Temp-Cast 2000 User manual

Temp-Cast 2000 Installation Manual October 2001
INSTALLATION MANUAL
READ THIS ENTIRE MANUAL INCLUDING THE WARRANTY
SECTION BEFORE STARTING THE INSTALLATION.

Temp-Cast 2000 Installation Manual October 2001
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TABLE OF CONTENTS
SECTION 1 -INTRODUCTION PAGE #
General Information 2
Site Preparation 2
Clearances 2
The Facade 3
Delivery & Handling 3
Tools 3
Additional Materials 3
Combustion Air Supply 4
SECTION 2 -CHIMNEYS & DAMPERS
General Requirements 5
Flue Connections 5
Masonry Chimneys 5
Factory Built Chimneys, Base-Exit Dampers 7
Roof-Top Chimney Dampers 8
SECTION 3 -STEP-BY STEP ASSEMBLY
Assembly Notes 9
Step-by-Step Installation 10
SECTION 4 -DOOR FRAMES & FACADE
The Door Frame Flange 36
Installing Fire Doors 37
Air Supply Doors 41
Clean-out (Soot) Doors 41
Installing "See-Through" Doors 42
Installing Bake Oven Doors 43
The Trim Plate Option 44
Installing the Facade 45
The Masonry Cap 46
SECTION 5 -AVOIDING INSTALLATION ERRORS 47
SECTION 6 –CERAMIC FIBRE CUTTING PLAN 48
SECTION 7 –WARRANTY 50

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Temp-Cast 2000 Installation Manual October 2001
SECTION 1:INTRODUCTION
GENERAL INFORMATION
The Temp-Cast 2000 is a modular "site-
built" fireplace kit. The assembled modules
form the "core" of the fireplace, including
internal flue passages. The Standard
Fireplace package also contains a cast iron
fire grate, two soot cleanout doors, refractory
joint-sealing mortar, corrugated cardboard
spacers, gasket material, and assorted
fasteners.
READ THESE INSTRUCTIONS
COMPLETELY BEFORE BEGINNING
THE INSTALLATION. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY
CREATE A FIRE HAZARD, HAMPER
THE PERFORMANCE OF THE
FIREPLACE AND VOID THE PRODUCT
WARRANTY.
IMPORTANT: Review Section 5,
"Avoiding Installation Errors"
before beginning the installation!
SITE PREPARATION
The following instructions detail the
assembly of the Temp-Cast 2000 Fireplace,
on a properly prepared and supported
concrete pad. Support requirements are
described in the Temp-Cast Planning
Guide, and related Plan Drawings.If you
require assistance with the support details for
the fireplace or other preparatory work,
please contact your dealer or the factory. If
you are unsure regarding any aspect of the
installation of this product, please contact:
TEMP-CAST ENVIROHEAT LTD
3324 Yonge St., P.O. Box 94059
Toronto, Ontario M4N 3R1
Tel: [phone] Fax: [phone]
Toll-free 1-800-561-8594
Email: [email protected]
CLEARANCES
A minimum clearance of 4" (100mm) from
the back and sides of the completed fireplace
(i.e. from the masonry facing) to combustible
materials is required. The clearance required
from the top of the heater is 10" (250mm).
48” (1200mm) clearance is required in front
of the door & a non-combustible hearth of
16” (400mm) deep is required, extending 8”
either side of the door.( approx. 38” [1m]
wide). Also, a clearance of 2" (50mm) is
required between the chimney and any
combustible construction.
(Refer to Fig 1)Fig 1

