Isokern FIRE-LITE series User manual

Isokern® Fireplace
FIRE-LITE SERIES
Installation, Operation, Maintenance and Owner’s Manual
Standard Models 36, 42 & 46 - Magnum Models 28,36,42 & 48
A PRODUCT OF EARTHCORE INDUSTRIES, LLC.
THIS FIREPLACE IS DESIGNED for USE with
SOLID WOOD LOGS, PLUMBED PROPANE
(LP) or NATURAL GAS (NG), ONLY
WARNING: If the information in this manual is not followed exactly, a re or explosion may
result causing property damage, personal injury or loss of life.
SBCCI NO. 9626 NYC-MEA 241-90-E
ICC Report NO. ESR-2316 LA RR NO. 25483
IBC 2006, IRC 2006, IMC 2006 Issued: April, 2011
Revision: 001
INTERTEK TESTING SERVICES REPORT NO. 3159656MID-008
© 2007 Earthcore Industries, L.L.C.
THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY
Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance in-
structions for the Fire-Lite application replace with the FTF-13 Chimney System. This manual must be-
come the property of and be reviewed by all current and future users of this product. It is the responsibility
of the general contractor and the installer of this product to ensure that the instructions in this manual are
followed exactly and, further that any allowed gas log appliance used in this product be installed in strict
accordance with NFPA 58, NFPA 54/ANSI Z223.1 and the gas log manufacturer’s explicit installation, siz-
ing and operation instructions. It is the responsibility of the general contractor to provide adequate clear-
ances from all rebox surfaces as specied in this manual.
INSTALLER: Leave this manual with the appliance
CONSUMER: Retain this manual for future reference
Be Sure to Read Entire Manual Before Beginning Construction.
Contents of this manual may change without prior notication.

TABLE OF CONTENTS
General Information .......................................................................................................................................
Intended Use Statement ......................................................................................................................................
Safety Instructions ..............................................................................................................................................
Warnock-Hersey Listing Label ...........................................................................................................................
Assembled Firebox & Smoke Dome Dimensions ..............................................................................................
Component List & Dimensions ..........................................................................................................................
Required Clearance to Combustibles .................................................................................................................
Rough Framing Dimensions & Corner Location Layout ...................................................................................
Assembly Instructions .................................................................................................................................
Access Modication ...........................................................................................................................................
Firebrick Installation ..........................................................................................................................................
Flush Wall Finish Detail .....................................................................................................................................
Required Clearances (When sheathing protrudes beyond front of rebox) .......................................................
Required Clearance to Combustible Framing ....................................................................................................
Required Clearances to Insulation and Vapor Barriers ......................................................................................
Flush Wall Fire Brick Finish Detail ...................................................................................................................
Flush Wall Brick Finish Detail ............................................................................................................................
Interior Masonry Veneer Fireplace Finishes & Clearances...................................................................
Masonry Veneer Construction Details ..................................................................................................
Non Combustible Finished Facing Requirements & Clearance to Combustible Trim .......................................
Concrete Support ...............................................................................................................................................
DM Chimney System ........................................................................................................................................
General Information ............................................................................................................................
Component List & Dimensions.............................................................................................................
Component Weights ............................................................................................................................................
Installation ...........................................................................................................................................
Lateral Support ....................................................................................................................................
Offset Block .........................................................................................................................................
Brick Ledge Installation .......................................................................................................................
Brick Ledge Load Capacity ..................................................................................................................
Crown Caps ..........................................................................................................................................
Height Requirements ..........................................................................................................................................
Structural Information / Wind Loads .................................................................................................
Common Chimney Terminations .........................................................................................................
Class “A” Metal Flue .........................................................................................................................................
Specialty Applications
See-Thru................................................................................................................................................
Two Story Stacked Installations ..........................................................................................................
Fire-Lite Application General Information..........................................................................................................
Fire-Lite Safety Instructions (See page 6)
Fire-Lite Application - Required Clearance to Combustibles ...............................................................
Fire-Lite Application - Combustible Floor System ...............................................................................
Fire-Lite Application - Raised Metal Platform .....................................................................................
Fire-Lite Application - Flush Wall Finish Detail .................................................................................................
FTF-13 or Equivalent Chimney System ..............................................................................................................
FTF-13 or Equivalent Installation Components...................................................................................................
Summary ..............................................................................................................................................................
Notes ....................................................................................................................................................................
3
4
5
6
7
8
9
10
11-14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30-39
31-32
33-36
36-37
38
39
40
41
42
43
44
45-46
47
48
49
50-51
52
53-54
55
56-57
58
2

