Installation, Operation and Maintenance Manual

LES FOYERS

FIREPLACES

DON-BAR

INSERTS

Les foyers DON-BAR Fireplaces, inc.Shop and Showroom: 741, St-Vallier Ouest, Quebec (Quebec) G1N 1E2

Phone: (418) 686-9114 - Fax: (418) 686-9117Website: www.don-bar.com - Email: don-bar@don-bar.com

REV. 2014-11

Keep these instructions for future use

LES FOYERS

DON-BAR

Installation, Operation,and Maintenance Manual

The manual is divided into 6 parts:

PART 1: Installation ............................................... PART 2: Security, Operation and Maintenance ...PART 3: Parts List ................................................. PART 4: Chimney Fires ..........................................

Page 3 Page 15 Page 22 Page 23 Page 24 Page 25

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

Page 2

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. 2014-11

APPENDIX 1: Requirements for existing fireplaces ....

THE INSERT SERIES FIREPLACES MEET THE REQUIREMENTS OF:ULC S627 in Canada, UL 1482 in the USAEPA: Certified EPA Exempt

1. Warnings and cautions 8. Finishing frames installation8.1 Flat and ventilated frames1.1. Modifications

1.2 Installation instructions9. Floor protection installation1.3 Applicable Codes9.1 Non-combustible floor protection1.4 Professional installation

1.5 Before your first fire 10. Combustible mantel1.6 Installation prohibited 10.1 Required clearances1.7 Chimney damper

11. Anti-smoke flap (optional)11.1 Anti-smoke flap installation2. Listed chimneys

2.1 Approved chimney liners12. Installation in a large-sized hearth12.1 Non-combustible materials3. Before beginning the12.2 Metal framing installation 12.3 Insert must be removable

3.1 Inspection of the existing hearth 12.4 Non-combustible finishing materials3.2 Chimney sweeping3.3 Preparation, insulation and painting of the existing 13. Lateral clearances hearth

13.1 Lateral clearances to combustible walls3.4 Cleaning the ash shaft3.5 Existing hearth minimum dimensions3.6 Chimney minimum height

4. Chimney liner installation4.1 Chimney liner required4.2 Manufacturer's instructions4.3 Chimney throat too narrow for the liner4.4 Jointing the liner sections4.5 Watertight flashing4.6 Chimney top

5. Insert installation5.1 Putting the insert in place5.2 Air space for the optional basement fan5.3 Jointing the liner to the insert adaptor5.4 Bolting the insert adaptor5.5 Last adjustments

6. Fan installation (optional)6.1 Fan installation

7. Exterior air intake installation (optional) 7.1 Exterior air intake7.2 Outside hood

PART 1: INSTALLATION

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PART 1: INSTALLATION

1. Warnings and Cautions

DO NOT OVERIFRE THE UNIT.

BURN WOOD ONLY. DO NOT USE OTHER FUELS.

REQUIRE THE USE OF THE PROVIDED INSULATION MATERIALS.

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.

IINSPECT AND CLEAN CHIMNEY FREQUENTLY. UNDER CERTAIN CONDITIONS OF USE, CREOSOTE BUILDUP MAY OCCUR RAPIDLY.

DO NOT USE GRATE TO ELEVATE FIRE. BUILD FIRE DIRECTLY ON TH HEARTH.

PART 1: INSTALLATION

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.

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 operating the fireplace.

1.6 Installation prohibited: DO NOT INSTALL THIS INSERT INTO A ZERO-C L E A R A N C E I N S U L A T E D PREFABRICATED FIREPLACE: Your insert is designed to be installed only inside a traditional solid masonry fireplace. If it is installed in an insulated zero-clearance fireplace, the high temperatures produced by the insert can cause a fire.

1.7 Chimney damper: The existing chimney damper must be set permanently in the open position.

1. Warnings and Cautions (con’t)

Page 5

Typical installation insidean existing masonry fireplace (with a rigid liner)

Stainless steelround top and flashing

Metal plate with insulation atthe damper levelto solidify the liner and make it airtight

Stainlesssteel rigidand/or flexibleliner into theexistingchimney

The existing ash shaft can be used witha fan in thebasement(optional)

Outside air intakewith insulated flexibleduct (optional)

Centrifugal fan(optional)

Insulation(for basement fan

airtightness)

Basement

DRAWING 1

Acousticalcase(optional)

Rockwoolinsulationsecured witha steel sheet(see art 3.3)

Fan thermodisc(optional)

Anti-turbulencedeflector (curvedmetal sheet)

Don-BarInsert

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Don-BarInsert

2. Listed chimney liners

4. Chimney liner installation

3. Before beginning the installation

mm) air space for expansion.

3.6 Chimney minimum height: 15 feet (4600 2.1 Approved chimneys liners: Your Don-Bar mm) for easy operation. This height is measured insert is designed to be installed with any rigid or from the floor where the insert is installed to the flexible stainless steel chimney liner bearing the top of the chimney.ULC label S-635 (2100 degrees). For liner diameters, see Page 14.

