Drolet SAHARA User manual

READ AND KEEP THIS MANUAL FOR REFERENCE
45138A
Printed in Canada 13-04-2012
OWNER’S MANUAL
SAHARA WOOD STOVE
US ENVIRONMENTAL PROTECTION
AGENCY PHASE II CERTIFIED
WOOD STOVE
Verified and tested following
ULC S627 and UL 1482 Standards
by:
Manufactured by : STOVE BUILDER INTERNATIONAL INC.
250, de Copenhague, Saint-Augustin-de-Desmaures (Québec) G3A 2H3
Tel : (418 ) 878-3040 Fax : (418 ) 878-3001
www.drolet.ca
This manual is available for free download on the manufacturer’s web site. It is a copyrighted
document. Re-sale is strictly prohibited. The manufacturer may update this manual from time to time
and cannot be responsible for problems, injuries, or damages arising out of the use of information
contained in any manual obtained from unauthorized sources.

2
INTRODUCTION
Stove Builder International, one of the most important wood stove and fireplace manufacturers in North
America, congratulates you on your purchase and wishes to help you get maximum satisfaction from your
wood stove. In the pages that follow, we will give you advice on wood heating and controlled combustion as
well as technical specifications regarding installation, operation and maintenance of the model you have
chosen.
The instructions pertaining to the installation of your wood stove in North America comply with ULC-S627
and UL-1482 standards.
We recommend that our wood burning hearth products be installed and serviced by professionals who are
certified in the United States by NFI (National Fireplace Institute®) or in Canada by WETT (Wood Energy
Technical Training) or in Quebec by APC (Association des Professionnels du Chauffage).
Read this entire manual before you install and use your new stove. If this stove is not properly
installed, ahousefiremay result. Toreduce therisk offire, followtheinstallation instructions. Failure
to follow instructions may result in property damage, bodily injury, or even death.
Consult your municipal building department or fire officials about restrictions and installation
requirements in your area and the need to obtain a permit.
KEEP THIS INSTRUCTIONS MANUAL FOR FUTURE REFERENCE.
CAUTIONS:
THE INFORMATION GIVEN ON THE CERTIFICATION LABEL AFFIXED TO THE APPLIANCE ALWAYS OVERRIDES
THE INFORMATION PUBLISHED,IN ANYOTHER MEDIA (OWNER’SMANUAL,CATALOGUES,FLYERS,MAGAZINES
AND/OR WEB SITES).
HOT WHILE IN OPERATION.KEEP CHILDREN,CLOTHING AND FURNITURE AWAY.CONTACT MAY CAUSE SKIN
BURNS.
DO NOT USE CHEMICALS OR FLUIDS TO IGNITE THE FIRE.
DO NOT LEAVE THE STOVE UNATTENDED WHEN THE DOOR IS SLIGHTLY OPENED DURING IGNITION.
DO NOT BURN WASTE,FLAMMABLE FLUID SUCH AS GASOLINE,NAPHTHA,OR MOTOR OIL.
DO NOT CONNECT TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
ALWAYS CLOSE THE DOOR AFTER IGNITION.
REGISTER YOU WARRANTY ONLINE
To receive full warranty coverage, you will need to show evidence of
the date you purchased your stove. Keep your sales invoice. We
also recommend that you register your warranty online at
http://www.drolet.ca/en/service-support/warranty-registration
Registering your warranty online will help us track rapidly the
information we need on your stove.

