DON-BAR ZERO CLEARANCE ZC Series Installation, Operation and Maintenance Manual

Brand: DON-BAR

Model: ZERO CLEARANCE ZC Series

Category: Stoves

Type: Installation, Operation and Maintenance Manual

Installation, Operation

and Maintenance Manual

LES FOYERS

FIREPLACES

DON-BAR

Les foyers DON-BAR Fireplaces, inc.

Shop and Showroom: 741, St-Vallier Ouest, Quebec (Quebec) G1N 1E2

Phone: (418) 686-9114 - Fax: (418) 686-9117

Website: www.don-bar.com - Email: [email protected]

REV. 2016-01

ZERO CLEARANCE

FIREPLACES (ZC)

Keep these instructions for future use

LES FOYERS

DON-BAR

Installation, Operation,

and Maintenance Manual

The manual is divided into 5 parts:

PART 1: Installation ................................................

PART 2: Security, Operation and Maintenance ...

PART 3: Parts List .................................................

PART 4: Chimney Fires ..........................................

Page 3

Page 16

Page 22

Page 23

Page 25

PART 5: Warranty ...................................................

Page 1

FIREPLACES

This document in its entirety is the intellectual property of Les Foyers Don-Bar inc.

Any unauthorized use will expose its author or authors to legal and financial penalties.

REV. 2016-01

THE ZC SERIES FIREPLACES MEET THE REQUIREMENTS OF:

ULC S627 in Canada, UL 1482 in the USA

EPA: Certified EPA Exempt

1. Warnings and cautions 9. Heating ducts installation (optional)

9.1 Heating an upper or lower floor

1.1. Modifications 9.2 Heating a lower floor

1.2 Installation instructions 9.3 Axial fan installation

1.3 Applicable Codes 9.4 Recommended ducts for heating

1.4 Professional installation 9.5 Heating an upper floor

9.6 Danger of overheating

1.5 Before your first fire

1.6 Installation prohibited 10. Fireplace finishing

10.1 Metallic studs mandatories

2. Typical interior installation 10.2 Ventilated frame

10.3 Non combustible cement boards

10.4 Fixing the cement boards against the insulated

3. Typical exterior installation case

10.5 Gypsum boards finish

4. Before beginning the

installation 11. Floor protection installation

4.1 Choosing the best location 11.1 Non-combustible floor protection

4.1.1 Chimney 11.2 Removing the existing resilient flooring

4.1.2 Chimney minimum height

4.1.3 Minimum clearances from combustible materials 12. Combustible mantel

12.1 Required clearances

5. Factory-built chimney installation

5.1 Listed parts 13. Anti-smoke flap (optional)

5.2 Maximum allowed offsets 13.1 Anti-smoke flap installation

5.3 Radiation shield/firestop

5.4 Chimney weight 14. Exterior air intake

14.1 Exterior air intake(optional)

6. Anchor plate installation

6.1 Fixing the anchor plate

7. Insert installation

7.1 Raised base

7.2 Insert positioning

7.3 Stainless steel liner installation

8. Factory-built chimney installation

8.1 Securing the anchor plate

8.2 Chimney lengths installation

8.3 Minimum chimney height above the roof

8.4 Flashing water tightness

8.5 Roof braces

8.6 Chimney top

PART 1: INSTALLATION

Page 2

REV. 2016-01

Page 2Page 3

IINSPECT AND CLEAN CHIMNEY

FREQUENTLY. UNDER CERTAIN

CONDITIONS OF USE, CREOSOTE BUILDUP

MAY OCCUR RAPIDLY.

1.1 Modifications: Any modification, change, or

substitution of any fireplace component and/or not

following the installation, operation, and

maintenance instructions will void the warranty and

can put your security at risk.

This unit is designed to receive only a Don-Bar

Insert. No other insert model can be installed

without ULC / UL approval.

1.2 Installation instructions: Before installation

begins, carefully read the manual and contact your

local building department to determine whether a

building permit is required to install a fireplace.

1.3 Applicable Codes: The installation must follow

the instructions in this manual and local building

codes. If there is a conflict, you must follow the

more restrictive measures.

1.4 Professional installation: For your security,

enlist the services of a professional fireplace fitter for

the installation.

1.5 Before your first fire: Before lighting your first

fire, read the instructions in Part 2 regarding

Security, Operation and Maintenance.

1.6 Log holder prohibited: Do not install a log

holder in the hearth or elevate the fire in any way.

1.7 Listed factory-built chimneys: Your Don-Bar

fireplace is designed to be installed with any 7” (174

mm) I.D. or 8” (200 mm) I.D. prefabricated chimney

bearing the ULC-S629 (2100 degrees) label in

Canada or the UL-103HT label in the USA.

