DON-BAR Inserts Instruction manual

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: [phone] - Fax: [phone]
Website: www.don-bar.com - Email: [email protected]
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 USA
EPA: Certified EPA Exempt

1. Warnings and cautions 8. Finishing frames installation
8.1 Flat and ventilated frames
1.1. Modifications
1.2 Installation instructions 9. Floor protection installation
1.3 Applicable Codes 9.1 Non-combustible floor protection
1.4 Professional installation
1.5 Before your first fire 10. Combustible mantel
1.6 Installation prohibited 10.1 Required clearances
1.7 Chimney damper
11. Anti-smoke flap (optional)
11.1 Anti-smoke flap installation
2. Listed chimneys
2.1 Approved chimney liners 12. Installation in a large-sized hearth
12.1 Non-combustible materials
3. Before beginning the 12.2 Metal framing
installation 12.3 Insert must be removable
3.1 Inspection of the existing hearth 12.4 Non-combustible finishing materials
3.2 Chimney sweeping
3.3 Preparation, insulation and painting of the existing 13. Lateral clearances
hearth 13.1 Lateral clearances to combustible walls
3.4 Cleaning the ash shaft
3.5 Existing hearth minimum dimensions
3.6 Chimney minimum height
4. Chimney liner installation
4.1 Chimney liner required
4.2 Manufacturer's instructions
4.3 Chimney throat too narrow for the liner
4.4 Jointing the liner sections
4.5 Watertight flashing
4.6 Chimney top
5. Insert installation
5.1 Putting the insert in place
5.2 Air space for the optional basement fan
5.3 Jointing the liner to the insert adaptor
5.4 Bolting the insert adaptor
5.5 Last adjustments
6. Fan installation (optional)
6.1 Fan installation
7. Exterior air intake installation
(optional)
7.1 Exterior air intake
7.2 Outside hood
PART 1: INSTALLATION
Page 3
REV. 2014-11

REV. 2014-11 Page 4 REV. 2014-11
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-
CLEARANCE INSULATED
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 inside
an existing masonry fireplace
(with a rigid liner)
Stainless steel
round top
and flashing
Metal plate with
insulation at
the damper level
to solidify the liner
and make it airtight
Stainless
steel rigid
and/or flexible
liner into the
existing
chimney
The existing
ash shaft can
be used with
a fan in the
basement
(optional)
Outside air intake
with insulated flexible
duct (optional)
Centrifugal fan
(optional)
Insulation
(for basement fan
airtightness)
Basement
DRAWING 1
Acoustical
case
(optional)
Rockwool
insulation
secured with
a steel sheet
(see art 3.3)
Fan thermodisc
(optional)
Anti-turbulence
deflector (curved
metal sheet)
Don-Bar
Insert
REV. 2014-11

Don-Bar
Insert
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 steel
flexible liner
Flexible liner
section to pass
through the
chimney troat
Fflexible liner
section to pass
through the
chimney troat
Typical installations
Stainless
steel rigid
liner sections
(female end up)
Flexible liner
Combination of
flexible and rigid liners
REV. 2014-11
Don-Bar
Insert

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 if
the hearth is too high
Choose this method to raise the insert, or when an exterior air
intake ond/or a base fan are needed. The raised base then replaces the
levelling plate of the Drawing B above.
Levelling bolts
Expansion
bolts to secure
the plate on the floor
Levelling
bolts Optional
levelling
plate
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 vapour
barrier
Exterior
wall cap
Sliding control for
the air intake
Thermodisc
(to splip under
the base) Ready to be connected
into a wall outlet
Axial fans (2)
Fan control
REV. 2014-11
Don-Bar
Insert
Don-Bar
Insert

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 the
insert
Retaining
collar
Stainless liner
(flexible or
rigid)
3 Stainless
screws
equally
spaced)
Fiberglass
stove gasket
1/2" (6 mm)
Adaptor
Bolt for securing the adaptor
to the insert from inside
REV. 2014-11
Adaptor
cover
Note: some insert
models are shipped
with a pyramidal
adaptor

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 centrifugal
fan illustrated in Drawing 5C
Thermodisc
Thermodisc
Speed
control
Speed
control
120V Plug
120V Line
Ground
Axial fans
Centrifugal
fan
A
Fan installation (fans are optional)
DRAWING 5
Centrifugal fan
with speed control
to be plugged to any
electrical outlet
Acoustical
case
Exx terior
air intake
(optional)
Fix the fan plate
to the foundation
wall
Thermodisc
(to place inside
the masonry
hearth)
Electrical
wire to slip
down into
the existing
ash shaft
Existing
ash trap
Basement fan
Fans under the raised base assembly
Side fans
BASEMENT
B
C
Thermodisc
(to slip into the
hearth)
Axial fans (2)
To place in the hearth
at each side of the insert
Speed control
Wire ready to be plugged
to a wall outlet
Axial fans (2)
(to slip under the base)
Raised base
(optional)
Speed control
Wire ready to be plugged
to a wall outlet
Thermodisc
(to slip under
the base)
REV. 2014-11