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TABLE OF CONTENTS
TIPS ON WOOD HEATING..............................................................................................4
SECTION 1.0 - INSTALLATION......................................................................................5
1.1GENERAL INSTALLATION ....................................................................................................... 5
1.2POSITIONING THE STOVE........................................................................................................ 5
1.3CLEARANCES TO COMBUSTIBLES AND FLOOR PROTECTOR .................................... 6
SECTION 2.0 CHIMNEY (FLUE SYSTEM)................................................................13
2.1DEFINITIONS .............................................................................................................................. 13
2.2CHIMNEY..................................................................................................................................... 13
2.2.1Step by step installation of your factory-built chimney.......................................................... 15
2.2.2Typical installation through an existing masonry chimney.................................................... 23
2.3 CHIMNEY CONNECTOR................................................................................................................ 26
2.4 DRAFT................................................................................................................................................. 28
2.5OUTSIDE COMBUSTION AIR.................................................................................................. 28
2.6THE BENEFITS OF INSTALLING A DROLET BLOWER.................................................. 29
SECTION 3.0OPERATION..........................................................................................30
3.1SAFETY INFORMATION .......................................................................................................... 30
3.2FUEL.............................................................................................................................................. 32
3.2.1The use of manufactured logs................................................................................................. 33
3.2.2Simple wood moisture test...................................................................................................... 33
3.3NOTES ABOUT FIRST FIRING................................................................................................ 33
3.4LIGHTING A FIRE...................................................................................................................... 33
3.5MAINTAINING THE FIRE........................................................................................................ 34
3.6FAN (BLOWER) OPERATION.................................................................................................. 35
SECTION 4.0MAINTENANCE ...................................................................................36
4.1CLEANING AND PAINTING YOUR STOVE ......................................................................... 36
4.2GLASS............................................................................................................................................ 36
4.3GASKETING................................................................................................................................. 36
4.4ASH REMOVAL USING THE ASH DRAWER....................................................................... 37
4.5CHIMNEY (FLUE) CLEANING................................................................................................ 38
SECTION 5.0SPECIFICATIONS................................................................................39
DROLET LIMITED LIFETIME WARRANTY............................................................40

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TIPS ON WOOD HEATING
Wood is a renewable energy. It is also a very clean heat source when used with appliances that are
certified by the U.S. Environmental Protection Agency (EPA), a standard accepted in Canada as well.
EPA-certified wood stoves are different than conventional wood stoves. Burning with an EPA-certified wood
stove may therefore require that you modify some of your heating habits. To get the most satisfaction out of
your new wood-heating system, please make sure you go through the following check list.
The chimney is the engine that drives the wood-heating system. Use a chimney that is UL-listed, with
an inner diameter to match the stove’s outlet collar (6” for all Drolet wood stoves);
Try to run the chimney inside the building for as much length as you can. A tall and warm
chimney will produce a good draft;
Try to install your chimney straight up and avoid 90 degree turns in the flue pipe and offsets in the
chimney;
Make sure that the chimney is tall enough and its top is clear of obstacles so it can produce a
stable draft;
Use a chimney thermometer installed at a distance of approximately 18 inches on the flue pipe
above the stove. Flue gases should reach at least 350oF before you close the stove’s primary air
intake completely. Operate your unit within the comfort zone indicated on the thermometer;
To reduce the risk of smoke spillage into the room upon reloading your stove, leave the primary
air intake completely open for a few minutes. This will heat up the chimney and build up draft
before you open the stove door;
Maximize hot air circulation! Our wood stoves are designed to easily receive a variable speed
blower that will improve heat distribution in front of the stove;
Remember that wood stoves produce radiant heat. Since heat rises, the use of floor traps will
greatly improve the heat transfer to rooms upstairs;
Use a mobile home approved stove if you are going to install your wood-heating system in a
mobile home. A fresh air kit must be connected to the stove. Never install your wood stove in a
bedroom;
Burn only dry cordwood;
Make sure you have a good bed of red coals before you load your stove with logs exceeding 3
inches in diameter;
Read and keep you owner’s manual. It will provide you with tips on how to run a successful
wood-heating system.