PART 1: INSTALLATION

1. Warnings and Cautions

DO NOT OVERIFRE THE UNIT.

DO NOT OBSTRUCT SPACE UNDER

FIREPLACE. CLEARANCES FROM

COMBUSTIBLE MATERIALS CANNOT BE

REDUCED.

BURN WOOD ONLY. DO NOT USE OTHER

FUELS.

DO NOT INSTALL IN A MOBILE HOME.

DO NOT CONNECT THIS UNIT TO A CHIMNEY

FLUE SERVING ANOTHER APPLIANCE.

ALWAYS PROVIDE A SOURCE OF FRESH AIR

IN THE ROOM. AN EXTERIOR FRESH AIR

SOURCE MAY BE REQUIRED.

DO NOT ALTER THE AIR CONTROL.

HANDLE THE GLASS DOOR WITH CARE. DO

NOT HIT OR CLOSE THE DOOR SUDDENLY.

DO NOT BUILD FIRE TOO CLOSE TO THE

GLASS. DO NOT CLEAN GLASS WHEN STILL

HOT.

DO NOT USE THE UNIT IF THE GLASS IS

BROKEN OR DAMAGED. REPLACE GLASS

ONLY WITH CERAMIC GLASS.

REV. 2014-11

1. Typical interior installation

2. Typical exterior installation

Page 4

REV. 2016-01

Storm collar

Round Top

Mandatory

2" air space

(50 mm)

Radiation

shield/firestop

Optional warm air

insulated duct

to heat an upper

floor

Optional warm air

insulated duct with axial fan

to heat the basement

Don-Bar

insulated

case

Chimney

anchor plate

Protection for

combustible floors

Don-Bar

insert

Flashing

Factory-built

insulated

chimney

2100 degrees

Roof support

DRAWING 1A

For an installation in a corner or

inside an insulated exterior chasing

see Pages 12 and 13

Must rest on a

finished surface

(masonry,

Durok, wood,

drywall)

Mandatory

2" (50 mm)

air space

across the

legnth of the

chimney

Wall support

Offset

support

15 | 30 | 45 deg. Elbow

Wall shield/firestop.

15 | 30 | 45 deg. Elbow

Anchor plate

Don-Bar insulated

case

Rigide stainless

liner 8" (200 mm)

Protection

for combustible

floors

Don-Bar

Insert

BASEMENT

FIRST FLOOR

DESSIN NO 1B

Round Top

Factory-built

insulated

chimney

2100 degrees

Flashing

4. . Before beginning the installation

4.1 Choosing the best location: Before

beginning the installation, make sure the spot you

have in mind for the fireplace and the chimney

meet the following requirements:

4.1.1 Chimney: Position the chimney to avoid,

as much as possible, offsets, elbows and the

cutting-out of structural elements. The weight of

the chimney must not rest on the insulated

case. Allow at least 2" (50 mm) for air space

between the chimney and any combustible

material including electrical cables, and plastic

plumbing pipes. Never fill this air space with

insulation. For example, if the chimney has an

inside diameter of 8" (200 mm), by adding the

required 2" (50 mm) air space, a 16" (410 mm)

free continuous path is required to install the

chimney. Do not connect this fireplace to a

chimney that is connected to another heating

device.

4.1.2 Chimney minimum height: 15 feet (4600

mm) for proper operation. This length is

measured from the floor where the fireplace is

installed to the top of the chimney.

4.1.3 Minimum clearances from combustible

materials (See Page 13): The location of the

fireplace must meet the minimal specified

clearances requirements from any combustible

material, including furniture, drapes and other

flammable objects. Note that Type X fire-

resistant gypsum board (Firecode) is considered

combustible for fireplaces installations.

5.1 Listed parts: Use only ULC or UL listed

parts supplied by the chimney manufacturer when

installing the chimney. The chimney must be

installation in accordance with the manufacturer's

instructions.

5. Factory-built chimney installation

Page 5

REV. 2016-01

Protection for

combustible

floor

Optional

fan

DRAWING 2

DON-BAR

insert

Rigid inox liner

8" dia. (200 mm)

DON-BAR

insulated case

Chimney anchor

plate

Attic

insulation

Note: Warm air ducts

are optional for upper

floor (wall or floor outlets)

Metal grilles

Joist

Metal duct

6" (150 mm) dia.

(flexible or rigid)

insulated 1" (25 mm),

or B-Vent duct

Attic radiation

shield/firestop

Flashing

Roof support

Factory-built

insulated

chimney

2100 degrees

Typical interior installation

with warm air ducts on upper floor

Round top

Storm collar

Roof

Joist

Radiant shield/

firestop

The warm air

ducts used

to heat an

upper floor by

gravity shall

rise as

vertically

as possible.

