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.
Copyright © 2014 - Les Foyers Don-Bar inc.
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
Combustible wall
18" (460 mm)
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
A
B
C
DF
K
L
G
H
J
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
A
B
C
D
F
G
H
J
K
L
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
3
3
2
2
1
1
1
2
3
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
roof support
wall bracket
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
round top
radiation
shield/firestop
radiation
shield/firestop
84" (2135 mm) min.
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)
7"
(180 mm)
8"
(200 mm)
9"
(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
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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)
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NOT TO SCALE
i
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
mm
610
718
502
502
489
438
362
mm
610
819
502
610
489
438
362
mm
718
518
610
406
540
438
413
mm
718
610
610
406
540
438
413
mm
718
718
610
502
540
438
413
mm
851
654
743
540
540
537
413
mm
851
756
743
540
540
537
413
mm
610
533
502
330
489
438
362
mm
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O
P
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”
24”
19-3/4”
19-3/4”
19-1/4”
17-1/4”
14-1/4”
24”
28-1/4”
19-3/4”
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”
24”
16”
21-1/4”
17-1/4”
16-1/4”
28-1/4”
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”
21-1/4”
21-1/8”
16-1/4”
33-1/2”
29-3/4”
29-1/4”
21-1/4”
21-1/4”
21-1/8”
16-1/4”
610
533
502
502
489
438
362
mm
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
*S
T
UY
X*Q
11 1/2”
c
R
finishing
cover joint
ventilated
frame
*Q and *S - spacers included
9" (230 mm)
Page 15
*S
*Q
Ø 6”
7”
c
c
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”
*Q
R
*S
T
U
X
Y
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
mm
591
1448
946
654
787
762
692
mm
591
1448
946
578
864
762
768
mm
591
1448
946
470
972
762
876
mm
591
1448
946
368
1073
762
978
mm
641
1448
1080
673
772
870
676
mm
641
1448
1080
578
864
870
768
mm
641
1448
1080
476
972
870
876
mm
638
1448
1226
533
908
1003
813
mm
638
1448
1226
438
1010
1003
914
mm
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.
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