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SECTION 1.0 - INSTALLATION
When installed and operated as described in these instructions, the Sahara wood stove is suitable for use as a
freestanding wood stove in residential installations. The Sahara wood stove is not intended for installation in
a bedroom or a mobile home.
In Canada, the CSA B365 Installation Code for Solid Fuel Burning Appliances and Equipment and the CSA
C22.1 Canadian National Electrical Code are to be followed in the absence of local code requirements. In the
USA, the ANSI NFPA 70 National Electrical Code and NFPA 211 Standard for Chimneys, Fireplaces, Vents
and Solid Fuel-Burning Appliances are to be followed in the absence of local code requirements.
In addition to the national installation and/or local building codes, fire officials (or other authorities having
jurisdiction) should be contacted to determine what restrictions and installation requirements might apply
locally.
1.1 GENERAL INSTALLATION
CAUTION:
MIXINGOF APPLIANCE ORFLUE SYSTEMCOMPONENTS FROMDIFFERENT SOURCESOR MODIFYINGTHE DIMENSIONAL
SPECIFICATION OF COMPONENTS MAY RESULT IN HAZARDOUS CONDITIONS.WHERE SUCH ACTION IS CONSIDERED,
THE MANUFACTURER SHOULD BE CONSULTED IN THE FIRST INSTANCE.
DO NOT CONNECT THIS UNIT TO ANY AIR DISTRIBUTION SYSTEM.
CRACKED AND BROKEN COMPONENTS,e.g. GLASS PANELS OR CERAMIC TILES,MAY RENDER THIS INSTALLATION
UNSAFE.
ASOURCE OF FRESH AIR INTO THE ROOM OR SPACE HEATED SHALL BE PROVIDED WHEN REQUIRED.
CONNECT THE STOVE ONLY TO A LINED MASONRY CHIMNEY CONFORMING TO NATIONAL AND LOCAL BUILDING
CODES FOR USE WITH SOLID FUEL,OR TO A LISTED FACTORY BUILT CHIMNEY SUITABLE FOR USE WITH SOLID FUEL.
1.2 POSITIONING THE STOVE
It is very important to position the wood stove in an area that will favour the most efficient heat distribution
throughout the house. The stove should therefore be installed in the room where the most time is spent, and
in the most spacious room possible. Recall that wood stoves produce radiating heat, the heat we feel when we
are close to a wood stove. A wood stove also functions by convection, that is through the displacement of hot
air accelerated upwards and its replacement with cooler air at the floor level. The stove’s convection effect is
facilitated by the installation of a blower.

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1.3 CLEARANCES TO COMBUSTIBLES AND FLOOR PROTECTOR
To install your appliance correctly, it is extremely important to respect all clearances to any combustibles as
indicated on your stove’s certification label.
Clearances to combustible materials
(see figure 1.3 to match each letter to a clearance)
CLEARANCES (SINGLE WALL PIPE)
CANADA USA
A 16" (410 mm) 16" (410 mm)
B 15" (385 mm) 15" (385 mm)
C 9" (230 mm) 9" (230 mm)
D 19" (485 mm) 19" (485 mm)
E 26" (665 mm) 26" (665 mm)
F 20" (510 mm) 20" (510 mm)
K 48" (1220 mm) 48" (1220 mm)
L 84" (213 cm) 84" (213 cm)
CLEARANCES (DOUBLE WALL PIPE)
CANADA USA
A 10" (255 mm) 10" (255 mm)
B 15" (385 mm) 15" (385 mm)
C 9" (230 mm) 9" (230 mm)
D 13" (335 mm) 13" (335 mm)
E 26" (665 mm) 26" (665 mm)
F 20" (510 mm) 20" (510 mm)
K 48" (1220 mm) 48" (1220 mm)
L 84" (213 cm) 84" (213 cm)

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FIGURE 1.3 Clearances to combustible materials and floor protection

