ISOKERN OUTDOOR FIREPLACE
A PRODUCT OF EARTHCORE INDUSTRIES, LLC.
INSTALLATION, OPERATION, MAINTENANCE and
OWNER’S MANUAL
ISOKERN MODELS:
Standard - 36, 42, 46 Magnum - 28, 36, 42, 48, 60 & 72
Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance
instructions for the Outdoor replace and EM 40 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, further
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 rebox surfaces as specied in
this manual.
INSTALLER: Leave this manual with the replace
CONSUMER: Retain this manual for future reference
Be Sure to Read Entire Manual Before Beginning Construction.
Contents of this manual may change without prior notication.
THIS FIREPLACE IS DESIGNED for USE with
SOLID WOOD LOGS, PLUMBED PROPANE
(LP) or NATURAL GAS (NG), ONLY
WARNING: If the information in this manual is not followed exactly, a re or explosion
may result causing property damage, personal injury or loss of life.
Issued: January 2012
Revision: 000
Table of Contents
General Information .................................................................................................................................... 3
Assembled Firebox Dimensions .................................................................................................................. 4
Fireplace Installation ................................................................................................................................... 5
Access Modication & Fire-Brick Installation ........................................................................................... 6
Cladding ...................................................................................................................................................... 7
Specialty Application - See-Thru ................................................................................................................ 8
Summary ..................................................................................................................................................... 9 -10
Notes-Maintenance Information..................................................................................................................11
Warranty
Note: Illustrations shown 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 specic design preferences. However,
always maintain minimum clearances to combustible materials and do not violate any specic installation requirements.
2
3
General Information
The Outdoor replace and EM 40 chimney system
is a prefabricated, refractory modular replace and chimney
system designed for eld assembly. The system consists of
interlocking precast parts which are glued together with a
masonry adhesive.
The parts of the Outdoor replace and EM 40
chimney system are precast using a proprietary mixture of
volcanic pumice aggregate and cement. It includes all the
parts necessary for assembly of a complete rebox, smoke
dome and chimney system.
Each Outdoor precast replace component is
designed for a specic part of the replace such that only one
means for assembly is possible.
The Outdoor replace requires a Outdoor refractory
re brick liner be applied to the interior of the rebox. Fire
brick must be a minimum thickness of one and one-eighth
inch (1-1/8”).
The Outdoor replace is available in nine sizes:
Magnum Series 28, 36, 42, 48, 60 & 72. Standard Series 36,
42 & 46. All units have either a 30” Finished opening height
(Standard Series) or a 36” nished opening height (Magnum
Series.
The EM 40 chimney system is a single module
refractory chimney system. The basic chimney consists of a
single casing block with 16” diameter ue hole. The DM 54
Chimney system can also be used. The chimney components
are eld assembled using Earthcore Mortar to glue the
components to the replace.
The various replace and EM 40 chimney
components will be described and illustrated in the following
pages. Close attention should be paid to each component
group’s specications and installation requirements as
described in this manual.
Important: Due to heat and weight issues, the Outdoor Series
replace and EM 40 chimney system installations require
that the system be built upon a non-combustible concrete
slab with no wood underpinnings supported to footings with
concrete or steel and designed to carry the total weight of the
Isokern replace and chimney system.