8” minimum

(200 mm)

from ceiling

8” minimum

(200 mm)

from floor

1” (25mm) min.

clearance from

joists or

manufaturer’s

instructions

Radiant shield/

firestop

5.2 Maximum allowed offsets: Don't install

more than 4 elbows in the chimney. Offsets

cannot be more than 30 degrees from the vertical

axis. The sum of all offsets (elbows) must never

exceed the number 120. For example, maximum

allowed offsets would include: two 30-degree

offsets (4 elbows x 30 degrees =120) or an offset

of 30 degrees plus another one of 15 degrees (2

elbows x 30 degrees + 2 elbows x 15 degrees =

90).

5.3 Radiation shield/firestop: Install a radiation

shield/firestop every time the chimney passes

through a combustible wall or ceiling.

5.4 Chimney weight: The weight of the

chimney must be supported at regular intervals

according to the manufacturer's instructions. The

weight of the chimney must never be

supported by the Don-Bar insulated case. In

addition, offset supports must be installed above

and as close as possible to each offset (elbow) in

the chimney.

6.1 Fixing the anchor plate to the insert: Bolt

the anchor plate (Drawings 3 and 4) on the insert

with the furnished bolts. Take care to insert a

fiberglass sealing gasket between the anchor plate

and the top of the insert to eliminate any smoke

leak.

6. Anchor plate installation

Page 6

REV. 2016-01

Rigid stainless

chimney liner same

dia. as the chimney

See details on

Drawing 4

Don-Bar insulated

case

Raised base

Outside air

intake: 4" (100 mm)

flexible insulated duct

Don-Bar Insert

2 ventilated frames plus

1 flat ventilated frame, 4 sides

Factory-built

insulated chimney

2100 degrees

Chimney anchor

plate

Jointing the chimney to the

insulated case

DESSIN NO 3

Thermodisc

under the

base

Speed control

Raised base details

Thermodisc

Speed

control 120V Plug

Axial

fans

Fan wiring

DRAWING 3

Axial fans (2)

to insert under the base

Electric cable

with 120 V plug

Do not connect the air intake

to an attic or a garage or

a room that can be under

negative pressure.

7. Insert installation

8. Factory-built chimney installation

7.1 Raised base: The insert is installed on a 6.5"

(165 mm) high raised base as indicated on

Drawing 3. The raised base can be fitted with 2

optional fans. The raised base is factory installed.

The insulated case must be fixed on the floor.

7.2 Insert positioning: Slip the insert on the

raised base into the insulated case and adjust the

alignment.

7.3 Stainless steel liner installation: Secure to

the anchor plate bolted on the top of the insert a

rigid stainless chimney liner of the same

diameter as the chimney. The height of the liner

must be 1/4" (6 mm) below the insulated case top.

Secure the liner to the anchor plate with 3

stainless steel screws as indicated in Drawing 4.

8.1 Securing the anchor plate for the factory-

built chimney: Use a standard factory-built

chimney anchor plate for securing the chimney to

the insulated case. Screw the anchor plate to the

insulated case top with 4 metal screws. Join the

anchor plate to the stainless rigid liner already

secured to the insert. The male end of the anchor

plate must slip into the stainless rigid liner for the

condensation water to drip and stay inside the

liner.

8.2 Chimney lengths installation: Continue

with the installation of the chimney by

positioning lengths with the male end up. The

attic insulation must never be in contact with the

chimney. Allow at least 2" (50 mm) for air space

between the chimney and any combustible

material.

Page 7

REV. 2016-01

Rigid stainless chimney liner

same dia. as the chimney

with a length 1/4"

(6 mm) lower than the top

of the insulated case.

Anchor plate

Securing the anchor plate and the

liner to the insert

DRAWING 4

The insulated case with the insert

and the chimney assembly

DRAWING 5

Stainless screws

(minimum 3,

equally

spaced)

Bolt for securing the adaptor

to the insert from inside

Fiberglass

stove gasket

1/2" (6 mm)

9.1 Heating an upper or lower floor

(Drawings 7 and 8): Your Don-Bar Zero

Clearance Fireplace is designed to permit the

heating of another floor - upper or lower. For this

reason, openings have been provided into the

sides of the insulated case to allow for the

installation of insulated heating ducts of 6" I.D.

(150 mm).

9.2 Heating a lower floor: The heating of a

basement requires the installation an insulated

duct with an axial fan. The insulated duct can run

inside or outside the insulated case (Drawings 7

and 8).

8.3 Minimum chimney height above the

roof: (Drawing 6): Extend the chimney at least 3

feet (1 m) above the roof or 2 feet (610 mm)

above any construction element within 10 feet (3

m) of the chimney.