4.1 Chimney liner required It is mandatory to connect your insert to a ULC-listed stainless steel chimney liner (flexible, rigid or a combination of 3.1 Inspection of the existing hearth: Before the two). The liner must be continuous from the beginning the installation, inspect the existing insert to the top of the chimney. fireplace hearth to be sure that it is in good

condition. Strengthen any loose or unstable part. See Appendix 1 (page 25) for the requirements.

3.2 Chimney sweeping: Sweep the existing chimney. Don't forget the smoke shelf.

3.3 Cleaning, insulation and painting of the walls of the existing hearth: Brush the walls of the existing hearth to remove all the loose soot particles. This will prevent your home from being soiled by the circulation of the air around the insert. Next, insulate the walls of the existing hearth with 1" (25 mm) thick semi-rigid rockwool insulation pads secured in place with a screwed galvanized steel sheet (note: insulation is not required on the masonry walls of the existing hearth which are visible on both sides and are at least 2" (50 mm) away from any combustible material). At last, apply a coat of black stove paint to seal the surfaces and make the colour of the walls uniform because they may remain visible around the insert.

3.4 Cleaning the ash shaft: If the ash shaft is to be used as a duct for an optional fan installed in the basement, be sure to clean it first. (Drawing 1).

3.5 Existing hearth minimum dimensions: Use the dimensions indicated in the tables on the Page 14 and comply with the following requirements: At the rear, provide a continuous 1" (25 mm) air space for air circulation and 2" (50 mm) at the top. On the sides, allow a minimum 1/2" (12

:

Page 6

DRAWING 2

Stainles steelflexible liner

Flexible linersection to passthrough thechimney troat

Fflexible linersection to passthrough thechimney troat

Typical installations

Stainless steel rigid liner sections(female end up)

Flexible liner

Combination offlexible and rigid liners

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Don-BarInsert

4.2 Manufacturer's instructions: The installation must follow the instructions in this manual and the chimney liner manufacturer's instructions. If there is a conflict, you must follow the more restrictive measures.

4.3 Chimney throat too narrow for the liner: If the chimney throat is too narrow to permit the passage of the liner cut a hole of the required diameter in the chimney throat to allow for the passage of the liner (Drawing 2).

(Drawing 2).

4.5 Watertight flashing: Install a metal roof flashing at the top of the chimney. Seal the joint between the chimney and the flashing.

4.6 Chimney top: Install a chimney round top at the end of the chimney.

5.1 Putting the insert in place: There are three ways to install the insert in a masonry hearth:

1. Installation directly on the hearth floor (Drawing 3A): If the floor of the hearth is sound and level, simply slip the insert inside the hearth. Adjust the level with the four levelling bolts located at each corner under the insert.

2. Installation of the optional levelling plate (Drawing 3B): Put the Don-Bar levelling plate on the hearth floor (use only the approved Don-Bar steel levelling base for this) and adjust its level with the four (4) levelling bolts. Secure the plate in place on the floor with expansion bolts to prevent slipping.

4.4 Jointing the liner sections: Always fix the liner sections together with the female end up. This way the condensation water will drip inside the liner, not outside

5. Insert installation

Page 7

DESSIN NO 3

Insert installation

Gasket (see Drawing 4)

Choose this method if the hearth floor is sound and the height limited

Choose this method if the hearth floor is not in good condition or ifthe hearth is too high

Choose this method to raise the insert, or when an exterior airintake ond/or a base fan are needed. The raised base then replaces the levelling plate of the Drawing B above.

Levelling bolts

Expansionbolts to securethe plate on the floor

Levellingbolts

Optionallevellingplate

Garket(see Drawing 4)

Installation directly on the floor (without the levelling plate)

Installation with the levelling plate

Installation with the raised base

A

B

C

Exterior air intake (Optional):4" (100 mm) flexible metal duct with insulated jacket and non-combustible vapourbarrier

Exteriorwall cap

Sliding control for the air intake

Thermodisc(to splip underthe base) Ready to be connected

into a wall outlet

Axial fans (2)

Fan control

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Don-BarInsert

Don-BarInsert

with the provided collar. The liner must be sandwiched between the collar and the insert adaptor. As indicated, use at least three (3) stainless steel screws to firmly secure these parts together (Drawing 4). Then install the adaptor cover. The 98-78 and 98-87 models, and the corner and see-through inserts are shipped with a special pyramidal adaptor.

5.4 Bolting the insert adaptor: Firmly secure the insert adaptor to the insert top with the two (2) specially provided bolts and the gasket.

5.5 Last adjustments: Slip the insert into the hearth and adjust its position. No securing is necessary. The insert's weight is sufficient to maintain it in place.