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Floor protector
If the stove is to be installed on top of a combustible floor, it must be guarded by a non combustible material
as shown on figure 1.3 (see the dotted line area).
FLOOR PROTECTOR*
CANADA USA
G 8’’ (205 mm) – Note 1 N/A (Canada only)
H 8’’ (205 mm) N/A (Canada only)
I 18’’ (460 mm)
From door opening 16’’ (410 mm) From door opening
J N/A (USA only) 8’’ (205 mm)
M 8’’ (205 mm) N/A (Canada only)
N N/A (USA only) Note 2
*Steel with a minimum thickness of 0.015’’ (0.38 mm) or ceramic tiles sealed together with grout. No
protection is required if the unit is installed on a non-combustible floor (ex: concrete).
Note 1 : The floor protection at the back of the stove is limited to the stove’s required clearance if such
clearance is smaller than 8 inches (205 mm).
Note 2 : Only required under the horizontal section of the connector. Must exceed each side of the
connector by at least 2 inches (51 mm).
Reduced clearances using shielding
You may decrease the clearances by installing heat radiation shields between the walls or the ceiling and the
stove. These heat radiation shields must be installed permanently, and can include sheet metal, a rigid non-
combustible sheet or a masonry wall.
Clearances of not less than 1" (25 mm) and not more than 3" (76 mm) between the bottom of the shield and
the floor and not less than 3" (76 mm) between the top ofthe shield and the ceiling must be respected to allow
vertical air circulation behind the shield. The shield must extend 20" (500 mm) above the stove top and 18"
(450mm) to each side of the stove (see graphic 1).
Following the installation of such a heat radiation shield, the clearances mentioned on the stove certification
plate may be reduced as stated in the following table.

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TYPE OF PROTECTION
Reducing Clearances With
Shielding
Sides and
Rear/Back Top
Sheet metal, a minimum of 0,024" (0,61mm) spaced out at
least 1" (25mm) by non-combustible spacers (see
graphic 2). 67% 50%
Ceramic tiles, or an equivalent non-combustible material on
fire-proof supports spaced out at least 1" (25 mm) by non-
combustible spacers (see graphic 3). 50% 33%
Ceramic tiles, or an equivalent non-combustible material on
fire-proof supports with a minimum of 0,024" (0,61 mm) sheet
metal backing spaced out at least 1" (25 mm) by non-
combustible spacers (see graphic 4)
67% 50%
Brick spaced out at least 1" (25 mm) by non-combustible
spacers (see graphic 5) 50% N/A
Brick with a minimum of 0,024" (0,61 mm) sheet metal
backing spaced out at least 1" (25 mm) by non-combustible
spacers (see graphic 6). 67% N/A

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Graphic 1
A- Minimum clearance required between the appliance and an unshielded combustible ceiling.
B- 20 in. (500 mm) minimum;
C- 1 in. (25 mm) minimum;
D- Between 1 in. and 3 in. (25 mm and 75 mm);
E- 3 in.(75 mm) minimum;
F- 18 in. (457 mm) minimum.
1- Shielding;
2- Non-combustible spacers;
3- Ceiling protector;
4- Combustible wall;
5- Ceiling;
6- Appliance (side view);
7- Appliance (top view).

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Graphic 2
A- 1 in.(25 mm) minimum;
1- Combustible wall;
2- Non-combustible spacers;
3- 0.024’’ (0.61mm) sheet metal.
Graphic 3
A- 1 in. (25 mm) minimum;
1- Combustible wall;
2- Non-combustible spacers;
3- Non-combustible support;
4- Ceramic tile or non-combustible material.
Graphic 4
A- 1 in. (25 mm) minimum;
1- Combustible wall;
2- Non-combustible spacer;
3- 0.024’’ (0.61 mm) thick sheet metal;
4- Non-combustible support;
5- Ceramic tile or non-combustible material.

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Graphic 5
A- 1 in. (25 mm) minimum;
1- Combustible wall;
2- Non-combustible spacers;
3- Brick.
Graphique 6
A- 1 in. (25 mm) minimum;
1- Combustible wall;
2- Non-combustible spacers;
3- 0.024’’ (0.61 mm) thick sheet metal;
4- Brick.

