INSTALLATION MANUAL - Foyer de masse Temp-Cast
Contents
1. Brick Stone Or Rock Flange Plan View Fig 11a Row Lock Bricks Ferrugated Spacer Ceramic Wool Door Frame A Row Lock Flange Row Lock Plan View November 2000 Section 4 Installation of Door Frames amp 37 INSTALLING FIRE DOORS Although experienced masons may use a different technique to attach the door frame the following method ensures two critical points e finished door frame will not be permanently attached directly to the core and will therefore not be affected by thermal expansion of the refractory See Fig 11b e Air slots in the bottom of the frame and in the concrete floor pad are properly aligned as in Fig 12 FIRE DOORS Step One Remove the doors from the frame and set them aside Position the door frame on the core so that the slope of the bottom inside edge of the frame i e the sill of the door frame and the slope of module 10 form a nearly continuous angle as in Fig 12 Level the frame and make a pencil mark on the cardboard spacer along its bottom edge Note rear doors on a See Through Fireplace are positioned slightly higher than the front doors about 1 5 Refer to Page 42 Fig 16 The door frame position can be adjusted up2. Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly STEP 8 The smoke throat course is started by installing module 18 This part is heavy and awkwardly shaped and may require a helper Weights 18 93 Ibs Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly STEP 9 Continue the smoke throat course with parts 19 amp 20 Note that the slightly beveled surfaces of these modules face in towards the firebox Weights 19 amp 20 35 Ibs Bevelled Surface step 9 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly STEP 10 Complete this course by installing 21 Remove all excess mortar and wipe the modules inside and out Weights 21 93 Ibs Temp Cast 2000 Installation Manual 21 step 10 November 2000 Section 3 Step By Step Assembly 20 STEP 11 These 2 parts 22 amp 23 form the floor of the secondary combustion chamber They are not keyed and are simply mortared in position with a thin bead of refractory mortar If this installation includes a Bake Oven these parts and subsequent courses are detailed on page 26 Tap firmly into place with the rubber mallet to create as thin a joint as possible Weights 22 amp 23 40 165 Thin bead of refractory mortar Temp Cast 2000 Installati
3. Now unbolt the frame from the 2 temporary brackets and take the door frame out If the coreflex spacer comes out with the frame replace it before the frame 15 re installed Using a masonry drill of the same thickness as the permanent bolts drill holes into the masonry at the marks made earlier These holes should be at least 1 25mm deep and on a slight angle about 5 degrees towards the firebox Fig 15 Re install the door frame and attach with the four permanent bolts the slightly angled holes will draw the frame tight to the ceramic wool gasket Do not re bolt the frame to the temporary brackets AIR SUPPLY DOORS If an air supply door is to be installed its frame is installed in the facade when it reaches the desired height See Fig 1b pg 4 The Temp Cast 2000 Installation Manual installer can use mortar lead anchors or tap con screws to secure the door frame CLEAN OUT DOORS Similarly clean out soot door frames are installed when the facade reaches the height of the clean out holes in the heat exchange channels The soot doors should be located on both sides of the heater at the bottom of both heat exchange channels in line with the cross manifold Part 3 When a side chimney connection is made one of the two clean out doors should be placed at the bottom of the chimney so that the bottom of the heat exchange channel on that side can also be accessed from the same door In the case
4. 3 x24 Door 3 x18 3 x18 Door Door Extra 44 x 24 Fireplace Lid Temp Cast 2000 Installation Manual 49 Section 6 Ceramic Wool Cutting Plan Note Using a marker amp measuring tape transfer these dimensions and piece numbers onto the ceramic fiber supplied before starting to make any cuts This will ensure that there will be sufficient ceramic fibre in the required shapes Ceramic Wool Cutting Plan Corner Fireplace Corner Bake Oven Corner See through 24 x 150 3 x72 Side Channel 3 x72 Side 5A x 24 Door 1 5 x40 Bake Oven Door 3 x18 318 Fireplace Lid Door 3 x24 3 x18 See Through 358 Side Trim top side strips on corner channels To correct length amp angle as required November 2000 Temp Cast 2000 Installation Manual Section 7 Ceramic Wool Cutting Plan 50 TEMP CAST ENVIROHEAT LTD WARRANTY Temp Cast Enviroheat Ltd warrants subject to the conditions and exceptions noted below that should this product become defective due to materials or workmanship within the specified warranty period Temp Cast Enviroheat Ltd will repair or replace the defective part at its option WARRANTY PERIOD Refractory Parts Three Years from date of purchase Metal Parts One Year from date of purchase EXCEPTIONS The following are not covered by this warranty A Hairline cracks in the refractory cause