6.1 Fan installation: There are three methods for installing a fan to increase the heating power of the insert:

1. Fan under the raised base (Drawing 5A): This kit is shipped with a thermodisc and a speed control switch. The kit comes complete 3. Installation with the raised base with an electrical plug ready to be connected (Drawing 3C): The Don-Bar raised base is to a wall outlet. Just tilt the fan at the required used to increase the height of the insert in the angle and slip it (with the thermodisc) under existing hearth, and is also required when the base. No securing required.installing an exterior air intake and/or base

fan (use only the approved Don-Bar steel 2. Side fans (Drawing 5B): This fan kit raised base for this). Put the raised base in includes a thermodisc and a speed control the hearth, adjust the levelling bolts, and switch ready to be plugged into any electrical secure it in place. oulet. Just put the fans on each side of the insert then adjust the tilt to the required angle. 5.2 Air space for the optional basement fan: If Also insert the thermodisc inside the hearth. the existing ash shaft is to be used as an air duct No securing required. for a centrifugal fan installed in the basement

(Drawings 1 and 5C), don't forget to fill the gap under the levelling plate with insulation in order to block the outflow of the air under the front of the insert (Drawing 1).

5.3 Jointing the liner to the insert adaptor: Secure the chimney liner to the insert adaptor

6. Fan installation (optional)

Page 8

DRAWING 4

Securing the liner to theinsert

Retainingcollar

Stainless liner(flexible orrigid)

3 Stainless screws equally spaced)

Fiberglassstove gasket 1/2" (6 mm)

Adaptor

Bolt for securing the adaptorto the insert from inside

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Adaptorcover

Note: some insertmodels are shippedwith a pyramidaladaptor

3. Basement fan (Drawing 5C): For maximum ventilation power, it is possible to use the existing ash shaft (if any) as an air duct for a centrifugal fan installed in the basement. In this case, it is important to allow a minimum 1" (25 mm) air space under the insert for the thermodisc wiring. The fan is shipped with a thermodisc (to be installed in the hearth, as indicated) and an acoustical case designed to receive an optional exterior air intake duct.

Page 9

Electrical wiring of the axial fans illustrated in Drawings 5A and 5B

Electrical wiring of the centrifugalfan illustrated in Drawing 5C

Thermodisc

Thermodisc

Speedcontrol

Speedcontrol

120V Plug

120V Line

Ground

Axial fans

Centrifugalfan

A

Fan installation (fans are optional)

DRAWING 5

Centrifugal fanwith speed controlto be plugged to anyelectrical outlet

Acousticalcase

Exx teriorair intake(optional)

Fix the fan plateto the foundationwall

Thermodisc(to place insidethe masonryhearth)

Electrical wire to slipdown into the existingash shaft

Existingash trap

Basement fan

Fans under the raised base assembly

Side fans

BASEMENT

B

C

Thermodisc(to slip into thehearth)

Axial fans (2)To place in the hearthat each side of the insert

Speed control

Wire ready to be pluggedto a wall outlet

Axial fans (2)(to slip under the base)

Raised base(optional)

Speed control

Wire ready to be pluggedto a wall outlet

Thermodisc(to slip underthe base)

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7. Exterior air intake installation

8. Finishing frames installation

9. Floor protection installation

7.1 Exterior air intake: (Drawing 3C): The exterior air intake is optional. Its installation requires the drilling of a 4" (100 mm) diameter hole in one of the walls of the existing masonry hearth. For the air intake, use only a flexible aluminum duct with a non-combustible insulated jacket. WARNING: Do not use ducts made of plastic materials, because the heat generated by the insert will rapidly melt them. The air intake duct should be extended to outside the building. It is forbidden to leave an air intake end in a garage, attic or any room with a negative pressure.

7.2 Outside hood: Install an exterior hood fitted with a screen. Seal the joint where the insulated duct passes through the masonry wall, inside and outside.

8.1 Flat and ventilated frames (Drawing 6): To install the flat and ventilated frames (three or four sides) just slip them into place on the insert. Many arrangements are possible (See Drawing 6 for all possible combinations). Please note that a ventilated air space - 2" on top (50 mm) - 1/2" on each side (12 mm) is always required if a finishing frame is not installed.

9.1 Non-combustible floor protection: A non-combustible protection must be placed in front of the fireplace to protect the floor from fallling embers. The floor protection must extend at least 18" (460 mm) in front of the insert door and 8" (200 mm) on each side. Existing floor protection should be modified as needed. IMPORTANT: Under floor protection there should be no combustible material to a depth of 8 "(200 mm) measured from the bottom of the glass Drawing 8

.

