Bellfires BCC-28 Tall User manual

Bellfires®
Close Clearance Models:
BCC-28 Tall
BCC-28
BCC-21 Tall
BCC-21
BCC-19
SLEEPY HOLLOW CHIMNEY SUPPLY, LTD.
85 Emjay Blvd.
Brentwood, New York 11717
1-800-553-5322 • FAX [phone]
www.sleepyhollowsupply.com • www.bellfiresusa.com
Version
120700

Bellfires® BCC
2
A properly installed Bellfires®BCC-28 fireplace and its associated components form
a safety tested system. This manual serves as a guide for the proper and safe installation
of a Bellfires®fireplace. It does not serve as a substitute for the necessary professional
judgment and skills of a trained installer. Instead, it should be used in conjunction with
standard safety considerations including, but not limited to, applicable state or provin-
cial and local fire codes, the National Fire Protection Association Standard NFPA 211 or
Canadian Standard B365, building and inspection codes, and the trained installer’s pro-
fessional judgment and skills to provide the owner with a safe installation. Please save
these instructions for any future repairs or use.
Consult the local and state or provincial building and fire safety code officials and
investigate the requirements for installing a factory-built fireplace in the homeowner’s
community. It is the responsibility of the installer to (1) obtain a building permit for
installation of a Bellfires®BCC-28 fireplace before construction begins and, (2) assure the
installation meets or surpasses all minimum requirements of the homeowner’s
jurisdiction.
It is highly recommended the homeowner install a smoke detector.
IMPORTANT SAFEGUARDS AND PRECAUTIONS
Safe and efficient operation of the Bellfires® BCC fireplace and its associated compo-
nents mandates installation of this unit in accordance with this installation guide.
Proper installation requires an installer skilled in standard construction techniques.
The installer must read and understand the contents of this manual before starting the
installation.
WARNING:
DO NOT PACK REQUIRED AIR SPACES
WITH INSULATION OR OTHER MATERIALS.!!!!
Failure to use components provided or specified by Sleepy Hollow Chimney Supply,
Ltd., manufacturers of Bellfires®, in accordance with this installation guide may create
a fire hazard. Use of other components or misuse of Bellfires® components voids the
Bellfires® warranty.

Bellfires® BCC
3
Important Safeguards and Precautions 2
Introduction 5
BCC Parts 6,7
BCC Spider Damper Parts 8
Safety Guidlines 9
BCC 28 Specifications & Dimensions 10
BCC 28 Steps to Installation 11
Layout 12,13
Bird’s Eye View Dimensions 13
BCC 28 Assembly & Chimney Installation 14-27
BCC 28 Hearth Extensions 16,17
BCC 28 HT Chimneys 24
BCC 28 Spider Damper 25,26
BCC 28 Framing 28,29
BCC 28 Finish 30
Build the Best Fire in the World 31
Operation & Maintenance 32
Warranty 33
Table of Contents

