FireplaceXtrordinair 44A-BI User manual

Page 1
TABLE OF CONTENTS Page
IMPORTANT INFORMATION
FEATURES AND SPECIFICATIONS..........................................................................................2
Installation Choices..................................................................................................................2
LIGHTWEIGHT BLOCK-IN INSTALLATION
PREPARATION FOR INSTALLATION - LIGHTWEIGHT BLOCK-IN .....................................3
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS .......................................................................4
Fireplace Placement ................................................................................................................5
Chase Framed Wall..................................................................................................................9
Facing .........................................................................................................................................11
Block-In.......................................................................................................................................13
Blower.........................................................................................................................................14
Hearth .........................................................................................................................................16
Factory-Built Chimney..............................................................................................................17
LIGHTWEIGHT BLOCK-IN INSTALLATION...............................................................................24
Chase Framed Wall Installation.............................................................................................24
Factory-Built Chimney Installation.........................................................................................24
Block-In Installation ..................................................................................................................24
Facing Installation.....................................................................................................................33
SOLID MASONRY INSTALLATION
PREPARATION FOR INSTALLATION - MASONRY .................................................................34
MASONRY INSTALLATION - SPECIFICATIONS.....................................................................35
MASONRY INSTALLATION..........................................................................................................38
ADDITIONAL INFORMATION
DETAILING THE FIREPLACE.......................................................................................................44
Acid Wash And The Fireplace Xtrordinair............................................................................44
Faceplate and Door Installation.............................................................................................45
Door Latch Adjustment ............................................................................................................47
Baffle Installation.......................................................................................................................48
INSTALLING A NATURAL GAS LINE.........................................................................................49
SAFETY LABEL ..............................................................................................................................50

Page 2
FEATURES AND SPECIFICATIONS
Installation Choices
¥ LIGHTWEIGHT BLOCK-IN: The lightweight block-in installation utilizes a masonry
enclosure around the Fireplace Xtrordinair yet still allows the use of a metal chimney.
This type of installation can be used in the place of a zero clearance fireplace, giving a
home a heat producing masonry fireplace without the cost of a masonry chimney.
¥ MASONRY INSTALLATION: A full masonry installation gives the look of a masonry
fireplace both inside and outside the home. This gives a home the distinction of quality.
¥ EPA Phase II approved.
¥ Heavy duty steel construction.
¥ Large firebox capacity - 4.3 cu. ft.
¥ Long burn time - 12 Hours.
¥ Large glass doors for maximum
visibility.
¥ Firebrick lining for firebox
protection.
¥ 388 CFM blower for convection
heat and outside combustion air.
¥ Thermostat for automatic control of
the blower.
¥ Gas line sleeve through the left
side of the firebox for easy
installation of gas log lighter or
gas log set.
¥ 8' leads for the power source and
the blower. (110 Volts A.C.)
¥ Set-up face that is on fireplace
during installation to prevent
damage to the decorative face
plate. It is also slightly larger
than the decorative face plate to
provide for heat expansion.
¥ 3 blower duct locations for a wide
selection of blower installation
options.
Heating Capacity ............................................................................up to 3000 sq. ft. maximum
Overall Efficiency ............................................................................77 % (DEQ Method)
Emissions grams/hr........................................................................2.3 (EPA Method)
Maximum Burning Time.................................................................12 Hours
Flue Opening Diameter ................................................................8 in.
Overall Width (Not Including Faceplate).....................................39 in.
Overall Depth...................................................................................23 in.
Fuel....................................................................................................Solid Wood or Natural Gas
BTU Output/hr..................................................................................10,700 to 75,700
Emissions, Efficiency, Heating Capacity and Burn Times may vary depending
on actual home floor plan, type of fuel used, and moisture content. Emissions
and efficiency numbers are those that have been certified by the U.S. E.P.A.
and the Oregon Department of Environmental Quality.

