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Home My WebLink AboutManual: Sokern-Magnum Installation Isokern® Standard Fireplace and Magnum Fireplace with Fire-Lite Application and DM Chimney System Installation, Operation, Maintenance and Owner's Manual Isokern Standard Models 36, 42 & 46 Magnum Models 28, 36, 42, & 48 A PRODUCT OF EARTHCORE Important:This manual contains assembly rules,installation steps,guidelines,use and maintenance instructions for the Isokern Standard and Magnum Series 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 64ERTzt � Issued: September 2012 Revision: 005 m� INTERTEK TESTING SERVICES REPORT NO. 3159656MID-008 �7 © 2007 Earthcore Industries, L.L.C. CUS Nock blelq' THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY TABLE OF CONTENTS General Information 3 Intended Use Statement 4 Safety Instructions 5-6 Warnock-Hersey Listing Label 7 Assembled Firebox&Smoke Dome Dimensions-Isokern Standard Series 8 Component List&Dimensions 9 Assembled Firebox&Smoke Dome Dimensions-Magnum Series 10 Component List&Dimensions 11 Required Clearance to Combustibles 12 Rough Framing Dimensions&Corner Location Layout 13 Assembly Instructions 14-17 Access Modification 18 Firebrick Installation 19 Flush Wall Finish Detail 20 Required Clearances(When sheathing protrudes beyond front of firebox) 21 Required Clearance to Combustible Framing 22 Flush Wall Fire Brick Finish Detail 23 Interior Masonry Veneer Fireplace Finishes&Clearances 24 Masonry Veneer Construction Details 25 Non Combustible Finished Facing Requirements&Clearance to Combustible Trim 26 Concrete Support 27 DM Chimney System 28-39 General Information 28 Component List&Dimensions 29 Component Weights 30 Installation 31 Lateral Support 32 Offset Block 33-35 Brick Ledge Installation 36 Brick Ledge Load Capacity 37 Flashing&Crown Caps 38 Height Requirements 39 Structural Information 40 Common Chimney Terminations 41 Metal Flue 42 Specialty Applications 43-45 See-Thru Applications 43 Two Story Stacked Installations 44-45 Fire-Lite Application 46-51 Fire-Lite Application General Information 46 Fire-Lite Application-Required Clearance to Combustibles 47 Fire-Lite Application-Load Calculations 48 Fire-Lite Application-Hearth Conditions 49 FTF-13 or Equivalent Chimney System 50-51 FTF-13 Installation Components 52 FTF-13 Offset Elevation Chart 53 FTF-13 Vertical Elevation Chart 54 Summary 55-56 Registration Card 57 3 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 will also require system. a design that will support the total weight of the Isokern fireplace 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 application.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: thirty-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. 3 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 and Report No.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 211). Note: The local authority having code jurisdiction, should be consulted before installation to determine the need to obtain a permit. Important areas of concern with the installation of these fireplaces are: construction of proper load bearing foundation and concrete support slab; code required hearth extension ,��,/ % substrates and supports; proper assembly of components; 0 #�`i01I Ili00* clearance to combustible materials; height of chimney; and, �� Az 411•0I0l 1' techniques employed in applying finishingmaterials to the �� 0ii 11 q OW � �. fireplace opening and hearth extension. iLik Suitable standard residential, minimum four inch (4") P* -51r �� thick,2500 psi concrete foundations on properly compacted fill i \/ can support installations up to thirty feet (30') overall height (brick ledge installations not included) Each of these important topics will be covered in detail \/ throughout this manual.Installation personnel must give special attention to each topic as the installation progresses. calk IMO All work performed on,near and adjoining the fireplace and chimney installation must meet or exceed the specifications L 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 1111004 x111 local building code. I► *4 responsible for other construction Earthcore is not work around the fireplace unit. I X0441 Important: The top plate of the firebox is not meant to be used �i1� as a structural support of any veneer. Please consult structural engineer for structural support of any veneer bearing weight on the Isokern top plate. 5 Safety Instructions 1.Before starting the 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 normal 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. Before 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 fuel or natural or LP gas log sets in this Caution: When used with the fireplace systems, all gas unit. Do not use artificial wax 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 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. 6" The installer indemnifies the manufacturer of all claims and y` 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 0,` A. on any claim by any party as to the modifications of the �� fireplaces. ,11\...., 0110415. Keep all insulation, vapor barriers, "house wrap" I paper and other insulating type membranes and products, `_. including fiberglass, cellulose and other insulation, 110 (anything that carries an"R"rating)a minimum of three , ' inches (3") away from all firebox and chimney surfaces. 1 / See exception.(Figure 34,Page 22) 1 1 / Exception: / If insulation is used in walls surrounding the 1 fireplace, insulation may be installed behind sheathing of 1 / 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 f 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 \/ fireplaces are in use. I wherever / `I I I I ? _ 7 Warnock Hersey Listing Label - Facsimile - 0 c us MODULAR REFRACTORY FIREPLACE OIsoicE N® STANDARD: ❑36" ❑42" ❑46" ❑MADE IN USA I ntertek 0 MADE IN DENMARK W/N 04895 WH- EARTHCORE DO NOT REMOVE INDUSTRIES OR COVER COMPLIES WITH APPLICABLE REQ.OF UL 127, ULC S610 JACKSONVILLE, THIS LABEL FL 32256 CLEARANCE TO COMBUSTIBLES: DO NOT USE A FIREPLACE INSERT OR OTHER PRODUCTS UNIT FRONT AND ISOKERN CHIMNEY =0 in. NOT SPECIFIED FOR USE WITH THIS PRODUCT. UNIT SIDES AND REAR =1.5 in. (38mm) "WARNING"THIS FIREPLACE HAS NOT BEEN TESTED FOR COMBUSTIBLE SHEATHING ABOVE OPENING TOP =8 in. (205mm205mm) SHEATHING OR TRIM TO OPENING SIDES =8 in. USE WITH GLASS DOORS.TO REDUCE THE RISK OF FIRE OR MANTLE ABOVE OPENING =14 in. (356mm) INJURY,DO NOT INSTALL GLASS DOORS.IF DOORS OPENING TO SIDEWALL =26 in. (660mm) ARE USED,OPERATE FIREPLACE WITH DOORS FULLY OPEN. HEARTH EXTENTION BEYOND FRONT =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 COMBUSTIBLE FLOOR =4 in. (102mm) POSITION.DO NOT OPERATE AN UNVENTED GAS LOG SET IN INSULATION 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 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. 8 Assembled Firebox & Smoke Dome Dimensions Isokern Standard Series 36, 42 & 46 G B I 1 III M o N 14_ _ # A ,E / C TOP PLAN VIEW D E - I � - — F — 7 \ I LI I 1 J A SIDE VIEW FRONT VIEW PLAN VIEW MODEL A B C D E F G I J MINIMUM FRAMING WEIGHT 36 43" 251/4" 63 1/4" 31 1/2" 36 1/8" 271/4" 33" 201/4" 5" (46"W)x(65"H)x(26 314"D) 1205 lbs 42 49" 25 1/4" 631/4" 31 1/2" 431/8" 33 1/4" 33" 20 1/4" 5" (52"W)x(65"H)x(26 3/4"D) 1325 lbs 46 53" 251/4" 631/4" 31 1/2" 471/8" 371/4" 43" 201/4" 5" (56"W)x(65"H)x(26 3/4"D) 1450 lbs TOP PLATE, MEDIUM TOP PLATE, LARGE Part No. Model Qty Part No. Model Qty 77 36 1 81 46 1 77 42 1 25 1/4" 25 1/4" 10 3/4" 33„ 10 3/4" 43" 4 43/4" 4 3/4" 9 Component List & Dimensions Isokern Standard Series 36, 42 & 46 SIDE WALL Part Fireplace 25114" 25114" V No.: Model: Qty: BASE PLATE A 20 36 6 II 20 42 6 y 0 Part Fireplace / 20 46 6 10112" No.: Model: Qty: A 21 36 1 43" 22 42 1 49" 3" 23 46 1 53" BACK WALL 10112°\ A SMOKE DOME-MEDIUM Part Fireplace No.: Model: A: Qty: Part Fireplace 25 36 26 314" 3 I No.: Model: Qty: 4 318 46 3742 32114 3 3611 5 11 42 2 DAMPER SUPPORT-LEFT 1%4N % 16" Part Fireplace No.: Model: Qty: 95L 36 1 95L 42 1 95L 46 1 SMOKE DOME LARGE DAMPER SUPPORT-RIGHT Part Fireplace Part Fireplace4„ No.: Model: Qty: No.: Model: Qty: ,N 95R 36 1 ft 13 46 2 95R 42 1 95R 46 1 14N 53" 16" A N 25114 3 DAMPER BEAM TOP-SLOPING N Part Fireplace 'N8" 1 No.: Model: Qty: A Part Fireplace 16" 68 36 2 43" \ No.: Model: Qty: 69 42 2 49" 34 36 2 1 70 46 2 53" 34 42 2 34 46 2 10 Assembled Firebox & Smoke Dome Dimensions Magnum Series 28, 36, 42 & 48 2314" G1 0 I 14" N /1 A / AK TOP PLAN VIEW U F _ C L E . — — m . 3" �5,� A SIDE VIEW FRONT VIEW PLAN SECTION A-A MODEL "A" "B" "C" "D" "E" "F" "G" MINIMUM FRAMING: WEIGHT 28* 35112" 28" 60 1/4" 28112" 31" 19 3/4" 22 1/4" 39"W x 61 1/2"H x 291/2"0 1040 lbs 36 43" 28" 69 314" 38" 38 318" 27114" 33" 46"W x 71"H x 29 1/2"D 1300 lbs 42 49" 28" 69 314" 38" 44112" 33114"" 33" 52"W x 71"H x 29 1/2"D 1420 lbs 48 53" 28" 69 314" 38" 48112" 37114" 43" 56"W x 71"H x 29112"D 1600 lbs *Model 28 comes with three(3)sidewalls and some components must be"field cut". Firebox & Smoke Dome Components List 61\0. 0. 10 143\0. 