Bellfires® BCC
4
BCC 19
BCC 21 and BCC 28

Bellfires® BCC
Early fireplaces were very inefficient, drawing a good deal of
the heat up the chimney while admitting an unbearable amount
of smoke into the room. In the late 1700’s, Benjamin
Thompson, Count of Rumford, recognizing that a fireplace
heats an area by radiation, began a series of experiments
aimed at improving its performance.
He discovered through observations and various constructions
that the exaggerated width of the chimney of his time, necessi-
tated by the need for room for a chimney sweep to climb
through the throat area into the flue, was a primary cause of
inefficiency and smokiness. He attributed the problem not only
to the chimney, but the width of the throat and also specific
fireplace dimensions and configurations. Using the knowledge
gained from his studies, Rumford modified the traditional fire-
place design into one that burned cleaner and hotter and,
most importantly, did not smoke. His efforts greatly improved
the performance of the fireplace.
Later, in the 1900’s, a series of scientific experiments were
conducted by Professor Peter O. Rosin, Dr. Ing., under the
auspices of the British Coal Utilisation Research Association.
The results are documented in his report, “The Aerodynamics
of Domestic Open Fires”. Through the use of laboratory equip-
ment, Dr. Rosin was able to observe air and smoke flow pat-
terns and thus developed the ideal firebox and chimney shape
for maximum efficiency. While expanding on Rumford’s work,
some of Dr. Rosin’s findings varied dramatically from
Rumford’s earlier theories; perhaps the most notable being the
smoke shelf theory, shown diagrammatically at the left.
The important point of Dr. Rosin’s work is that it was per-
formed in a scientific manner and pointed the way to a much
more efficient and functional fireplace. Bell of England took
this information and applied it to develop the Bellfire
Fireplace, providing the ideal firebox and throat shape to guar-
antee a smoke-free efficient fireplace capable of producing
maximum radiant heat with minimum fuel. It was commonly
used to heat the complete home until the second World War.
Since then it has been further developed by using more mod-
ern aerodynamic concepts and thermal insulation techniques
to improve the design.
Sleepy Hollow Chimney Supply has optimized the Bellfires®
designs, and produced a superior radiant firebox combining
advanced casting techniques and high temperature, high alu-
mina ladle cast refractory. We feel confident that our
Bellfires® units are the finest heat- producing open fireplaces
to be found, whether used to upgrade old metal or masonry
fireboxes or in new construction.
The Bellfires® Close Clearance (BCC) Wood Floor Fireplace
makes available to homeowners, businesses, and restaurants
the possibility of having a super efficient, heating fireplace in
locations where a conventional masonry fireplace is not possi-
ble. Suitable for new construction or renovation, the BCC
requires no foundation or footings. The refractory firebox is
designed in a half-pear shape in order to give it the greatest
efficiency possible. The Bellfire® BCC refractory firebox,
hearth, side flares, and smoke chamber, are enclosed in a
heavy 20 gauge steel outer shell (ideal for installation in
seizmic areas). The BCC 28’s pre-cast refractory firebox com-
ponents are wrapped with ceramic insulation and the area
between the firebox and outer steel cabinet is filled with perlite
beads at the building site.
Using a pear shaped firebox design, proprietary thermal insu-
lation technology, and meticulous metal fabrication found no
where else, the BCC can be installed on a wood floor and posi-
tioned within two (2) inches to combustible rear and side
walls. BCC-28 Fireplace Models have been tested and found to
be in compliance with UL 127-1988 and ULC S610-M93
“Standard for Factory-Built Fireplaces.” The Rumford style
smoke chamber vents into any eight (8) inch diameter listed
Type HT factory-built chimney that meets UL 1482 or ULC S627
standards. A top mounted round damper with a control key at
the firebox level helps to prevent cold air from draining into
an unused fireplace and help ensure a warm flue for instant
draft. Super radiant heat output and thorough combustion pro-
vide ample warmth and fuel efficiency that sets new standards
for the open hearth. The refractory firebox stores heat and
warms the house long after the flames have died out.
5
Introduction

Bellfire BCC Component Identification
6
Close Clearance Wood Floor Parts
1” Pre-cut Hollow Wool
Insulation Blanket...............(Supplied) (Part # 6)
22 Gauge 304-L SS Pan......(Assembled)
Insulating Board .................(Assembled) (Part#4)
” Hot Rolled Steel Base
Comes All ready insulated..(Assembled)
20 Ga. Galvanized
Wood Floor Protector..........(Supplied) (Part # 6)
Pre-Cut ” Cera-Foil Wood
Floor Insulated Blanket.......(Supplied) (Part #5)
Three Hammer Drive
Pins (Supplied)
(Part # 17)
Required Chase Vents
Model BCC 28
Only (Part # 18)
1” Hollow Wool
Gasket......(Supplied)
(Part # 15)
Removable Top
Lid (Part #2)
Removable Front
Face Panel (Part #3)
Bellfires® 20 Ga. Galvanized Outer
Shell (Supplied) (Part # 1)