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SECTION 2.0 CHIMNEY (FLUE SYSTEM)
2.1 DEFINITIONS
For clarity, the following definitions should be used with respect to these instructions:
A chimney system consists of a connector off the top of the stove, and a chimney, which attaches to
the connector and terminates outside the house.
A chimney can be a masonry chimney (of masonry construction with an inside liner), or a factory
built chimney.
A factory built chimney can be a double walled chimney (two concentric pipes with insulation -
sometimes referred to as an insulated solid pack) or an air cooled chimney (three concentric pipes,
with insulation between the first and second pipes, and air between the second and third pipes).
A single walled connector is a single pipe.
A double walled connector has two concentric pipes, no insulation, and is an air cooled connector.
2.2 CHIMNEY
CAUTION:
DO NOT fill any framed space around the factory-built chimney with insulation or any other material.
Insulation placed in this area could cause adjacent combustibles to overheat.
Do not use makeshift compromises during installation as they may be safety hazards, and a fire could
result.
Do not connect this unit to a chimney system serving another appliance.
Do not cut rafters or ceiling joists without first consulting a building official to ensure structural
integrity is not compromised.
Your wood stove may be hooked up with a factory built or masonry chimney. If you are using a factory built
chimney, it must comply with UL103 (USA) or ULCS629 (Canada) standards. It must therefore be a 6”
(152mm) HT Type (2100°F) chimney. It is extremely important that it be installed according to the
manufacturer's specifications. The manufacturers’ installation instructions and specified clearances should
always be followed in accordance with local and national installation codes. In Canada the CSA B365 and the
CSA C22.1 installation codes are to be followed. In the USA the ANSI NFPA 70 and ANSI NFPA 211
installation codes are to be followed.

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If you are using a masonry chimney, it is important that it be built in compliance with the specifications of the
Building Code. It must be lined with fire clay bricks, or clay tiles, sealed together with fire cement, or have a
listed solid fuel burning stainless steel liner. Round chimneys are the most efficient.
The interior diameter of the chimney should be identical to the stove's smoke exhaust. A chimney which is
too small may cause draft problems, since it may not have the required volume to properly evacuate the
quantity of smoke resulting from the combustion. A chimney whish is too large may also cause draft
problems. In fact, a large chimney will be harder towarm-up and may not reach high enough temperaturesto
create a proper draft effect. Note that it is the chimney which creates the draft effect, not your stove.
Your stove's performance is therefore directly dependent on an adequate draft from your chimney.
The following recommendations may be useful for the installation of your chimney:
Do not connect your stove to a chimney serving another appliance.
The chimney must rise above the roof at least 3' (0.9 mm) from the uppermost point of contact. See
Figure 2.2.
The chimney must exceed any part of the building orother obstruction within a 10' (3.04 m) distance
by a height of at least 2' (0.6 m). See Figure 2.2.
The minimum overall height of the chimney system, measured from the stove top to the exterior
termination cap of the chimney should be at least 12'(3.66m). A chimney which is too short may lack
the “tunnel effect” required to obtain a proper draft.
Installation of an interior chimney is always preferable to an exterior chimney. Chimneys constructed
outside of the home on an exterior wall should be avoided if possible, especially in colder climates.
The gas which circulates into an interior chimney will cool more slowly, thus reducing the build-up
of creosote and the risk of flue fires.
All else being equal, cooler chimneys will have less draft than hotter ones. This problem will be
amplified if the chimney is excessively long. A chimney which is excessively long may be very hard
to warm-up due to its higher volume. A cool chimney may even down draft (reverse flow) due to the
difficulty in heating it up to operating temperature while trying to evacuate the stack gases.
If an exterior chimney is used, the best results will be obtained by using a connector vertically off the
unit to the highest possible point before elbowing off horizontally to the exterior chimney. For
efficiency and safety reasons the stove must not be installed with an insulated chimney connected
directly to the appliance.
Using a fire screen at the extremity of the chimney requires regular inspection in order to insure that it
is not obstructed, thus blocking the draft. It should be cleaned when necessary.