Temp-Cast 2000 Installation Manual October 2001
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If necessary, a metal or masonry convection
shield may be placed between your fireplace
facade and the combustible structure,
reducing clearances by up to 67%. Contact
your dealer, local building inspector or the
factory for details. (In new construction, a
non-combustible solid masonry wall or metal
stud and "wonderboard" wall will eliminate
concern with clearances.)
FAILURE TO MAINTAIN THE
MINIMUM CLEARANCES TO
COMBUSTIBLES MAY CREATE A
FIRE HAZARD.
THE FACADE
Once the core is assembled, it must be faced
with additional suitable heat-storing masonry
material, usually installed by a professional
mason. (See also Section 4.) Suitable
facade materials include brick, rock,
fieldstone, soapstone, solid concrete block
and tile or stucco, or any other solid masonry
materials. (Hollow units must be filled. If
using solid bricks, they should not be
perfectly flat on both sides -a depression is
needed to ensure that bricks do not move
during thermal expansion.) THE FACADE
MUST BE APPROX. 4" (100mm) OF
SOLID MASONRY, STONE OR ROCK.
(Substantially thinner facings may not
comply with building codes, due to higher
surface temperatures, requiring greater
clearances to combustibles. Thicker facings
will make the heater slower to respond &
more difficult to regulate.)
DELIVERY & HANDLING
The fireplace kit weighs 2800 lbs and is
delivered on a wood pallet, covered with
plastic. If unloaded by forklift, it should be
placed on a level and even surface, so that
parts will not fall when the strapping is cut.
Unpacking should be done by at least 2
persons, following the unpacking
instructions.
As soon as possible after delivery, the
fireplace should be unpacked and dry
assembled, to become familiar with all the
parts, to ensure the delivery is complete and
to check for damage. ANY DAMAGED
PARTS SHOULD BE REPORTED TO
BOTH THE TRUCKING COMPANY
AND THE FACTORY WITHIN 3 DAYS.
The pieces must be handled with reasonable
care to avoid damage, although minor chips
to corners and edges are acceptable and do
not affect installation or performance. The
modules should be stored indoors, in a dry
area. When possible, in cold weather, the
modules should be left in a heated area for a
few days prior to beginning the installation.
TOOLS
The following tools are required to simplify
the assembly process:
•48" (1.2m) and 12” levels
•powered cutting tool -options include:
1. 4” grinder with diamond blade
2. circular saw with diamond blade
3. masonry “water” saw or gas concrete
saw (less accurate & convenient on
smaller cuts)
•1/2" (12.5mm) hammer drill & masonry bits
•large rubber mallet
•2" (50mm) margin or pointed trowel
•2" packing tape (eg. “Scotch” tape)
•black magic marker
•pencil
•utility knife
•bucket, water & sponge
•measuring tape
•caulking gun
•20 ft (10m) tie-down or web-clamp, for
temporary support of side channels (Step
18).

Temp-Cast 2000 Installation Manual October 2001
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ADDITIONAL REQUIRED
MATERIALS:
•all masonry facing & chimney materials
•Portland cement (to level the base)
•chimney cleanout for rear connections
(see Section 4, pg 41)
•optional air supply door & frame (for slab-
on-grade installations -refer to Fig 1B)
•optional chimney damper (see pg. 7)
•6” or 8” combustion air supply duct (e.g.
galvanized duct -see next section)
COMBUSTION AIR SUPPLY:
The Temp-Cast heater requires an
unrestricted air supply for proper combustion
and maximum performance.
Combustion air can be drawn from outside or
inside the house and delivered by way of a
15" x 2" (380mm x 50mm) air intake formed
in front of the heater during construction of
the concrete floor pad. Air is then directed
up behind the facing masonry, and into the
hollow door frame through slots on the
bottom. The air travels up inside the door
frame and feeds the fire from above, creating
an "air-wash" across the doors to keep the
glass clean. (See Fig. 1a)
If the installation is designed to use inside air
from the same room as the heater, (such as in
a basement installation ), then an optional
"air supply door" must be purchased and
installed under the loading doors. This will
allow combustion air to be drawn from the
room, travel up behind the facade and into
the hollow door frame. (Refer to Fig. 1b).
In a basement installation, outside air can
still be brought into the fireplace, if ceiling
height permits. In this case, a raised hearth
can be constructed, and 6" (150mm) of fresh
air can be fed into this structure. (A "false"
chimney can be used for this fresh air
supply.) The air is brought to the front of the
heater into a 15" x 2" (380mm x 50mm)
masonry slot or custom-fabricated "boot"
and treated as a normal outside air
installation.
In a "See-Through" fireplace, 8” of
combustion air must be supplied and divided
equally to both door frames to provide an
"air wash" for each door glass. (See Fig. 16,
pg. 42)