Les Foyers Don-Bar 5005 User manual

Installation, Operation
and Maintenance Manual
LES FOYERS
FIREPLACES
DON-BAR
OPEN FIREPLACES
Les foyers DON-BAR Fireplaces, inc.
Shop and Showroom: 741, St-Vallier Ouest, Quebec (Quebec) G1N 1E2
Phone: [phone] - Fax: [phone]
Website: www.don-bar.com - Email: [email protected]
71207120
71007100
50055005
70057005
70077007
REV. 2014-11
Keep these instructions for future use

LES FOYERS
DON-BAR
Installation, Operation,
and Maintenance Manual
The manual is divided into 5 parts:
PART 1: Installation ...............................
PART 2: Operation and Maintenance....
PART 3: Parts List ..................................
PART 4: Chimney Fires ..........................
Page 2
Page 21
Page 26
Page 27
Page 28
PART 5: Warranty ..................................
Page 2
IMPORTANT
Don-Bar fireplaces are not designed to be connected to air-
ventilated factory-built chimneys (chimney without insulation)
This document in its entirety is the intellectual property of Les Foyers Don-Bar inc.
Any unauthorized use will expose its author or authors to legal and financial penalties.
Copyright © 2014 - Les Foyers Don-Bar inc.
REV. 2014-11
THE 7000 SERIES FIREPLACES ARE APPROVED:
ULC S627 - Space Heater for use with Solid Fuel
EPA - Certified EPA Exempt

1. Important notice 11. Fireplace installation
11.1 Preliminary insertion of the hearth plate
bolt (Fireplace 7100 only)
2. Listed chimneys 11.2 Heat shield
2.1 Compatible chimneys 11.3 Fireplace mounting
11.4 Joint between the fireplace and the chimney
3. Before beginning the
installation 12. Floor protection installation
3.1 Choosing the best location 12.1 Floor protection
3.2 Chimney 12.2 Removing the existing resilient flooring
3.3 Chimney minimum height 12.2 Protection under the pedestal
3.4 Minimum clearances for combustible
materials 13. Fireplaces 5005, 7005, 7007, 7120:
3.5 Exterior doors and windows Refractories and hearth plate
13.1 Refractories installation
4. Preparation before anchoring the 13.2 Mounting of the central and the two lateral
wall support bracket steel hearth plates
4.1 Required solid backing
4.2 Interior partitions 14. Fireplace 7100: pedestal and
4.3 Exterior walls hearth plate mounting
14.1 Pedestal mounting
5. Installation of the wall bracket 14.2 Hearth plate installation
5.1 Regular wall support bracket 14.3 Installation of the optional decorative finish on
5.2 Modified wall support bracket the table
5.3 Wall bracket height and aligment
5.4 Anchoring the wall support bracket 15. Firescreen installation
15.1 Fireplaces 5005, 7005, 7007, 7120
6. Types of installations 15.2 Fireplace 7100
6.1 Chimney outlets
16. BBQ grill installation
7. Chimney - Wall outlet 16.1 Fireplaces 5005, 7005, 7007, 7120
7.1 Height of the chimney wall outlet 16.2 Fireplaces 7100
7.2 Alignment of the wall support bracket 16.3 BBQ grill mounting
7.3 Diameter of the hole for the chimney passage
17. Outside air intake installation
8. Chimney - Regular ceiling 17.1 Important note
8.1 Regular ceiling adaptor 17.2 Duct type and diameter
8.2 Radiation shield/firestop 17.3 Sealing the vapor barrier
17.4 Outside hood
9. Chimney - Cathedral ceiling
9.1 Cathedral ceiling adaptor
9.2 Decorative collar
9.3 Rigid fiberglass insulation
10. Factory-built chimney installation
10.1 Listed parts
10.2 Manufacturer's instructions
10.3 Obstructions
10.4 Maximum allowed offsets
10.5 Chimney weight
10.6 Starting a chimney on a ceiling adaptor
10.7 Radiation shield/firestop
10.8 Minimum chimney height above the roof
10.9 Flashing watertightness
10.10 Roof braces
10.11 Chimney top
PART 1: INSTALLATION Contents
Page 3
REV. 2014-11