General Information
The Fire-Lite replace is a prefabricated, refractory
modular replace designed for eld assembly on a combustible
oor. The system consists of interlocking precast parts which
are glued together with a masonry adhesive.
The parts of the Fire-Lite replace are precast using
a proprietary mixture of volcanic pumice aggregate and
cement. It includes all the parts necessary for assembly of a
complete rebox and smoke dome. The design and installation
require that the system use FTF-13, Class A metal ue, or
equal. Also the Fire-Lite assembled unit must sit on a raised,
noncombustible platform. Each Fire-Lite precast replace
component is designed for a specic part of the replace such
that only one means for assembly is possible.
The rebox and smoke dome are designed to be
tted with a traditional cast iron, poker-style throat damper.
However, chimney top dampers are an option.
The Fire-Lite replace requires a Fire-Lite refractory
re brick liner be applied to the interior of the rebox. Fire
brick must be a minimum thickness of one and one-eighth
inch (1-1/8”).
The Fire-Lite replace is available in many sizes:
The Standard series 36, 42 & 46 and the Magnum sizes 28, 36,
42 & 48. The various Fire-Lite replace and DM 54 chimney
components will be described and illustrated in the following
pages. Close attention should be paid to each component
group’s specications and installation requirements as
described in this manual.
Intended Use Statement:
The Fire-Lite is intended to burn solid wood fuel, propane
or natural gas. The replace is intended for use as a
supplemental heat source only and is not intended for heavy
use as
a primary heating system.
Note(s):
1. The local authority having code jurisdiction
should
be consulted before installation to determine the need to
obtain a permit. Important areas of concern with the
installation of these replaces are: construction of proper load
bearing combustible foundation and clearance platform; code
required
hearth extension substrates and supports; proper assembly
of components; clearance to combustible materials; height
of chimney; and techniques employed in applying nishing
materials to the replace opening and hearth extension.
Each of these important topics will be covered in detail
throughout this manual. Installation personnel must give
special attention to each topic as the installation progresses.
3

Intended Use Statement
Notes continued:
2. All work performed on, near and adjoining the
replace and chimney installation must meet or exceed
the specications and requirements in this manual and the
prevailing local building code. Isokern is not responsible for
other construction work around the unit.
3. Recommended minimum overall height
requirements for the Fire-Lite replace and chimney system is
eighteen feet (18’-0”) when the chimney is straight and twenty-
one feet (21’-0”) when a chimney is offset.
Maximum overall height is eighty feet (80’ - 0”).
4. Do not scale drawings. Illustrations in this manual are
not to scale and are intended to show “typical” installations.
Nominal dimensions are given for design and framing
reference only, since actual installations may vary due to
job specic design preferences. Always maintain the stated
minimum clearances to combustible materials. Do not violate
any specic installation requirements.
The Fire-Lite has been tested and listed by Intertek (Report
# 3159656MID-008) to UL 127. These units are intended
for installation in residential homes, and other buildings of
conventional construction.
Fire-Lite replace systems are also designed for installation
in accordance with the National Fire Protection Association
Standard for chimneys, replaces, vents and Solid Fuel-
Burning Appliances (NFPA 211).
4