8.4 Flashing water tightness: Install a metal

roof flashing with a storm collar where the

chimney pass meets the roof. Seal the joint

between the chimney and the storm collar and the

joint between the roofing and the flashing.

8.5 Roof braces: Any chimney that extends

more than 6 feet (2 m) above the roof needs to be

laterally strengthened with a pair of telescopic

roof braces.

8.6 Chimney top: Install a chimney round top

at the end of the chimney.

9. Heating ducts installation

(Optional)

Page 8

REV. 2016-01

10 feet (3 m) Radius

2 feet min (610 mm) min.

3 feet (1 m) min.

Warning: Lateral roof braces need to

be installed when the unsupported

chimney height above the roof

is more than 6 feet (2 m).

Chimney minimum height above

the roof

DRAWING 6

Duct for heating by gravity an

upper floor (at right, left or both,

on the top of the insulated case.)

Outside air intake,

4" (100 mm) I.D.

(optional) with a

sliding mecanism

(left or right). Use

only a flexible

aluminium duct with

a non-

combustible

vapour barrier.

Lower floor

heating duct

(at right, left

or behind the

insulated case)

Lower floor

heating duct (pre-

installed duct - left

or right)

Axial fans, 105, 245 or 438 cfm

(to slip and secure inside the duct)

Heating ducts must be made of metal,

6" (150 mm) I.D., with a 1" (25 mm) fiberglass insulating jacket

finished with an aluminized covering.

Installation alternatives for the

optional warm air ducts

DRAWING 7

10. Fireplace finishing

9. Heating ducts installation

(Optional) Cont'd

10.1 Metallic studs mandatories: Use only

metallic studs for the framing around the

9.3 Axial fan installation: The axial fan for fireplace.

basement heating must be installed near the

basement ceiling at the end of the heating duct.

The easiest way to secure the fan in place is to

insert it into the heating duct and use a t-wrap

around the duct to tighten the fan.

9.5 Heating an upper floor (Drawings 2, 7, 8):

The heating of an upper space shall be done by

gravity only, without a fan, by using the outlets

provided on the top of the insulated case. For the

best results, the duct must be installed in a

vertical position without offsets that could reduce

the airflow. The duct can be secured on the top of

the insulated case using one of the pre punched

holes, on the left or on the right, at choice. The

outlet grille at the end of the duct must be made

of metal and designed to allow a non restricted

airflow.

9.6

9.4 Recommended ducts for heating: Use only

non combustible ducts of 6" (150 mm) I.D.

insulated with a fiberglass layer and a flexible

protective covering. (total: 8" / 200 mm O.D.)

Don't use ducts that have an inner side made of

combustible plastics.

Danger of overheating: Never install the

heating ducts horizontally or downward

because they will overheat and can cause a fire

(Drawing 8).

Page 9

REV. 2016-01

Danger of overheating

DRAWING 8

Never use the outlets

on the top of the insulated

case for heating down

or horizontally, and this,

even with a fan.

Overheating

here

Metal studs

mandatory

Gypsum board or

plywood or particle

board mandatory

behind the insulated

case

IMPORTANT: The Durok must

rest and be secured directly

against the front of the insulated

case (without any air space)

Chimney

2100 degrees

Gypsum board

1/2" (12 mm)

18" (460 mm)

Non combus-

tible board

1/2" (12 mm)

(Durok)

Durok

18" (460 mm)

minimum

Durok

8" (203 mm)

minimum

Ventilated

frame

Metal band

of 5" (130 mm)

width to

slip 2.5"

(65 mm) under

the insulated

case to protect

against the

infiltration of

embers

Protection for

combustible

floors

16" ( 410 mm) wider than

the glass door

Don-Bar insulated case framing

DRAWING 9

10. Fireplace finishing

12. Combustible mantel

13. Anti-smoke flap

14. 7. Exterior air intake (optional)

11. Floor protection installation

Cont'd consist of:

.1 Stone tiles or slabs (marble, granite, slate,

10.2 Ventilated frame: Prior to framing, install etc.) or ceramic at least 3/8" (8 mm) thick,

temporarily the ventilated frame around the insert secured in place;

in order to facilitate the taking of the

measurements. Leave a 1/8" (3 mm) air space .2 Concrete or terra-cotta brick, secured in

between the ventilated frame and the framing to place;

accommodate metal expansion.

.3 For temporary floor protection, a sheet of

10.3 Non combustible cement boards (Durok metal of at least 0.015" (0,38 mm) thickness

or Unifix): The finishing around the ventilated or a non-combustible composite cement

frame shall be done with non combustible cement board (Durok or Unifix type) of at least 3/8"

boards only, Durox, Unifix or equal. These boards (10 mm) thickness may be used.

shall not contain wood fibre particles (Drawing

9). The non combustible finishing shall extend at 11.2 Removing the existing resilient flooring:

least 8" (200 mm) on each sides of the Prior to installing the floor protection, remove

ventilated frame, at least 18" (460 mm) over and any existing resilient flooring. (carpet, etc.)

