore Mortar owner of the fireplace is mandatory.If ownership changes,
hangtag should be given to the new homeowner.
� Step 7:Insert support brackets so that the largest angled portion
slides into the side wail cavity toard the front of the sidewall
slots.The smaller angles should be facing upward toward the
inside of the firebox.
12
Assembly Instructions - 36 C
Step 8: Center the Catalytic Combustor in the firebox
and rest it on top of the support brackets making sure
that the filter is equally settled on the brackets. The filter
should be set toward the rear of the firebox.
Step 9:If grouting the inside of the sidewalls,leave the
top
1 3/4"without grout or else measure and locate the
mounting clip to the exact dimension(based on the
thickness of the brick&mortar used to line the inside of
the firebox backwall).
Step 10: Set the back smoke dome component across the
rear side walls in a bed of mortar and flush with the back
face of the back wall.
Set the front smoke dome component in mortar
across the front side walls flush with the front of the
sidewalls.
Step 11:Position the smoke dome's sloping sidewalls at
each end of the smoke dome components.
The sloping sidewalls fit in between the front
and rear smoke dome components and also fit into the
haunches at the ends of the front and rear smoke dome
components.Mortar all contact surfaces thoroughly.
Note: The smoke dome sloping sidewalls have a
beveled bottom edge so that they will sit tight onto the
flat top of the side walls.
Step 12:Make sure that all component contact surfaces
have been properly sealed with approved mortar.
Check smoke dome front and back walls to see
that they are plumb, level and in alignment with mating
components.
Check alignment of the smoke dome sloping
sidewall components to see that they are fully seated.
Step 13: Set the smoke dome top plate into position on
top of the smoke dome wall assembly.
One side of the smoke dome top plate shows a
thickened center.This side is the bottom face of the top
plate.
The fourteen inch(14")diameter flue hole in
the top plate is centered in the smoke dome from side to
side but is offset from front to back.
Make sure that the top plate is set so that the
flue hole is closer to the back wall of the smoke dome
assembly.
Be sure to set the smoke dome top plate flush
with the front,back and sides of the smoke dome assem-
bly.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 flue
components.
13
Assembly Instructions - Access Modification
Through-Wall Accesses:
1.Combustion Air Inlet:Combustion air inlet kits though not required
by Isokern may help improve fireplace operation in homes tightly sealed
and with other ventilating appliances installed.Check local codes for
combustion air inlet requirements.
The following is a general representation of a generic com-
bustion air kit and not a requirement of Earthcore Industries,LLC.
Local building codes prevail and should be checked before
installation.
FIGURE 22 � Generic fireplace combustion air kits typically consist of a
� sliding stainless steel access door affixed 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 preven-
tion screen of a maximum one-quarter inch(1/4")wire mesh completes
� the kit. (Figure 20)
The access door is fitted into the finished fire brick lining at
the interior sidewall of the firebox.The twelve inch(12")long sleeve
can be introduced into the firebox side wall or back wall by core drilling
Typical placement of an a ro riatel sized hole at the selected firebox location.Keep the
gas or electric I�ne PP 1� Y
(see detail below) top of the four inch(4")diameter access hole no more than six inches
(6")above the finished firebrick floor.The hole size should allow for a
Supplyairventilation one-quarter inch(1/4")mortar joint around the air access s(eeve for heat
(if required by code)
expansion.
The sleeve passes through the firebox wall and must
be connected to metal pipe(by other)-either flexible or rigid-that leads
Firebrick to the source for outside combustion air,as directly as possible from the
side Standard EPA qualified fireplace(Few to no bends)with a maximum
length of sixty feet(60').
Gasorelectric WARNING: Do not use combustible duct material.Avoid installing
line a combustion air inlet where the opening could be blocked by snow,
NOTE:Fillanygapsaround bushes or other obstacles.Air inlet must terminate a minimum ofthree
line with Earthcore Mortar feet below the chimney cap level.Air inlet ducts shall not terminate in
attic spaces.
Flexducttofireplace 2.Gas Line Feed:For a fireplace having the provision for installation of
firebox(all pans non-combustible) a gas pipe,the provision is intended only for connection to a decorative
gas appliance.
Exterior wall
CAUTION: When using the decorative appliance,the fireplace damper
must be set in the fully open position.