Page 3
PREPARATION FOR INSTALLATION - LIGHTWEIGHT
BLOCK-IN
READ THIS ENTIRE MANUAL BEFORE INSTALLING THE NEW FIREPLACE. FAILURE TO
FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR
EVEN DEATH.
PACKING LIST:
Your Fireplace Xtrordinair 44A-BI is packaged with the following items included:
¥ 44A-BI Fireplace
¥ Side Firebrick
¥ Grate
¥ Blower Assembly
¥ Flex Duct Ð 3' Length, 6" Diameter (For Blower System)
¥ Start Collar (For Blower System)
¥ Fiberglass (For Expansion Buffer)
¥ Vent Hood (For Chase Ventilation and Cooling)
¥ Vent Hood Storm Collar (For Chase Vent Hood Listed Above)
PREPARATION:
1. Remove all tape and packaging.
2. Remove the wood shipping frame from around and under the fireplace.
3. Check that no parts have become loose and the fireplace has not been damaged during
shipping.
4. Remove the hardware pack from the fireplace.
5. READ THIS INSTALLATION MANUAL BEFORE PROCEEDING.
¥ Fireplace should be located such that no doors, drapes, furniture or other
combustibles can be placed close or swing closer than the minimum 36"
clearance.
¥ The fireplace must be installed in a level, secure position.
REQUIRED HEARTH:
The hearth must have a minimum size of 60" width by 18" depth of non-combustible material.
Certain other restrictions and exceptions apply. See the hearth section in the specifications
portion of the lightweight block-in installation instructions.
Chimney Height Maximum Minimum
Vertical 35 Feet 15 Feet
Before lifting the fireplace, consider removing some of the interior components to make it
lighter. Refer to the section "REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS" in
the owner's manual for the proper sequence of removal and replacement of internal
components.

Page 4
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS
READ THIS ENTIRE MANUAL THROUGH BEFORE STARTING TO INSTALL A
LIGHTWEIGHT BLOCK-IN FIREPLACE. THERE ARE CERTAIN SPECIFICATIONS AND
MEASUREMENTS THAT MUST BE MET TO INSURE A PROPER INSTALLATION. FAILURE
TO FOLLOW THESE SPECIFICATIONS MAY PRESENT A FIRE HAZARD.
IMPORTANT NOTE:
The specifications listed in this section are addressed in separate sections detailing each
portion of construction of a lightweight block-in fireplace (i.e. "Hearth", "Chase Framed Wall",
etc...). It is very important to detail the building plans before starting to build. Certain portions
of construction, for example the facing, can affect other portions. Read through the entire list
of specifications before beginning to detail the building plans. Failure to totally understand
this type of construction may result in construction that will have to be torn down and re-built.
Travis Industries, Inc. recommends that the installer first read through the specifications and
installation instructions thoroughly. Then make a detailed floorplan that includes all
measurements of each portion of construction. After completing the detailed floorplan, go
through the detailed measurements and make sure they follow the items listed in the
specifications listed in this section.
Each portion of construction is listed in its own section that lists its specifications. Below is a
chart detailing each portion of construction along with a description that will help give a
complete picture of constructing a lightweight block-in fireplace.
PORTION OF
CONSTRUCTION
DESCRIPTION
Fireplace Placement Outlines minimum clearances that the fireplace must have
and how to select an ideal location
Chase Framed Wall Outlines minimum clearances the wall around the
fireplace must have and the mandatory chase vent
Facing Details the types of facing that can be used and how it
affects the other portions of construction
Block-In Details the specifications that must be met when
constructing the concrete blocks that surround the
fireplace
Blower Addresses the various options for installation of the
fireplace blower
Hearth Outlines the minimum clearances and other
considerations that must be met when making the hearth
Factory-Built Chimney Outlines the types of factory-built chimneys that can be
used and the use of offsets to insure proper minimum
clearance
--- SEE THE FOLLOWING PAGE FOR AN ILLUSTRATION ---

Page 5
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Each of the following items listed in this illustration have important specifications that must be
followed.
Block-In
Blower
Hearth
Factory-Built
Chimney with
Chimney Adapter
Block-In
Block-In
Facing
Chase
Fr a m ing
Fireplace
Placement
Chase
Fr a m ing
Fireplace Placement
To determine the most efficient location for the fireplace, consider such factors as room traffic,
location of doors and windows, and construction above and below the installation area. A
location that requires cutting the least number of joists or roof rafters will make the installation
easier and reduce the cost. This may mean moving only one or two inches from the selected
ideal location.