Bellfires® BCC Component Identification
7
Masonry Turbo
(supplied) (Part#14)
Rumford Smoke
Dome (supplied)
(Part # 13)
Hollow Wool Gasket
(supplied) (Part # 12)
Refractory Firebox
(supplied) (Part # 9)
Two Refractory Flares
(supplied) (Parts # 10a & 10b)
Two Piece Refractory Hearth
(supplied) (Parts # 11a & 11b)
One Bag of Perlite for Model BCC 21
(supplied)
Two Bags of Perlite for Model BCC 28
(supplied) (Part # 16)
One can of Spray Glue
(Supplied) (Part # 8)
Pre-sized 3 x 8 lb.
density Hollow Wool
Blanket (Supplied)
(Part # 7)
Bellfires® Hearth Extension Pad
(Optional) (Suggested)
(Part # 19)
Slip connector
(supplied)
(Part #20)

Bellfires® BCC Component Identification
8
BCC Spider Damper Parts
1- Drop In Damper
(Part #21)
28' Stainless Steel Cable
(Part #22)
1 -Bracket
(Part #23)
2 -Hammer Drive Pins
(Part #24)
1- Stainless Steel Sash Chain
(Part #25)
1 -Stainless Steel Ring (attach to chain)
(Part #26)
1 -Stainless Steel Clamp (attach to cable)
You need....
Ladder
Hammer Drill
1/4 inch Masonry Drill Bit
Safety glasses
Wire Cutters
Marker
Flat Gasket or Silicone Caulk

Bellfires® BCC
9
A. Bellfires® fireplaces are not approved for use in mobile homes.
B. There must be an air space clearance between the outermost portion of any section of the chimney system and
any combustible surface. Although two inches is a typical clearance, adhere to the requirements set forth by the chim-
ney manufacturer. Combustible surfaces include: ceilings, joists, flooring, walls, electrical wiring, insulation and roof
structures.
C. Never fill any required air space with insulation or other material.
D. The chimney system must be vented to the outside.
E. The chimney must extend at least three feet (900mm) above the roof and at least two feet (600mm) above any
portion of the roof within 10 feet (3m).
F. Maximum chimney height from the top of the firebox to the top of the chimney should not exceed 40 feet when
supported solely by the fireplace, or 90 feet when resupported at or above 40 feet according to the chimney manufac-
turer's resupport specifications.
G. Minimum chimney height from the top of the firebox to the top of the chimney must be 10 feet.
H. The chimney must not be inclined more than 30 degrees from vertical. Greater angles result in hazardous
deposits of soot and ash in flue.
I. A maximum of two offsets (4 elbows total) is allowed in a chimney.
J. Firestops and joist shields must be used at each floor level through which the chimney rises.
K. There should not be any forced air furnace registers in the room within ten feet of the fireplace. They can cause
negative pressure and create chimney down-drafts.
L. Never mix parts of one chimney system with those of a different manufacturer. Do not install damaged chimney
parts. Remember, more fires are caused by chimneys than by solid-fuel appliances.
M. Practice good workmanship. Sloppy work could jeopardize the safety of the installation.
Safety Guidelines
3 feet minimum
2 feet minimum
10 feet or more
3 feet minimum 2 feet minimum
Less than 10 feet
Ridge
Chimney Height Requirements

Bellfires® BCC
10
BCC 28 Specifications & Dimensions
SPECIFICATIONS
NAME: BELLFIRES®Close Clearance
MODELS and WEIGHT:
BCC21 STANDARD 500 lbs.
BCC21 TALL 575 lbs.
BCC28 STANDARD 765 lbs
BCC28 TALL 840 lbs.
FIREBOX MATERIAL:
3000˚ 70% High alumina castable refractory
3” thick stainless steel fiber reinforced
SMOKE CHAMBER:
Advanced reinforced design
3000˚ 70% High alumina castable refractory
3” thick stainless steel fiber reinforced
THERMAL INSULATION:
3” x 8 lb. Hollow Wool™
Blanket/Perlite insulation
OUTER SHELL:
20 Gauge galvanized steel
” thick hotrolled steel
Suspension base
BCC28 TALL
BCC 28 STANDARD
43 ” 43 ”
11” 11”
10” 10”
4 ” 4 ”
71 ” 71 ”
33 ”
40 ”
6 ”
28 ”
6 ”
66 ”
35 ”
432”432”
26”
66 ”
26”
33 ” 33 ”