3" (75 mm) below at floor. The joints can be

finished like ordinarily gypsum boards joints or

alternatively, covered with ceramic tiles, marble,

granit.

12.1 Required clearances: See Drawing 12 for

10.4 the required minimum clearances if a combustible

fireplace mantel is to be installed.

13.1 Anti-smoke flap (optional): For installation

10.5 Gypsum details, see Drawing 27.

14.1 Outside air intake (Drawing 7)

IMPORTANT: The air intake must take air

directly from the outside and not be connected to

an attic or a garage or another interior space

11.1 Non combustible floor protection: When

under negative pressure.

the fireplace is installed on a combustible floor, a

non-combustible protection must be placed under

and in front of the fireplace to protect the floor

from falling embers (Drawing 9). A metal strip of

5" wide (115 mm) must be inserted half and half

under the insulated case and under the floor

protection. In addition, the joints of the floor

protection shall be perfectly fitted or filled with

grout. The floor protection must extend at least

18" (460 mm) in front of the fireplace door and

8" (200 mm) on each side. Floor protection may

Fixing cement boards against the

insulated case: Above the fireplace door, the

cement boards shall be screwed directly against

the insulated case (no air space) to prevent warm

air from seeping between the box and finishing.

board finish: With the exception

of the parts to be protected by incombustible

cement boards indicated in 10.3, the framing of

the fireplace can be covered with gypsum boards.

Finish the joints as usual.

Page 10

REV. 2016-01

Page 11

REV. 2016-01

Clearances from combustible

materials

Non combustible cement

board (Durok type).

8" (200 mm) wide, on

each side of the ventilated frame

and 18" (460 mm) over the frame

(Drawing 9)

Door clearance:

48" (1220 mm)

minimum from

any furniture

combustible

material

Floor protection:

Shall exceed the width of

the door plus 8" (200 mm)

on each side

Combustible wall

18" (460 mm)

DRAWING 11

18"

(460 mm)

minimum

Combustible mantel

or shelf

IMPORTANT

Combustible

material ARE NOT

allowed at less

than 18 "(460 mm)

over the fireplace

door. Beyond this

height, the width

of any combustible

shelf shall follow

a 45-degree line,

as indicated.

45 deg.

8" (200 mm)

minimum

8" (200 mm)

minimum

18"

(460 mm)

minimum

Combustible

mantel

Corner installation

18" (457 mm)

floor

protection

Series 69

62-7/16" (1586)

50-9/16" (1284)

38-11/16" (983)

87-15/16" (2234)

21-7/16" (545)

30-5/16" (770)

62-3/16" (1580)

44-3/16" (1122)

54-3/4" (1391)

88-5/16" (2243)

56-11/16" (1440)

46-1/16" (1170)

35-1/2" (902)

82-1/8" (2086)

20-1/4" (514)

28-5/8" (727)

58-1/16" (1475)

40-1/16" (1018)

50-1/4" (1276)

80-1/8" (2035)

Series 80 Series 90/98

DRAWING 10

DRAWING 12

Clearances for the installation

of a combustible mantel

There are 3 choices for framing:

Small footprint framing

Angle framing

Wall to wall framing

66-3/8" (1686)

54-7/16" (1383)

42-9/16" (1081)

91-13/16" (2332)

23-3/8" (594)

33-1/16" (840)

64-15/16" (1649)

46-15/16" (1192)

60-3/16" (1529)

93-7/8" (2384)

DANGER OF FIRE

Never fill (stuff) with insulation

the empty spaces around the

insulated case and around the

insert. Moreover, non-mineral

insulation (foams, cellulose,

cotton, etc.) needs a minimum

12" (300 mm) clearance from

the fireplace and the

insulated case.

Incombustible

materials

Page 12

REV. 2016-01

fiberglass

insulation

fiberglass

insulation

fiberglass

insulation

fiberglass

insulation

vapour barrier

(sealed with the

vapour barrier

of the wall)

vapour barrier

(sealed with the

vapour barrier

of the wall)

MANDATORY:

plywood,

particle or

gypsum boards

MANDATORY:

plywood,

particle or

gypsum boards

roof support

wall bracket

2100 chimney

7" or 8" I.D.

(180 ou 200 mm)

2100 chimney

7" or 8" I.D.

(180 or 200 mm)

offset

to center the

chimney

roof support

metal

flashing

23" min.