Page 6
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Fireplace Placement (Continued)
Floor Load:
The fireplace and the masonry (4x8x16 Nominal Size Blocks, Actual Size 3 1/2"x7 1/2"x15
1/2", 60 ea.) weigh approximately 1200 lbs. which is the equivalent to a 130 lbs. per square
foot floor load. Heavy facing such as brick or stone may require additional support (consult
local building codes). Make sure the floor will handle this weight.
The fireplace is shipped with a lifting handle attached to each side. These handles should be
used to lift the fireplace into its final position and then removed with a 3/8" wrench.
Dimensions:
25"
12 1/2"
7"
11"
39"
7"
12 1/2"
8" ID Collar
44"
24"
Arched set-up face
31
1/2"
8"
23"
32"
3 1/2"
Blower Duct
Knockout
5"
Power Lead
Blower Lead
12"
Top square set-up face extension
Loosen these screws on each side to
remove the square set-up face extensions.

Page 7
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Fireplace Placement (Continued)
Determining the exact placement of the fireplace is crucial for construction and safety
purposes. Such factors as facing material depth, masonry enclosure size, and chimney
location all factor in to the final location of the fireplace. The illustration below and on the
following page outlines the considerations that must be followed for proper fireplace
placement. The fireplace faceplate must be a minimum of 29 1/2" in front of any chase
framed wall. The fireplace body must have a 1" airspace between it and the masonry
enclosure on both sides and the back (to be filled with insulation as an expansion buffer).
The masonry enclosure must be made with lightweight concrete block (75% pumice) with the
nominal dimensions of 4 by 8 by 16 (actual size is 3 1/2" thick by 7 1/2" tall by 15 1/2" wide).
There must be a minimum thickness of 3 1/2" on the side and back and 7 1/2" on the top of
the fireplace. The bottom of the enclosure requires 11" of masonry constructed as illustrated
in the following instructions.
24"
Typical
2" Min.
3 1/2" Min.
29 1/2" Min. 26" Best
18" Min.
With brick facings offsets are
needed to obtain minimum 4 1/2"
horizontal clearance to header.
CHASE FRAMED WALL
MASONRY BLOCK-IN
FIREPLACE XTRORDINAIR
Adjacent Sidewall
1" Min.
Required 6" Cooling Vent (Optional Location)
3 1/2"
1" fiberglass insulation for expansion
buffer on both sides, top, and back
Blocked-in
Blower Box
(Optional
Placement)
When determining the placement of the fireplace it is also important to calculate the minimum
clearance to combustibles. Minimum clearance to combustibles measured from the faceplate
of the Fireplace Xtrordinair should meet or exceed:
¥ 18" to adjacent sidewall
¥ 4 1/2" on sides to combustible facing
¥ 26" on top to combustible facing
¥ Raised hearth extension must extend 16" in front and 8" to each side.

Page 8
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Fireplace Placement (Continued)
Corner Placement
If installing the fireplace into a corner, follow all of the specifications listed in this manual
along with the additional specifications listed in the illustration below. These minimum
clearances are:
¥ 22" from edge of faceplate to sidewall
¥ 20 1/2" from sidewall to center of chimney pipe
¥ 45" from front of faceplate to corner
¥ 63" from wall touching faceplate to corner
ADDITIONAL SPECIFICATIONS FOR CORNER PLACEMENT
63" Min.
2" Min.
45"
22" Min. Edge of Faceplate
Clearance From
Masonry Block
to Wall
20 1/2"
Required 6" Cooling Vent
(Optional Location)
Masonry
Masonry
(Block)
(Block)
Block-In Drying Time
The block-in must dry for one month before using the fireplace. This will prevent the block-in
from cracking due to the heat generated from the fireplace.
Special Precautions
In some states the block-in may require special construction to meet earthquake
requirements. This may include having to mortar the block-in to expanded metal and/or a
tied down block-in construction. Check with your local building department for requirements
in your area.