146\« 427 " \4 3/4" 43+ \4 314" TOP PLATE,SMALL 134 149\0. PART FIREPLACE QTY: NO.: Model: 36 28 1 TOP PLATE,LARGE PART FIREPLACE QTY: NO.: Model: 34. / \4314" 81 48 1 TOP PLATE,MEDIUM PART FIREPLACE QTY: NO.: Model: 77 36 1 77 42 1 11 Component List & Dimensions Magnum Series 28, 36, 42 & 48 riris \ BACK WALLS c;�F *Model 28 Only Part Fireplace Qty: > �8._ Field Cut Back Walls Model: G: �j 655 28 Cut to 20" 3 7 , 65 36 26 3/4" 4 <,.3 - I �� BASE PLATE 9 3 66 42 32 1/4" 4 -E Part Fireplace Size Qty: 67 48 37" 4 c 9 No.: Model: A: Ilk %,, 91 28 Cut to 35 1/2" 1 91 36 43" 1 92 42 49" 1 93 48 53" 1 '''` e I /Z, I>, t.. I i *Cut as shown in the field; 4 9'2' mortar pieces together and Mstagger joints when stacking 9 / 1 „ for installation. DAMPER SUPPORT(LEFT) Part Fireplace Qty: / 94L Model: SMOKE DOME 94L 28 1 Part Fireplace Size Qty: sem,_ 94L 36 1 No.: Model: A: ' 16„ 94L 42 1 12 28 321/2" 2 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 fC ' til\'a 94R 36 1 94R 42 1 94R 48 1 TOP-SLOPING 1 16, Part Fireplace Qty: DAMPER BEAMS IP No.: Model: 1- 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 9 .1. >e\ Front of I ' l � Smokedome g (above) REAR , SIDE WALL Part Fireplace Qty: � No.: Model: ,=-- FRONT / 90 28 6 90 36 8 90 42 8 90 48 8 12 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) 0"CLEARANCE Note: "Combustibles" are defined as "normal construction materials"and are considered to be: wood framing materials, ii 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"clearance. 11N ,All combustible sheathing materials that protrude beyond , , front of firebox must be held 8" away from the sides of the /I-\ / firebox opening and 8"above the top of the firebox opening. i ��/\� Wherever insulation is used, the Fireplaces must I not be placed directly against it. Keep all insulation,vapor 4-0I barriers, "house wrap" paper and other insulating type I 1`I _ ;6. membranes and products, including fiberglass, cellulose FIGURE 3 �V� and other insulation,(anything that carries an"R"rating) ' 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 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. 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 2cr finish materials. (Figure 4) LMIN. 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 /�///----- against the underside thereof. Wooden forms used during11 a 1 11 N a a a e .:, the construction of hearths and hearth extensions must be ri,removed when the construction is complete. t D. If a raised fireplace floor and raised hearth extension arepreferred, te raisedunderlyingstructure /Combustible hUnderpinnings 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 LI �� agnum Ni-i- r , Model 28 38 1/2" 611/2" 29.5" GcaNiModel36 46" 71" 29.5" o ® Model 42 52" 71" 29.5" Model 48 56" 71" 29.5" . Isokern Standard L 1 Model 36 46" 65" 26 3/4" Model 42 52" 65" 26 3/4" Model 46 56" 65" 26 3/4" Notes: 1. "B"includes the 3"thick base plate."B"is reduced by 3"if the base Fp,, -14 q plate is eliminated to create a"flush hearth". ODp, 2. "Raised hearth" requires additional rough opening height at "B" equal to the height of the raised hearth detail. 3. Rough framing dimension for width "A" allows for the required 1-1/2"clearance at the sides of the Fireplaces. FIGURE 5 4. Rough framing dimension for depth "C" allows for the required 1-1/2"clearance at the back of the Fireplaces. Corner Location Layout The following chart of dimensions is intended to aid in the positioning of a fireplace in a corner condition where the DM chimney must turn 45° degrees to align with overhead framing. Magnum A B C D Model 28 33 1/2" 18 1/4" 24" 65 1/2" Model 36 43" 16 3/4" 32" 78 3/4" Model 42 49" 26 1/2" 36" 83" _y_FUi•I• '_ Model 48 53" 28 1/2" 39" 85 3/4" Isokern Standard Model 36 43" 49" 35" 72" v '- ••::-;0 .s, . Model 42 49" 52" 37" 75" Model 46 53" 54" 39" 79" oTo turn flue 45°,first set one offset block on the firebox so that O the chimney offsets 3"toward the back of the firebox. (Figure 6) I Set a DM outer casing onto this offset block so that the outer 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 In 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 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 supplied dry, in 50 pound pails. Earthcore mortar is mixed with clean water to a smooth, workable texture (without lumps or dry pockets) I, 1 of a "toothpaste" consistency. This mixture is suitable for application onto Isokern components by using a masonry grout bag supplied with the unit. I' / Attention should be paid that the mortar mixture is not too thin or runny, as this will not allow the mortar to reach its II maximum bonding strength. 11111 / 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 ECI 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 'rl 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 HEIGHT grout any and all gaps resulting from shim insertion to maintain components to full bearing. r 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 floating it in a bed of Earthcore Mortar to full bearing against FIGURE 10 the underlying noncombustible support surface. ij 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 / i directly on the concrete support slab.The fire brick floor of the I, ` / firebox is then set directly to the concrete support slab. This 1 e, makes the fireplace finished fire brick floor approximately I- i I � • I one and one-half inches(1-1/2")above the top of the concrete \I�%�' \II support slab.(Figure 11) \��II If the design preference is for a raised hearth(floor �3'ull / I` of the fireplace elevated above the room's floor),then the base II 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 II 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 'll 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 I. 4 with a noncombustible hearth extension set tight against the I-41110111 fireplace front and extending at least 20 inches out from the finished fireplace and at least 12 inches beyond the finished Isides of the fireplace opening.For all "raised hearth" construction where concreteI blocks are used to create the raised platform, it is necessary I1to use the base plate. Be sure to mortar the concrete block `I� / I\� 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. c,79/ It may be convenient to dry set the first course of side wall and back wall into place on the Isokem base plateFIRST COURSE and then to trace their position on the base plate with a pencil. SIDEwALL 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, 1,,,404 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 JJ TWO COURSES component contact surfaces with Earthcore Mortar. Check for /� BACKWALL complete sealing of each contact joint while assembly progresses. EC I\\ � 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 I 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 I side wall to back wall connection when setting each component to its mate.(Figure 14) 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 SUPPORT IN with the approved mortar. PLACE Step 4: When all of the firebox wall components are set, check gi 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. I (Figure 9) I Any gap created under the wall components during the IShim leveling process must be filled with mortar to full bearing II against the base plate. IStep 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. The damper beam assembly consists of two long lintel FRONT DAMPER 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 15) 110.4111114The 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 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. 1" DAMPER Step 8: Position the cast iron damper so that its front flange i is approximately one inch(1") away from the inside face of the front smoke dome component. (Figure 17) FRONT , REAR Run a thin bead of mortar around the four sides of the cast iron damper or tack the comers of the flange to avoid __■l 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 Isokem Standard front smoke dome component in mortar across the front damper beam and flush / END X17" with it. Set the Magnum front smoke dome component in t mortar accross the front damper beam and 2 -1/4 inches '`,. back from the front of the front damper beam lintel. This Damper Beam N '> placement should create a space of 17 inches (17")between the front and rear smoke dome components. Step 9:Position the smoke dome's sloping sidewalls at each end of the smoke dome components.(Figure 18) li The sloping sidewalls fit in between the front andrear 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. Illustration only.IsokernStandard 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. , 010 3/4" Check smoke dome front and rear walls to see that they are plumb, level and in alignment with mating / components. 1 , Check alignment of the smoke dome sloping Obi" , sidewall components to see that they are fully seated. I' / Step 11: Set the top plate into position on top of the smoke I-\ /, dome wall assembly.(Figure 19) I/`I One side of the top plate shows a thickened center. This side is the bottom face. The flue hole in the top plate is centered in the I/ 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 Duct To Fireplace, 1. Combustion Air Inlet: Combustion air inlet kits though (All Parts Noncombustible) 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 i for combustion air inlet requirements. 