Gas line for gas log sets used in the Isokern firebox can be
Exteriorairvent routed through the side wall back wall or floor of the firebox by drilling
with dress plate �
an appropriately sized hole using a masonry drill bit.
3.Electrical Line Feed can be routed through the firebox back wall,side
walls or floor by drilling an appropriately sized hole using a masonry
NOTE:Gas lines and combustion drill bit. Be sure to follow the gas log appliance manufacturer's explicit
a���e�c�iano�Pia�eme„c�a�be,e�e,sed. electrical line connection instructions for vented fireplace installations.
This page used for illustretion of systems
°"�y. Gas line and electric line must be fed through separate access
holes.
CAUTION:All access holes must be grouted with mortar—after line or
conduit feed-to seai any gaps or cracks around line feed conduits.
14
Assembly Instructions - Fire Brick Installation
Fire Brick Installation:
The manufacturer requires that the Standard EPA
qualified firebox be lined with a minimum one and one-eighth
(1-1/8")thick rated fire brick.The pattern for the fire brick lin-
ing is an owner option.Standard N-Type brick mortar is a suit- FII'9b�Ck Flool'
able fire brick mortar for the Standard EPA qualified fireplace �d Backwall
and good masonry practices should be followed. (BUilt FIfSt)
All required through-wall accesses(gas and electrical
line feeds and combustion air supply access holes)should be
drilled before the required fire brick lining is installed.
It takes a total of about five gallons of N-Type brick
mortar mix(dry measure)to fire brick line a fireplace.
Face joints of one quarter inch(1/4")to three-eights
inch(3/8")give a good appearance to the finished brickwork
however,this is just a suggestion and other face joint
dimensions are also acceptable.
Step 1.Wet mop the inside of the Standard EPA qualified
fireplace with a damp sponge to remove dust and loose EXpanSlOn
particles from the interior before installing fire brick. G8p
(Both Sides)
Step 2. Start the fire brick at the front edge of the floor of the
Isokern firebox,proceeding inward toward the back.
HINT:Dip each firebrick into water before applying.
Step 3.Next,apply fire brick to the back wall of the unit start-
ing at the bottom of the back wall and working upward to the
top of the back wall.
Step 4.Finally,set the side wall fire brick by starting at the
front edge of the unit's side wall and working inward toward
the back wall fire brick.
Isokern makes no claims as to the performance
of fire brick or fire brick mortar(s).It is typical for heat
stress cracks to appear in the fire bricks in wood burning
fireplaces.
Firebridc Floor
and Backwall
(Built First)
15
Summary
1.WARNING: A twenty-four hour cooling off period must be
Fireplace and chimney systems will only draught prop- observed following second lighting.
erly when they are installed according to the instructions,in an After first and second fire,continue use of the unit with three
appropriate location and with the proper chimney height.Install- or four small fires of short duration(sixty minutes or so)and
ing the fireplace according to the instructions,choosing an ap- small fuel load.
propriate location,and choosing an appropriate chimney height A$er these first five or six small fires of short dura-
are the responsibility of the designer and the building contractor. tion normal use of the fireplace can proceed.For normal use
Tightly insulated and sealed homes,two story interior the maximum recommended fuel load is twelve to sixteen
spaces and high vaulted ceilings can cause negative air pressures pounds of dry firewood at a time.This fuel load is consid-
within the house which can impair drafting performance.HVAC ered to be approximately three to five cured hardwood logs
return air ducts near the fireplace opening will adversely affect of about three inches(3")to six inches(6")in diameter.As
the fireplace drafting performance. the fire burns down,refueling should be only one or two logs
It is the responsibility of the designer,the building added at a time.
contractor and their mechanical contractor to determine that the
building's internal air pressures are conducive to positive fire- Important: Do not burn construction debris or trash of any
place drafting. kind in the Fire-Lite fireplace.
Avoid placing any fireplace in an area near tall trees,tal( Whereas it is not uncommon for construction debris
buildings,or high land masses.These structures can reduce am- and refuse to be burned in a fireplace by site personnel on
bient air flow pressure as well as produce down draughts,either a project that is under construction,this activity must be
of which can impair fireplace drafting performance. avoided.