Page 9
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Chase Framed Wall
The next consideration is the framing that may surround the fireplace. The opening must be
framed to the dimensions shown in the illustration below for the size of the fireplace being
installed. Fireplace Xtrordinair suggests that the shaded framing in the illustration below be
framed in after the fireplace is installed to make the chimney installation easier. If this framing
must be installed prior to the fireplace installation be sure to account for the hearth height (if
greater than 11") before determining the header height. It must be a minimum of 17 1/2"
above the masonry enclosure. Consider installing the fireplace and masonry in the desired
location and then constructing the framing around it to the proper clearances. This method
would be preferred by the installer constructing the masonry.
It is suggested that this portion is
framed after masonry is completed.
Must be above the
mantle and a
minimum of 17 1/2"
above the masonry
block-in.
53" Min., 56" Suggested
68 1/2"
Min.
To determine the depth of the chase, certain details such as facing depth and type of
masonry enclosure need to be determined before a depth can be calculated. The ideal
chase depth for a tile face is 28 1/2". For a brick face it is 26 1/2". When determining the
depth, make sure to adhere to all of the minimum clearances outlined in this manual. Make
sure to carefully check all of the specifications and make a detailed sketch outlining all the
distances for this construction before beginning. If the chase does not work out to be the
desired depth based on the facing material, additional framing may be added to the front of
the existing framing to shim the facing to the needed location.

Page 10
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Chase Framed Wall -- Chase Venting
Block
Enclosure
Chase Wall
Cooling Air Vent
24" Maximum
(Measured From
Center of Vent)
The chase must be vented with a minimum 28 square inch of cross sectional opening duct (6"
diameter round vent is sufficient). Failure to vent the system will create a fire
hazard. This vent helps circulate air into the air space between the chase walls and the
masonry enclosure and provides cooling air for the double-wall chimney. The vent must
terminate within 24" of the chase floor (see illustration above). The maximum length for 6"
diameter round duct is 12' and 25' for 8" duct. The duct can go to an attic or crawl space
providing they are vented. Some building codes may require that the ducts continue through
the attic or crawl space to an outside wall.
Check with the local building department if venting anyplace other than outdoors. This
includes the attic, crawl space, or garage. This type of venting may require a special type of
venting duct such as a venting duct with a fire curtain.
This vent should be installed before starting the block-in procedure to allow for the space
needed to measure and cut the hole for the duct.

Page 11
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Facing
TOP VIEW
Fiberglass Insulation
Expansion Buffer
Fireplace
Face
Plate
1/2" Sheetrock
1/2" Cement
Fiberboard Must Be
Sealed To Block
Tile Or Marble Facing 4 1/2" Minimum (Flush Fit
Allowed With 1/2"
Non-Combustible Facing)
Bl ock F ir epl ac e
Fr ami ng
2" Minimum
3 1/2" Minimum
1"
Constructing a facing can add extra beauty to the fireplace. It must be made of a non-
combustible material such as stone, brick, marble or tile. For thin facing such as marble or
tile 1/2" cement fiber board (see illustration above) must be used as a backing to attach the
facing material. The facing used to finish off the fireplace needs to be determined before the
installation begins because it determines the size of other construction. The facing depth
determines where the block and the framing will end up in relation to the face plate of the
fireplace. When calculating the facing depth, take into consideration any masonry that will be
included. If using tile with cement fiberboard attached to the back, make sure to include the
depth of the fiberboard. If using a brick facing, include the size of any mortar joint that will be
used. It is very important to determine whether the facing will be an inside fit or flush fit (See
the illustration below). A flush fit has the faceplate overlap the facing material while the
inside fit has the faceplate butt up against the facing. After determining the style of facing,
make sure to carefully calculate the appropriate distances needed for the other portion of
construction (i.e. block-in, fireplace placement). The facing must also extend a minimum of 4
1/2" from the edge of the faceplate. The illustration above displays the use of tile and 1/2"
cement fiberboard with a flush fit.
NOTE: The set-up face is identical to the finished face except that it is 1/4" larger on each
dimension. Use it as a guide while installing the facing. Do not install facing material over
the front of the set-up face. Doing so will prevent the installation of the finished faceplate.
TOP VIEW
INSIDE FIT FLUSH FIT
Fi rep la ce
Non-Combustible
Facing Material
Faceplate
Fi rep la ce
Faceplate
Non-Combustible
Facing Material