(585 mm)

chimney flashing

roof flashing

storm collar

round top

radiation

shield/firestop

radiation

shield/firestop

84" (2135 mm) min.

Free depth

See table

Drawing 14

Free depth

See table

Drawing 14

Durok 18 "

(460 mm)

Insulated exterior chasing

for a covered chimney

Insulated exterior chasing

with a non covered chimney

air barrier air barrier

Durok 18 "

(460 mm)

gypsum board

on metal

studs

gypsum board

on metal

studs

floor

protection

18" (460 mm) floor

protection

18" (460 mm)

12 4

Maximum

slope for

flashing

Insulated exterior chasing - Construction details

DRAWING 13

DANGER OF FIRE

Never fill (stuff) with insulation

the empty spaces around the

insulated case and around the

insert.

free

space

17" min.

(430 mm)

free

space

17" min.

(430 mm)

Page 13

REV. 2016-01

DRAWING 14

84" (2135 mm) min.

58" (1470 mm) min.

For the chasing depth:

See the table below

Free interior dimensions

of the insulated

exterior chasing

Non combustible

protection

Durok

8" (200 mm)

minimum

8" (203 mm)

minimum

18" (460 mm)

minimum

Non combustible

cement board

1/2" (12 mm)

(Durok)

Durok

18" (460 mm)

minimum

Gypsum

board

1/2" (12 mm)

MANDATORY:

metal studs

Non combustible

floor protection:

(Shall exceed the width of

the door plus 8" (200 mm)

on each side

Free depth of the exterior insulated chasing

(varies according to the exterior wall thinkness)

* The exterior wall inludes

everything from the exterior

finish to the interior finish.

In case of doubt, please

call Don-Bar.

27"

(685 mm)

28"

(710 mm)

29"

(740 mm)

30"

(760 mm)

31"

(790 mm)

32"

(810 mm)

32"

(810 mm)

32"

(810 mm)

(180 mm)

(200 mm)

(230 mm)

10"

(255 mm)

11"

(280 mm)

13"

(330 mm)

12"

(305 mm)

14"

(355 mm)

Exterior wall

thickness (*)

Minimum free

depth

Minimim free

width

Minimum free

height

58"

(1470 mm)

84"

(2135 mm)

Insulated exterior chasing - dimensions

DANGER OF FIRE

Never fill (stuff) with insulation

the empty spaces around the

insulated case and around the

insert. Moreover, non-mineral

insulation (foams, cellulose,

cotton, etc.) needs a clearance

from the fireplace and the

insulated case of 12" minimum

(300 mm) .

Fireplace insert Not to scale

Note: Flat and ventilated frames can be also made to measures.

Flat frame 4 sides Flat frame 3 sides Ventilated frame 3 sides

or 4 sides

Optional frames

7" or 8" I.D.

(175 or 200 mm)

7" or 8" I.D.

(175 or 200 mm)

7" or 8" I.D.

(175 or 200 mm)

6 " (154 mm)

1-1/16" (28 mm)

3-1/8" (79 mm)

1" (25 mm)

NOT TO SCALE

Page 14

REV. 2016-01

24”

17-3/8”

19-3/4”

13”

19-1/4”

17-1/4”

14-1/4”

610

441

502

330

489

438

362

610

718

502

489

438

362

610

819

502

610

489

438

362

718

518

610

406

540

438

413

718

610

406

540

438

413

718

610

502

540

438

413

851

654

743

540

537

413

851

756

743

540

537

413

610

533

502

330

489

438

362

69-52 69-61 69-69 69-80 69-90 80-60 80-69 80-80 98-78 98-87

24”

21”

19-3/4”

13”

19-1/4”

17-1/4”

14-1/4”

24”

19-3/4”

19-1/4”

17-1/4”

14-1/4”

24”

28-1/4”

19-3/4”

19-1/4”

17-1/4”

14-1/4”

24”

32-1/4”

19-3/4”

24”

19-1/4”

17-1/4”

14-1/4”

28-1/4”

20-3/8”

24”

16”

21-1/4”

17-1/4”

16-1/4”

28-1/4”

24”

16”

21-1/4”

17-1/4”

16-1/4”

28-1/4”

24”

19-3/4”

21-1/4”

17-1/4”

16-1/4”

33-1/2”

25-3/4”

29-1/4”

21-1/4”

21-1/8”

16-1/4”

33-1/2”

29-3/4”

29-1/4”

21-1/4”

21-1/8”

16-1/4”

610

533

502

489

438

362

69-52 69-61 69-69 69-80 69-90 80-60 80-69 80-80 98-78 98-87

Don-Bar Insulated Case Not to scale

Optional:

2 axial fans of 5" (125 mm)

under the raised base

X*Q

11 1/2”

finishing

cover joint

ventilated

frame

*Q and *S - spacers included

9" (230 mm)