Earthcore Industries L.L.C.does not warrant drafting It is the responsibility of the building contractor
and is not responsible for it. to insure that the required dry-in period is met and that the
required lighting sequence is performed by the owner or by
2.Standard EPA qualified fireplace and Fire-Lite Fireplace the owner's agent.
Curing Instructions:
It is critical that the Isokern masonry elements in the 3.Log grates are required for burning solid fuel in the
firebox and smoke dome assembly be dry before firing of the Isokern fireplace.Grates allow for easy air flow up through
unit.Moisture le8 in the components from exposure during stor- the burning logs thus creating a more complete and efficient
age and shipping,as well as moisture from the installation phase, burning of the fuel.
must be eliminated before the unit is put to its intended use.
The first step in reducing the ambient moisture is to be 4.How to Build a Fire:
sure that the comp(eted fireplace rest totaliy in a dried-in setting First set the fireplace damper in the full open posi-
for a minimum of 28 days after construction of the unit is com- tion. Begin laying the fire by placing several pieces of wad-
plete. ded up paper directly on the log grate.Place kindling(small
The next step in curing the fireplace is to be sure that splits of dry pine or other dry softwood)on top of the paper,
the first five or six fires are of short duration. enough to loosely cover the paper.Next arrange several
The first fire of the unit can take place once the mini- smal(,dry hardwood or softwood logs or log splits on top of
mum twenty-eight day drying period has passed.This fire should the kindling layer.
be especially short. Finally,arrange two or three larger hardwood logs
Start the first fire slowly with a small amount of paper (oak,hickory,etc.)or log splits on top of the stack.
and kindling(small dry wood splits or twigs)and a maximum Ignite the paper at the bottom of the stack.The burning
load of four to six pounds of dry firewood,estimated to be no Paper will ignite the kindling which will,in turn,set the
more than two or three logs each of about three inches(3")to remaining fuel on fire.
four inches(4")diameter. Be sure to stack all firewood in such a way that it
The first fire should burn for no more than thirty to sixty �'ill settle into the log grate as the paper and kindling layers
minutes and then allowed to go out.Do not refuel the fireplace are burned away.Additional logs can be set onto the fire as
during the first lighting. each fueling burns down.
A cooling off period of twenty-four hours,at a mini- Ideally,fuel logs should be of a hardwood species
mum,should follow the first fire. that have been air dried for one year or longer.Use of cured
The second fire should be the same as the first fire. or uncured pine logs and uncured hardwood logs for fuel
The second fire should burn for no more than thirty to should be avoided.Pine logs and uncured hardwood logs
sixty minutes and allowed to go out.Do not refuel the fireplace �'�»tend to smolder and burn at relatively low temperatures
during the second lighting. producing high levels of soot and creosote.
Important: Do not throw,toss,jam,kick or otherwise force
logs into the fireplace.
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• � Summary
WARNING: Chimneys must be installed so that access is provided for
Never use gasoline,gasoline type lantern fuel,kero- inspection and cleaning.The chimney should be inspected
I sene,charcoal lighter fluid or other similar liquids to start or monthly during the heating season.
"freshen up"the fire in this fireplace or in any fireplace. Inspect the entire flue from the top down for obstruc-
tions such as birds'nests,leaves,etc. Such obstructions must
WARNING: be removed.
If processed solid fuel firelogs are used: Do not poke Check spark arrestor screens for clear flow of smoke
or stir the logs while they are burning.Use only firelogs that every two to four weeks during the heating season.
have been evaluated for the application in fireplace and refer Inspect the flue periodically during the heating season for the
to firelog warnings and caution markings on packaging prior presence of soot and creosote build up.If creosote or soot
to use. has accumulated,it should be removed to reduce the risk of
chimney fire.
5.Avoid over-firing this fireplace.Some examples of over- Have your chimney cleaned by a professional chim-
firing are: ney sweep if you have doubts about your ability to do it.
a.Burning of scrap lumber,construction debris,pine branches Use a plastic,wood or steel brush to clean the chimney.
and brush or cardboard boxes; Scrub the spark arrestor/chimney cap with a wire brush.
b.Burning small diameter twigs,branches or any Remove any chimney cap for flue cleaning from the
other small sized combustible materials in quantities which top.Open the damper in the firebox for cleaning access from
exceed the volume of the normal log fire; below.
a Use of artificial wax base logs,trash or other chemicals or Clean the inner portion of the flue by using a flexible
chemically treated combustibles. handled chimney cleaning brush.