5. Qut jh Masonry Heaters INSTALLATION MANUAL MODEL 2000 FIREPLACE READ THIS ENTIRE MANUAL INCLUDING THE WARRANTY SECTION BEFORE STARTING THE INSTALLATION TABLE OF CONTENTS SECTION 1 INTRODUCTION PAGE General Information 2 Site Preparation 2 Clearances 2 The Facade 3 Delivery amp Handling 3 Tools 3 Additional Materials 3 Combustion Air Supply 4 SECTION 2 CHIMNEYS amp DAMPERS General Requirements 5 Flue Connections 5 Masonry Chimneys 5 Factory Built Chimneys 7 Chimney Dampers 8 SECTION 3 STEP BY STEP ASSEMBLY Assembly Notes 9 Step by Step Installation 10 SECTION 4 DOOR FRAMES amp 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 Temp Cast 2000 Installation Manual November 2000 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 COM
6. Temp Cast 2000 Installation Manual Carbon monoxide has the potential to be fatal We therefore strongly recommend installation of a carbon monoxide alarm available where smoke alarms are purchased to guard against this possibility Fig 7 Koof top damper Damper Cable _ qS See Detail 7a 2 Chimney M Lyemdamp 9 Detail 7a Damper Cable Flue Tile Detail a cdr NOTE the chimney damper bracket should be placed out of view whenever possible provided it can still be accessed easily November 2000 Section 3 Step By Step Assembly SECTION 3 STEP BY STEP ASSEMBLY ASSEMBLY NOTES 1 Dry assemble the heater upon delivery to check the condition of all parts and to familiarize yourself with the modules If all of the parts are not numbered you may find it helpful to do so using this manual before taking the unit apart again 2 Outting of flue tiles and fireplace modules should be done outdoors due to the excessive dust created WEAR SUITABLE EAR EYE AND LUNG PROTECTION 3 A4 grinder with a diamond blade is best for cutting holes in flue tiles and fireplace modules Or round holes can be cut as six or eight sided shapes with a gas water or circular saw or drilled every inch 25mm and then cut with a reciprocating saw fitted with a masonry blade Rounding or
7. Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 29 STEP 19 Set the middle heat exchange channels s 32 amp 33 in place using a thin joint of refractory mortar between channels f mortar squeezes out on the inside surface of the heat exchange channels wipe if off Keeping the mortar back from the inside edges will prevent having to reach in to wipe off excess mortar from this area Slightly compress the ceramic fibre using the tie down and secure these two channels with 2 bands of packing tape as illustrated The packing tape can be left in position when the facing is being applied and then any visible tape can be cut out Weights 32 amp 33 95 Ibs 19 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 30 STEP 20 Install the upper heat exchange channels 34 amp 35 Note that these are slightly different than the other 4 with a transition formed on the inside upper surfaces and an enclosed top Use a thin refractory mortar joint between these and the previous channels and secure these parts with the tie down and packing tape Weights 34 amp 35 95 Ibs 2 oe TL E 54 Eee a Step 20 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 31 S
8. Using a small amount of refractory mortar glue a 3 wide strip of ceramic wool to the face of the core where the cardboard was removed Pieces thru 5 on the ceramic wool cutting plan Place the door frame in position amp brace it firmly with a length of 2x4 wedged under the one of the hinges amp nailed to the floor A second 2x4 can be braced under the upper door opening Alternately the frame is fitted with 2 small brackets which can be used to temporarily secure the frame to the core with the tap con screws supplied NOTE ensure that the ceramic gasket is slightly compressed but not crushed WARNING It is important that the ceramic fibre be slightly compressed and glued in place so that it cannot fall out This will ensure that live embers cannot fall into the space between the door and the heater core or into the air intake and create a potential fire hazard No combustible materials should be installed in the foundation or under the foundation due to the potential fire risk WRAP BOTH SIDES amp TOP OF THE DOOR FRAME WITH COREFLEX FLEXIBLE CARDBOARD OR CORRUGATED SPACER If a spacer is not used between the frame amp the masonry facing thermal expansion of the frame could crack the facing and or the mortar joints Temp Cast 2000 Installation Manual Cover the door frame to keep it clean for the rest of the installation Continue to Step 3 IF THE FLANGE WILL NOT COVER THE