1. Before starting the assembly of the Fire-Lite read these
installation instructions carefully to be sure you understand
them completely. Failure to follow them could cause replace
malfunction resulting in serious injury or property
damage.
2. Always check local building codes governing replaces
and replace installations. The Fire-Lite must comply with
all local, regional, state and national codes and regulations.
3. The Fire-Lite must be installed with FTF-13 Class A Metal
Chimney System, or equivalent.
The Fire-Lite systems are intended for use in any application
where a traditional masonry type replace would apply.
The chimney system must always vent to the outside of the
building.
4. Creosote and soot formation and the need for removal:
When wood is burned slowly it produces tar and other
organic vapors which combine with expelled moisture to
form creosote. The creosote vapors condense in the relatively
cool chimney ue of a slow burning re. As a result,
creosote residue accumulates on the ue lining. When
ignited this creosote makes an extremely hot re.
Because of creosote and soot buildup, it is necessary
to inspect and clean the replace and chimney prior to use
and periodically during the heating season. Cleaning of the
replace and the chimney system should be done annually at
a minimum. In colder climates chimney cleaning may need
to be done periodically throughout the heating season.
5. Before servicing, allow the replace to cool. Always shut
off any electricity or gas to the replace while working on
it.
6. Use only solid fuel or natural or LP gas log sets in this
unit. Do not use articial wax based logs, chemical chimney
cleaners or ame colorants in this replace.
7. Never use gasoline, kerosene, gasoline-type lantern fuel,
charcoal lighter uid, or similar liquids to start or “freshen
up” a re in this replace. Keep all ammable liquids at a
safe distance from the replace.
8. Always keep the ue damper open when heat is present
in the replace.
9. Do not use a replace insert or any other product not
specied for use with the Fire-Lite systems unless written
authorization is given by Isokern. Failure to heed this
warning may cause a re hazard and will void the Isokern
warranty.
10. This replace is not intended to heat an entire home or
to be used as a primary heat source. It is designed to ensure
homeowner comfort by providing supplemental heat to the
room.
11. Always ensure that an adequate supply of replacement
combustion air from the outside of the house is accessible to
the re to support normal combustion. Fireplaces consume
large volumes of air during the normal ring process.
In the event the home is tightly sealed and has modern energy
efcient features, the optional combustion air supply kits may
not provide all the air required to support combustion and
the proper ow of combustion gases up the chimney. The
manufacturer is not responsible for any smoking or
related problems that may result from the lack of adequate
air supply owing into the house. It is the responsibility of
the builder/contractor to ensure that adequate air supply has
been provided for the replace.
12. “Smoke free” operation is not warranted nor is the
manufacturer responsible for inadequate system draft caused
by mechanical systems, general construction conditions,
inadequate chimney heights, adverse wind conditions or
any unusual environmental conditions or factors beyond the
manufacturer’s control.
13. When used with the Fire-Lite replace system, all gas
log sets must be operated with the damper clamped in the
open position. This includes unlisted “vent free” log sets.
Only listed “vent free” log sets may be operated with the
damper in the closed position.
14. Never install an Fire-Lite replace component or chimney
component, or any accessory that has visible or suspected
physical damage. When in doubt about a component’s
usability consult your Isokern distributor or authorized
Isokern representative for advice.
15. Do not alter or modify an Fire-Lite replace components
under any circumstances. Modication to Fire-Lite components
may void warranties, listings and approvals and could
result in an unsafe and potentially dangerous installation.
Alterations to the Fire-Lite rebox opening height and
width are not allowed without prior written approval and
instructions from Earthcore Industries, L.L.C.
16. Wherever insulation is used, the Fire-Lite replace must
not be placed directly against it. Keep all insulation or vapor
barriers a minimum of three inches (3”) away from all replace
and chimney components.
It is recommended that insulation and vapor barriers, if
used, rst be covered with gypsum board, plywood, particle
board or other material to assure that insulation and vapor
barriers remain in place.
17. Do not pack of ll required air spaces with insulation or
other material. No material is allowed in these spaces.
18. Never leave children unattended when there is a re
burning in the replace.
19. Burning some fuels (such as charcoal) can be hazardous
due to the possibility of producing carbon monoxide, a colorless,
odorless gas. Early signs of carbon monoxide poising
resemble ue symptoms, including headaches, dizziness or
nausea. Over exposure to carbon monoxide can lead to illness
and death.
It is strongly recommended to install smoke and carbon
monoxide alarm / detector devices wherever replaces are
in use.
5
Safety Instructions

Warnock Hersey Listing Label
- Facsimile -
6
Isokern Fireplace and Chimney Systems are tested and listed to UL Fire-Lites: UL 127, ULC S610, and UL 103HT.
The listing label shown in Figure 1 above outlines the listed clearances to combustibles and indicates that the units are
suitable for use with solid fuel or listed gas appliances. Refer to the manufacturer’s installation manual for detailed description of
clearances to combustibles and all other installation information.
A metal listing label similar to that shown above is afxed to each Fire-Lite Series replace.
Do not remove the listing label from the Fire-Lite Series replace.
Prior to beginning installation, contact your local building ofcial to determine the need to obtain a permit.
FIGURE 1

Assembled Firebox & Smoke Dome Dimensions 36, 42 & 46
7

Component List & Dimensions 36, 42 & 46
8
Isokern reserves the right to make changes at any time, without notice in design, materials and specications and also to discon-
tinue styles and products. Please call [phone] for an Isokern dealer near you.