EM 40 Single Module Chimney System
DM 54 Dual Module Chimney System
4
Fireplace Dimensions
J
C
G
D
A
I
B
E
F
SIDE VIEW FRONT VIEW PLAN VIEW
STANDARD SERIES
"C"
33”
43"
33”
48"
36"
42"
MODEL
28”
53"
43"
49"
"A"
28"
28”
"B"
SIDE VIEW
48 1/2"
38 3/8"
44 1/2"
38”
38”
38”
"D" "E"
FRONT VIEW PLAN VIEW
TOP PLAN VIEW
E
B
F
28"
“F”
G
A
D
16"
27 1/4"
AA
33 1/4”"
C
5"
2 3/4"
“G”
69 3/4"
69 3/4"
37 1/4"
69 3/4"
28" ** 35 1/2" 28" 22 1/4"
31" 19 3/4"
60 1/4" 28 1/2”
WEIGHT
1040 lbs
1300 lbs
1420 lbs
1600 lbs
** 28” Model comes with three (3) sidewalls
MAGNUM SERIES
*60”
*72”
28”
28”
38”
38” 69 3/4”
57 1/4”
85 1/2 ”
73 1/2”
85 3/4 ”
85 3/4” 69” 55 1/2“
65 1/2”81 1/4”
2500 lbs
2900 lbs
* Models 60 & 72 require 2 flues
MODELS 60 & 72
33”
43"
33”
46"
36"
42"
53"
43"
49"
25 1/4"
47 1/8"
36 1/8"
43 1/8"
27 1/4"
33 1/4”"
63 1/4"
63 1/4"
37 1/4"
63 1/4"
31 1/2” 1205 lbs
1325 lbs
1450 lbs
"C"
MODEL "A" "B" "D" "E" “F” “G” WEIGHT
25 1/4"
25 1/4"
31 1/2”
31 1/2”
20 1/4”
20 1/4"
20 1/4”
“I”
5”
5"
5”
“J”
TOP PLAN VIEW
25 1/4”
16"
3”
3”
5
Fireplace Installation
Earthcore reserves the right to make changes at any time without notice in design, materials and specications. Earthcore further
reserves the right to discontinue styles and products. Please call 1-800-642-2920 for an Isokern dealer near you.
Mortar All
Components
A
A - Base Plate
B - Side Wall
B
C
D
F
E
G
H
I
C - Back Wall
D - Damper Beam
E - Damper End
F - Smoke Dome
G - Top Sloping
H - Top Plate
I - EM40 Mono Block
** Number of Components
May Vary with Different Kit
Sizes
Typical 4” Reinforced
Concrete Slab
Note:
The system should be built
upon a non-combustible
concrete slab with no wood
underpinnings designed to carry
the total weight of the Isokern
Fireplace and Chimney System.
The DM 54 Dual Module
Chimney System can also be
used on an outdoor Isokern
fireplace.
6
Access Modication and Fire Brick Installation
Through-Wall Accesses:
Gas Line Feed: The provision for installation of a gas pipe
is only for connection to a decorative gas appliance or a gas
log lighter. The decorative gas appliance must comply with
Outdoor for Decorative Gas Appliances for installation
in Vented Fireplaces, ANSI Z21.60. The decorative gas
appliance should be installed in accordance with the National
Fuel Gas Code, ANSI Z223.1.
Important: Gas line for gas log sets used in the Isokern
rebox can be routed through the side wall, back wall or oor
of the rebox by drilling an appropriately sized hole using a
masonry drill bit.
Be sure to follow the gas log Appliance
Manufacturer’s explicit electrical line connection instructions
for vented masonry replace installations.
Note: Gas Line and Electric Line must be fed through separate
access holes.
CAUTION: All access holes must be grouted with mortar to
seal any gaps or cracks.
Fire Brick Installation:
The manufacturer requires that the rebox be lined
with a minimum one and one-eighth (1-1/8”) thick rated re
brick. The pattern for the re brick lining is an owner option.
Standard N or S -Type brick mortar is a suitable re brick
mortar. Add a small portion of Earthcore mortar to make it a
sticky consistency with a 1/4” notch trowel bed joint. Because
of different climates, the use of good masonry practices for
your area should also be considered.
Hint: Before application, wet down the surface area, then
apply water dipped rebrick for improved adherence.
All required through-wall accesses (gas and electrical
line feeds and combustion air supply access holes) should be
drilled before the required re brick lining is installed.
It takes a total of about ve gallons of mortar mix
(dry measure) to re brick line a rebox. (60 & 72 will require
more mortar)
Face joints of one quarter inch (1/4”) to three-eighths
inch (3/8”) give a good appearance to the nished brick-work
however, larger face joint dimensions are also acceptable.
Step 1. Wet mop the inside of the rebox with a damp sponge
to remove dust and loose particles from the interior before
installing re brick.
Step 2. Start the re brick at the front edge of the oor of the
Isokern rebox, proceeding inward toward the back.
Step 3. Next, apply re brick to the back wall of the unit
starting at the bottom of the back wall and working upward to
the top of the back wall.
Step 4. Finally, set the side wall re brick by starting at the
front edge of the unit’s side wall and working inward toward
the back wall re brick.
Earthcore makes no claims as to the performance
of re brick or re brick mortars.