PART 1: INSTALLATION
WARNING: Any modification, change, or
substitution of any fireplace component and/or
not following the installation, operation, and
maintenance instructions can void the
warranty and put your security at risk.
1.1 Before installation begins, carefully read the
manual and contact your local building
department to determine whether a building
permit is required to install a fireplace.
1.2 The installation must follow the instructions
in this manual and local building codes. If there is
a conflict, you must follow the more restrictive
measures.
1.3 For your security, enlist the services of a
professional fireplace fitter for the installation.
1.4 Before lighting your first fire, read the
instructions of Part 2 regarding operating and
maintenance of the fireplace.
1.5 Your fireplace produces heat and provides
great ambiance but it should not be used as the
main source of heating.
2.1 Approved chimneys: Your Don-Bar
fireplace is designed to be installed with any 8"
I.D. ((200 mm) masonry or prefabricated
chimney bearing the ULC label S-604 (1200
degrees) or S-629 (2100 degrees) or, in the USA,.
the UL-103HT label.
1. IMPORTANT NOTICE
2. Listed chimneys
DRAWING 1
Attic
Insulation
Radiation
Shield/Firestop
Radiation/Dust
Shield
Fireplace
DON-BAR
Don-Bar
Ceiling
Support
Floor
Protection
Round Top
Storm Collar
Roof
Flashing
Roof Support
Factory-built
Insulated Chimney
8 inches I.D.
(200 mm)
Typical installation with a ceiling
chimney outlet
Page 4
REV. 2014-11

Wall
Shield/Firestop
Wall Support
Floor
Proctection
Fireplace
Don-Bar
7007
Mandatory
2" minimum
air space
(50 mm)
Wall
Band
Round Top
Storm Collar
Flashing
3. Before beginning the installation 3.2 Chimney: Position the chimney to avoid, as
much as possible, offsets, elbows, and the cutting-
out of structural elements. The weight of the
chimney must not be supported by the
3.1 Choosing the best location: Before
fireplace. Allow at least 2" (50 mm) for air space
beginning the installation, make sure the spot you
between the chimney and any combustible
have in mind for the fireplace and the chimney
material including electrical cables and plastic
meet the following requirements:
plumbing pipes. Never fill this air space with
insulation. For example, if the chosen factory-
built chimney has an outside diameter of 10" (250
mm), by adding the required 2" (50 mm) air
space, a minimum 14" (355 mm) free
continuous path is required to install the
chimney. If the fireplace has a ceiling outlet, it is
usually easier to install the fireplace first, then the
chimney. Do not connect this fireplace to a
chimney connected to another heating device.
3.3 Chimney minimum height: 15 feet (4600
mm). This length is measured from the floor
where the fireplace is installed to the top of the
chimney.
3.4 Minimum clearances from combustible
materials: Position the fireplace (Drawing 3) to
allow for the minimum mandatory clearances
DRAWING 2
Typical installation with a wall
outlet
Page 5
Fireplace
DON-BAR 7007
Floor
Protection
24" min.
(610 mm)
Fireplace clearances from
combustible materials
Combustible
Wall
DRAWING 3
IMPORTANT:
Clearances and floor
protection dimensions
vary with each
fireplace model.
Consult the chart
specific to your
fireplace:
5005: Page 16
7005: Page 17
7007: Page 18
7100: Page 19
7120: Page 20
Factory-built
Insulated Chimney
8 inches I.D.
(200 mm)
Roof Support
REV. 2014-11

Solid backing for the fixation of
wall support bracket
DRAWING 4
from combustible materials (including furniture,
drapes and other flammable objects). Note that
Type X fire-resistant gypsum board (Firecode) is
considered combustible for fireplaces
installations and as such, requires the minimum
48" (1220 mm) clearance.
3.5 Exterior doors and windows: As much as
possible, avoid installing the fireplace too close to
an outside door or window because air turbulence
and drafts disrupt the chimney draft.
4.1 Solid backing required Before installing
the fireplace on a wood-framed wall, the wall
must be reinforced to provide a solid backing to
anchor the fireplace wall support bracket. A
gypsum board, wood or plywood wall finish is
mandatory (Drawing 4).
4.2 Interior partitions: Horizontally install
three 2" x 8" (50 mm x 200 mm) between the
studs of the partition as shown in Drawing 4.
4.3 Exterior walls: Install a 3/4" (18 mm)
thick plywood. The plywood should be flush with
the wall furring. The objective is to build a solid
backing to anchor the wall support bracket.
5.1 Regular wall support bracket (Drawing
5): The fireplace is shipped with a wall support
bracket in the form of an inverted T. When
installed against a wood framed wall, it is
necessary to provide a solid wood backing for the
fixation of the bracket long bolts. If the fireplace
is installed on a masonnery wall, the bracket is
fixed directly on the wall by steel expansion nuts
and bolts.
4. Preparation before anchoring the
wall support bracket
5. Installation of the wall bracket
:
Page 6
2" x 8"
(50 mm x
200mm)
16"c/c
(400mm)
+
_
Interior Partition
Exterior Wall
3/4"(18 mm)
plywood
Furrings
Gypsum Board or Wood Wall Finish Mandatory
16"
(400 mm)
24"
(610 mm)
REV. 2014-11
DO NOT INSTALL THE
FIREPLACE ON
INSULATION OR VAPOUR BARRIER
Gypsum Board or Wood
Wall Finish Mandatory