Bellfires® BCC
11
Steps to a Bellfires® BCC Installation
LAYOUT
1ASSEMBLY
& CHIMNEY
INSTALLATION
2
FRAME
3FINISH
4

Bellfires® BCC
12
LAYOUT
LOCATE THE FIREPLACE
When planning the BCC installation, it is necessary to
a) Locate the fireplace, and
b) Plan for framing the enclosure.
When selecting a location for the Bellfires® BCC fire-
place in a planned or existing residence it is important
to consider:
1) positioning of the fireplace with respect to
air and traffic flow,
2) floor and surrounding walls,
3) ceiling joists and roof penetration.
Consider the impact on traffic flow in adjacent rooms
and the position of forced air returns or registers near
the proposed fireplace before deciding on the final
location.
The Bellfires® BCC 28 must be installed on a flat, hard,
level surface, such as a wood floor or raised platform.
CAUTION: The BCC must not be installed on carpet-
ing, vinyl, or soft surface materials.
The location must be able to support the sustained
weight of the BCC 28 fireplace (765 pounds) plus the
chimney system, framing, sheathing, finish, and
hearth protection.
Bellfires® may be installed against a combustible wall
providing the two (2) inch minimum air is main-
tained.
The figure above shows a typical installation view of an
interior installation on an existing wall.
Snap chalk lines
for enclosure and
hearth extension
Find centerline
for chimney
Decide where and
how joists and rafters
are to be boxed for
proper chimney
clearance
Distance from centerline
to rear wall

Bellfires® BCC
13
By setting the Bellfires® BCC fireplace in the desired
location in the room and using a plumb line, the
position of a straight chimney above the fireplace
can be simulated. Whenever possible, the BCC
should be moved to minimize the cutting of ceiling
joists and roof rafters or the use of chimney offsets.
Once the desired location is determined, the floor,
wall, and ceiling should be marked for cuts and
framing, rechecked, and any reframing at the ceil-
ing and rafters can be done.
Plans for framing the enclosure should be thor-
oughly checked. This is discussed more completely
in the section on framing.
Corner Installation
2” (50mm)
1” (25mm)
2” (50mm)
20” (508mm)
1” angled wall clearance
18” (458 mm) minimum
clearance to sidewalls
67 ” (1715 mm)
67 ” (1715 mm)
20” (508mm)
2” (50mm)
Ember
guard
extension
2” (50mm)
Sidewall Installation
18” (458 mm) minimum
clearance to sidewalls
2” (50mm)
2” (50mm)
67 ” (1715 mm) Minimum

Bellfires® BCC
14
BCC 28 Assembly & Chimney Installation
BCC 28 with firebox
installation completed.
Notice 2” ember guard
extension projecting from
beneath the front base of
the Bellfires® shell.
The Bellfires® BCC is the most advanced
factory-built fireplace on the market
today. Most factory-built fireplaces are
light weight attempts at simulating a
traditional masonry fireplace and only
use simulated veneer fire brick in the
firebox. They mistakenly continue to
use a smaller rendition of the “tradi-
tional” American fireplace firebox that
is notoriously inefficient.
Unlike them, Bellfires® BCCs use the
same highly efficient refractory firebox
used in all the Bellfires® masonry mod-
els, from restoration designs to the new
construction models, and houses them
in a 20 gauge galvanized sheet metal
shell that is the strongest, best built in
the industry.
Bellfires® BCC fireplaces are unusual
for factory builts in many ways. They
are shipped with the refractory pieces
boxed separately from the metal shell.
The BCC is then assembled onsite.
Following, on the next few pages, are
the assembly instructions.
The BCC 28 is designated
for use with a listed Type
HT pre-fab chimney that
meet requirements from UL
1482 or ULC 5627