Firebrick
side
Gas or Electric
line
NOTE: Fill any gaps around
line with Earthcore Mortar
Typical placement of
gas or electric line
(see detail below)
1/2” Expansion
Gap
1/2” Expansion
Gap
Fire Brick Floor
(Built First)
Fire Brick
Floor
(Built First)
NOTE:
The 60 & 72 Models
Require Minimum 4” Fire Brick
on the Side Walls, 1 1/8”
Minimum Fire Brick on the
Floor and Back Wall.
7
Cladding
The material that makes up the Isokern replaces
has a porous surface which allows most facing material to
be applied directly to the Isokern rebox without additional
framing. It is recommended that when applying veneers to
the Isokern material directly, it is best to attach lathe to the
rebox, scratch coat and apply plaster, brick, stone or stucco
as the nish.
When facing material is installed directly to the
surface of the Isokern replace unit, be sure that when
the required noncombustible nished facing materials are
applied that no gaps or voids are left. This would create a
“false chimney” which must be avoided. Completely seal
all gaps and voids in the noncombustible nished facing
materials directly to the Isokern unit with Earthcore mortar
or other noncombustible grout.
Brick, stone or other masonry veneer nished
fronts to Outdoor replaces are possible. Special attention is
required with regards to:
(1) the placement of the proposed masonry veneer facing and
its interface with the Outdoor re brick lining, and
(2) Clearance to combustible framing (if any) and sheathing
from any steel “L” support used in the masonry veneer around
the front of the unit behind the veneer facing.
Any proposed brick, stone or other masonry veneer
facing must have sufcient foundation to support the full
weight of the veneer work. This may require review by a
local structural engineer prior to construction.
The veneer facing, when installed, must present a tight seal
with the leading edge of the re brick lining at the sides of
the rebox opening. A steel “L” will need to span the top of
the nished replace opening to carry the masonry veneer as
it spans over the rebox opening.
By code requirement this steel “L” must have a minimum
four inch (4”) end bearing. This bearing surface area shall be
provided in the veneer work. 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
the steel “L” and the damper beam front.
Avoid “False Chimneys”
Seal all gaps completely.
4"
2"6"
BEARING
4x6 STEEL L
ISOKERN UNIT WIDTH DIM'N.
EXTENT OF STEEL L
MIN.
4x6 STEEL L MASONRY VENEER
ENDS OF ISOKERN
STEEL L ALIGN
FIREBOX UNIT AND
2"6"
4" 2"
BEARING
2"6"
WOOD (FLAMMABLE)
SHEATHING
MIN. CLEARANCE
MIN. CLEARANCE
BRICK
VENEER
WOOD (FLAMMABLE)
SHEATHING
MASONRY VENEER
4x6 STEEL L
MASONRY BEYOND
AIR SPACE
MORTAR JOINT
MASONRY VENEER
IF APPLICABLE
8
Specialty Applications: See-Thru
The rebox side walls must sit three inches (3”)
on the base plate. Since the side wall components air from
three inches (3”) at the narrow end to eight inches (8”) on
the wide end, the side walls will overhang the base plate by
approximately ve inches (5”) at their wide end. Support this
overhang with masonry.
See-Thru or two-sided replaces can be constructed
from the one-sided unit components by eliminating the back
wall assembly.
In this installation the rebox side wall components
are reversed so that the side wall taper sits to the outside of the
box leaving the inside of the see-thru rebox with two straight
and parallel interior walls.
Angle steel three inch by three inch by one quarter
inch (3” x 3” x 1/4”) should be set on top of the side wall
assembly to span each of the openings of the see-thru before
the top plate is set into place.
The steel can be set with the angle leg either up or
down.
B
A
C
Model ABC
36” 43” 36 1/8” 53”
42” 49” 43 1/8” 59”
46” 53” 47 1/8” 63”
9
Summary
1. WARNING:
Earthcore Industries L.L.C. does not warrant drafting
and is not responsible for it.
2. Isokern Fireplace Curing Instructions:
It is critical that the Isokern elements rebox and smoke
dome assembly be dry before ring of the unit. Moisture left in the
components from exposure during storage and shipping, as well
as moisture from the installation phase, must be eliminated before
the unit is put to its intended use.
The rst step in reducing the ambient moisture is to be
sure that the completed replace rest totally in a dried-in setting for
a minimum of 28 days after construction of the unit is complete.
The next step in curing the replace is to be sure that the
rst ve or six res are of short duration.
The rst re of the unit can take place once the minimum
twenty-eight day drying period has passed. This re should be
especially short.