Page 12
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Facing (Continued)
Square or Arched Faceplate
The set-up face shipped with the fireplace is for a square faceplate. To use the arched set-up
face, the top and two side pieces of the square set-up face will need to be removed. Loosen
the six set-up face screws and pull the three pieces from behind the arched set-up face, then
re-tighten the set-up face screws (see the illustration below).
Arched set-up face
Loosen these screws on each
side to remove the square
set-up face extensions.
Top square set-up face extension
Side square
set-up face
extension
Slide the square
set-up face
extensions from
behind the arched
set-up face.

Page 13
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Block-In
The Fireplace Xtrordinair requires a masonry block-in to surround the fireplace and act as a
thermal barrier. It must be made of lightweight concrete blocks.. It must be a minimum of 3
1/2" thick on all sides and extend over the top of the fireplace with a minimum of 7 1/2" of
masonry. It must have a 1" clearance around the fireplace. Insulation is to be placed in this
space wherever there is a possibility that mortar or masonry could come in contact with the
fireplace. Contact of the fireplace to the masonry could cause the masonry to crack when the
fireplace expands with heat. The block-in must not have a clearance over 1" between the top
of the fireplace and the top masonry enclosing it. The top of the block-in must be at least 7
1/2" thick. Underneath the block-in there must be a 36" by 52" piece of 26 gauge galvanized
tin vapor barrier and mesh screen for holding the blocks in place. The block-in must be a
minimum of 48" wide and have a depth of 27 1/2" including the depth of the facing. The
block-in must be at least two inches away from the back and side walls of the chase. See the
illustration below.
Header
17 1/2"
Min.
Mantle (Optional) - Must Be
Non-Combustible
Header must be at least
4" above mantle
11"
Min.
7 1/2"
Min.
2" Min.
4 1/2" Min.
1" Max.
Second to last course
of blocks
Last course of blocks
Diagonal
Block
Chimney Adapter

Page 14
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Blower
The blower system on the Fireplace Xtrordinair is located away from the fireplace on an
outside wall. It draws air in from outside, circulating it around the fireplace, and delivering it
as heated air to the home. This type of blower system will create a positive pressure inside
the home, reducing cold air infiltration.
Connecting the Blower Duct:
After a location for the fireplace has been determined, the location for the blower housing
must be considered. The best location for the blower housing is on an outside wall as close
as possible to the fireplace so the 6" blower duct can be easily connected. The maximum
length for 6" diameter duct is 15'. If a blower duct run of more than 15' is desired, 8" diameter
duct can be used. It can have a maximum distance of 25'. If 8" duct is used there will need to
be two 8" to 6" reducers to make the connections to the fireplace and the blower housing. Do
not put more than two elbows in the system (regardless of whether 6" or 8" diameter duct is
used).
NOTE: If the blower is to take air from a crawlspace or attic you must first check with your
local building inspections department to confirm that this type of installation is
permitted. In some areas this type of installation may require a special type of duct
termination like one with a fire curtain.
Blower Housing
Intake grill
must be
accessible.
Snap conduit
connector into the
hole in the top of
the blower housing.
Wire Plugs
Start Collar
Flex Duct
6"
Knockout
Power Source (110 Volt A.C.)
Locking Tabs
Stove
13"
11 1/2"
6"
11"
1 1/2"
TOP
VIEW
Ring for duct
Hole for
Conduit
FRAMING DIMENSIONS: Height: 13"
Width: 11"
Depth: 11 1/2"