9. Ceramic Wool Gaskets bake Fig 17 Position the door frame level and plumb it and secure it with four tap con screws Slight pressure should be used to gently compress the ceramic gasket Fill any remaining gaps between top and sides of the frame and the bake oven opening with ceramic wool See Fig 18 Bake Oven Attachment Without Trim Piate Bake Oven Floor Temp Cast 2000 Installation Manual November 2000 Section 4 Installation of Door Frames amp Facade 44 THE TRIM PLATE OPTION The Bake Oven Trim Plate option simplifies the installation and creates a neater finished appearance With the trim plate in position the masonry facade can be set away from the door frame without exposing the heater core To install the trim plate cut out the opening of the bake oven in the corrugated spacer Hold the trim plate in position and mark the rectangle of the trim plate on the corrugated spacer Cut the spacer out of this area Using the trim plate as a template cut a piece of 1 4 rigid coreboard ceramic fibre supplied Trim Plate Front View Note Masonry work should be kept 1 to 172 back from edge of opening in trim plate on all sides Line of finished masonry Centre this fibre in the opening and glue it to the core with refractory cement Attach the trim plate to the core with the tap con screws supplied Position the
10. FACADE If the masonry facade will not be hidden behind the door flange care must be taken to ensure that an expansion gap is created between facade and door frame Glue a 3 strip of ceramic wool pcs K13 thru 5 onto the core where the cardboard was just removed Place the door frame in position amp bolt it or brace it with 2x4s The bottom flange of the door frame rests on the masonry Place 4 100mm wide strips of corrugated spacer or coreflex on the top and sides of the frame Continue with Step 3 However ensure that an expansion gap of about 1 8 3mm is left between the masonry and the side and top flanges of the door frame See Fig 14 Fig 14 Door Frame Expansion gap needed on sides and top Frame flange reete on maeonry DFAFdet nov 95 November 2000 Section 4 Installation of Door Frames amp 40 FIRE DOORS Step Three cavity is created around the area of the bolt Refer to Fig 15 Continue with the masonry facade up to the level of the first permanent bolt attachment Continue raising the facade filling the space around the bolt with mortar tight to the Insert the four permanent bolts into the frame coreflex spacer Chip or cut the brick or other masonry so that a Fig 15 Facade Applied tight to spacer or gaps filled with mortar Fireplace Core Corrugated Spacer Ceramic Wool Fi
11. beveling the inside edges of the hole in the module creates the least resistance to the flow of smoke and gases maximizing draft and performance See Fig 8 4 When using the ceramic fibre gasket material it should only be slightly compressed Compressing it too much will defeat its purpose as an expansion gasket A small amount of refractory mortar can be used to cement the gasket in position 5 Refractory casting occasionally leaves behind rough spots or small bumps on the modules If these rough spots should occur in a joint between 2 modules they may prevent a tight joint and make installation of subsequent parts more difficult Remove any such bumps with a rasp or scraping tool before assembling 6 Hefractory mortar should be used sparingly applying a small 1 4 to Temp Cast 2000 Installation Manual 3 8 bead between modules The finished joint should have a very thin skin of refractory mortar which is the strongest In addition the parts will only fit properly if the thinnest possible joint is created Apply a small amount on the outside edges of the part where indicated by the shaded areas Do not use a full bed of mortar Seat the parts completely using a rubber mallet so that a little mortar squeezes out After each course scrape off and save excess mortar for possible later use Periodically wipe the modules inside and out with a damp sponge to ensure that excess mortar has not been left be
12. during the installation of the facade Fig 19 All spaces between corrugated spacer and masonry facing must be filled See Fig 19 The masonry courses directly below the fire doors must be sliced in half or stepped out This will provide a permanent air slot which will feed combustion air from below into the bottom of the door frame and into the fire See Fig la amp Ib page 4 An expansion break must be created between the masonry cap amp the facing to allow for unrestricted vertical expansion of the core See Figs 19 amp 20 The facade must be continuous on all four sides and top of the heater The heater core must not be left exposed at any point Masonry Cap Ceramic Wool Gasket WARNING It is important that the no air be able to get into the space between heater core amp facing on all 4 sides and top FAILURE TO SEAL THIS SPACE MAY RESULT IN A FIRE HAZARD Temp Cast 2000 Installation Manual Fireplace Lid Corrugated Spacer Continuous Facade Applied tight to spacer or spaces must be filled CSFACADE 1193 Fireplace Core November 2000 Section 4 Installation of Door Frames amp Facade THE MASONRY CAP The facade must be continued at least 4 100mm above the top of the fireplace modules Fill the resulting space between facade and sides of the fireplace lid with ceramic wool Place a layer of 1 2 12mm ceramic woo