1 Exterior Wall The following is a general representation of �l��I�IIIIIII, • ''Y Y a generic combustion air kit and not a requirement of Earthcore Industries. Local building codes prevail and should be checked before installation. i► i Generic fireplace combustion air kits typically Exterior Air Vent 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 20with dress plate,weather hood and rodent prevention screen of a maximum one-quarter inch(1/4")wire mesh completes IIthe kit. (Figure 20) IIThe access door is fitted into the finished fire brick II lining at the interior sidewall of the firebox.The twelve inch [� (12")long sleeve can be introduced into the firebox side wall II ''� by core drilling an appropriately sized hole at the selected / firebox location.Keep the top of the access hole no more than I� 1 / six inches (6") above the finished firebrick floor. The hole \3 size should allow for a one-quarter inch (1/4") mortar joint 1k i'\r, around the air access sleeve for heat expansion. I/ The sleeve passes through the firebox side wall and Ler `I/ must be connected to metal pipe (by others) - either flexible I w�, or rigid-that leads to the source for outside combustion air, ��/� �� as directly as possible from the fireplaces (Few to no bends) � with a maximum length of sixtyfeet 60' . Typical Placement of �I $t ( ) Gas or Electric Conduit '." (See Detail Below) �/ WARNING: Do not use combustible duct material. Avoid Supply Air Ventilation 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 ir Fire Brick Side fireplace damper must be set in the fully open position. IA 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). ITA 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 Installation: The manufacturer requires that the fireplace fireboxes H H be lined with a minimum one and one-eighth (1-1/8") thick Ifire 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 adhereExpansion the fire brick to the inside of the firebox and to create the //111 1/2"Gap 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 lbs Earthcore mortar * Six parts sand(1 1/2 bucket) *One part Fire Clay(optional) *Water to a sticky,toothpaste consistancy These instructions may vary because of different climates and conditions. The use of good masonry practices for your area should also be considered. It takes about 25 lbs. of mortar mix(dry measure)to fire brick line a fireplace. Expansion Installation Instructions: 1/2"Gap 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. Fire Brick Floor pr (Built First) 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 /\K the 1/2"expansion gaps where both the floor fire brick and the i back wall fire brick were held off the units side walls. (Figure No Gaps 24) / All required through-wall accesses(gas and electrical line feeds and combustion air supply access holes) should be Fire Brick Floor drilled before the required fire brick lining is installed. and Back Wall Earthcore makes no claims as to the performance (Built First) of fire brick or fire brick mortar(s).It is typical for heat stress i cracks to appear in the fire brick in fireplaces. FIGURE 25 " " " 20 Flush Wall Finish Detail IIII Framing Protrudes III Il�r 11 Past Firebox Front I� r ,,, I �I� \ILIIIll° '1 IIIii , ;1 .o' I. � ►II / 11 y 010 MagnumSeries ,iiiiik...._ AW FIGURE 26 Drywall Flush with Firebox Front FIGURE 28 8" Minimum Noncombustible Facing Material To Span Framing I�1` 1 0 Members I / it- Al!_1._. 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 of the 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 required 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) X N K VH/ iiiiiiiiiiiiiii . L x 1� .J Jr, ..-.-. v w . v v Plywood 1 1/2"MIN TO r Sheathing COMBUSTIBLE FRAMING Noncombustible FINISHED OPENING Facing 8" 8" FIGURE 29 MIN MIN • W**D ••M:dSTI: E) EA IN z ,—,/ , , FIRE BRICK $ d $„ MIN ; ^,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 :, .,� �r;1_: COMBUSTIBLE Fireplaces are tested and listed for one and one-half FRAMING 1 inch(1-1/2')clearance to combustible framing material at the +;� II firebox sides and back. IF �� Installation and use practices that are beyonda the 1 1/2' MIN IIII■ �4 ■�■ 1 N control of the manufacturer* can result in situations where IVr •��i •I� clearance requirements (as determined through testing and a B as stated by the manufacturer) are not maintained due to 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 FRAMING BLE spaces with insulation or other material.No material is allowed in these areas.(Figures 31 &32) *The manufacturer is not responsible for installation and use 1 N,. — MIN' ; practices that are beyond the scope of the product as defined in FACE OF the product listing and in the installation manual. COMBUTIBLE FRAMING 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, ►_►,IMilMO il_'1E (anything that carries an "R" rating) a minimum of three 11/2IFinches(3")away from all firebox and chimney surfaces.See exception.(Figure 34) i 1MIN Exception: � �� If insulation is used in walls surrounding the fireplace, 1.11'.11'.I k....j1j1l0,1,et.-ir insulation may be installed behind sheathing of gypsom board, plywood, particle board or other material on the side facing MIN FIGURE 33 the Isokern.The facing material cannot be within 1 1/2"to the 11/2• fireplace sidewalls. MIN 1111111111111 When Fireplace installations are surrounded by walls �� that are to be insulated,the walls must have enough clearance 3"min When It4 Insulation Behind sheathinUnsuppoded1io1/n"eClhindshe9 to the Isokern unit in order to maintain the three inch (3") en Supportedlitl � minimum clearance to insolation for unsupported insulation. m (Figure 34) /;1 i It Never spray the Fireplaces with any type of sealer, T insulation or other material. N 12" 12" o min Hearth Extension min i 1 1/2" 0 1091 Do Not Place Sheathing I1►`l, Within the 1 1/2"Required E' Clearance to Combustibles r 77 lig ��►,►, 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 walls of the firebox-be set flush with the ��. 1 1/2° �� rough firebox front. This will aid in the overall fit and finish 1 1/2" �. of the fireplaces front when the code required noncombustible A E A 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 wall surface. •�� Important: Since there is no fire brick set along the top of . I the firebox opening,when setting the noncombustible finished facing material(code required and supplied by others)across Noncombustible Min the top of the firebox opening there may be a gap between Facing Material the back of the noncombustible finish material and the rough 1 rA front face of the fireplace damper beam. �, 41,— Be sure to check for and fill any such gap with /�� I 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. LFIGURE 35 Important: Failure to seal any gaps between the front face of the damper beam and the back of the noncombustible finished facing material will create what is known as a"false (--X----- / chimney".A"false chimney", in this case, is the narrow gap (mentioned above) between the back of the noncombustible facing material at the top of the firebox opening and the rough _./ FILL 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. WITH EC GAPIt is acceptable to apply noncombustible finish WITH EC MORTAR TO p pP Y AVOID FALSE CHIMNEYS — facing to the front and below the firebox opening to create an arched look, etc. When doing so, make sure to check for and fill any such gap with noncombustible Earthcore 1110 I III Mortar in conjunction with placement of the code required I noncombustible finish facing material. I I I I I NOTE: You must still keep a minimum 8" from the firebox I ,I, opening to any combustible materials. M FIGURE 36 24 Interior Masonry Veneer Fireplace Finishes & Clearances II II II II II II II II II II • ___-----I 1001 II I� 'OM: ST ;LE I II ' II II II I. SH.AT IG -Et II II �', II II IME- iMMI II '•JI II II In II II II II II I II II li'•%. II II l• 4 I 11 II `•. 11 II 1—. • _ II_n ill nn I II II IM 4 x 6 STEEL _ I II II II I I II I M "L"ANGLE `D II II I V II II TDII I II I I � O SO. R C1Mo JI II II IR :OX . IT d A ll II I• S •EL' 'AL N1 III II III I� I=In1• II II IM 011 31/2" 11 II I=M II II IM 0 II 2" �� II II II II iIn � 11 I II IIM 4 V N N / 1 N 7 i . 7 N J VA I --- 4 x 6 STEEL"L" I j/jjfA j �ALIG ALIGN 2" �f MIN ISOKERN UNIT WIDTH DIM'N. BEARING 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 L 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. N MIN.CLEARANCE ,LAny proposed brick, stone or other masonry veneer w facing must have sufficient foundation to support the full weight S of the veneer work.This may require review by a local structural z. 