Page 15

Ø 6”

7”

Ø 9”

TYP.2

11 1/2”

Ø 6” Ø 4”

5 1/16”

10 7/8”

13 1/16”

REV. 2016-01

23-1/4”

57”

37-1/4”

29-3/8”

27-3/8”

30”

23-5/8”

23-1/4”

57”

37-1/4”

25-3/4”

31”

30”

27-1/4”

23-1/4”

57”

37-1/4”

22-3/4”

34”

30”

30-1/4”

23-1/4”

57”

37-1/4”

18-1/2”

38-1/4”

30”

34-1/2”

23-1/4”

57”

37-1/4”

14-1/2”

42-1/4”

30”

38-1/2”

25-1/4”

57”

42- 1/2”

26-1/2”

30-3/8”

34-1/4”

26-5/8”

25-1/4”

57”

42- 1/2”

22-3/4”

34”

34-1/4”

30-1/4”

25-1/4”

57”

42- 1/2”

18-3/4”

38-1/4”

34-1/4”

34-1/2”

25-1/8”

57”

48-1/4”

21”

35-3/4”

39-1/2”

32”

25-1/8”

57”

48-1/4”

17-1/4”

39-3/4”

39-1/2”

36”

591

1448

946

746

695

762

651

591

1448

946

654

787

762

692

591

1448

946

578

864

762

768

591

1448

946

470

972

762

876

591

1448

946

368

1073

762

978

641

1448

1080

673

772

870

676

641

1448

1080

578

864

870

768

641

1448

1080

476

972

870

876

638

1448

1226

533

908

1003

813

638

1448

1226

438

1010

1003

914

69-52 69-61 69-69 69-80 69-90 80-60 80-69 80-80 98-78 98-87

1. General operation 7. Glass firescreen maintenance

1.1 Combustion control 7.1 Glass maintenance

1.2 Air intake control 7.2 Replacing a glass pane

1.3 Smoke outlet control 7.3 Door gaskets

1.4 Danger of burns

8. BBQ installation

8.1 BBQ grill installation

2. Precautions before lighting your

first fire 9. Chimney maintenance

2.1 Adequate air supply

2.2 Preventing smoke returns 9.1 Creosote build-up and removing

9.2 Inspection and regular maintenance

9.3 Soot build-up removal

3. Firewood

3.1 Allowed fuels 10. Firescreen

3.2 Forbidden fuels

3.3 Recommended wood species 9.1 Firescreen

3.4 Green wood

11. Anti-smoke flap

9.1 Anti-smoke flap installation

4. The fire

4.1 Opening the high efficiency HE smoke damper 13. Humidity and condensation

4.2 Open fires

13.1 Excessive humidity and condensation

4.3 Controlled combustion fires

4.4 How to start a fire

4.5 Firescreen is mandatory with open fires

4.6 Preventing overfiring

4.7 Forbidden flammable liquids

4.8 Smoke release during the first fire

4.9 Caution: Very hot!

4.10 Gloves and poker

4.11 Smoke detector

5. Ashes

5.1 Ashes removal

5.2 Metallic container

5.2 Natural fertilizer

6. Fireplace maintenance and protection

6.1 Finish maintenance

6.2 Repainting

6.3 Fireplace storing before installation

PART 2: SECURITY, OPERATION AND MAINTENANCE

Page 16

REV. 2016-01

1. General operation

1.1 Combustion control: Two valves are used

to control combustion. The first one (Drawing

20), controls the air intake in the combustion

chamber. The second one control the smoke outlet

(Drawing 21). These two valves are controlled by

the same removable handle.

1.2 Air intake control (Drawing 20): The sliding

valve controlling the air intake is located above

the insert glass door. A special multi-purpose

removable handle is provided to open or close it.

Pull the handle to admit more air into the

combustion chamber. Push the handle to reduce

the air intake. In practice, the best position for

the valve will vary according to three factors: fire

intensity, chimney draught and wood humidity.

As a general rule, a fire will last longer if less air

is admitted in the combustion chamber. If a hot

and blazing fire is wanted, then open the air

intake fully.

1.3 Smoke outlet control: This sliding valve is a

part the of the high efficiency HE deflector

system (Drawing 22). It is located in the middle

of the insert just above the air intake control

(Drawing 21). Use the multi-purpose handle to

operate it. Close it to increase the combustion

efficiency by reburning the gases contained in the

smoke. Open fully to start a fire or when using a

firescreen or the BBQ grill.

1.4 DANGER OF BURNS: Danger of burns by

the excessive heat if the handle is left in place

when using the device. Always remove the

handle and store out of reach of children.