13. or down slightly to accommodate the facade so that the frame will sit on top of a masonry or stone course However ensure that the door frame still covers the firebox opening particularly on the top in the case of an arched frame See Fig 13 Note Use an angle iron to support the masonry when a rectangular door frame is installed Fig 11b Temporary Bolt ayn P Fermanent Bolt Temp Cast 2000 Installation Manual Door Frame Temporary Bracket Door Flange November 2000 Section 4 Installation of Door Frames amp Fig 12 M Firebox Inside Sill of Frame 10 Door Frame Corrugated Spacer 6 Air Intake Slot Fig 13 To keep the door clean it can be removed from the Firebox Opening Note Adjust height of frame to frame and installed when OE EOS RSE the facing is completed Temp Cast 2000 Installation Manual November 2000 Section 4 Installation of Door Frames amp Facade FIRE DOORS Step Two Build up the masonry facade to the bottom of the firebox door Adjust the height of the door frame as needed to suit the masonry courses ensuring the frame still covers the firebox opening Trace the frame on the cardboard spacer
14. round flue tile and a clean out access built into it Both flue tiles should be wrapped with a corrugated or ceramic wool spacer and cemented in position An approved anchor plate for the factory built chimney is installed on top of the masonry section and the factory built chimney continues from this point as in Fig 5 Confirm this connection method with your local building official desired a sliding chimney damper can be built into the masonry chimney section Other methods of connecting factory built chimneys may be acceptable Consult the chimney manufacturer a certified installer or your local building official We recommend that the anchor plate located hidden from view between the 1st amp 214 floor joists only Side Channel oor joists masonry section is visible the first floor amp the pre fabricated chimney Starts at the 2 floor Chimney Anchor Flate amp Round Flue Tile w Clean out Soot Door fansi 1793 Flue Masonry Support Connector Temp Cast 2000 Installation Manual November 2000 Section 2 Chimneys 4 Dampers INSTALLING THE ROOF TOP CHIMNEY DAMPER An optional roof top chimney damper can be installed to allow the chimney to be closed off when the fire is out This will let the chimney mass hold additional heat and greatly improve the overall heating efficiency of the syst
15. tempcast com Temp Cast 2000 Installation Manual Chimney 10 HH H ELE Is OH 2 H N W X November 2000 Section 1 Introduction 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
16. the heater across the width at the front and rear as illustrated Note the fibre should be roughly flush with the outside edges of the heater Now fill in the remaining spaces with strips marked K7 amp K8 3 x16 Top Side The next layer of gasket is staggered overlapping the joints of the first layer starting with the 2 strips marked K9 amp K10 3 x22 Top Side placed at either side of the fireplace and running the full depth Then the front and rear pieces are filled in with strips marked K11 amp K12 3 x30 Top Front or Top Rear Trim the strips as required for a snug fit Corner fireplace gaskets are placed with the same principle in mind Note if the tops of the side channels amp the heater do not end up even use extra ceramic wool to make the top edges even to within approximately 1 4 all around Use double gasket of ceramic wool on top amp stagger gasket joints Step 21 Step 21 Corner Fireplace Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 33 STEP 22 Place the two halves of the fireplace lid on top using a refractory mortar between them The smoothest side should be placed down the parts are interchangeable left to right Note that no mortar is used between the lid and the ceramic gasket Since the lid is slightly smaller than the top of the fireplace an equal amount o
17. B 114 lbs 29B 27 Steps 11 to 16 Bake Oven Model Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 27 STEP 17 Find the ceramic fibre Cutting Plan in Section 6 for the model you are installing With a tape measure magic marker amp straight edge transfer the Cutting Plan dimensions amp piece numbers to the ceramic fibre Cut out the four 4 strips marked 3 x72 Side Channels thru K4 and glue them to the exterior of the core as shown below using five or six evenly spaced small dabs of refractory mortar Temporary Wooden Jig If required i Ceramc Wool Gaskets 2M a WLA Step 17 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 28 STEP 18 If the flue connection is on the side of the fireplace the hole for the flue connector is cut at this point as shown See below for important suggested cutting technique Refer also to Fig 3 amp 4 on Page 5 For a Corner Fireplace see page 31 for Steps 18 to 20 Dry assemble the lower heat exchange channels 30 amp 31 and mark the location of the flue hole The hole in the heat exchange channel should be cut as tightly as possible up to about 1 4 larger all around than the flue tile In addition cut a 6 x 6 hole in the opposite heat exchange channel on the non chimney side for a soot c