Page 15
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Blower (Continued)
Connecting the Blower Duct (Continued):
Provided with the fireplace is a start collar with a section of 6" flex duct that can be used as
the blower duct. The flex duct connects to the blower housing and the start collar connects to
one of the three blower duct hook-ups on the fireplace (right side, left side, and bottom). To
connect the blower duct to either of the side hook-ups, remove the knock-out on the side
being used, insert the start collar, and bend the locking tabs on the start collar outwards to
hold it in place. If the bottom hook-up is chosen, a hole needs to be cut through the floor for
the duct to pass through.
Routing the Conduit:
During assembly match the plug on the end of the wires coming from the conduit with the
plug coming from the top of the blower housing (See Drawing on Previous Page). Snap the
conduit connector into the hole on top of the blower housing. A metal junction box is required
between the conduit providing power to the fireplace and the 110 Volt A.C. power source. If
the blower is located to the left, or if the power supply is located to the left, the electrical
conduit(s) can be run behind the fireplace. If the conduit is run behind the fireplace, the
framing or chase construction may need to be notched or modified to allow for the extra
space needed to run the conduit behind the fireplace. CAUTION: DO NOT RUN THE
CONDUIT OVER THE TOP OF THE FIREPLACE.
Snap this piece
into the top of the
blower housing
White (Common)
Junction
Box
Exposed (Ground) Black (Hot)
Screw this piece into the junction box Use wire nuts or other approved method to connect
the power conduit wires to a power source
Power Conduit
Blower Conduit
Weatherproofing the Blower:
The blower should be weatherproofed if it
is located on an external wall. To
weatherproof the blower, apply caulk
around the perimeter of the blower housing
where it contacts the external wall. The
blower cover must be removed prior to
applying the caulk. Because the blower
cover will overlap the caulk, apply the caulk
sparingly. See the illustration to the right.
Blower
Housing
External Wall
Caulk (Around
All Four Sides)
Blower Cover
Top
V i e w

Page 16
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Hearth
MINIMUM HEARTH EXTENSION
18" Min.
(Check Local
Building Codes)
Fireplace
1/2" Cement fiberboard or equivalent
non-combustible material
Tile or marble
11" Min.
If the block-in is constructed on a combustible floor, a hearth extension is required to protect
the floor in front of the fireplace. The hearth extension must have a layer of 1/2" thick cement
fiberboard or equivalent non-combustible material (minimum). It must be 18" deep
(measured from front of faceplate), and 60" wide. Hearth extensions that are 6" and higher
can be 16" deep if local building codes permit (See illustration below). Raised platforms
for hearths must be constructed with non-combustible materials. No hearth shall
rise above the bottom of the faceplate. Otherwise the faceplate would not be able to be
installed. If the hearth is over 6" tall, it must have a hollow cavity to allow better heat
dissipation and prevent the floor below it from becoming too hot (See illustration below). All
hearth construction must be non-combustible.
Fireplace Bottom
Fireplace
Xtrordinair
Hearth Brick Support
(Nominal Block Size of
4x8x16 - Actual Size of
3 1/2" x 7 1/2" x 15 1/2"
Block - 7 each)
16" Min. (Check Local Building Codes)
Leave Air Space
Open Under Bricks
Block Supports
6" or greater