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) LA steel "L" will need to span the top of the finished fireplace opening to carry the masonry veneer as it spans over the VEICK VENEERfirebox opening. (Figure 37) By code requirement this steel"L"must have a minimum fJ fJ II 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 / rJ as it spans the firebox opening must, in all cases, have a two —' ,/// r COMBUSTIBLE inch(2")minimum clearance to all combustible materials.The SHEATHING vertical leg of the steel "L" cannot exceed six inches (6") in / X MASONRY VENEER height. /, / GV Note: Properly placed combustible sheathing is kept a minimum of eight inches (8") away from the firebox opening sides and top. �� / /l Important: Combustible framing members, normally set at 1k one and one-half inch (1-1/2") clearance to the sides of the 4x6STEEL"L" 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 framing members two inches(2")away from the firebox side walls will maintain the minimum required two ,--r, MORTAR,OINT S inch (2") clearance from the steel "L" and, at the same time J allow full four inch(4")end bearing required for the steel"L". L 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 fireplaces12" 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 /\K 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 off-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 / / // / /2/ , 1///a/ i to the same building code safety clearances to combustible 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. ADJOINING Combustible projecting mantles-up to twelve inches ROOM WALL (12") of projection - shall not be placed less than fouteen inches(14")from the top of the 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 N _ greater clearances for projecting combustible mantle shelves. Be sure to check local building codes regarding required clearances to projecting combustible mantles. Adjoining Walls. Side walls and walls to rooms adjoining fireplace installations cannot be closer than twenty-six inches (26")to the finished fireplace opening. (Figure 41) HEARTH 0 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 10: 0 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: MEN 1.Slab on grade:standard residential,minimum four inch(4")thick,2500 psi concrete foundation on properly compacted fill.This type foundation can support Isokem installations up to thirty feet (30')* overall height without additional structural support. (brick ledge installations not included)(Figure 42) *Minimum height. See page 3 for specific models. 2. Slab-on-grade foundations, thickened and reinforced: for additional load carrying.(Figure 43) FIGURE 42 I 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 M 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,Isokern 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 V�� 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 Fireplace weights* and"foot print"areas: The total fireplace weight and footprint for each model listed below j includes:Fireplace pumice components only: A.Model Magnum 28: 1040 lbs.-35.5"x 28"=6.90 sf. B.Model Magnum 36: 1300 lbs.-43"x 28"= 8.36 sf. C.Model Magnum 42: 1420 lbs.-49"x 28"= 9.52 sf. D.Model Magnum 48: 1600 lbs.-53"x 28"= 10.3 sf. A.Isokern Standard 36- 1205 lbs. -43"x 25 25"=7.54 sq. ft. B.Isokem Standard 42- 1325 lbs. -49"x 25.25"=8.59 sq. ft. .i. C.Isokem Standard 46- 1450 lbs. -53"x 25.25"=9.29 sq. ft. is • _I„ „I *Totals are exclusive of any chimney components. See page 30 for Isokem DM chimney component weights. 11.1s I "Footprint" areas listed above are base plate dimensions a_ 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, \.P. the outer casing block and an inner liner. General Information: /,/ This chimney system is designed for installation in accordance with the National Fire Protection Standard for Chimneys and Solid Fuel-Burning Appliances, NFPA 211 and in accordance with codes �'� I such as ICC, BOCA Basic/National Codes, the standard Mechanical Code and the Uniform BuildingCode. o Note: Illustrations shown reflect"typical"installations with nominal 010 dimensions and are for design and framing reference only. Always II 1►� maintain minimum required clearances to combustible materials and ,III` do not violate any specific installation requirements. III /1111 IIS Required DM Chimney Clearance: 11:111 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 chimneyIchase at zero clearance to wood framing members. IWARNING: Keep all insulation minimum of three inches (3") II away froall DM chimney components. If insulation is used inIwalls surrounding the chimney, insulation may be installed behind 1I 0 sheathing of gypsom board,plywood,particle board or other material , I 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 11/1 / . or practices other than those described in this manual may create a fire hazard and void the limited warranty. 1 Note: A firestop is required wherever a chimney passes between one f" // 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 1 \/ materials"and are considered to be:framing materials,particle board, mill board, drywall, plywood paneling, plywood sub flooring, and 1 wood flooring. ' IMechanical Vent Systems: '\I/, It is acceptable to use mechanical draft systems, if the venting P Y companies do the engineering calculations and make the necessary recommendations for fan size and flue vent diameter following I/ ' 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 4(4111.*0 ‘ 6" -" 1111.111rWillilbl -- INNER STARTER LINER 11 13/16" 16 1/2" 12"or 14" SMALL -‘411111 I CROWN CAP 3" 12" HIGH INNER LINER DM 54 Note:DM 44 12"High Inner Liner will have a 6"or 8"Diameter Flue hole. 37 1/2" 4 37 1/2" -• 21 1/2" 21 1/2" a1 _-..mNIIIIIIIII IIIIMMIIIftw.--- 1 . 4 (2) • . ,., ' .C. ' 12" LARG71111NYPirr: CROWN CAP 13/16" OUTER CASING 11" 3" 21 1/2" alk 11111, 31 1/2" .,---', 311/2" : . ,-- ... OFFSET BLOCK BRICK LEDGE ah ,e 3" 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,brick/stone 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 0 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(11)0 offset sequence. (See pages 33-35) Consult a structural engineer for specific,individual structural requirements. o7 BRICK LEDGE Notes: Plan chimney configuration carefully before constructing 40.„---- 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) 1 0 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 'Doc) for proper job-specific support structure design, sizing and load c) 4bearing specifications. %.c).0Unless 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 CASIN Olk OFFSET BLOCK 31 DM Chimney System: Installation Instructions DM Chimney Alignment: o Where the chimney run is to be a straight vertical run o the DM outer casing block sits directly onto the Isokern smoke �oO dome lid.The DM outer casing block,properly set is intended to be flush with the back face of the firebox smoke dome OUTER CASING 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 /off 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", 441 0 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 10 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 4'7 000 liners and the outer casing blocks. Starting with the six inch(6") tall inner liner starter lh \00 piece creates six inch(6")staggered horizontal joints between Ip the inner liner and the outer casing block. / Both the outer casing block and the inner liner 1111 `, components have tongue and groove type detailing on each \/ , end to assure alignment and interlock of the pieces as they are I' stacked and glued together. li Notes: If the "factory" inner liner starter piece is broken or otherwise unavailable then a full twelve inch(12") tall inner III liner piece can be cut to six inches (6") in height to make an IIinner liner starter piece. DM chimney inner liners can be stacked with either II II the male or the female end up. In either case start the inner / liner stack with a six inch(6")starter piece. II 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 1► lower outer casing block.This assures proper alignment of the two components. Next place a full height inner liner onto the mortared (� SMp �S top end of the previously set inner liner. Proceed this alternate stacking of outer casing blocks and inner liners until the desired S d 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 S ..?".""kN \\ *0 (4') intervals up the structural wall adjoining the chimney, (� connect one 18 gauage strap tie to the structural wall with C 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 C4:00.,...) walls the DM chimney outer casing block is to be laterally im braced at ceiling and roof penetrations. _ Pressure treated two inch (2") by four inch (4") -Illimi------_______A% blocks,set at each side of the flue between the trusses or rafters and fastened to the pre-engineered roof trusses or rafters with ,I4 M two 16d common nails at each end, provides lateral support, parallel with the framing.Additionally,a two inch(2")by four inch (4") by six feet (6') minimum pressure treated member \� ("rat run")installed on each side of and butted up to the outer casing block will provide lateral support perpendicular to the 00, direction of the truss or rafter framing system. a /` Fasten the perpendicular member with two 16d common nails to each intersecting truss or rafter. The tA'\ perpendicular bracing should be installed on the top side the ceiling level framing as well as on the bottom side of the rafters. '/ (Figure 51) Note:A firestop is required wherever a chimney passes between q0 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. FIGURE 51 33 DM Chimney System: Offset Block DM Offset Chimney Block: For vertical DM chimney to bypass overhead obstructions, ill II hilliiiiiP s, the Isokern offset chimney block is used. Offset blocks are six inch (6")thick,single module chimney components,measuring twenty-one and one-half inch(21-1/2")wide by twenty-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 flue component on top of %.°4-0:0 othe 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 4 support is required. 