Required Clearance to Combustibles
9
The Fire-Lite is tested and listed for installation with
“clearance to combustibles” as follows:
Four inches (4”) clearance to the combustible oor.
Zero inch (0”) clearance at the Fire-Lite smoke dome
front wall (Figure 2).
One and one half inches (1-1/2”) clearance at the Fire-
Lite rebox and smoke dome back wall;
Two inches (2”) minimum air space to combustibles at
all FTF-13 metal chimney components’ outer layer;
Three inches (3”) clearance to insulation from all Fire-
Lite rebox and smoke dome and chimney components.
Important: “Combustibles” are dened as “normal construction
materials” and are considered to be: wood framing materials,
particle board, mill board, plywood sub-ooring, plywood
paneling and wood ooring. Sheathing materials, such as
plywood, particle board and drywall may cover the smoke
dome front at zero inch
(0”) clearance.
All combustible sheathing materials must be held eight
inches (8”) away from the sides of the rebox opening and eight
inches (8”) above the top of the rebox opening.
Drywall must be cut two inches (2”) back from the
rebox opening sides and eight inches (8”) above the top of the
opening.
CAUTION: Maintain a minimum of three inch (3”) clearance
to insulation and vapor barriers. (Figures 36)
CAUTION: Combustible objects, such as furniture, placed in
front of the replace must be kept a minimum of forty-eight
inches (48”) from the replace opening.
Notes:
1. The Fire-Lite Application is designed, tested and approved
for installation at a minimum of Four inches (4”) above
combustible oor systems per the installation specications
given in this manual. Any portion of the combustible oor
system left exposed under the base plate is to be covered with
min. 1” thick ceramic ber insulation board rated to 2100
degrees Fahrenheit (Figure 10).
2. All Fire-Lite Series result in the nished re brick oor of the
rebox being at least Eight and a half inches (8 1/2”) above the
combustible oor system (Figure 1).
3. The combustible oor in front of the replace must be
covered with a noncombustible hearth extension material set
tight against the replace front and extending at least 20 inches
out from the nished front of the replace and at least 12 inches
beyond the nished sides of the replace opening (see page
27).
4. If raised hearth extensions are preferred, the raised structure
underlying the noncombustible hearth extension must be built
of noncombustible material (Figure 3).
5. It is the responsibility of the building contractor or the
project’s structural engineer to assure that the combustible
oor system intended to support the Fire-Lite Application be
engineered to carry the loads associated with this installation in
addition to any and all other live and dead loads that the oor
system would normally be
required to carry. (See page 10, following, for estimated
system weights.)
FIGURE 4
FIGURE 3
FIGURE 2

10
Rough Framing Dimensions
Corner Location Layout
Rough Framing Dimensions
Model Width Height Depth
A B C
Standard Series:
Model 36 46” 68 3/4” 26 3/4”
Model 42 52” 68 3/4” 26 3/4”
Model 46 56” 68 3/4” 26 3/4”
Magnum Series:
Model 28 38 1/2” 65 3/4” 29 1/2”
Model 36 46” 75 1/4” 29 1/2”
Model 42 52” 75 1/4” 29 1/2”
Model 48 56” 75 1/4” 29 1/2”
Notes:
A. A “Raised hearth” higher than the Fire-Lite stand requires
additional rough opening height at “B” equal to the height of the raised
hearth detail.
B. Rough framing dimension for width “A” allows for the required
1-1/2” clearance at the sides of the Fire-Lite replace.
C. Rough framing dimension for depth “C” allows for the required
1-1/2” clearance at the back of the Fire-Lite replace.
The following chart of dimensions is intended to aid in the positioning of
a Fire-Lite replace in a corner condition where the DM 54 chimney must
turn 45° degrees to align with overhead framing.
Firebox A B C D
Standard Series:
Model 36 43” 49” 35” 72”
Model 42 49” 52” 37” 75”
Model 46 53” 54” 39” 79”
Magnum Series:
Model 28 33 1/2” 18 1/4” 24” 65 1/2”
Model 36 43” 16 3/4” 32” 78 3/4”
Model 42 49” 26 1/2” 36” 83”
Model 48 53” 28 1/2” 39” 85 3/4”
Model 60 73 1/2” 39” 53 1/2” 102 1/2”
Model 72 85 1/2” 45” 62” 111”
To turn ue 45°, rst set one offset block on the rebox so that
the chimney offsets 3” toward the back of the rebox. (Figure 6)
Set a DM 54 outer casing onto this offset block so that the outer
casing is at 45° to the rebox and square to the overhead framing system.
Run the vertical DM 54 chimney through the overhead framing.
More offset blocks can be used - if necessary to align with
overhead framing - before running the vertical DM 54 chimney outer
casing and liner.
FIGURE 5
FIGURE 6
Note:
Support the third offset down to footings and at each
third offset block thereafter.