Page 10

Frames and trims

DRAWING 6

Ventilated frame (2 louvreson 3 sides

Ventilated frame (2 louvreson 4 sides

Ventilated frame (2louvres on 3 sides) plus a flat frame on3 sides

Ventilated frame (2louvres on 4 sides)plus a flat frame on4 sides

NOTE: other modelsavailable on request

REV. 2014-11

10.1 Required clearances: See Drawing 8 for the required minimum clearances if a combustible fireplace mantel is to be installed. The mantel must be located at least 18" (460 mm) above the insert door and the jambs must be spaced at least 8" (200 mm) from the door as. Its horizontal projection must follow a 45-degree angle as indicated.

Floor protection may consist of:

.1 Stone tiles or slabs (marble, granite, slate, etc.) or ceramic at least 3/8" (8 mm) thick, secured in place;

.2 Concrete or terra-cotta brick, secured in place;

.3 For temporary floor protection, a sheet of metal of at least 0.015" (0,38 mm) thickness or a non-combustible composite cement board (Durok type) of at least 3/8" (10 mm) thickness may be used.

10. Combustible mantel

Page 11

DESSIN NO 7

Non-combustible floor protection

18" (460 mm)

(from theglass door)

8" (200 m

m)

8" (200 m

m)

Non-combustiblefloorprotection

8" (200 mm)minimum

8" (200 mm)minimum

18" (460 mm)

minimum

Combustiblemantel

Non-combustiblematerials

Required clearance for a combustible fireplace mantel

DRAWING 8

18" (460 mm)

minimum

Combustibleshelf

IMPORTANTCombustiblematerials are notallowed below 18"(460 mm) abovethe door of theinsert. Beyond thatheight, thewidth of thecombustible shelf must follow aclearance lineof 45 degrees,as indicated.

45 deg.

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Minimum clearance of 8 "(200 mm) from combustible materials including those under the floor protection measured from the bottom of the glass

Glass bottom

8”

11. Anti-smoke flap

12. Installation in a large-sized hearth

opened. For installation details, see Drawing 27.

11.1 Anti-smoke flap (optional): This part is used when the flue draught is not sufficient or when there is a negative pressure in the house. The anti-smoke flap will prevent the smoke from spilling into the room when the insert door is 12.1 Non-combustible materials (Drawing 9 :

Use only 100% non-combustible materials to reduce the area of an over large hearth. When in doubt, don't hesitate to contact Don-Bar.

12.2 Metal framing: Use only metal studs to frame the hearth. Allow for thermal expansion by cutting all studs 1/8" (3 mm) shorter than necessary.

12.3 Insert must be removable: The insert must always be easily removable from the hearth. Provide a 2" (50 mm) free space between all metal studs and the ventilated finishing frame. Do not secure metal studs to the insert or to its finishing frame.

12.4 Non-combustible finishing materials (Drawing 9): Use only 100% non-combustible composite cement boards (Durok or equivalent). Fill the joints or cover the boards with ceramic tile.

Page 12

100% non-combustiblecomposite cementboard (Durok orequivalent). Finishby filling joints orrecover with ceramictiles, at choice.

Ventilated frame

Metal studsIMPORTANT: Allowfor thermal expansion.Cut all the studs 1/8" (3 mm) shorter thannecessary

Don't secure theinsert to the studs. Provide a 1"(25 mm) freespace betweenthe metal framingand the insert.

The insert mustalways beremovable.

Non-combustiblefloor protection(See Drawing 7for minimumdimensions)

DRAWING 9

Framing a large-sized hearth

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Page 13

13. Lateral clearances

13.1 Minimum clearances to lateral walls: Follow the indications of Drawing 10 when the insert is installed near a combustible wall..

DRAWING 10

Minimum lateral clearances

24" (610 mm) min.

Note: Measures are took on the insert door

24" (

610 m

m) m

in.

combustible wall

masonry

mas

onry

com

bu

stib

le w

all

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Page 14

No scale

i

J D

C

6" or 7" dia. int. (150 or 175 mm)

10,5"(267 mm) 10,5"(267 mm)

6"(150 mm)

8"(203 mm)

98-7898-87

Pyramidal adaptor for the 98 Series and the See-Through models(option)

Note: All frames can also be made-to-measure.

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

Optional Frames

6" or 7" I.D.. (150 or 175 mm)

6’ or 7’ I.D. (150 or 175 mm)

6 "

(15

4 m

m)

1-1/

16"

(28

mm

)

3-1/8" (79 mm)

1" (25 mm)i

O

MP

J D

C

NOT IN SCALE

i See-through inserts also available

28" (710 mm) (or made to measure)

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Don-BarInsert

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

I J C D M 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

1. General operation 7. Glass firescreen maintenance1.1 Combustion control 7.1 Glass maintenance1.2 Air intake control 7.2 Replacing a glass pane1.3 Smoke outlet control 7.3 Door gaskets1.4 Danger of burns

8. BBQ installation8.1 BBQ grill installation2. Precautions before lighting your

first fire9. Chimney maintenance2.1 Adequate air supply

2.2 Preventing smoke returns 9.1 Creosote build-up and removing9.2 Inspection and regular maintenance9.3 Soot build-up removal3. Firewood