1 Offset sequences are best when built as low as possible in the AA I chimney run to maximize performance.Do not make support columns of brick, stone or wood. All support columns must bear onto proper 41 Anoncombustible foundations. Isokern Offset Chimney Block Installation: 1 1 Isokern offset chimney blocks are stacked in a stair step 111111116" 11 fashion with each successive block overhanging the previous offset 11 block by three inches(3"),allowing the flue to rise at an angle of thirty I/ 11 I (30°)degrees off of vertical.(Figure I� ( 52) When building offset sequences check the interior flue 41111 alignment as each offset block is set to avoid creating overhanging jil ledges on the inside of the flue. Such internal overhangs will inhibit flue drafting. I Each offset block is to be set fully in a bed of Earthcore Mortar, completely sealing each offset block to the underlying component. 440V Offset chimney block sequences can be built to shift the chimney run to the left,right or to the rear of the firebox/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: // AWhen 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 block sequences that clear the side wall of the firebox below,it is allowable to support the first offset block that clears 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 _II�I of smoke dome assembly while the DM chimney passes up the backside of the wall. Iii' For a nominal 2"by 6"wall thickness the chimney can IM 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 Iface of the DM outer casing block. This allows for the smoke = dome to sit flush with the inside face of the 2"by 6"wall and the FIGURE 55 straight chimney to run up the outside of the wall. (Figure 55). = For a wall thickness of 9",nominal 8"CMU plus 1-1/2" furring strip - 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) 1 �� Greater offset distances can be accomplished by - building with more offset chimney blocks.(Figure 56) _11- Offset block Support Foundations: != It is required that every third Isokern offset chimney 11/1 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 �M •• •• 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 set a DM outer ' casing block in its proper location on top of the completed Il I f 1111 I firebox/smoke dome assembly as though starting a straight I I IIIMES chimney. I II I MEI i If the offset sequence is to move to the left then,starting I I= I II� from the right side of the temporary DM outer casing measure LJ- LJ IJ 1.111! left ward to the far face of the overhead obstruction that needs to . = IJi 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 MI- 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 I; required travel distance. ,p ,..ff _ To calculate the height that the offset block sequence will require, take the total number of offset blocks ul° needed to accomplish the travel distance (described above) I� multiplied by 6". This number is the height (inches) that the offset sequence will require. 35 DM Chimney System: Offset Block (cont.) MEASURE TRAVEL When establishing the "far face" of the overhead DISTANCE obstruction,be sure that the DM chimney blocks can run straight 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 block in a sequence o 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 El 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 TRAVEL applied to it. DISTANCE 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 blocks in sequence. F)By code the maximum angle of offset for a chimney `,I system is 30°off of vertical. II ` I DM Brick Ledge: i II I The DM brick ledge is a 3"thick,31-1/2"square,steel I reinforced,concrete and pumice slab(Figure 60). The Brick ledge provides a 5" ledge at all four sides I`•, f 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 reinforcing rods and subsequent grouting.(Figure 60&61) \�\ti 77/c2, The brick ledge is intended for use in chimneys that rise through the roof only where all four sides of the chimney O are bounded by the roof. WARNING: To maintain structural performance the DM brick 0(11)0 ledge must not be cut or altered in any way. O \\\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 casingand inner liner assembly Y ��`,. approaches the roof penetration set an outer casing block to a level ,, ` 4.0 , as close to the the low side of the roof framing as possible.(Figure *I ��, `I�III D11.0 � 62) `\\\\Ill�lp��/1 , 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 . , \\\\\f /:0,;0 1l g p Y �,� ,#� � :.i 11 casing block. � , '' /I Set the Isokem 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. 400)j 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 %0 brick ledge,(In some cases,a minimum recommendation could be 5'). Consult local structural engineer for proper job-specific o 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. Suitable grout can be a pourable mixture of Portland cement and sand or Portland cement,sand and pea gravel.The rebar must be fully embedded in grout. Leave enough of the #4 steel reinforcing rod exposed above the brick ledge so that as the stacking of outer casing blocks continues to termination the reinforcing rods and grout can continue through the stack.Reinforcing shall continue to chimney termination. All DM chimneys that include the brick ledge must be reinforced as described above. CAUTION:When using the Isokern brick ledge it is required that the 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 Information" 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 j the exposed height of the chimney mass. S = 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 C the ridge,etc.). _ s I I ISOKERN It is relatively simple to calculate the total physical load BRICK LEDGE on the brick ledge resulting from the physical weight of applied s 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, S �-- — eave height and roof pitch of the structure, as well as height of chimney mass exposed to wind. The total of physical load and load due to wind must not exceed ninety four hundred(9400)pounds. Notes: Calculation of wind load requires the services of a local X 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 / /\K applying veneers. Build veneers equally on all four sides of the brick ledge. d A 4 + FIGURE 62 38 DM Chimney System: Flashing & Crown Caps Brick ledge Veneer Finish and Flashing Details: When applying brick, stone or other masonry veneer ii oll, to the Isokem brick ledge standard good building practices for j masonry veneer work should govern weather-proofing details and ‘.,,,frtr the placement of flashings. A typical flashing detail would be to field fabricate an aluminum or galvanized sheet metal flashing, approximately thirty-two inches(32")square with a twenty inch(20")square hole INNER in it,to serve as an inner flashing. (Figure 63) FLASHING Place the inner flashing on the first DM outer casing block 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 Ill III 1 DM chimney up to the required termination height. WA Once the masonry veneer is in progress the inner flashing iis set into a horizontal joint in the veneer at a level above all other roof deck flashings, chimney-to-roof flashings and counter ,A 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 I casing and the chimney veneer,inner flashings as described above will help to divert such moisture to exterior face of the veneer 11A% by way of the weep holes and thereby keep such moisture from working its way down between the veneer acing and the DM outer ill casing and into the interior of the structure below. In 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 ill 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 Isokem brick ledge. The small crown cap is also suitable where DM chimneys are to receive --4111141111111111.— 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 FIGURE 65 weather cap for masonry veneer chimneys. The large crown cap measures 37-1/2"square and is 3"thick at its center. The component has an octagonal hole at its center so that Allillielli ---- the top inncrpi he sf the thM coimneyos stacDM can pass thr ughlock it. The crown cap then sits on the top most DM outer casing block. yporr 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. LARGE Mortar the top of the last outer casing block. Set the large CROWN CAP crown cap over the inner liner and onto the top of the last outer 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 q z_ CHIMNEY (1) If the horizontal distance from the roof ridge to the opening CRICKET in 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 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 POINT111, N z Note: The "2 foot in 10 foot rule" is necessary in the interest HIMN of fire safety but does not ensure smoke-free operation of the q fireplace. Trees, buildings, adjoining roof lines, adverse wind SECTION CRICKET ' conditions, etc. may require a taller chimney for the fireplace to THRU ROOF -'411Mdraft properly. `,,111141% 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 requirements and shall be structurally independent of the Isokern chimney.As with all chimney installations, avoid overhead obstructions such /1!