18. PLETELY 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 CLEARANCES 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 amp 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 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 1f 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 P O Box 94059 Toronto Ontario MAN 3R1 Tel 416 322 5197 Fax 416 486 3624 Toll free 1 800 561 8594 Email staywarm 2
19. TEPS 18 THU 20 Corner Fireplace If the chimney connection is to be made in the side of the fireplace dry assemble the first corner channel and mark the location of the flue hole on the designated surface Mark a location for a clean out soot door on the opposite channel Cut these holes outside Re assemble the first two corner channels using a little refractory on their bottom edges Use a tie down and 2 bands of packing tape or fiberglass reinforced tape around each pair of channels so they do not fall during the next few steps Continue with the other four corner channels using refractory mortar between them Secure each pair of channels with 2 bands of packing tape or fiberglass re inforced tape as they are installed Weights 30C to 35C T 130 lbs 35C 0 nr p 33C 32C Refractory Mortar 31C a Tie Down Fiberglass Tape X f 30C Cut bottom channels P for flue connection or clean out as required Steps 18 to 20 Corner Fireplace Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 32 STEP 21 Install a gasket of strips of ceramic wool to the top of the fireplace as illustrated below and described as follows A little refractory mortar can be used to keep gaskets in place Glue down the 2 strips marked K5 amp K6 3 x36 Top Front and Top Rear to the top of
20. 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 amp more difficult to regulate DELIVERY amp HANDLING The fireplace kit weighs 2800 Ibs 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 Temp Cast 2000 Installation Manual 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 weat
21. bake oven door and attach it with the 4 machine screws supplied which go behind the trim plate Check that it is level and plumb Leave the door off or cover it to keep it clean during masonry work Note when the masonry facing is installed a space of 1 to 112 must left between the door and the masonry to allow the door to fully open amp for full movement of the door handle See below Assembly Side View Front Wal Fach Vv n P 25 Rigd Ceramic Wool Tap con i 4 board Screw Bake Trim Plate Bake Oven Door Frame Frame 5 Ceramic wool a Trim Plate Masonry Facing 25 Rigid Ceramic Wool Roll board Corrugated Spacer Assembly Plan View Trim Plate ome Dx ES 4 25 Rigid Ceramic Wool Door Frame Bot 4 Door E ul d Masonry 1to 177 Facing Temp Cast 2000 Installation Manual pp Oven Door l 1 to 1 November 2000 Section 4 Installation of Door Frames amp Facade 45 INSTALLING THE FACADE Most facades will be installed by professional masons who will have their own methods of planning and working Refer also to FACADE FLANGE OPTIONS earlier in this section Several details concerning the installation of the masonry facade are unique to Temp Cast fireplaces and must be considered Expaneion Gap The following must be followed
22. cades to be concealed behind the door flange FOR FACADES UP TO 4 25 THICK Glue an extra layer of 1 2 ceramic fibre between the door frame and the heater core on top of the standard 1 2 layer When slightly compressed this extra layer will provide up to 3 8 additional space behind the door flange Refer to Fig 11 FOR FACADES OVER 4 25 THICK For facades more than 4 25 thick a row lock bond can be employed in which half bricks are cut to approx 3 and laid around the door frame fitted behind the flange Thicker facade materials can then be laid up next to these row lock bricks See Fig 11a Alternatively attach fire brick splits around the door frame opening with refractory mortar before the ceramic wool is applied These splits up to 1 5 thick increase the space between the core and the flange allowing for a thicker facade material to fit behind it all cases increase the combustion air space under the door by the thickness of the added splits e g cut an extra 1 5 from the facing under the door if 1 5 splits are added Temp Cast 2000 Installation Manual Fig 11 2 Layere of Ceramic Wool Door Frame Thicker Facade
23. channels mark the correct placement with a pencil If the chimney is to be connected at the rear of the fireplace mark the cross manifold 3 to be cut for the flue connection Take this part outdoors and cut a hole for the flue connector being used For flue tile or HT chimney cut the hole the same size as the inside dimensions of the flue connector The flue connector or HT adapter will then be mortared or attached to the outside of the cross manifold Part 43 Holes for a side connection are discussed at Step 18 Once the layout of fireplace and chimney connection all dimensions and locations of cleanout doors have been confirmed draw a line on the Leveling Pad to mark the outside edges of the base course Now remove the modules cut the flue hole in 3 if required and re assemble using a small amount of the refractory mortar provided on the bottom edges and between modules Seat the parts with the rubber mallet then reach inside the cross manifold and wipe off all excess mortar NOTE once final assembly has been started the entire core should be assembled in a continuous operation so that minor adjustments to previous courses can be made before the refractory mortar has set Place the firegrate in position which should fit loosely to allow for expansion Cover it to keep clean Weights 3 61 Ibs 48 5 82 Ibs 6 22 lbs Firegrate Optional Knock out Plug Use for clean out access to manifold or chimn