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 louvres
on 3 sides
Ventilated frame (2 louvres
on 4 sides
Ventilated frame (2
louvres on 3 sides)
plus a flat frame on
3 sides
Ventilated frame (2
louvres on 4 sides)
plus a flat frame on
4 sides
NOTE: other models
available 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"(460mm)
(fromthe
glassdoor)
8"(200mm)
8" (200 mm)
Non-combustible
floor
protection
8"(200mm)
minimum
8"(200mm)
minimum
18"
(460mm)
minimum
Combustible
mantel
Non-
combustible
materials
Required clearance for a combustible
fireplace mantel
DRAWING 8
18"
(460mm)
minimum
Combustible
shelf
IMPORTANT
Combustible
materials are not
allowed below 18"
(460 mm) above
the door of the
insert. Beyond that
height, the
width of the
combustible
shelf must follow a
clearance line
of 45 degrees,
as indicated.
45 deg.
REV. 2014-11
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-combustible
composite cement
board (Durok or
equivalent). Finish
by filling joints or
recover with ceramic
tiles, at choice.
Ventilated frame
Metal studs
IMPORTANT: Allow
for thermal expansion.
Cut all the studs 1/8"
(3 mm) shorter than
necessary
Don't secure the
insert to the studs.
Provide a 1"
(25 mm) free
space between
the metal framing
and the insert.
The insert must
always be
removable.
Non-combustible
floor protection
(See Drawing 7
for minimum
dimensions)
DRAWING 9
Framing a large-sized hearth
REV. 2014-11

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 mm) min.
combustible wall
masonry
masonry
combustible wall
REV. 2014-11

Page 14
No scale
i
J
D
C
6" or 7" dia. int.
(150 or 175 mm)
10,5"
(267 mm)
10,5"
(267mm)
6"
(150 mm)
8"
(203 mm)
98-78
98-87
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 " (154 mm)
1-1/16" (28 mm)
3-1/8" (79 mm)
1" (25 mm)
i
O
MP
J
D
C
NOT IN SCALE
iSee-through inserts also
available
28"(710mm)
(or madeto measure)
REV. 2014-11
Don-Bar
Insert
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 maintenance
1.1 Combustion control 7.1 Glass maintenance
1.2 Air intake control 7.2 Replacing a glass pane
1.3 Smoke outlet control 7.3 Door gaskets
1.4 Danger of burns
8. BBQ installation
8.1 BBQ grill installation
2. Precautions before lighting your
first fire 9. Chimney maintenance
2.1 Adequate air supply
2.2 Preventing smoke returns 9.1 Creosote build-up and removing
9.2 Inspection and regular maintenance
9.3 Soot build-up removal
3. Firewood
3.1 Allowed fuels 10. Firescreen
3.2 Forbidden fuels
3.3 Recommended wood species 9.1 Firescreen
3.4 Green wood
11. Anti-smoke flap
9.1 Anti-smoke flap installation
4. The fire
4.1 Opening the high efficiency HE smoke damper 13. Humidity and condensation
4.2 Open fires
13.1 Excessive humidity and condensation
4.3 Controlled combustion fires
4.4 How to start a fire
4.5 Firescreen is mandatory with open fires
4.6 Preventing overfiring
4.7 Forbidden flammable liquids
4.8 Smoke release during the first fire
4.9 Caution: Very hot!
4.10 Gloves and poker
4.11 Smoke detector
5. Ashes
5.1 Ashes removal
5.2 Metallic container
5.2 Natural fertilizer
6. Fireplace maintenance and protection
6.1 Finish maintenance
6.2 Repainting
6.3 Fireplace storing before installation
PART 2: SECURITY, OPERATION AND MAINTENANCE
Page 15
REV. 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 to
adjust the air
intake
DRAWING 20
Using the removable handle to
control the air intake
Page 16
DRAWING 21
Using the handle to control the
sliding smoke deflector
closed
open
Use the handle to
control the damper
REV. 2014-11
IMPORTANT: Always
open this key before
opening the door or
lighting a fire

3. Firewood
2. Precautions before lighting
your first fire
supply to maintain the combustion. If the room is
under a negative pressure, if the house is too
airtight, or if a ventilation device is in operation it
may be necessary to open a door or a window to
compensate.
2.2 Preventing smoke returns: Your fireplace
is designed to operate without smoke returns
during normal operating conditions and when
installed according to the instructions outlined in
the manual. However, some conditions out of our
control can create smoke returns. Don-Bar
Fireplaces cannot guarantee the absence of smoke
returns but if this phenomenon occurs special
attention should be given to the following
situations: mechanical ventilators in operation
(kitchen hood, dryer, air heating system, air
exchanger), drafts, room or house negative
pressure, inadequate chimney height, exterior
structures harmful to the chimney draft or capable
of causing smoke returns, an indoor moisture
level that is too high and causes ice build-up in
the flue and reduces chimney draft, too many
elbows in the chimney, crushed outside air intake
duct, strong winds, etc.
3.1 Allowed fuels: Your fireplace is designed to
burn wood only. To start a fire, use only
newspaper and small pieces of firewood.
3.2 Forbidden fuels: Anthracite, melamine,
pressure treated or painted wood, wood particle
boards and other composite materials. These
materials reach very high temperatures and
release corrosive gases, which may irreparably
damage your installation and void the warranty.
2.1 Adequate air supply: A wood fire requires
plenty of air. Always be sure there is enough air
DRAWING 22
Using the handle to control the
HE sliding smoke deflector
Open fully the smoke damper
to start a fire, when opening the
door or when making
an open fire with the firescreen
Close the smoke damper
for a long-lasting high efficiency
fire (close the door first).
closed
open
Use the handle to
control the damper
Page 17
REV. 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 handle
to lock or unlock
the door
Page 18
REV. 2014-11
DANGER OF BURNS
Never 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 19
REV. 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 maintenance
Glass Pane Replacement
DRAWING 24
1/2" (12 mm)
U-shaped gasket
Securing strips
and screws
5 mm ceramic glass
Insert door
BBQ grill installation
DRAWING 25
Adjust the height
of the support bar
Insert the central long bar
into one of the holes
provided on the back
hearth plate
Page 20
REV. 2014-11