\ 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 installed behind sheathing of gypsom board, plywood, particle board or ��- other material on the side facing the Isokern material.The facing \ $ 44 � 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 v structural lintel. Consult a structural engineer to design proper structural support. . ',�� This steel angle shall span the firebox opening,bearing I 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) , STEEL ANGLE I' r Important: The application of the steel angle as described 4x4x3/8 MIN I,' / I above is also required in all fireplace installations where the I 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. I/ 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 Plate related loads. G' 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. STEEL ANGLE Irot , Wind Load Calculations: Using the required Earthcore 4x4x3/8 MIN i. % Mortar to install the DM chimney system,the maximum height / .0 above the roof line of a one story residence with an exposure I classification C without additional structural support is: I 90 MPH 26'-0" 100 MPH 24'-0" 11‘11111161/110 MPH 21'-8" 120 MPH 19'-8" 130 MPH 18'-0" 140 MPH 17'-6" 146 MPH 16'-8" 150 MPH 16'-4" For two story residences,please call the Technical Department at: 800-642-2920. FIGURE 70 Important: The top plate of the 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 OA. Their caps designed to provide a weather cap to the DM chimney system. , � � may, Their design is typical of the cement caps found on traditional masonry ,`� �-` 1 chimneys. ., , �`��IIII ' ��. Due to owner preference and architectural design criteria other �, `\��\I��I��Q�0 . chimney terminations can be used alone or in conjunction with the �,, %'.,. . j ,, crown caps. Special design caps may be designed and constructed by ,, \..rit others and must be fashioned so as not to restrict the flow of smoke and % �� VE ►� gasses out the topof the flue opening.Figure 71 depicts some common VE / 1 p g p�, ,w►-N� � chimney terminations. �I LARGE Check with local building codes to establish the need for qp CROWN CAP chimney caps and spark arrestors or for any limitations to their design and use. 4 WA IIII Ilil6 ��_ _�i •♦�� .- ,1 ilii II ��i �, . SMALL I,I , PA\\\\011*/ I, IICROWN CAP � • 14 0) � 1 g/ ,_ _ .,11 I ur 11,1, „ I \ .� °III �.„,,,, . III ' IIIA I k• -1 . . R ,). ot ). %.• FIGURE 71 42 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 hon any Isokern system. (Figure 72) :kb*" IIIM II 41111°1� Metal Flue Types: • :\ III The selected factory-built metal chimney for use with 4 the fireplaces, at a minimum, must be listed by a recognized t'I �; 0 �\ agency for solid fuel and as tested to UL 103,for continuous use , /PY-`_0- of one thousand degrees(1000°)Fahrenheit and intermittent use I,� �� of seventeen hundred degrees(1700°)Fahrenheit. The factory-built metal flue design can be from the following ki types: METAL FLUE 1.Non-insulated completely thermal siphoning,double-wall,air- cooled solid fuel rated chimneys listed to UL 103,ULC S629. A.611 2.Double-wall with solid-pack insulation. `C 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 `Idegree(1700°)Fahrenheit requirements of UL 1777 or ULCS635 or ULC640 may also be used with Isokern fireplaces. 9 Note: The selected, approved chimney manufacturer must provide the masonry anchor plate designed to fit their flue system. FIGURE 72 (Figure 73) Al%iimo All chimneys and chimney liners must be installed in '.� '; accordance with the manufacturer's installation instructions and ANCHOR under the terms of their listing for use with open faced fireplaces. PLATE Maximum height of a metal flue system is not required FIGURE 73 as all the load can be taken off the firebox. Refer to metal flue manufacturer for number of offsets, \/ approved chimney shrouds, clearance to combustibles and any INSWOOL information specific to that flue system. Earthcore does not BLANKET manufacture these components and defers to manufacturers instructions. SMOKE DOME 6/ TOP PLATE 43 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- VERTICAL SIDE sided fireplace this type of fireplace can be difficult to get to 4 FACE INSIDE FIREBOX reach and to maintain proper drafting. ,,iii (BOTH SIDES) Constructing a See-Thru Unit: � STEEL ANGLE 1)Set the base plate in place. I� " Notes: If the design preference is for a"flush hearth"(fireplace floor flush with the room's floor),the base plate can be omitted STEEL ANGLE from the assembly and the firebox walls built directly on the 4 x 4 x 3/8 MIN , �e concrete support slab as long as there are no combustible . �` underpinnings underneath the concrete slab. II►� Whether a flush hearth is preferred or a raised hearth, the combustible floor on front of the fireplace must be covered I 1 NOTCH FOR STEEL with a noncombustible hearth extension set tight against both FRONT op, �IP ANGLE PLACEMENT (60TH SIDES) open sides of the fireplace and extending at least 20 inches out VIEW 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 AL TIC firebox side walls are set, reversed from their normal position, FIGURE 74 VVERERE C IN their flared faces set to the outside of the firebox. (Figure 74) . The firebox side walls must sit a full 3"on the front& t 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 1 1/2" Carl OVERHANG rear of the unit.(Figure 76) 3) Once the side wall assembly is complete it is necessary to place a steel angle minimum 4"x 4"x 3/8" across 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" 1 1/2" thickness of the steel as shown. Each end of the steel angles MIN* HEARTH MIN* EXTENSION must bear fully at least 3"onto the side wall assembly. (Figure h 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 r 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 will 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 35 1/2" 45 1/2" 36 43" 53" 42 49" 59" 46/48 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 0(.11-0 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 0 width of the upper fireplace plus the width of the by-passing chimney system rising from the lower unit. (Figure 77) I 0,1 Dimensions for each fireplace unit can be found on the website at:www.earthcore.co. I'The slab for the lower unit will need to be built withenough width to provide support for the lower fireplace unit \/ plus the bearing surface for the support columns needed to carry `I the offset chimney sequence of the lower system. (Figure 77) I— I Floor-to-Floor Height Considerations: \'I In order for the lower fireplace installation to have 'I r( / 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 ra‘, 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 1 4 *> installation is determined by calculating the total horizontal i$ id \onpages34&35) \� The total amount of horizontal chimney offset travel I �\�� distance will be determined by two factors: I 1.The width dimension of the upper unit and II 2.The horizontal distance between centerlines of the I/ I proposed upper and lower units. 1/' \/I Example: 11 1 1 I If the upper fireplace and the lower fireplace sit on the I/�� \�I same centerline then the required floor-to-floor dimension is ata I/I 11 maximum(See Figure 78 and chart,page 45 dimension,column I/I %i4 For every 3" of horizontal distance separating the III centerlines of the upper and lower units the overall height of the 14 offset sequence is reduced by one offset block or by 6". Notes: I' A raised hearth at the lower fireplace will increase /01,/0/ 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 -/0 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 assume that both the upper and lower fireplace units sit on the same centerline. Note: Widths of both Isokem Standard and Magnum fireplaces _ — I are the same. Only the depth of the firebox and the height of the finished opening differ. —. — I Upper/Lower A B C D E F — — i 36/36 43 51 30 81 70 142 _ — 36/42 43 51 33 84 70 142 _ _ 36/48 43 51 35 86 70 142 42/36 49 54 33 87 70 148 — — I 42/42 49 54 33 87 70 148 42/48 49 54 35 89 70 148 — — 48/36 53 56 35 91 70 149 48/42 53 56 35 91 70 149 — — A O O 48/48 53 56 35 91 70 149 _. _ _ O Chart Dimension Description: (Figure 78) +� �{ - ° p ( b'u r.: "A"is the outside width dimension of the Fireplace model chosen for the upper unit. i LI_J "B" dimension represents distance (taken in the direction of the ::=D j U chimney offset) from the centerline of the lower fireplace to the outside face of the eight inch(8")thick bearing wall underpinning L. Q . j Q Pp unit's floor system. the upperI-- - � "C" dimension is the distance (taken away from the direction of the chimney offset) from the centerline of the lower or the upper ? - fireplace, whichever is the larger plus eight inches (8") to thenn j outside of the eight inch(8")thick bearing wall for the upper unit's --.11n supp ort slab. I1 ll Q. j:::n "D" is the outside-to-outside dimension of the two eight inch(8") Ill thick bearing walls underpinning the upper unit's support slab."D" Ill is also the width of the upper unit"s support slab and includes the I d additional space for the width of the DM chimney as it bypasses the upper unit. "D"is also the sum of`B"plus"C". � n "E" is the height of the Fireplaces chosen for the lower unit and f- ! �° includes the Isokem three inch thick baseplate.p I:::_ j -p "F" is the dimension from the top of the support slab of the lower n Q..1 unit to the top of the floor of the upper unit. Q Q O O Notes: If raised hearths are planned for the lower unit then "F" I B ! C '`-f- dimension will increase by the height of the raised hearth at the I =°°°[ '- lower unit. D = i= In the interest of clarity the drawings on page 44 and 45 Mi' ° .. (Figures 77 &78) of the offset chimney sequence do not show the __)_ °---�__ offset block support columns as required for offset sequences. See '° - ° pages 33 &34 for complete offset support instructions. Consult local structural engineer for support slab load FIGURE 78 calculations. 