3.1 Allowed fuels10. Firescreen3.2 Forbidden fuels

3.3 Recommended wood species 9.1 Firescreen3.4 Green wood

11. Anti-smoke flap9.1 Anti-smoke flap installation4. The fire

4.1 Opening the high efficiency HE smoke damper13. Humidity and condensation4.2 Open fires13.1 Excessive humidity and condensation 4.3 Controlled combustion fires

4.4 How to start a fire4.5 Firescreen is mandatory with open fires4.6 Preventing overfiring4.7 Forbidden flammable liquids4.8 Smoke release during the first fire4.9 Caution: Very hot!4.10 Gloves and poker4.11 Smoke detector

5. Ashes5.1 Ashes removal5.2 Metallic container5.2 Natural fertilizer

6. Fireplace maintenance and protection6.1 Finish maintenance6.2 Repainting6.3 Fireplace storing before installation

PART 2: SECURITY, OPERATION AND MAINTENANCE

Page 15REV. 2014-11

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 when opening the door, starting 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 toadjust the airintake

DRAWING 20

Using the removable handle to control the air intake

Page 16

DRAWING 21

Using the handle to control thesliding smoke deflector

closed

open

Use the handle tocontrol the damper

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IMPORTANT: Alwaysopen this key before opening the door orlighting 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 theHE sliding smoke deflectorOpen fully the smoke damperto start a fire, when opening thedoor or when makingan open fire with the firescreen

Close the smoke damperfor a long-lasting high efficiencyfire (close the door first).

closed

open

Use the handle tocontrol the damper

Page 17REV. 2014-11

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 Drawings 21.

4.2 Open fires: The smoke sliding damper and

4. The fire

DRAWING 23

Using the handle to open the door

Turn the handleto lock or unlockthe door

Page 18REV. 2014-11

DANGER OF BURNSNever leave the handle on the door during a fire.

4.7 Forbidden flammable liquids: Never use potash, phosphorus, and ideal for acidic soils. flammable liquids or accelerators such as gas, lamp oil, kerosene, BBQ starters, or other flammable substances to start or stir up a fire. Always keep these products away from the fire when using the fireplace.

4.8 Smoke release during the first fire: It is possible that, while making your first fire, the 6.1 Finish maintenance: Your fireplace is fireplace releases smoke for about 20 minutes. covered and protected by a special high- This smoke release is normal and is usually temperature paint finish. Normal maintenance caused by the "baking" of the fireplace paint requires only a simple dusting using a dry and finish. Open a window and the smoke will soft duster or a feather duster. Avoid splashing disappear by itself in a few minutes. Caution: liquids on the fireplace. This smoke can trigger a smoke detector causing a false alarm! 6.2 Repainting: If, over time, it becomes

necessary to freshen up the fireplace finish, you 4.9 Caution: Very hot! Your fireplace can can spray directly on the old finish a coat of become very hot. Be careful when coming close "Stove Bright" high temperature stove paint. The to it. Keep clothes, furniture, drapes, pets and standard color used by Don-Bar is Metallic Black young children away from the fireplace. no 6309.

4.10 Gloves and poker: In order to operate the 6.3 Fireplace storing before installation: To fireplace safely, always keep a poker on hand. prevent rusting, always store the fireplace and its Heat resistant gloves are also recommended and components in a dry space. can be very useful when you have to handle hot parts during an emergency.

4.11 Smoke detector: For your safety install a smoke and carbon monoxyde detector in the room

7.1 Glass maintenance: To clean the glass, where the fireplace is installed. begin with a duster and, preferably, a stove glass cleaner. These aerosol glass cleaners are sold by stove and fireplace dealers. They are specially formulated to dissolve creosote without damaging

5.1 Ashes removal: Your fireplace must be the glass. Then, to get a sparkling surface, finish emptied regularly. Always keep a bed of ashes of with a clean duster and a domestic glass cleaner about 1" (25 mm) in the fireplace to protect the such as Windex. Warning: Wait until the glass hearth bottom. Do not use a log grate. has completely cooled before attempting to clean

it. Never use an abrasive cleaner on the glass. 5.2 Metallic container: To collect ashes, use a metal container with an airtight lid.. Dispose of 7.2 Replacing a glass pane: If a glass pane them on the ground, outside, away from any shatter, replaced it with a 5 mm ceramic glass combustible material. If you plan to bury ashes pane of the same dimensions. or dispose of them another way, keep them in an airtight container until completely cooled.

5.3 Natural fertilizer: Ashes are useful as natural plant fertilizer. They are rich in lime,

6. Fireplace maintenance and protection

7. Glass firescreen maintenance

5. Ashes

Page 19REV. 2014-11

back of the fireplace (Drawing 25).