Bellfires® BCC
15
REMOVE TOP LID
REMOVE
FRONT FACE
PANEL
1. Once it is determined the exact place the fireplace will rest, place the supplied ” x 48” (12.5 mm x 122 cm) sheet
of Cera-foil ceramic fibre blanket on wood floor, foil face up. (15-1) If the BCC is to be installed on a combustible floor
lay the 20 gauge galvanized sheet metal protection (part # 6) on the floor over the ceramic insulation. (15-2) Again, if the
BCC is being installed on a combustible floor and the hearth extension area in front of the fireplace is combustible
extend excess width of the galvanized metal floor protection forward two (2”) inches (50mm), creating an ember guard
at front edge of hearth and fireplace facing. (See 16-1 & 16-2 and the discussion on pgs. 16-17.)
2. Position metal fireplace shell(Part 1) in position at intended final location, properly centered over wood floor protec-
tion. At this time double check alignment to insulated flue above, observing a two inch clearance to combustibles. (15-3)
3. Remove ” hex head screws in the top lid and front face panel of metal shell enclosure.(15-4) Shell should now be
open and accessible to install the refractory components. (15-5)
15-1
15-2
15-3 15-4
15-5

Bellfires® BCC
16
Hearth Extensions
BCC fireplace
front edge
Subfloor
Minimum 20”
Galvanized floor protection
extends beyond BCC front
for 2” to act as ember guard
2”
BCC Insulated Hearth Extension
BCC Flush hearth extension BCC Raised hearth extension
BCC fireplace
front edge
Bellfires® galvanized
floor protection
“Z” strip ember guard
safety strip projecting
minimum 2” under BCC
and minimum 2” on floor
under insulating pad
BCC Insulated Hearth Extension
Hearth Extensions
Combustible floors directly in front of the fireplace
must be protected from sparks, embers, logs rolling out
of the fireplace, and heat by using non-combustible
floor protection–a hearth extension. The BCC 28 fire-
place requires a minimum protection of 20” in front of
the fireplace and 12” inches to each side of the fire-
place firebox opening for a total width of 672”. Local
codes may require even larger dimensions. Total R
value of the non-combustible hearth extension must be
a minimum of R 2.2.
Be certain hearth extensions are securely fastened so
they cannot be moved or easily dislodged and that they
are constructed from durable, non-combustible materi-
als such as brick, tile, slate, etc.
Ember Guards
In many areas ember guards are known as metal seal-
ing strips, or sheet metal bridges. Their function is
critical in pre-fab fireplace installations. If a BCC 28 is
installed on a combustible floor or a combustible
raised hearth, or the hearth extension support is com-
bustible, a metal ember guard strip with a minimum
width of 4” and the full length of the BCC opening
must be placed under the front of the BCC and extend-
ed the same length to the front of the BCC. This is
absolutely necessary to seal the crack between the BCC
and the hearth extension so that embers, coals, sparks,
or ashes cannot come in contact with combustibles in
the area below. In raised hearth designs a special “Z”
strip design will have to be constructed onsite. The
Bellfires® Hearth Extension pad should be laid over the
ember guard and cover the whole area of the hearth
extension, a minimum of 20” deep and 672” wide.
Over this is placed the noncombustible finish hearth
extension material–brick, tile, slate, etc. Finally, a bead
of non-combustible material is used to seal the con-
nection of hearth extension with the BCC.
Noncombustible Decorative Hearth Extension Material
Seal Gap
Noncombustible decorative hearth
material
Seal
gap
16-1 16-2