24. d by normal thermal expansion Defects or cracks of any kind in the masonry facade Any other materials or labour including removal and replacement of masonry facades Damage caused by incorrect installation or by failing to follow Temp Cast installation instructions Damage caused by incorrect operation or abuse or by failing to follow Temp Cast operating instructions CONDITIONS Registration Card must be completed and mailed within 30 days of installation to Temp Cast Enviroheat Ltd P O 94059 3324 Yonge St Toronto Ontario Canada MAN 3R1 At least 4 Installation Photos or VHS video tape must be included with the Registration Card showing the completed core the core with partial facade erected the completed installation and one showing a normal fire following the curing process this photo can be sent separately at a later date All defective parts must be properly crated and shipped pre paid to the Factory Proof of Purchase must be included showing the date of retail purchase Temp Cast must be contacted for approval prior to any part being returned for warranty claim REGISTRATION CARD STREET ADDRESS STATE PROV ZIPCODE TEL PURCHASE DATE INSTALLATION DATE DEALER TEL INSTALLER MASON Ci TEL MODEL 20000 20010 PURCHASED PRIMARILY AS Primary Heater O Supplementa
25. e Place these 2 cut pieces on the front of the heater starting at the bottom Continue with other pieces of corrugated spacer around the heater but pre cut any holes for cleanouts air doors bake ovens etc using the same technique as the firebox doors to prevent cutting the packing tape Tape the spacer in place For corner units a flexible coreflex spacer is supplied Wrap this around the heater twice to get the correct thickness Also cut out a section of spacer in the area of the air intake slot directly under the firebox as illustrated The core of the Temp Cast 2000 is now complete The next section details installing the facade and the doors gt Spacer Removed From Firebox Opening L Do Not Remove Packing Tape Until Facing Is Installed Not Use Corrugated Spacer in This Area Step 24 Temp Cast 2000 Installation Manual November 2000 Section 4 Installation of Door Frames amp Facade 36 SECTION 4 DOOR FRAMES amp FACADE THE DOOR FRAME FLANGE The Temp Cast door system was designed so that a standard brick with a nominal thickness of 3 75 could be easily installed behind the door flange However since brick sizes vary greatly across North America masons often cannot find a suitable brick in these dimensions In addition natural stone and rock often cannot be found in these dimensions FACADE FLANGE OPTIONS The following techniques will allow thicker fa
26. e channels Wrap the flue connector and the first vertical flue tile with extra ceramic wool coreflex or cardboard spacer and mortar them solidly in position with common mortar ALL JOINTS MUST BE SEALED WITH REFRACTORY MORTAR TO BE SMOKE TIGHT Fig 1O amp x12 Flue Tile Pal em d C O m I PM Pag 12 ER PERA SANET gt Flue Connecto First Vertical Chimney Flue Optional Cleanout Minimum Rise is 1 Fer Foot Flueconn 1 95 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 35 STEP 24 Remove the tie down but leave the tape in place The heater now needs to be completely wrapped with the corrugated spacer supplied but openings for fire doors bake ovens air doors and cleanouts may have to be pre cut so that the packing tape is not inadvertently cut To pre cut the opening for the firebox lay 2 pieces of corrugated spacer on the floor with their longest sides butting Measure up from the bottom of the spacer 13 and draw a horizontal line across the spacer Measure over 6 from either side edge and draw a vertical line at this point Remove the door from the frame and place the frame on the spacer using the two lines drawn to position the bottom and left edges of the frame Trace around the entire frame and then remove the frame Cut the approximately 2 larger than the traced line on all sides amp remove the piec