9.1 Creosote build-up and removing: When wood burns slowly, tar and organic vapors are released. These combustion by-products combine with moisture to form creosote. When creosote vapor comes in contact with a relatively cold surface, such as a chimney flue during a slow burning fire, it condensates. As a result, creosote residues build up inside the chimney. When this creosote deposit catches fire, the chimney can reach dangerously high temperatures.

9.2 Inspection and regular maintenance: The chimney must be inspected regularly during the heating season in order to determine whether is creosote build-up. In order to avoid chimney fires, the chimney must be cleaned if the creosote build-up reaches a 1/8" (3 mm) thickness.

The ceramic replacement glass (pyroceram) can usually be ordered from a local glazier or ordered directly from Don-Bar Fireplaces. (Note: the glass panes are not warrantied against breaking). Warning: Never replace a broken door glass with an ordinary or tempered glass: it will shatter and may cause serious injuries.

7.3 Door gaskets: The gasket ensuring the door airtightness must be changed periodically. Replace it with a similar fiberglass 3/8" (10 mm) round stove gasket. To replace the gasket around the glass, use a U-shaped 1/2" (12 mm) fiberglass stove gasket.

8.1 BBQ grill installation: First, adjust the height of the metal bar supplied with the grill to support it at front. The BBQ grill is set in place by simply inserting the central long rod into one of the holes provided on the hearth plate at the

8. BBQ grill installation

9. Chimney maintenanceGlass Pane Replacement

DRAWING 24

1/2" (12 mm)U-shaped gasket

Securing stripsand screws

5 mm ceramic glass

Insert door

BBQ grill installation

DRAWING 25

Adjust the heightof the support bar

Insert the central long barinto one of the holesprovided on the back hearth plate

Page 20REV. 2014-11

9.3 Soot build-up on the HE smoke sliding deflector (Drawing 26): During the chimney cleaning, be sure to remove any creosote or soot build-up over the HE smoke deflector. The build-up of soot on the deflector can prevent the flow of smoke.

10.1 Firescreen: The optional firescreen is simply put in place in the front of the insert. Just tilt it a little and slip it into the opening. Integrated clips will keep it in place.

11.1 Anti-smoke flap installation (optional): See details on Drawing 27.

12.1 Excessive humidity and condensation: In winter, high humidity levels inside the house can cause chimney problems such as condensation, and ice build-up eventually dripping into the fireplace. In extreme cases, the condensation water can even infiltrate the chimney insulation. To avoid these problems, it is necessary to maintain a 30-35% humidity level inside the house.

10. Firescreen installation

11. Anti-smoke flap

12. Humidity and condensation

Anti-smoke flap installation(optional)

DRAWING 27

The anti-smoke flap comes down automatically when openingthe door. It raises when the door is closed.

Slip the pins at the endsof the flap into the predrilled holes on each side of the insert

Screw the small plateretaining the arm intothe predrilled holeson the door frameInstall this way

Page 21

Cleaning of the HE smoke deflector

DRAWING 26

To prevent soot build-up thesmoke deflector must becleaned at regular intervals

Cleaning sequence

Unscrew the rod that controlthe sliding damper. Access the nut from inside the fireplace.

Unscrew the 4 bolts thathold the smoke deflector.

Take out the deflector. Tilt it down to unhook it from its bracket on the back of the fireplace.

1

1

2

3

2

3

REV. 2014-11

PART 3: REPLACEMENT PARTS LIST

HE Combustion SystemSliding damperDeflector (without the sliding damper)Rod and plate assembly for the sliding damperChimney adaptor

Standard PartsSliding plate for air intake controlHearth plateAnti-smoke flap

Insert door including glass retaining barsCeramic glass, 5 mmGlass retaining bars only (2 short, 2 long)Glass pane gasketDoor gasket

Tilted fan assembly (2) to slip under the raised baseSide fan assembly (1)Centrifugal fanInsulated box for the centrifugal fan ThermodiscSpeed control

Levelling plate complete with levelling boltsRaised triangular base

Metal firescreen

BBQ grillBBQ gril support rod

Ventilated frame (3 sides)Ventilated frame (4 sides)

Fireplace handle (to operate the fireplace)

Sliding damper assembly for the exterior air intake

Page 22

To order a part:1) Check the replacement part required 2) Specify the year of the fireplace installation _________________3) Fax this list with your coordinates to 418-686-9117

REV. 2014-11

69-6

169

-69

69-8

0

69-5

2

80-6

069

-90

80-6

9

98-8

798

-78

80-8

0

Page 22

PART 4: CHIMNEY FIRES

DIRECTIVES IN CASE OF A CHIMNEY FIRE

- Odour: Smell of smoke in the air. - Immediately alert the occupants of the building about - Sight: The colour of the pipe change. Flames at the potential danger. the top of the chimney on the roof. - Hearing: Abnormal rumbling. - Call your local fire department or 911.