46 Fire-Lite Application - General Information General Information: The Fire-Lite is an application of the Isokern Standard III 1 and Magnum fireplaces designed, tested and listed with the ability to be installed on a combustible floor system.The design and installation require that the system use Class A metal flue, or equivalent.The Fire-Lite assembled unit must sit on a raised, noncombustible platform allowing a minimum 4" air space between the Isokern base plate and the combustible 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 installation7_=_> requirements specific to the Fire-Lite system. , Intended Use Statement: The Fire-Lite fireplace is designed to sit on a 1 , combustible floor system and is intended to burn solid wood I► , ' I 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. I Notes: The local authority having code jurisdiction should be I I 7 consulted before installation to determine the need to obtain a I 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 specific1411 design preferences. Always maintain the stated minimum 6 clearances to combustible materials.Do not violate any specific 0 0 Apoi installation requirements. 0 The Fire-Lite has been tested and listed by Warnock 0 p 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 �+� ... , ,a Association Standard for chimneys, fireplaces, vents and Solid r�I Fuel-Burning Appliances(NFPA 211). 4 �� .0 Though any Class A or UL 103 metal chimney can be .p, installed with a Fire-Lite,the following installation instructions 4/pt* ��..... . ,, refer to the FTF-13 chimney system. If an equivalent metal / chimney system is used, follow the metal flue manufacturer's `/� explicit installation instructions. II 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 The Fire-Lite is tested and listed for installation with 2"min.— 2"min. "clearance to combustibles"as follows: FTF 13 p� Metal Chimney (or equivalent) 1)Four inches(4")clearance to the combustible floor. Zero Clearance tai'M 1%i"min.to 2) Zero inch (0") clearance at the Isokern smoke dome front wall "MI Combustible (Figure 77). I,=, Framing 3)One and one half inches(1-1/2")clearance at the Isokern firebox ' back walls and side walls. I Fire-Lite Stand 4)Two inches(2")minimum air space to combustibles at all FTF- Hearth Extension Support with (4"min) 13 metal chimney components'outer layer. Noncombustible Material. ' 20"min Important: "Combustibles" are defined as "normal construction m*8 1/z" ............. P min I� O • _. materials" and are considered to be: wood framing materials, particle board,mill board,plywood sub-flooring,plywood paneling WSJ .,.,4� 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 the 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. -�rl1i1111111111�1 P,'IY1111l!'ll" require 1 1/2"clearance.(Figures 80&81) �t':'uuuuuU�,��' "uuutu''tr' 3"min When11/2"mi�� Unsupported c // When Supported* "Keep all insulation, vapor barriers, house wrap paper and I; ir.1 Pius width of backing other insulating type membranes and products, including Noncombustible fiberglass,cellulose and other insulation,(anything that carries 1 1/2" 2" Hearth Extension o g > Y g Min 12" 12" a an "R" rating) a minimum of three inches (3") away from all min min 5. firebox and chimney surfaces. 11/2" 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 01 Isokern. (Figure 81) ��1 Combustibles Must i Have 1 1/2""min �i Clearance The sheathing material holding back the insulation cannot be ►� closer than 1 1/2"to the fireplace sidewalls,backwall or chimney system.(Figure 83) �— o��i��_� uniw When Fireplace installations are surrounded by walls CORRECT that are to be insulated, the walls must have enough clearance to i..the Isokern unit in order to maintain the three inch (3") minimum 11 1/2 FIGURE 82 clearance to insulation for unsupported insulation.Never spray the Fireplace or chimney system with any type of sealer,insulation or other material. P = Combustibles Must Have 11/2""miNotes: Clearance. The Fire-Lite Application is designed,tested and approved k DO NOT ENCROACH ON for installation at a minimum of four inches(4")above combustible s , CLEARANCE WITH COMBUSTIBLES! floor systems per the installation specifications given in this manual. ♦ ~a�� Any portion of the combustible floor system left exposed under the base plate is to be covered with minimum 1" thick INCORRECT ceramic fiber insulation board 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 floor 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=Isokem Standard Series ' a.Model 36 MFP: 1300 lbs. - 36 SFP: 1205 lbs. 111 b.Model 42 MFP: 1420 lbs. - 42 SFP: 1325 lbs. 11111111111" ' , c.Model 48 MFP: 1600 lbs. - 46 SFP: 1450 lbs.2.Damper,fire brick and mortar:450-500lbs.3.Raised 40lbs. 110% lip platform: 4.Fireplace finished facing: approx.200 lbs. 10111111111, (dependant on facing used) 5.Weight of metal flue:negligible By adding the weight of the appropriate Fire-Lite Model listed in#1 above to the allowance given for each item in2 through 5, above,the total weight of the Fire-Lite Series can be estimated. The floor area for each model is as follows: Magnum: �\ Model 28 FP @ 35.5"x 28"= 6.90 sq.ft. Model 36 FP @ 43"x 28"= 8.36 sq.ft. �� Model 42 FP @ 49"x 28"= 9.52 sq.ft. •0 Model 48 FP @ 53"x 28"= 10.3 sq.ft. 140 Isokem Standard: `r�, �� Model 36 FP @ 43"x 25.25"=7.54 sq.ft. Model 42 FPII @ 49"x 25.25"=8.59 sq.ft. Model 48 FP @ 53"x 25.25"=9.29 sq.ft. FIGURE 84 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 indicate the presence of an underlying floor system. Magnum Series Shown for Illustration Purposes Only 49 Fire-Lite Application - Hearth Conditions L-25%:1 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. 1000.1 Raised Platform: V-eIII 1/ min. Nominal four inch(4")metal base. (Figure 85). Set the I � Fire-Lite base plate in a mortar bed on to the non-combustible Fire-Lite Stand I raised platform. 4°or 8"Heights ' Available Metal safety strip-a generic 26 ga.,four inch(4")wide ' Noncombustible 14GA.Metal Joists galvanized metal strip - must be inserted to approximately two 20"Hearth Substrate ' @ 12"O.C.with a 3"Dia. inch(2")beneath theplatform at the front of the noncombustible A Hole for Air Dissipation 8%"MIN im • a I.=. raised platform. The safety strips must extend out from the front of the raised platform at least two inches (2") and must 11111111111111111 extend to at least two inches (2")beyond the ends of the raised Combustible platform.Any overlaps in the length of the safety strips should Floor System lnsboard or Inswool Cut and be a minimum of two inches (2") for continual coverage of the Placed Between 26 Gauge Metal Sections combustible floor at the front of the fireplace(Figure 85). Safety Strip The exposed combustible floor within the perimeter �y?...4.*} Air Dissipation formed by the noncombustible raised platform must be 0 �� completely covered with Inswool or Insboard ceramic fiber . ° 4:"4 insulation(Figure 84).The Inswool or Insboard is dry laid to the "��% floor within the block perimeter. '1V*'FF /�` The ceramic fiber must have a thermal conductivity FIGURE 85 rating equal to or greater than 0.4 Btu-in/hrsq. ft-degree Fahrenheit. (Reference: Harbison-Walker, 600 Grant St., Pittsburgh, PA 15219, ph. 412-562-6200: "Insboard 2100" or equivalent.) Fire Brick Installation: Follow instructions on page 19 of this ;_; manual. '=' i % Recessed Fire-Lite: FM 1 I 1If the design preference is for a flush hearth Fire-Lite application (floor of the fireplace at the same level the room's I I I floor),with advanced planning,the metal stand can be lowered, I set and attached to the joist system. (Figure 86) Noncombustible Hearth Extension Required min. 1 1�.1 min 20"min �. . O O 0 0 When calculating flush hearth height be sure to allow min Ii" 11,..411 i for the four or eight inch(4"or 8")metal stand,three inch(3") �=14: uI � nl thick base plate plus the one and one half inch(1-1/2")thick fire ��IW=�=�� A ;+r vl 1 TI iii�� brick floor. Support Heats Extension Secure Fire-Lite Floor Framing With Noncombustible Material Stand To Trusses By Others Whether a flush hearth is preferred or a raised hearth, SIDE VIEW FRONT VIEW the combustible floor in front of the fireplace must be covered .tee. with a noncombustible hearth extension set tight against the11` 1�� '-'" Note:Field Verified Dimensions Should Make All nee for Hearth 11� 1 Extensions in Front end and Sides Cie ea.From Fireplace Opeinin. fireplace front and extending at least 20 inches out from the Also 4replei Sides and Rear,1 1/2'Clearance to Combustibles 1 finished fireplace and at least 12 inches beyond the finished sides Field Verify Dimensions: Field Verify Dimensions: g i,;iiIIIiiiof the fireplace opening. Megriomsedea: sokemstandsVsedea: 28 55 3/4"W x 49 1/2"D 36 58 1/4W x 46 3/4"0 12" For all "Fire-Lite" construction, it is necessary to use 36 581/2°W x491/SD 42 64 1/4W 046 3/4"D min Hearth Extension 42651/2°W x491/2"D 48 681/4'06x463/4"D Required 20" the base plate.Be sure to secure the Fire-Lite metal stand to the 46 691206x491/2"D min "Consult Local Structural Engineer for Specific Structural Suppot. floor framing system, then mortar the base plate to the metal Use Metal Flue Only stand for stability. PLAN VIEW FIGURE 86 *For seismic anchorage design and instructions of the fliush hearth application, please contact the Technical Department at 1-800-642-2920. 