11
Assembly Instructions
General Isokern Assembly Instructions:
Floor framing for a Fire-Lite installation will need to be
designed and built to accept substantial dead loads spread
over a relatively small oor area.
The following weights and sizes can be used to
calculate Fire-Lite loading. Consult with local structural
engineer for proper sizing of structural oor frame members
for specic installations.
Load Calculations:
Total dead load amounts include (but
are not necessarily limited to) the following items and their
corresponding weight estimates listed below:
1. Fire-Lite unit model weights:
a. See weights in Model installation manuals.
b. Average weight of the 4” metal stand: 36 lbs
Add the weight of the metal stand to the rebox.
2. Damper, re brick and mortar: avg. 450 lbs.
3. Fireplace nished facing: approx. 200 lbs.
4. Weight of metal ue: negligible
By adding the weight of the appropriate Fire-Lite Model
listed in #1 above to the allowance given for each item in
2 through 4 above, the total weight of the Fire-Lite Series
can be estimated.
The oor area for each model is as follows:
Model 36 Standard Series @ 43” x 25.25” = 7.54 sq. ft.
Model 42 Standard Series @ 49” x 25.25 = 8.59 sq. ft.
Model 46 Standard Series @ 53” x 25.25” = 9.29 sq. ft.
Model 28 Magnum Series @ 35.50” x 28” = 6.90 sq. ft.
Model 36 Magnum Series @ 43” x 28” = 8.36 sq. ft.
Model 42 Magnum Series @ 49” x 28 = 9.53 sq. ft.
Model 48 Magnum Series @ 53” x 28” = 10.31 sq. ft.
Notes:
1. Dead load totals are in addition to the live load
and other dead load requirements for the specic site’s
proposed oor.
2. Isokern is not responsible for structural oor support
details for the Fire-Lite replace. Unless otherwise noted
all oor framing drawings in this manual are merely illustrations
to indicate the presence of an underlying oor system.
3. Consult your local structural engineer for proper
oor system design, sizing and specications.
FIGURE 7
FIGURE 8
FIGURE 9
FIGURE 10

12
Assembly Instructions - (cont.)
Installation:
Earthcore Mortar (a thin-set type masonry adhesive)
is used to glue all Isokern components together during eld
assembly of the unit. The mortar is supplied dry, in either 15
pound or 50 pound pails.
Earthcore Mortar is mixed with clean water to a
smooth, workable texture (without lumps or dry pockets)
of a “toothpaste” consistency. This mixture is suitable for
application onto Isokern components by using a masonry
grout bag supplied with the unit.
Attention should be paid that the mortar mixture is
not too thin or runny, as this will not allow the mortar to reach
its maximum bonding strength.
Earthcore Mortar is squeezed from a grout bag onto
the contact surfaces of the Isokern components as they are
tted together.
It is important that a one-half inch (1/2”) bead of
mortar on all the components’ contact surfaces is applied at
about one-half inch (1/2”) in from all edges of the contact
surface of the component. (Figure 14)
When setting the next component onto the mortared
contact surface of the rst component, some mortar should
squeeze out along the face of the entire joint as a sign of
complete and proper sealing of the joint.
On broader contact surfaces it is advisable to apply
several additional one-half inch (1/2”) beads of the Earthcore
Mortar to the area to assure proper sealing of the joint.
Properly mortared rebox and smoke dome assembly requires
approximately 5 gallons (dry measure) of Earthcore Mortar.
Step 1: Set the Fire-Lite base with Earthcore Mortar at on
a proper support foundation allowing 1 1/2” clearance to
combustible framing from the sides and rear of the rebox.
Do not set the Fire-Lite base so that it is in span. Level the
Fire-Lite base plate by oating it in a bed of Earthcore Mortar
to full bearing against the underlying support surface.
The exposed combustible oor within the perimeter of the 4”
metal stand must be completely covered with one inch thick
ceramic ber insulation board (Figure 10). The board is dry
laid to the oor within the frame partitions.
Notes: If the design preference is for a “ush hearth” (replace
oor ush with the room’s oor), please contact the technical
department at: 800-642-2920 for details. (Figure 11)
If the design preference is for a raised hearth (oor
of the replace elevated above the room’s oor), then the
Fire-Lite base can be set on a proper support foundation that
is built up to the desired raised hearth height on the support
slab.
When calculating raised hearth height be sure to
allow for the three inch (3”) thick base plate plus the one and
one half inch (1-1/2”) thick re brick oor in addition to the
height of the four inch (4”) Fire-Lite base. (Figure 12)
FIGURE 11
FIGURE 13
FIGURE 12