Start the rst re slowly with a small amount of paper
and kindling (small dry wood splits or twigs) and a maximum
load of four to six pounds of dry rewood, estimated to be no
more than two or three logs each of about three inches (3”) to four
inches (4”) diameter.
The rst re should burn for no more than thirty to sixty
minutes and then allowed to go out. Do not refuel the replace
during the rst lighting.
A cooling off period of twenty-four hours, at a minimum,
should follow the rst re.
The second re should be the same as the rst re.
A twenty-four hour cooling off period must be observed
following second lighting.
After rst and second re, continue use of the unit with three or
four small res of short duration (sixty minutes or so) and small
fuel load.
After these rst ve or six small res of short duration
normal use of the replace can proceed. For normal use the
maximum recommended fuel load is twelve to sixteen pounds
of dry rewood at a time. This fuel load is considered to be
approximately three to ve cured hardwood logs of about three
inches (3”) to six inches (6”) in diameter. As the re burns down,
refueling should be only one or two logs added at a time.
Important: Do not burn construction debris or trash of any kind
in the replace.
Whereas it is not uncommon for construction debris and
refuse to be burned in a replace by site personnel on a project
that is under construction, this activity must be avoided.
It is the responsibility of the building contractor to insure
that the required dry-in period is met and that the required lighting
sequence is performed by the owner or by the owner’s agent.
3. Log grates are required for burning solid fuel in the
Isokern replace. Grates allow for easy air ow up through
the burning logs thus creating a more complete and efcient
burning of the fuel.
4. How to Build a Fire:
Begin laying the re by placing several pieces of
wadded up paper directly on the log grate. Place kindling
(small splits of dry pine or other dry softwood) on top of the
paper, enough to loosely cover the paper. Next arrange several
small, dry hardwood or softwood logs or log splits on top of
the kindling layer.
Finally, arrange two or three larger hardwood logs
(oak, hickory, etc.) or log splits on top of the stack. Ignite the
paper at the bottom of the stack. The burning paper will ignite
the kindling which will, in turn, set the remaining fuel on re.
Be sure to stack all rewood in such a way that it will
settle into the log grate as the paper and kindling layers are
burned away. Additional logs can be set onto the re as each
fueling burns down.
Ideally, fuel logs should be of a hardwood species
that have been air dried for one year or longer. Use of cured or
uncured pine logs and uncured hardwood logs for fuel should
be avoided. Pine logs and uncured hardwood logs will tend
to smolder and burn at relatively low temperatures producing
high levels of soot and creosote.
Important: Do not throw, toss, jam, kick or otherwise force
logs into the replace.
WARNING:
Never use gasoline, gasoline type lantern fuel,
kerosene, charcoal lighter uid or other similar liquids to start
or “freshen up” the re in this replace or in any replace.
WARNING:
If processed solid fuel relogs are used: Do not poke
or stir the logs while they are burning. Use only relogs that
have been evaluated for the application in replace and refer
to relog warnings and caution markings on packaging prior
to use.
5. Avoid over-ring this replace. Some examples of over-
ring are:
a. Burning of scrap lumber, construction debris, pine branches
and brush or cardboard boxes;
b. Burning small diameter twigs, branches or any
other small sized combustible materials in quantities which
exceed the volume of the normal log re;
c. Use of articial wax base logs, trash or other chemicals or
chemically treated combustibles.
WARNING: Over-ring can permanently damage this
replace system.
10
Summary
6. Fireplace Doors and Screens:
This replace has not been tested for use with doors.
To reduce the risk of re or injury, do not install doors. If
doors are required by the local authority having jurisdiction
then doors must be kept in the fully open position when the
replace is in operation. Earthcore does not limit the use of
replace screens.
7. Disposal of Ashes:
It is recommended that the rebox be cleaned of
excessive ashes before each use. It is necessary to remove
ashes from the open front of the replace. To do so, proceed
in the following manner:
Allow the re to go out and the ashes to cool for at
least six to eight hours.
After the cooling period carefully pick up the ashes
from the rebox with a small, metal replace shovel or other
metal scoop and place them in a metal container with a tight
tting lid.
If possible do not sweep the ashes as this will stir
them into the air and disperse them into the room.
The closed container of ashes should be placed on
a noncombustible oor or on the ground, well away from
all combustible materials, pending nal disposal. If the
ashes are disposed of by burial in soil or otherwise locally
dispersed, they should be retained in the closed container
until all cinders have thoroughly cooled.