PART 2: OPERATION AND MAINTENANCE

closed

open

Use the handle to

adjust the air

intake

DRAWING 20

Using the removable handle to

control the air intake

Page 17

DRAWING 21

Using the handle to control the

HE sliding smoke deflector

closed

open

Use the handle to

control the damper

REV. 2016-01

IMPORTANT: Always

open this key before

opening the door or

lighting a fire

3. Firewood

2. Precautions before lighting

your first fire

supply to maintain the combustion. If the room is

under a negative pressure, if the house is too

airtight, or if a ventilation device is in operation it

may be necessary to open a door or a window to

compensate.

2.2 Preventing smoke returns: Your fireplace

is designed to operate without smoke returns

during normal operating conditions and when

installed according to the instructions outlined in

the manual. However, some conditions out of our

control can create smoke returns. Don-Bar

Fireplaces cannot guarantee the absence of smoke

returns but if this phenomenon occurs special

attention should be given to the following

situations: mechanical ventilators in operation

(kitchen hood, dryer, air heating system, air

exchanger), drafts, room or house negative

pressure, inadequate chimney height, exterior

structures harmful to the chimney draft or capable

of causing smoke returns, an indoor moisture

level that is too high and causes ice build-up in

the flue and reduces chimney draft, too many

elbows in the chimney, crushed outside air intake

duct, strong winds, etc.

3.1 Allowed fuels: Your fireplace is designed to

burn wood only. To start a fire, use only

newspaper and small pieces of firewood.

3.2 Forbidden fuels: Anthracite, melamine,

pressure treated or painted wood, wood particle

boards and other composite materials. These

materials reach very high temperatures and

release corrosive gases, which may irreparably

damage your installation and void the warranty.

2.1 Adequate air supply: A wood fire requires

plenty of air. Always be sure there is enough air

DRAWING 22

Using the handle to control the

HE sliding smoke deflector

closed

open

Use the handle to

control the damper

Page 18

REV. 2016-01

Open fully the smoke damper

to start a fire, when opening the

door or when making

an open fire with the firescreen

Close the smoke damper

for a long-lasting high efficiency

fire (close the door first).

the air intake control must be fully open. Always

3.3 Recommended wood species: For an

use a firescreen with an open fire. Note that the

efficient and economical operation, use only dry

air intake control is inoperative when the door is

hardwood such as maple, oak, wild cherry, birch,

open.

etc. The use of dry hardwood reduces creosote

formation. Avoid softwoods, coniferous and

4.3 Controlled combustion fires: First, follow

green woods. These produce a lot of creosote.

the instructions at 4.2 for open fires. Later,

following the formation of embers, the flame will

3.4 Green wood: If your firewood is too green,

be less intense, the chimney flue warmer and you

place it in a well ventilated space, sheltered from

will be able to close gradually the sliding smoke

rain, as long as necessary to allow it to dry. Dry

damper. You will also be able to close gradually

wood is easy to identify: it is cracked at the ends

the air intake control to increase the heating

and much lighter because it contains less water.

power of the fire.

4.4 How to start a fire: To light a good fire,

begin by placing 4 or 5 newspaper balls in the

fireplace. Next, place 5 to 8 small pieces of dry

firewood over the newspaper. Then add 2 or 3

small-sized logs. Light the newspaper in 4 or 5

spots. When the small firewood begins to burn,

add 1 or 2 medium-sized logs.

4.5 Firescreen is mandatory when the insert is

used with an open door: In order to prevent

dangerous spark discharges and falling embers,

always use a firescreen (supplied separately - not

shipped with the insert) when making an open

fire.

4.6 Preventing overfiring: Don't overload your

fireplace. Don't make fast and hot fires (such as

those using only paper, cardboard or small wood).

These fires can generate very high temperatures

that may damage your chimney if they last longer

than 2 minutes.

4.1 Opening the HE smoke sliding damper:

Before lighting a fire, completely open the smoke

sliding damper. Use the provided handle as

indicated in Drawing 21.

4.2 Open fires: The smoke sliding damper and

4. The fire

DRAWING 23

Using the handle to open the door

Turn the handle

to lock or unlock

the door

Page 19

REV. 2016-01

DANGER OF BURNS

Never leave the handle on the

door during a fire.

Page is loading ...

DON-BAR ZERO CLEARANCE ZC Series Installation, Operation and Maintenance Manual

Brand: DON-BAR

Model: ZERO CLEARANCE ZC Series

Category: Stoves

Type: Installation, Operation and Maintenance Manual

Download PDF

report

DON-BAR ZERO CLEARANCE ZC Series Installation, Operation and Maintenance Manual

DON-BAR ZERO CLEARANCE ZC Series Installation, Operation and Maintenance Manual

Other documents