Whether a ush hearth is preferred or a raised
hearth, the combustible oor on front of the replace must
be covered with a noncombustible hearth extension set
tight against the replace front and extending at least 20
inches out from the nished replace and at least 12 inches
beyond the nished sides of the replace opening.
For all “raised hearth” construction where
concrete blocks are used to create the raised platform,be
sure to mortar the concrete block platform together. CMU
used for base plate support should be rated ASTM 90.
Step 2: Set the rebox base plate with mortar so that the
front, rear and side walls are all ush with the front, rear
and sides of the Fire-Lite base. Mortar to the base with
Eartcore mortar. For seismic anchorage, please call the
technical department at: 800-642-2920.
Step 3: Set the rst course of the rebox back wall and
side walls into place.
It may be convenient to dry set the rst course
of side wall and back wall into place on the Isokern base
plate and then to trace their position on the base plate with
a pencil.
After outlining the dry set pieces, remove them
and apply Earthcore Mortar to the areas traced on the base
plate where the side walls and back wall are to sit. By doing
this, the rst layer of wall components can be set directly
into mortar already applied to the proper areas on the base
plate.
Be sure to put Earthcore Mortar on the contact
surfaces of the vertical joints where the side wall and back
wall components connect. (Figure 15)
Broken Components: Components broken into 2 or 3
pieces can be repaired by using Earthcore Mortar along the
break line as the component is set into place. Components
broken into multiple small pieces should be discarded and
replaced.
Leveling And Aligning Components: Be sure to assemble
all Fire-Lite components level and ush with adjoining
components.
Leveling and alignment adjustments are made by
the use of small plastic shims (supplied with the unit). The
shims can be inserted under a component to level and align
it with adjacent Standard components (Figure 16). Be sure
to re-grout any and all gaps resulting from shim insertion.
Notes:
A. Do not mix Earthcore Mortar with spirits or antifreeze
agents.
B. The maximum recommended mortar joint thickness at
Isokern components is one-quarter inch (1/4”).
C. Earthcore Mortar can be troweled over the face of a joint
where it has squeezed out while setting components.
It is not intended that the exposed faces of the Standard
components be completely covered with the mortar.
13
Assembly Instructions - (cont.)
FIGURE 14
FIGURE 15
FIGURE 16

14
Assembly Instructions - (cont.)
Step 4: Continue assembly of the second and third courses of
the side wall and back wall. Apply mortar to the top of each
layer of wall components, then set the next course above into
place.
Be sure to mortar all vertical joints of the side wall to back wall
connection when setting each component to its mate.
(Figure 18)
Look for some Earthcore Mortar to squeeze out along the joints
of all contact surfaces as sign that the joint is thoroughly sealed
with Earthcore Mortar.
Step 5: Once all the rebox wall components are set check the
top surface of the rebox for level. Shim leveling process must
be lled with mortar to full bearing against the base plate.
Step 6: Begin the smoke dome assembly by setting the rear
bottom smoke dome component on top of the back wall assembly
in a bed of Earthcore Mortar. The Fire-Lite back wall assembly
should sit ush with the backside of the Firebox. (Figure 19)
Step 7: Set the cast iron throat damper on top of the damper
lifter blocks so that the damper’s operating plate is up and faces
the back of the rebox. (Figure 20)
Step 8: Set the front bottom smoke dome component across the
rebox opening so that the smoke dome piece spans the rebox
opening and is ush with the front of the rebox.
Step 9: Position the smoke dome’s sloping sidewalls at each
end of the bottom smoke dome components (Figure 21). The
sloping sidewalls t in between the front and rear smoke dome
components and also t into the haunches at the ends of the
front and rear smoke dome components.
FIGURE 17
FIGURE 18
FIGURE 19