-

- Burn only dry firewood. - Evacuate the house. - Clean the chimney at least once a year before the heating season or after burning 4 or 5 cords of - Following a chimney fire, don't reuse your fireplace firewood. until a professional has inspected it. A chimney fire - Don’t let creosote built-up in the chimney. can overheat the chimney components, wrap it - Don’t burn coniferous, construction wastes, inside, curve, crack or dislocate certain components. or materials containing glues, paints, or other chemicals. - Do all the recommendations of the professional - Always have a fire extinguisher on hand. and replace any part that is damaged or judged

unsafe.

- - .

Cut all the sources of air that can feed the fire (windows, air intakes, doors, etc...)

Do not throw water on the fire.Do not block the top of the chimney

How to avoid chimney fires

How to detect a chimney fire

What NOT to do

What to do

REV. 2014-11

1. The first 5 years: If, during this 5- year period, and in the course of a normal use, a component part of the fireplace becomes defective due to a material or workmanship defect, this part will be replaced or, at our discretion, repaired free of charge. The following parts are excluded from this warranty:

Any fireplace modified, altered or containing substituted componen ts o r when the instructions for installation, operation or maintenance have not been followed.

1.4 Gaskets: Fireplace gaskets are 8. The duration of the warranty on any warranted for 90 days following the part that is the object of a claim mustdate of purchase. never exceed the total duration of the

original warranty of the part shipped with 2. 20-Year Replacement Plan: After the fireplace.the expiration of the first 5 years, and for an additional 20 years period following 9. Draft and smoke returns: All Don-the date of purchase, we will ship (at the Bar fireplaces are designed and tested to exception of transport expenses and operate with a positive draft, without

1.1 Hearth back plate, smoke parts described in the articles 1.1, 1.2, smoke returns, when installed according deflector, HE deflector system, 1.3 and 1.4) any defective part for a price to the manu facturer 's inst ruct ions . grate, ash drawer/tray, wood not exceeding 50% of its retail price. Smoke returns caused by environmental basket, fireguard, refractories, factors (negative pressure, lack of air, metal fire screen, BBQ grill, 3. These warranties shall never be turbulence, etc.) are not covered by the electric fan blower: Being subject interpreted as covering workmanship on present warranty.to high temperatures, these parts site. Don-Bar takes no responsibility for may have to be replaced from time to damages to the building following the 10. The warranty does not cover:time; this is regarded as normal repair or the replacement of any part maintenance. However, all the 10.1 Broken glasscovered by the warranty. original parts shipped with the 10.2 Damages caused by a fireplace are warranted against chimney fire;4. No representative, employee or agent material or workmanship defects for 10.3 Shipping damages not of Don-Bar is authorized to change or 1 year following the date of reported on delivery; extend the present warranty.purchase. 10.4 Faulty installation;

10.5 Damages caused by 5. The warranty is valid only if the 1.2 Chimney: Since the chimney abnormal or abusive use.installation, the operation, and the and its components are not 10.6 maintenance of the fireplace have been manufactured by Don-Bar, please done in accordance with the fireplace refer to the warranty of the chimney manufacturer written instructions.manufacturer for any claim about it.

6. Don-Bar takes no responsibility for any 1.3 Fireplace paint finish: The damage to the fireplace, the chimney or fireplace is painted with a high the building if fireplace repairs done by temperature paint that needs to be 11. Caution: Improper operation or lack third parties are executed with non freshen up from time to time. of maintenance can endanger your original parts. However, the original finish applied safety.to the fireplace is warranted for 1 7. Any part that is the object of a claim in year following the date of purchase. 12. Send any communication or claim to accordance with the present warranty The warranty is limited to the supply the following address: must by returned to the shop (transport of the paint required for repainting prepaid) with a proof of purchase. All the fireplace. Foyers Don-Bar Fireplaces, inc.returns must be approved by the

741, St-Vallier Ouest, Québec,manufacturer before shipping. (Quebec) Canada G6V 3N9Phone: 418-686-9114Fax: 418-686-9117Website: www.don-bar.comEmail: don-bar@don-bar.com

25 YEAR LIMITED WARRANTY LES FOYERS

FIREPLACES

DON-BAR

Page 24REV. 2014-11

5.3.6 Hearth and Hearth Extensions

5.3.6.1 Hearth Extension and Fire Chamber Depth

The distance from the back wall of the fire chamber to the front edge of the hearth extension shall be not less than 28 in. (700 mm), and the hearth extension shall extend not less than 16 in. (400 mm) in front of the fireplace opening.

.

5.3.6.2

Where the hearth floor is elevated at least 6 in. (150 mm) above the hearth

extension, the width of the hearth extension shall be increased by:

(A) 2 in. (50 mm) for an elevation of between 6 in. (150 mm) and12 in. (300 mm); and

(B) an additional 1 in. ( 25 mm) for every 2 in. (50 mm) in elevation

above 12 in. (300 mm)

5.3.6.3

All hearth extensions shall extend not less than 8 in. (200 mm) beyond each side of the fire chamber.