backing on the rear wall, Don-Bar can furnish, on
request, a modified wall support bracket. This
5.2 Modified wall support bracket (Drawing modified bracket consists of a steel plate that will
5):If it is impossible to install a solid wood allow you to drill the necessary holes to reach the
structural elements of the wall according to the
conditions.
5.3 Wall bracket height and alignment:
.1 Fireplaces 7007, 7100, 7120: In order
for the top of the fireplace hood to touch the
ceiling, calculate the height of the wall
support bracket as follows: Measure the
distance between the top of the fireplace
hood and the first (higher) hole of the
bracket. Transfer this measurement onto the
wall from the ceiling. Center the bracket on
the chimney if the chimney is already
installed.
.2 Fireplaces 5005, 7005: Install the wall
support bracket at the height of your choice
(usually 15" (380 mm) above the floor). If
the chimney is already in place, install the
wall bracket at the height required to ensure a
fitted connection with the fireplace chimney
sleeve. Center the bracket on the chimney if
the chimney is already installed.
5.4 Anchoring the wall support bracket: The
wall support bracket must be firmly anchored to
the rear wall because the fireplace rests on it. If
you have a wood-framed wall, fix the bracket
with long bolts. Use metal expansion nuts and
bolts to anchor the bracket against a masonry or
concrete wall. In either case, the bolts must have
a minimum diameter of 5/16" (8 mm) and
penetrate at least 1-1/2" (40 mm) in the solid
background. Install at least 4 bolts with 2 bolts
located at the top of the bracket. In order to
securely anchor the fireplace add more bolts if the
site conditions require it.
Page 7
17" (432 mm)
23" (580 mm)
18" (460 mm)
25"
(635 mm)
2-1/2" (64 mm)
3-1/2"
(89 mm)
3" (76 mm)
4,5" (114 mm)
Floor
The special bracket must be drilled on
the site to install the anchor bolts.
Use the number of bolts required according
to site conditions (never less than 4)
.
Long bolts to
anchor the bracket
against the wall
(minimum 4
with 2 at the
top of the
bracket)
Regular
Bracket
DRAWING 5
Wall Support Bracket
Special
wide
bracket
for off-
center
fixing
Wall
REV. 2014-11

6. Types of installation
7. Chimney - Wall Outlet
of the fireplace hood and the center of
fireplace chimney sleeve and transfer this
measurement onto the wall. Usually, the
6.1 Chimney outlets: Three are typically three distance between the ceiling and the center of
types of chimney outlets. the fireplace chimney sleeve is 16" (400 mm)
(Drawing 6).
1. Wall chimney (Drawing 6 )
2. Regular ceiling chimney .2 Fireplaces 5005 and 7005: The fireplace
( Drawing 7) can be placed at any height but the center of
3. Cathedral ceiling chimney the fireplace chimney sleeve is usually
( Drawing 8) located at 46" (1170 mm) above the finished
floor. (Drawing 6).
7.2 Alignment of the wall support bracket:
Before drilling a hole into the wall, verify that the
7.1 Height of the chimney wall outlet: chimney is centered on the wall support bracket.
.1 Fireplaces 7007, 7100, 7120. In order for
the top of the fireplace hood to touch the
ceiling, measure the distance between the top
Page 8
DRAWING 6
Chimney - Wall outlet
Fireplaces 7007, 7100, 7120 Fireplaces 5005, 7005
8"
(200 mm)
4"
(100 mm)
Standard
height under the
finished ceiling:
16" (400 mm)
Mandatory
2" (50 mm)
Minimum
Air Space
Mandatory
2" (50 mm)
Air Space
Radiation Shield/Firestop
Decorative Collar
C
Factory-built
Chimney
8" I.D.
(200 mm)
Interior Wall Finish
(Gypsum board,
wood or plywood
mandatory)
Female Chimney
End
8"
(200 mm)
Fireplace 7005: 4" (100 mm)
Fireplace 5005: 2,5" (64 mm)
Standard Height
Above The Finished
Floor: 46" (1170 mm)
Mandatory
2" (50 mm)
Minimum
Air Space
Mandatory
2" (50 mm)
Air Space
Radiation
Shield/Firestop
Decorative Collar
C
Factory-built
Chimney
8" I.D.
(200 mm)
Floor
Female Chimney
End
REV. 2014-11
Interior Wall Finish
(Gypsum board,
wood or plywood
mandatory)