For straight run flue the proper size brush can be
WARNING: Over-firing can permanently damage this pulled up through the flue from the firebox with the damper
fireplace system. open.
If the chimney has an offset chimney section,brush
6.Fireplace Doors and Screens: cleaning from the chimney top down to the offsetlreturn and
This fireplace has not been tested for use with doors. then from the firebox up to the offset section is the proper
To reduce the risk of fire or injury,do not install doors.If inethod.
doors are required by the local authority having jurisdiction In either case,cover the fireplace opening with a
then doors must be kept in the fully open position when the damp sheet(sealed to the opening with masking tape)before
fireplace is in operation. Isokern does not limit the use of brush cleaning.Do not remove sheet until the soot has settled.
fireplace screens. It is advised to vacuum loosened soot.Do not sweep loosened
soot as sweeping will disperse soot into the air and about the
7.Disposal ofAshes: room.
It is recommended that the firebox be cleaned of ex-
cessive ashes before each use.lt is necessary to remove ashes WARNING: Do not use chemical fireplace and chimney
from the open front of the fireplace.To do so,proceed in the cleaners that are poured on a hot fire.These can be dangerous
following manner: and generally work only on the flue section nearest the
Allow the fire to go out and the ashes to cool for at fire,leaving the rest of the flue unaffected.
least six to eight hours.
After the cooling period carefully pick up the ashes 9.Exterior Maintenance:
from the firebox with a small,metal fireplace shovel or other Annually,at a minimum,check all metal flashings
metal scoop and place them in a metal container with a tight and weather seals around the exterior chimney where it
fitting lid. penetrates the roof surface;inspect any chimney top spark
If possible do not sweep the ashes as this will stir arrestors,metal cowlings and weather hoods to make sure they
them into the air and disperse them into the room. are secure and weather tight.
The closed container of ashes should be placed on Seal any cracks or gaps in chimney-to-roof flashings
a noncombustible floor or on the ground,well away from all to prevent possible roof and chimney chase leaks.
combustible materials,pending final disposaL If the ashes are Inspect any cement chimney cap or clay chimney pot
disposed of by burial in soil or otherwise locally dispersed, terminations to make sure they are not diverting water into the
they should be retained in the closed container until all cin- structure.Seal any suspected cracks or gaps in these masonry
ders have thoroughly cooled. components.
8.Inspection and Cleaning:
At least twice a year in warm climates or monthly
during the heating season in colder climates,thoroughly
inspect the Fire-Lite firep(ace and chimney system.
17
Catalytic Combustor Warranty '
Clear Skies warranty obligations for the HearthCAT Emissions Control System are limited to the
terms set forth below: Clear Skies Unlimited, Inc. ("Clear Skies") warrants to the consumer who purchases
a new solid fuel burning fireplace containing a HearthCAT Emission Control System as a new component,
to replace the catalyst at no charge should it cease to function within three years from the date of purchase.
The HearthCAT Catalytic Component is designed to perform efficiently for three years of fireplace
operation. ONLY recommended fuels should be burned. Follow the fueling directions in manufacturers
operating manual. For warranty purposes,proof of fireplace or HearthCATTM purchase is required. Labor
for removal and/or re-installation of the catalytic component is not the responsibility of the manufacturer.
This warranty applies only to CS-100 Series HearthCATTM catalytic components manufactured by Clear
Skies Unlimited Inc. For replacement of a Clear Skies catalytic combustor under the conditions of this
warranty,please contact the manufacturer @ www.clearskiesunlimited.com
NEITHER CLEAR SKIES UNLIMITED INC.NOR THE DEALER WHO SELLS THE HEARTHCATTM
EMISSION CONTROL SYSTEM IS RESPONSIBLE FOR INDIRECT, INCIDENTAL, SPECIAL,
PUNITIVE OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE IMPROPER USE OF THIS
PRODUCT OR THE CONTINUED USE OF THIS PRODUCT BEYOUND THE REQUIRED
REPLACEMENT PERIOD.
18