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FIGURE 2.2 Minimum Height of the Chimney
2.2.1 Step by step installation of your factory-built chimney
Thewaytoinstallyourchimneymayvaryfromonechimneymanufacturertoanother.Theinstructions
contained in this manual are based on the recommendations of chimney manufacturers whose
products are sold at many North American retailers of wood stoves and related heating accessories.
Wall support system
If your chimney must rise along an outside wall, you need to connect it to your stove through an
adjacent wall. For this type of installation, the following items are normally required :
Chimney
Suitable lengths of chimney (enough to go up to your roof)
An adjustable wall support
A wall thimble
Anadequatenumber ofwallbands(oneforevery8feetofchimney,excludingtheroofportion)
A stove pipe adapter
One insulated tee & plug
A roof flashing kit (if necessary)
A chimney cap.
Roof guys (if required)
Stove pipe
An adequate number of stove pipe sections.
A 90o elbow
Typical installation through the wall

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FIGURE 2.2.1 (A) Typical installation through the wall
1- Start by positioning your stove where you would like it to go, taking into account the minimum
clearancesto combustiblematerial. You will thenbeableto determinewherethechimneywill
pass through the wall. You will probably have to adjust the stove position slightly to ensure
that your chimney will run between the studs. You can use a stud finder to locate the studs.
Use a spoke saw or jig saw to cut a hole, remembering that you need to maintain a clearance
of 2 inches between the chimney and any combustible materials. For concrete walls, cut a
hole slightly larger than the outer diameter of the chimney.

17
2- Once the opening completed, you need to frame in the area to allow for the installation of a
wall thimble. A wall thimble is not required for installations through concrete walls.
3- You must first secure the wall thimble into the exterior wall surface. Then, do the same inside
and fasten the trim plate.
4- Then,from outside the building, slide ashortchimney length (attachedtothetee) through the
wallthimble.The chimney must extendatleast 3 inchesintothe living spacewhereitattaches
to the stove pipe.

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5- You can now install the wall support. Simply slide the wall support up to the tee, ensuring that
the adapter on the support engages with the female coupler on the bottom of the tee. When
the wall support is level and properly positioned,youcanuse lag boltsto secure it intothewall
studs. TO complete the installation, install an insulated tee plug below the wall support.
6- You can start to add chimney sections. We recommend that you also use locking bands to
secure all connections. You will need to secure the chimney to the house using wall bands.
Wall bands wrap around the chimney and then attach to the wall. Install the first one 3 feet
abovethewall support. Then, you willneedanother bandforeach8feetofchimney. Note: if
your chimney must be installed through your soffit, install a roof flashing above and
finishing plate below where the roof is cut. Consult the following section called
“CEILING SUPPORT SYSTEM” for more details.
7- Authorities require that the chimney extend not less than 3 feet above thehighest point where
it passes through the roof of a building and not less than 2 feet above any portion of the
buildingwithin10 feet. If the chimneyextendsmore than 5 feetabovethe roofdeck,roofguys
with telescoping legs and draw bands are required.

19
8- Finally, twist on your rain cap and you can head back inside.
9- You are now ready to connect your chimney to your stove. Simply install the inter-connecting
stovepipebetween thestovepipeadapter and the stove. You can follow the instructions in the
following section (section 2.3) of this manual called « CHIMNEY CONNECTOR».
Ceiling support system
If your chimney must rise inside the house and go through the ceiling, you need to connect it to
your stove at the ceiling level. For this type of installation, the following items are normally
required :
Chimney
An adequate number of chimney sections (enough to go up to your roof)
A ceiling support kit with stove pipe adapter
An attic insulation shield
A roof flashing kit
A chimney cap
Roof guys (if necessary)
Stove pipe
Suitable lengths of stove pipe

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Typical installation through the ceiling
FIGURE 2.2.1 (B) Typical Installation Through the Ceiling
1- Place your stove where you would like it located and use a plumb line to mark the ceiling
directly above your stove flue. You will probably have to adjust this position slightly to ensure
that your chimneywill run between the joists.Youcanuseastudfindertolocatethejoists.You
also need to take into account the minimum clearances to combustible materials. After you
have determined where the chimney will go through the ceiling, use a spoke saw or power jig
saw to cut a hole, remembering that you need a minimum 2-inch clearance between the
chimney and any combustible materials. Depending on whether you have a one or two story
structure, you will need to cut a matching hole through the floor of the attic or second floor
living space.