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 14 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 lit 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 211 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:gFailure to use manufacture's rovided arts P p 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 /I construction materials. 10 Note: "Normal construction materials" are considered to be: framing materials,particle board,mill board,plywood,paneling, O flooring,and drywall. I 0 . O I iii41 !. Chimney Height Requirements: . /� •IIIIIRefer to flue manufacturer for chimney height •�•," � - requirements and recommendations. FIGURE 87 51 FTF-13 or Equivalent Chimney System (cont.) Installation of the FTF-13 Metal Chimney System for the Isokern Fire-Lite: 1101 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 I / 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). 1%kiStep 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 Blanket not over torque masonry screws into the Isokern material.(Figure 90) - Chimney Terminations: FTF-13 chimney pipe requires a termination component to be installed at or near the top of the chimney chase flashing. kThe FTF-13-CTD Round Termination is the recommended termination.(See page 52)Installation:Step 1.Hold the FTF-13-CTD over top of last chimney section. Step 2.Center inner slip section in inner 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 , I are made in abnormally adverse or corrosive environments such as near lakes and oceans or,in areas with consistently high humidity , Inswool Blanket conditions. Consult the paint manufacturer's instructions for El❑■proper preparation and application. 11110��■ Chimney Height Requirements: Refer to page 39 of this manual. FIGURE 90 52 FTF-13 Installation Components OEM llppui11ilii.Il,llll1� j piiiiiiiiiiiiiiiiii I Round Termination Fire Stop Spacer(30° Offset) rE-D7 AIN Fire Stop Spacer _♦� Offset Return Package (30°) Chimney Flue Section ir)41011...1 e-1-1 61, TGJ Combination Offset 141.1 Return Elbow Stabilizer 1 ❑ / Locking Band Anchor Plate 53 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 14 1/4 33 1/2 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 25 1/4 52 1/2 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 37 1/4 73 1/4 1 0 0 2 1 38 1/4 75 1 0 0 0 2 39 1/4 77 1 0 2 1 1 41 1/2 80 1/2 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 45 1/4 87 1/2 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 59 1/2 111 3/4 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 82 150 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 17 1 5 0 1 0 318 3/4 26 8 3/4 1 0 9 616 1/4 51 4 1/4 0 0 18 21 3/4 1 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 1 9 1/4 2 0 0 328 3/4 27 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 57 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 7 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 7 11 1/2 1 1 2 421 1/4 35 1 1/4 1 0 12 729 60 9 1 0 21 1031/4 8 7 1/4 0 0 3 4271/4 35 7 1/4 0 1 12 735 61 3 0 1 21 113 1/2 9 5 1/2 1 0 3 431 1/2 36 11 1/2 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 9 0 0 22 129 1/3 10 9 3/4 1 1 3 445 1/2 37 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 38 5 1/2 0 1 13 769 64 1 0 1 22 147 3/4 12 3 3/4 1 0 4 465 1/2 38 9 1/2 2 0 13 773 1/4 64 5 1/4 2 0 22 471 1/2 39 3 1/2 1 1 13 153 3/4 12 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 4 787 65 7 0 0 23 164 13 8 1 1 4 489 1/2 40 9 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 23 182 15 2 1 0 5 499 3/4 41 7 3/4 2 0 14 188 15 8 0 1 5 505 3/4 42 1 3/4 1 1 14 807 1/2 67 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 24 198 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 17 11 3/4 1 0 6 534 44 6 2 0 15 837 1/2 69 9 1/2 0 1 24 222 18 6 0 1 6 8413/4 70 13/4 2 0 24 540 45 0 1 1 15 847 3/4 70 7 3/4 1 1 24 226 1/4 18 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 19 4 1/4 1 1 6 558 46 6 1 0 16 240 20 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 1 0 7 871 3/4 72 6 3/4 0 1 25 568 1/4 47 4 1/4 2 0 16 875 3/4 72 11 3/4 2 0 25 256 1/4 21 4 1/4 0 1 7 574 1/4 47 10 1/4 1 1 16 881 3/4 73 5 3/4 1 1 25 260 1/2 21 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 0 0 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 26 284 1/2 23 8 1/2 1 0 8 602 1/4 50 2 1/4 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 maximum 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 fireplace. 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 fireplace 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 drafts,either 3. Log grates are required for burning solid fuel in the of which can impair fireplace drafting performance. Isokern fireplace. Grates allow 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 fireplace rest in a dried-in setting for a Finally, 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 should burn for no more than thirty to sixty to smolder and burn at relatively low temperatures producing minutes and then allowed to go out. Do not refuel the fireplace high levels of soot and creosote. during the first lighting. A cooling offperiod of twenty-four hours,at a minimum, Important: Do not throw, toss,jam, kick or otherwise force should follow the first fire. logs into the fireplace. The second fire should be the same as the first fire. A twenty-four hour cooling off period 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 materials 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 offset/return 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. If 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 Please tear out along dashed lines and send to: Earthcore Industries Attn: Technical Dept. 6899 Phillips Industrial Blvd. Jacksonville, FL. 32256 Or register your Isokern online at: www.earthcore.co WARRANTY CARD Purchased From: Date of Purchase: Name: Address: City, State &Zip: Phone No: Gas Log Burner Size: (Circle One) 24" 30" Other Fireplace Series/Size: Magnum Isokern Standard IBV Vent-Free Green Tech ISO'ven Fire-Lite Stand? (Circle One) Yes No Gas Control Valve Type: (Circle One) Remote Control Safety Pilot Gas Type: (Circle One) Natural Gas Propane Buyer: Date of Installation: (Completed) Name: Address: City, State &Zip: Phone No: Fireplace Serial Number: (Located on Rating Plate Inside Fireplace) Installed By: Address: Phone Number 58 Notes 59 �� q �7�• i'F -- ',f• 1. - a ;S " rt.: : ..`i#k ... '•ALL. • arranhJ & Disclaimer l4 , ISOKERN FP r'EPLACE _ , '. ISOKERN offers a lifetime warranty for all Isokern components,to be free from defects in materials that '',+X ' negatively affect system performance from the date of purchase,subject to the terms and conditions of this limited warranty. 0,4'4 This warranty covers only the above stated components,and NO WARRANTY,EXPRESS OR IMPLIED, ;:; • -•• EXTENDS TO ANY OF THE HARDWARE,FOOTING,VENTS,DUCTING,METAL FLUES,FIRE BRICK 7: OR ACCESSORIES.THIS WARRANTY DOES NOT COVER DRAFTING, SMOKING OR PUFFING OF THE 4, . FIREPLACE SYSTEM.Factors beyond the manufacturer's control affect fireplace drafting, ‹. smoking,and puffing,and ISOKERN cannot guarantee these aspects of performance. If a component is found to be defective under the terms of this warranty the party to whom this warranty is , v..le ... extended shall,notify ISOKERN,6899 Philips Industrial Blvd,Jacksonville,Florida 32256,in writing,by `t registered mail,within thirty(30)days following the discovery of the defect within the lifetime warranty period. The notice shall contain(1)the date of purchase;(2)place of purchase; (3)address of installation;(4)name,ad- -.._ dress and phone number of the owner;and(5)a brief description of the defect. ., ,...A. ,,„:„, sic: ISOKERN,or any division thereof,is not responsible for any labor costs or indirect costs incurred for the replacement of defective components. f t ISOKERN is not responsible for misuse or mishandling of components.Nothing in this warranty makes - t•'•;# ISOKERN,or any division thereof,liable in any respect for any injury or damage to the building or structure in `'+ . _. which the fireplace or chimney system has been installed or to persons or property therein arising out of the use, ' misuse,or installation of properly manufactured ISOKERN product. . - '' ISOKERN,OR ANY DIVISION THEREOF,SHALL NOT BE HELD LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OR EXPENSES ARISING OUT OF THE USE OF THE ..,. ....• ,rr FIREPLACES OR CHIMNEY SYSTEMS.ALL SUCH DAMAGES AND EXPENSES ARE HEREBY �:;• `fEXCLUDED. ,I 4 This warranty is null and void when the fireplace or chimney systems are not installed pursuant to the installation instructions provided by ISOKERN or local building codes have not been followed completely. This warranty applies only to those 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 -r�. force and effect.1111 III ; ;.:' ISOKERN HEREBY DISCLAIMS ALL GUARANTEES AND WARRANTIES,EXPRESS OR IMPLIED,BE- 4, ' YOND THE WARRANTIES SET FORTH HEREIN. ...0—. .. _ t • earthcore® .4 Pro T' hore % ' ., 6899 PHILIPS INDUSTRIAL BLVD. •JACKSONVILLE,FLORIDA 32256 a, TEL(904)363-3417•TOLL 1 (800)642-2920•FAX(904)363-3408 • . • tti {+rt 1.`vie eli'Y ll . . .r . . . i.4 •• ;.ri'. .i.L :i�' - r"