27. em Refer to the Temp Cast Owner s Manual for proper use of the chimney damper The damper is cemented to the top of the uppermost flue tile of the chimney and is controlled by a cable through the centre of the chimney See Fig 7 The cable is routed through the side of the flue tile during construction of the chimney and masonry facing Note Installation of the damper cable is greatly simplified if the protective sleeve and steel cable are installed in the desired area when the chimney is being built If this has not been done then a string will have to be fished through the sleeve amp secured to the steel cable The cable bracket should be attached to the outside of the chimney in a convenient and unobtrusive location but out of the reach of small children Refer to Detail 7a For 8 round chimneys including factory built models a Round to Square adapter and a 13 x 13 damper will be required NOTE When a stainless steel chimney is used penetrating the steel chimney is not permitted We recommend first building a masonry section amp routing the cable through this Install an approved masonry adapter amp start the factory chimney at this point See Fig 5 CAUTION Whenever a full closure damper is used care should be taken to ensure that the fire is completely out before the damper is shut Closing the damper prematurely could cause combustion gases especially carbon monoxide to be spilled into the home
28. ermotect board or on the concrete floor pad so that the air intake slot is not obstructed and is centered in front of the Leveling Pad Ensure that the 6 150mm diameter ash drop is located within the cut out section of the base CHECK THAT THE FLOOR IS REASONABLY LEVEL BEFORE STARTING TO INSTALL THE LEVELLING PAD ADDITIONAL MORTAR MAY BE NEEDED TO LEVEL IT AS REQUIRED Lay the two halves of the Leveling Pad in a 1 2 12mm bed of common mortar using refractory mortar between them Using the 48 level tap the base into the mortar ensuring that it is level Before the mortar has set tap down along the centre line of the leveling pad so that the centre of the pad is about 3 16 lower than the sides See illustration below This centre line gap will ensure that parts in the upper courses lean in slightly simplifying installation Levelling Pad Weights 1 amp 2 49 Ibs 1C amp 2C 59 Ibs Refractory mortar Step 2 RS Step 2 Comer Fireplace Level 3 16 Gap Leveling Base Mortar Concrete Pad Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 12 STEP 3 When the Leveling Pad can support weight dry assemble the first course of modules including the grate as in the accompanying drawings to check for proper fit This course is to be centered on the Leveling Pad so that equal space is left on both sides for the heat exchange
29. ey where side clean outs are not possible Apply refractory mortar on pad or on bottom edge of modules Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 13 STEP 4 Assemble the second course parts 7 8 amp 9 A small bead 12 of refractory mortar is laid on the outside edges where the two parts meet The bead can be laid either on the part being laid on or the previous part whichever is easier Note that the parts are numbered in the order that they should be placed For a Temp Cast See Through fireplace these 3 parts are slightly different as in the accompanying illustration Use the rubber mallet to seat the modules Remove excess mortar and wipe inside and out with a damp sponge as work progresses NOTE When installing the modules on this course and subsequent courses around the firebox opening take care that the parts are flush at the front of the fireplace This will produce the most level surface on which to install the door frame later 46 48ST 9 lt S Refractory 8 Mortar 8ST Step 4 See Through Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 14 STEP 5 Install Part 10 as shown and then assemble modules 11 12 amp 13 using refractory mortar Center Part 10 in the space and then fill in on each side with some ceramic wool Note that parts 11 thru 13 are identical to the previ
30. f space should be left all around Weights 36 amp 37 80 Ibs 36C amp 37C 95 lbs Step 22 Step 22 Corner Fireplace Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 34 STEP 23 Cut the flue connector to the correct length and with the correct angle so that it rises up 1 ft 25mm 300mm towards the chimney Install the flue connector with refractory mortar to the heat exchange channel and support it in the correct position NOTE extra care must be taken to be certain that the flue connector does not go beyond the inner surface of the heat exchange channel Ideally the connector should penetrate the heat exchange channel no more than one inch 25mm Refer also to Fig 3 page 6 Reach inside the flue connector to smooth and round the corners of the connection Remove excess refractory mortar from the inside edges of the flue connector Cut the first vertical flue tile as shown in Figure 10 Note that the chimney cleanout is shown in the preferred position in line with the flue connector If this alignment is not possible the cleanout can be on either of the other 2 available sides Ifa chimney clean out is planned for a lower level a soot door should still be installed at the flue connection level for inspection and removal of fly ash which will accumulate at the bottom of the heat exchang