15
Assembly Instructions - Access Modication
Through-Wall Accesses:
1. Combustion Air Inlet: Combustion air inlet kits though not required
by Isokern may help improve replace operation in homes tightly sealed
and with other ventilating appliances installed (Figures 19 & 20). Check
local codes for combustion air inlet requirements.
The following is a general representation of a generic com-
bustion air kit and not a requirement of Earthcore Industries, LLC.
Local building codes prevail and should be checked before installa-
tion.
Generic replace combustion air kits typically consist of a
sliding stainless steel access door afxed to a three inch (3”) or four inch
(4”) diameter stainless steel sleeve approximately twelve inches (12”)
long. An exterior vent with dress plate, weather hood and rodent preven-
tion screen of a maximum one-quarter inch (1/4”) wire mesh completes
the kit. (Figure 20)
The access door is tted into the nished re brick lining at
the interior sidewall of the Fire-Lite rebox. The twelve inch (12”)
long sleeve can be introduced into the rebox side wall or back wall by
core drilling an appropriately sized hole at the selected rebox location.
Keep the top of the four inch (4”) diameter access hole no more than six
inches (6”) above the nished rebrick oor. The hole size should allow
for a one-quarter inch (1/4”) mortar joint around the air access sleeve for
heat expansion.
The sleeve passes through the rebox wall and must
be connected to metal pipe (by other) - either exible or rigid - that leads
to the source for outside combustion air, as directly as possible from the
Fire-Lite Fireplace (Few to no bends) with a maximum length of sixty
feet (60’).
WARNING: Do not use combustible duct material. Avoid installing
a combustion air inlet where the opening could be blocked by snow,
bushes or other obstacles. Air inlet must terminate a minimum of three
feet below the chimney cap level. Air inlet ducts shall not terminate in
attic spaces.
2. Gas Line Feed: For a replace having the provision for installation of
a gas pipe, the provision is intended only for connection to a decorative
gas appliance.
CAUTION: When using the decorative appliance, the replace damper
must be set in the fully open position.
Gas line for gas log sets used in the Isokern rebox can be
routed through the side wall, back wall or oor of the rebox by drilling
an appropriately sized hole using a masonry drill bit (Figure 18).
3. Electrical Line Feed can be routed through the Fire-Lite rebox back
wall, side walls or oor by drilling an appropriately sized hole using a
masonry drill bit (Figure 18). Be sure to follow the gas log
appliance manufacturer’s explicit electrical line connection instructions
for vented masonry replace installations.
Gas line and electric line must be fed through separate access
holes.
CAUTION: All access holes must be grouted with mortar – after line or
conduit feed - to seal any gaps or cracks around line feed conduits
(Figure 19).
FIGURE 17
FIGURE 18
FIGURE 19

16
Assembly Instructions - Fire Brick Installation
Fire Brick Installation:
The manufacturer requires that the Fire-Lite
Series replace rebox be lined with a minimum one and one-
eighth (1-1/8”) thick rated re brick. The pattern for the re
brick lining is an owner option. Fire-Lite N-Type brick mortar
is a suitable re brick mortar for the Fire-Lite replace and
good masonry practices should be followed.
All required through-wall accesses (gas and electrical
line feeds and combustion air supply access holes) should be
drilled before the required re brick lining is installed.
It takes a total of about ve gallons of N-Type brick
mortar mix (dry measure) to re brick line a Fire-Lite
replace.
Face joints of one quarter inch (1/4”) to three-eights
inch (3/8”) give a good appearance to the nished brickwork
however, this is just a suggestion and other face joint
dimensions are also acceptable.
Step 1. Wet mop the inside of the Fire-Lite replace with a
damp sponge to remove dust and loose particles from the inte-
rior before installing re brick.
Step 2. Start the re brick at the front edge of the oor of the
Isokern rebox, proceeding inward toward the back.
HINT: Dip each rebrick into water before applying.
Step 3. Next, apply re brick to the back wall of the unit start-
ing at the bottom of the back wall and working upward to the
top of the back wall.
Step 4. Finally, set the side wall re brick by starting at the
front edge of the unit’s side wall and working inward toward
the back wall re brick.
Isokern makes no claims as to the performance
of re brick or re brick mortar(s). It is typical for heat
stress cracks to appear in the re bricks in wood burning
replaces.
FIGURE 23
FIGURE 22
FIGURE 21