8. Inspection and Cleaning:
At least twice a year in warm climates or monthly
during the heating season in colder climates, thoroughly
inspect the Fire-Lite replace and chimney system.
Chimneys must be installed so that access is provided for
inspection and cleaning. The chimney should be inspected
monthly during the heating season.
Inspect the entire ue from the top down for
obstructions such as birds’ nests, leaves, etc. Such
obstructions must be removed.
Check spark arrestor screens for clear ow of
smoke every two to four weeks during the heating season.
Inspect the ue periodically during the heating season for the
presence of soot and creosote build up. If creosote or soot
has accumulated, it should be removed to reduce the risk of
chimney re.
Have your chimney cleaned by a professional
chimney sweep if you have doubts about your ability to do
it. Use a plastic, wood or steel brush to clean the chimney.
Scrub the spark arrestor/chimney cap with a wire brush.
Remove any chimney cap for ue cleaning from the
top. Open the damper in the rebox for cleaning access from
below.
Clean the inner portion of the ue by using a exible
handled chimney cleaning brush.
For straight run ue the proper size brush can be
pulled up through the ue from the rebox with the damper
open.
If the chimney has an offset chimney section, brush
cleaning from the chimney top down to the offset/return and
then from the rebox up to the offset section is the proper
method.
In either case, cover the replace opening with a
damp sheet (sealed to the opening with masking tape) before
brush cleaning. Do not remove sheet until the soot has
settled. It is advised to vacuum loosened soot. Do not sweep
loosened soot as sweeping will disperse soot into the air and
about the room.
WARNING: Do not use chemical replace and chimney
cleaners that are poured on a hot re. These can be dangerous
and generally work only on the ue section nearest the
re, leaving the rest of the ue unaffected.
9. Exterior Maintenance:
Annually, at a minimum, check all metal ashings
and weather seals around the exterior chimney where it
penetrates the roof surface; inspect any chimney top spark
arrestors, metal cowlings and weather hoods to make sure
they are secure and weather tight.
Seal any cracks or gaps in chimney-to-roof ashings
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.
Notes - Maintenance Information
11
Warranty & Disclaimer
Isokern Fireplace
Earthcore offers a lifetime warranty for all Isokern reboxes, to be free from defects in materials that
negatively affect system performance from the date of purchase, subject to the terms and conditions of this
limited warranty.
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 OR ACCESSORIES. THIS WARRANTY DOES NOT COVER DRAFTING, SMOKING OR
UFFING OF THE FIREPLACE SYSTEM. Factors beyond the manufacturer's control affect replace
rafting, smoking, and pufng, and Earthcore 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
extended shall, notify Earthcore, 6899 Philips Industrial Blvd, Jacksonville, Florida 32256, in writing, by
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, address and phone number of the owner; and (5) a brief description of the defect.
Earthcore, or any division thereof, is not responsible for any labor costs or indirect costs incurred for the
replacement of defective components.
Earthcore is not responsible for misuse or mishandling of components. Nothing in this warranty makes
Earthcore, or any division thereof, liable in any respect for any injury or damage to the building or structure
in which the replace 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.
EARTHCORE, OR ANY DIVISION THEREOF, SHALL NOT BE HELD LIABLE FOR ANY INCIDENTAL
OR CONSEQUENTIAL DAMAGES OR EXPENSES ARISING OUT OF THE USE OF THE FIREPLACES
OR CHIMNEY SYSTEMS. ALL SUCH DAMAGES AND EXPENSES ARE HEREBY EXCLUDED.
This warranty is null and void when the replace or chimney systems are not installed pursuant to the
installation instructions provided by Earthcore or local building codes have not been followed completely.
This warranty applies only to those replace and chimney systems installed in the continental United
States, Alaska, and Canada. If any part of this warranty is found to be unenforceable, the remaining parts
shall remain in force and effect.
EARTHCORE HEREBY DISCLAIMS ALL GUARANTEES AND WARRANTIES, EXPRESS OR
IMPLIED, BEYOND THE WARRANTIES SET FORTH HEREIN.
6899 PHILIPS INDUSTRIAL BLVD. • JACKSONVILLE, FLORIDA 32256
TEL (904) 363-3417 • TOLL 1 (800) 642-2920 • FAX (904) 363-3408
/