How to determine if alternate floor protection materials are acceptable.
All floor protection materials must be non-combustible (i.e., metals, brick, stone, mineral fiber boards, etc.). Any organic
materials (i.e., plastics, wood, paper products, etc.,) are combustible and must not be used. The floor protector specified
may include some form of thermal designation such as R value (thermal resistance), k-factor (thermal conductivity), or
C-factor (thermal conductance).
Procedure:
1) Convert specification to R-value:
i. R-value given–no conversion needed.
ii. K-factor is given with a required thickness (T) in inches: R = 1/k x T
iii. C-factor is given: R = 1/C
2) Determine the R-value of the proposed alternate floor protector.
i. Use the formuli in step (1) to convert values not expressed as “R”.
ii. For multiple layers, add R-values of each layer to determine overall R-value.
3) If the overall R-value of the system is greater than the R-value of the specified floor protector, the alternate is
acceptable.
EXAMPLE:
The specified floor protector should be w”thick material with a k factor of 0.84. The proposed alternate is
4” brick with a C-factor of 1.25 over 8” mineral board with a k-factor of .29.
Step (a): Use formula above to convert specification to R-value.
R = 1/k x T = 1/ .84 x .75 = .893
Step (b): Calculate R of proposed system.
4” brick of C = 1.25, therefore Rbrick = 1/C = 1/1.25 = .80
8” mineral board of k = .29, therefore Rmin. Bd. = 1/.29 x .125 = .431
Total R = Rbrick + Rmineral board = .8 = .431 = 1.231
Step (c): Compare proposed system R of 1.231 to specified R of .893. Since proposed system R is greater than
required, the system is acceptable.
Definitions:
Thermal conductance = C = Btu = W
(hr)(ft2)(0F) (m2)(0K)
Thermal conductivity = k = (Btu)(in) = W = Btu
(hr)(ft2)(0F) (m)(0K) (hr)(ft)(0F)
Thermal resistance = R = (ft2)(hr)(0F) = (m2)(0K)
Btu W
Bellfires® BCC
17
Material
Insulboard 300™
Insulboard 230™
Insulboard 180™
Common brick
Cement mortar
Marble
Limestone
Ceramic Tile
(Btu)(in)
(hr)(ft2)(0F)
Typical materials that might be
substituted for hearth extensions
k in.
.458
.43
.34
5.00
5.00
11.00
6.5
12.5

Bellfires® BCC
18
Lay 1” (25mm) precut Hollow Wool Insulation Blanket (Part # 6) on 22ga. 304-L SS floor pan of shell. (Part # 4) Be sure
that supplied insulating blanket fits tight against floor of enclosure. (18-1) Position supplied precut 3” thick Hollow Wool
Thermal Insulating Blanket (Part #7) around rear of shell. (18-2) Using provided spray glue ( Part #8) spray front of pre-
cut Hollow Blanket (Part # 7). Center Bellfires® refractory firebox (Part # 8) into shell enclosure. (18-3) Place side flare
panels ( Parts 9a & 9b) in place on either side of firebox, striving for a tight flare joint. Snug up Hollow Wool tightly
against rear of refractory firebox and flares. Insulating blankets must fit snugly against fireback to allow for perlite insulat-
ing fill.
Place hearth components ( Parts #11a & 11b) into enclosure. Keep front edge of hearth stretcher flush with front edge of
fireplace base. This will set correct firebox position. (18-4)
18-1
18-2
18-3
18-4

Bellfires® BCC
19
Spray adhesive glue on top of firebox and flare edges. (19-1) Place insulation gasket (
Part #12) on top of firebox edge and flares. (19-2 & 19-3)
19-1 19-2
19-3

Bellfires® BCC
20
Place Masonry Rumford Dome
(Part # 13) on top of firebox-
gasketing, resting on the fire-
box and flares.
Use spray adhesive to cement
gasket material on top of
Rumford Dome. (20-2, 20-3)
Using provided spray glue,
position supplied Hollow Wool
Thermal Insulating Blanket
(Part # 7) around rear of
Masonry Rumford Dome.
(20-4)
Important Installation
Reminder —
To insure that flame and
smoke paths are as
smooth as possible, be
sure to align the rear
firebox wall, the Rumford
Dome, and the Masonry
Turbo at and on the rear
inside wall, not the rear
outside walls.
20-1 20-2
20-3 20-4