5.3.6.4

The hearth and hearth extension shall be supported on not less than a 4 in.

(100 mm) thick reinforced concrete slab. For cantilevered, raised hearth

extensions, this slab may taper to not less than 2 in. (50 mm) at the front

edge and ends except as provided in Clause 5.3.6.5.

5.3.6.5

(A) When a fireplace opening is raised 8 in. (200 mm) or more from a

combustible floor, the hearth extension or pad may be placed on the

combustible floor and shall be not less than 2 in. (50 mm) thick when made

of a single unjointed unit of artificial or natural stone, or of reinforced

concrete.

(B) When thin material less than 1 in. (25 mm) thick (ie, tile or slate) is used a bedding of steel mesh reinforced grout or concrete shall be provided. The composite thickness shall be not less than 2 in. (50 mm)

(C) Jointed units of tile, slate or other noncombustible material more than 1 in. (25 mm) thick may be installed in conformance with Item (B) or shall be placed over a continuous layer of sheet metal with a thickness of not less than 0.5 mm.

(D) Mastic or grout used to place tile, slate or other thin masonry units shall be noncombustible.

,

, .

If the hearthis elevatedbetween 6” and 12” *

* If the hearth is elevated more than 12” see Article 5.3.6.2. B)

8”

16”

18”

8”

Before installing a Don-Bar insert the owner must ensure that its existing masonry fireplace meets the requirements of CSA A405 (excerpts below). Failing this, the

required modifications must be executed by a licensed contractor.

MINIMUM DIMENSIONS FOR THEHEARTH EXTENSION

If the hearthis elevatedprotect thevertical surfaceunder the hearthas specifiedin theArticle5.3.6.7

PROTECTION OF THE VERTICAL SURFACE UNDER THE HEARTH

Note: The CSA A405 Standard governs the construction of masonry fireplaces and contains several other articles.

APPENDIX 1 - REQUIREMENTS FOR EXISTING FIREPLACES

Page 25REV. 2014-11

(E) ln the area for which a hearth extension is required (see Clause 5.3.6.3), the joint between the wall face below the hearth and the hearth extension shall be provided with a firestop of sheet metal.

5.3.6.6A vertical face below a fireplace opening shall be of noncombustible material, shall extend to the top of the hearth extension, and shall extend at least 8 in. (200 mm) on each side.

5.3.6.7When tile veneer is used (25 mm or less) on the vertical face below a fireplace opening, it shall

(A) be backed with a sound, dry, rigid plane surface consisting of masonry, reinforced concrete, or cement plaster on metal lathe; and

(B) be applied to its noncombustible backing by means of full embedding in Type M mortar or other approved means with ail joints filled.

5.3.9 Clearance of Combustible Material

5.3.9.1Combustible material shall not be placed on or near the face of a fireplace within 6 in. (150 mm) of the fireplace opening, except that where the combustible material projects more than 1-1/2 in. (38 mm) from the face of the fireplace above the opening, such material shall be placed at least 12 in. (300 mm) above the top of the opening. Material below the opening shall conform to Clause 5.3.6.

5.3.9.2Metal exposed to the heated interior of a fireplace, such as the damper control mechanism or a built-in glass door, shall have at least a 2 in. (50 mm) clearance from any combustible material on the face of the fireplace where such metal penetrates through the face of the fireplace.

5.3.9.3When a fireplace is equipped with heat circulating outlet ducts above the fireplace opening, the distance from such a duct or metal duct grill to the combustible material above shall beat least 12 in. (300 mm) where the combustible material projects more th an 1-1/2in. (38 mm) from the face. Where the combustible material projects less than 1-1/2 in. (38 mm), the distance between the combustible material and the duct shatl be not less than 6 in. (150 mm).

REQUIREMENTS FOR THE HEARTHEXTENSION

CLEARANCE FROM COMBUSTIBLE MATERIALS

Min. 6” ofnoncombustible

6”

12”

Flush fireplace:6” clearance betweenthe hearth and acombustible material

Fireplace with a 1-1/2” projecting shelf (or more):6” clearance on each side and12” clearance at the top

Flush heating grill6” clearance

Heating grill recessed 1-1/2” behind the surface12” clearance

Cantilevered reinforced concrete slab of 4”tapered to 2” min.

Standard hearth

2” min. Reinforcedconcrete slab

Metalfire shield

Elevatedhearth of8” min.

Choice no1: 8” min

Grouted ceramic tile or stone, 1” thick min, over a metal sheet of 0.5 mm

Metalfire shield

Choice no 2:

8” min

4”

2”

min. 6” ofnoncombustible

Min 12” &

Page 26REV. 2014-11

APPENDIX 1 (Con’t)

16”

18”

18”