17
Flush Wall Finish Detail
Fire-Lite Series replaces are designed to be installed so that the rough front face of the rebox and smoke dome sit ush to
the room face of the rough framing members that create the room wall nish. (Figure 24)
CAUTION: Do not frame a wall in front of the Fire-Lite Series rebox / smoke dome assembly, as shown in gure 25
Wall framing must not be placed across the front face of the  rebox and smoke dome assembly.
Clearance to Drywall: Drywall can be placed directly in contact with the front of the rebox and smoke dome. (Figure 24)
Drywall can be hung on the framing members and pass across the face of the smoke dome and in contact with it. If necessary, the
drywall can be afxed to the face of the Fire-Lite Series replace with drywall screws, maximum length 1” - do not use nails.
The drywall must be cut back a minimum of 2” from the sides of the rebox opening and 8” back from the top of the
rebox opening.
These drywall cut back areas must be lled with grout in conjunction with the installation of the required re brick lining of the
rebox and with the application of code required noncombustible nish facing material.
FIGURE 24 FIGURE 25
FRAMING PROTRUDES
PAST FIREBOX FRONT
DRYWALL FLUSH
WITH FIREBOX
FRONT

FIGURE 27
FIGURE 26
Required Clearances (when sheathing protrudes beyond front of rebox)
18
The Fire-Lite Series Isokern replace is tested and listed for 1 1/2” clearance to un-insulated wood framing material at the
rebox sides, back and at the smoke dome front, sides and back. However installation and use practices that are beyond the control
of the manufacturer* can create situations where a zero clearance installation can jeopardize the safety of combustibles in contact
with the Isokern surfaces resulting in re damage to property, personal injury or loss of life.
*The manufacturer is not responsible for installation and use practices that are beyond the scope of the product as dened
in the product listing and in the installation manual.
WARNING: Do not pack or ll the air spaces with insulation or other material. No material is allowed in these areas.
The manufacturer strongly recommends that wherever possible, all combustible framing materials be kept a minimum of
1-1/2” clearance from the Isokern replace unit at the side walls and back walls. It is the responsibility of the General Contractor
to insure that listed clearances to combustible framing and to insulation are maintained throughout the construction of the project
subsequent to the installation of the Isokern unit.
FIGURE 28

Combustible sheathings must be held a minimum of 8” away from each side and a minimum of 8” above the top of the
nished replace opening. (Figures 29 & 30)
Do not frame a wall in front of the Isokern replace unit.
When sheathing is installed directly to the front face of the Isokern replace unit, be sure that when the required
noncombustible nished facing materials are applied that no gaps or voids are left behind the nished facing materials.
Completely seal the required noncombustible nished facing materials directly to the Isokern unit with Earthcore mortar or other
noncombustible grout.
19
Required Clearance to Combustible Framing
FIGURE 29
FIGURE 30 FIGURE 31

20
Clearance to Insulation & Vapor Barriers
FIGURE 33
The Fire-Lite Series rebox back wall, the rebox side walls and the smoke dome back require 1-1/2” clearance.
(Figure 32) Keep all insulation and vapor barriers a minimum of 3” away from all Isokern replace surfaces.
Keep all insulation, vapor barriers, “house wrap” paper and other insulating type membranes and products, including
berglass, cellulose and other insulation, a minimum of three inches (3”) away from all Fire-Lite surfaces. (Figure 33)
When Fire-Lite replace installations are surrounded by walls that are to be insulated, the walls must have enough clearance to the
Isokern unit in order to maintain the three inch (3”) minimum clearance to insulation. (Figure 33) Never spray the Fire-Lite replace
with any type of sealer, insulation or other material.
If insulation or vapor barriers are used in walls surrounding the Fire-Lite replace, it is strongly recommended that the walls be
sheathed with gypsum board, plywood, particle board or other material on the side facing the Isokern to assure the insulation and
vapor barriers remain in place and a minimum of 3” away from the unit.
FIGURE 32