7.3 Diameter of the hole for the chimney chimney. Gypsum boards are considered
passage: combustible materials and any wall that
contains them is considered a combustible
.1 Combustible wall: If your wall is made wall. (See the previous article).
out of combustible materials (gypsum board,
wood, insulation, etc), drill a hole at least 4"
(100 mm) more in diameter than the
chimney's exterior diameter to permit the
passage of the chimney plus its mandatory 2" 8.1 Regular ceiling adaptor (Drawing 7):The
(50 mm) minimum air space. A radiation regular ceiling adaptor is 19" (480 mm) wide by
shield/firestop must also be installed around 17" (432 mm) deep. Locate the center of the
the chimney where the chimney passes chimney at a distance of 8" (200 mm) from the
through the wall. A decorative collar is wall. The diameter of the hole for the chimney
available to conceal the empty space around must be sufficient to include the mandatory 2"
the chimney. (50 mm) minimum air space. Make sure that the
hole does not extend beyond the dimensions of
.2 Incombustible wall : If you are working the ceiling adaptor. If the chimney must be
with a 100% incombustible wall (like a installed before the fireplace, it must project 1/2"
co nc re te fo un da ti on wa ll wi th ou t a (12 mm) below the finished ceiling. The ceiling
combustible finish), drill a hole of a diameter adaptor has 4 holes for its fixation against the
sufficient to allow for the passage of the ceiling. Plan the wood supports required for its
8. Chimney - Regular Ceiling
Page 9
Dust/Radiation Shield
8" (200 mm)
17" (432 mm)
1/2" (12 mm)
Mandatory
2" (50 mm)
Minimum
Air Space
Joist or Roof
Truss
Joist or Roof
Truss
C
Factory-built
Chimney
8" I.D.
(200 mm)
DRAWING 7
Support - Regular Ceiling:
19" width x 17" depth (480 x 432 mm)
Female Chimney
End
Female
Chimney
End
Decorative
Collar - 3"
(76 mm)
Cathedral
Adaptor
16" (407 mm) Depth
8"
(203 mm)
DRAWING 8
Support - Cathedral Ceiling:
17" width x 16" depth (432 x 407 mm)
Fireplace Hood
(presoldered
to the cathedral
adaptor)
Fireplace Hood
(presoldered
to the ceiling
adaptor)
CC
Factory-built
Chimney
8" I. D.
(200 mm)
Wall Finish: Gypsum board,
wood or plywood mandatory
Wall Finish: Gypsum
board, wood or plywood mandatory
REV. 2014-11
rigid rockwool insulation

fixation. The ceiling adaptor is not designed to 10.3 Obstructions:
support the weight of the chimney.
8.2 Radiation shield/firestop: Install a radiation
shield/firestop around the chimney where it If electrical
passes through the ceiling. Insulation material cables or plastic plumbing pipes are in the way, a
must not come in contact with the chimney. specialized contractor should remove them..
10.4 Maximum allowed offsets: Don't install
more than 4 elbows in the chimney. Offset
cannot be more than 45 degrees from the vertical
axis. The sum of all offsets (elbows) must never
9.1 Cathedral ceiling adaptor (Drawing 8):exceed 120 degrees. For example, maximum
The cathedral ceiling adaptor is 17" (432 mm) allowed offsets would include: Four 30-degree
wide by 16" (407 mm) deep. You will need to
pierce an opening in the ceiling of the same
dimensions measured from the wall. Anchor the
cathedral adaptor with screws on the inside of the
cathedral adaptor box. Fix the screws on the
adjacent wall and on wood support pieces
installed for that purpose in the ceiling. The
cathedral adaptor is not designed to support the
weight of the chimney.
9.2 Decorative collar: Three 3" wide (75 mm)
finishing strips of adjustable length are supplied
with the fireplace to provide a finishing touch and
conceal the joint between the ceiling and the
cathedral adaptor.
9.3 Rigid rockwool insulation: Install the rigid
insulation pads that are supplied with the
fireplace inside the cathedral adaptor. Do not
completely fill the cathedral adaptor with the
insulation. There must always be at least 2" (50
mm) free for air space between the insulation and
the chimney.
10.1 Listed parts: For the installation of the
chimney, use only ULC or UL listed parts elbows (4x30=120) or two 45-degree elbows plus
supplied by the chimney manufacturer. two 15-degree elbows (2x45+2x15=120).
10.2 Manufacturer's instructions: The 10.5 Chimney weight: The chimney must be
installation must follow the instructions in this supported at regular intervals according to the
manual and the chimney manufacturer's instructions of the chimney manufacturer. Its
instructions. If there is a conflict, you must follow weight must never rest on the fireplace or on the
the more restrictive measures.
9. Chimney - Cathedral Ceiling
10. Factory-built chimney installation
If a joist obstructs the path of
the chimney and the mandatory 2” (50 mm)
minimum clearance, the joist should be moved or
cut. In either cases, the structure must be
reinforced to maintain its solidity.
10 feet (3 m) radius
2 feet min.
(610 mm) min.
3feet (1 m) min.
Warning: Lateral roof braces need to
be installed when the unsupported
chimney height above the roof
is more than 6 feet (2 m).
Chimney minimum height above
the roof
DRAWING 9
Page 10
REV. 2014-11