Page 17
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Factory-Built Chimney
The lightweight block-in installation is designed to be used with a factory-built double-wall
chimney. Use only the brands of chimney listed in this section. It is very important to follow
the clearance specifications listed in this section. The chimney can be installed at any point
after the fireplace position is precisely determined. It is easier to install the chimney in the
chase prior to setting the fireplace in position. It can be held up out of the way with a 2 x 4
nailed across the chase.
Chimney Adapter:
The block-in installation requires the use of the Travis Industries chimney adapter built
specifically for the Fireplace Xtrordinair. This chimney adapter accommodates the chimney
brands listed in this section. Follow the directions below for attaching the chimney adapter.
To attach the chimney adapter to the fireplace, center the adapter over the fireplace and push
it into the flue opening on top of the Fireplace Xtrordinair until it is fully seated. The adapter is
designed to accommodate the different chimney brands with the use of a stepped outer liner
connector and an inner liner that has a ledge along the inside. When attaching the chimney
pipe to the adapter, first insert the inner liner of the chimney pipe into the inner liner of the
chimney adapter. Certain brands of chimney pipe will stop at the ledge, while others will
insert beyond the ledge. When the chimney pipe is fully seated and aligned, drill three holes
in the chimney pipe where it lines up with the holes in the chimney adapter. Secure the
chimney adapter to the chimney pipe with three sheet metal screws. If there are any large
gaps between the chimney pipe and chimney adapter, use furnace cement to seal (allow 24
hours to dry before burning the fireplace). The outer liner of the chimney pipe attaches to the
outer liner connectors on either the upper or lower step. Drill four holes into the outer liner of
the chimney pipe where it lines up with the holes in the outer liner connectors. Secure with
four sheet metal screws.
NOTE: When the chimney system is fully installed, air should be allowed to
pass into the space between the inner and outer liners on the chimney
adapter. This space allows proper ventilation for the fireplace and
chimney system. Failure to allow air into this space presents a fire
hazard.
Inner Liner (Ledge Along
Inside Accepts Different
Sized Chimney Pipes)
Outer Liner Connector
(Stepped Construction
Allows Different Sized
Chimney Pipes)
Connect Inner Liner to the
Chimney Pipe with Three
Sheet Metal Screws in the
Holes Provided
Use Four Sheet Metal
Screws to Attach the
Outer Liner Connector to
the Chimney Pipe.
Use the Upper or Lower
Hole Depending on the
Chimney Pipe Diameter
The Crimped End is
Inserted Into the
Flue Opening of the
Fireplace Xtrordinair

Page 18
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Factory-Built Chimney (Continued)
Chimney Height
The system height,
measured from the
floor the fireplace
sets on to the top of
the chimney cap,
must not exceed 35'
or be below 15'.
(See the illustration
to the right). Chimney must be totally
enclosed when passing
through living space with a
minimum 2" clearance to
combustibles.
3' Min.
2' Min.
10'
System Height
35' Max.
15' Min.
2" Min. Air
Space to
Combustibles
Rain Cap
Storm Collar
Flashing
Roof Framing (See Roof Opening Table)
Firestop Between Floor Levels
Attic Firestop
Chimney Adapter

Page 19
LIGHTWEIGHT BLOCK-IN - SPECIFICATIONS (Cont.)
Factory-Built Chimney (Continued)
Using Offsets
Offsets can be used to align the
chimney and to gain clearance
to combustibles. When using
offsets, make sure to follow all of
the specifications below.
A system can have no more
than a total of 2 offsets (Four 30
degree elbows). Each offset
elbow must be used with a
return elbow. A system using
one offset is allowed to have a
maximum of 8' of inclined
chimney between the elbows.
For every 6' of inclined chimney
a flue support is needed (See
parts list). For systems
incorporating two offsets there is
a maximum of 4' allowed
between each set of offsets
(See the illustration to the right).
Max. of 30
degrees
4' Max.
Chimney must be totally
enclosed when passing
through living space with a
minimum 2" clearance to
combustibles.
Firestop
Firestop
2"
Min.
Chimney Adapter