31. fe and effective heater Review this list before starting the installation and as the work progresses This is particularly important if you are hiring someone to do the installation 1 ENSURE THE CORRUGATED SPACER IS ATTACHED TO ALL 4 SIDES OF THE CORE BEFORE STARTING THE FACING See Pg 35 amp 38 2 USEA CERAMIC WOOL GASKET BETWEEN DOOR FRAMES AND HEATER CORE This is necessary to isolate the different thermal expansion rates of the two materials Refer to Fig 11 12 amp 15 Similarly use ceramic wool between core amp angle iron used over a rectangular door 3 WHEN THE DOOR FRAME IS TEMPORARILY ATTACHED TO THE HEATER ENSURE THAT THE AIR SLOT IN THE BOTTOM OF THE DOOR FRAME IS ALIGNED WITH THE AIR SLOT IN THE CONCRETE PAD This is the reason the frame cannot be mounted on the outside of the masonry work when the facade is thicker than 4 the air slot will not line up properly See Pg 4 and Fig 12 on Pg 38 4 DON T OBSTRUCT THE AIR SLOT BELOW THE DOOR FRAME Remove excess mortar ceramic wool or other debris See Fig 1a amp 1b on Pg 4 5 PROVIDE ADDITIONAL COMBUSTION AIR AND A NON COMBUSTIBLE HEARTH FOR BOTH DOORS OF A SEE THROUGH FIREPLACE 8 dia of air needed divided between the 2 doors This creates an air wash for each glass door See Fig 16 Pg 42 6 COVER THE TOP AND SIDES OF THE DOOR FRAME WITH CARDBOARD SPACER This creates an expansion joint between masonry and metal See Fig 1a amp 1b a
32. her 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 e 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 amp convenient on smaller cuts large rubber mallet 2 50mm margin or pointed trowel 2 packing tape eg Scotch tape black magic marker pencil utility knife bucket water amp sponge measuring tape caulking gun 20 ft 10m tie down or web clamp for temporary support of side channels Step 18 November 2000 1 2 12 5mm hammer drill amp masonry bits Section 1 Introduction ADDITIONAL REQUIRED MATERIALS e all masonry facing amp chimney materials Portland cement to level the base chimney cleanout for rear connections see Section 4 pg 41 optional air supply door amp 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 fron
33. hind Fig 8 Plan view of side connection Side T Flue Tile these edges on all sides of flue tile amp rough opening Cross Manifold Bevel 1 95 November 2000 Section 3 Step By Step Assembly 10 STEP 1 THERMOTECT INSULATING BOARD If an optional insulating board is to be installed it is installed before starting the Leveling Pad Cut the board to size as indicated and place it in position Check that it is square to the concrete floor pad Ensure that the air intake hole is located immediately in front of the board and centered It is also advisable at this point to double check that there will be sufficient clearances to combustible construction around the fireplace If you have followed the Temp Cast Planning Guide the area around the 6 diameter Ash Drop hole in the concrete pad will be sloped towards the hole for a few inches all around Cut an appropriately sized hole in the insulating board so that the sloped area around the hole is not obstructed Lay the board in position as illustrated Dia Ash Drop Area around hole should be sloped towards it Air Intake Optional Thermotect Board step 1 s Step 1 Corner Fireplace Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 11 STEP 2 Dry assemble i e without mortar the two halves of the Leveling Pad Part 1 amp 2 on the Th
34. l pc K23 on top of the fireplace ensuring that it runs up the sides and ends of the facade See Figs 19 amp 20 A continuous masonry cap of at least 2 50mm must be added to the top of the fireplace It can be poured concrete stone brick or other solid masonry material Remember to include an expansion joint refer to Figs 19 amp 20 The facade can now be continued to the ceiling if desired In this case open spaces should be created in the top course of the masonry facade or decorative metal grills should be installed to vent the trapped heat and humidity The installation of your Temp Cast fireplace is now complete The fire can be lit immediately to begin the curing process or left with doors and dampers open in warm weather to allow trapped moisture to escape IMPORTANT Before firing the heater refer to the Owner s Manual for curing and firing procedures Fig 20 Flan View Fireplace Lid Ceramic Wool Gasket Temp Cast 2000 Installation Manual Masonry Cap Brick Facade Expansion Joint Between Facade and Masonry Cap TOPPLAN 95 November 2000 47 SECTION 5 AVOIDING INSTALLATION ERRORS The Temp Cast modular system was designed to be as fool proof as possible It is easily and properly installed when the installation instructions are followed This section reinforces the most important installation points which cannot be ignored or altered for a sa
35. le See Fig 10 page 34 November 2000 Section 2 Chimneys amp Dampers 6 Fig 5 Side Channel Flue tile penetrates side channel 1 UP UV UU UU UUL UL UUU LULU UU UU UU UL UD UNL UL UU UU UU UUM Url 8 x 12 Flue Tile 1 Provide support under flue tile 2 Seal joints with refractory mortar 5 Wrap with spacer or ceramic wool 4 Mortar in position A 4 grinder with a diamond blade is ideal for cutting accurate amp neat holes in the refractory concrete modules Fig 4 See notes Fig 3 Side Channel 8 Round Flue Connector Length to suit Cut hole 1 2 larger than flue tile O D avavavavavavavavavavavavavavavavavavavatavavavadi tar Temp Cast 2000 Installation Manual November 2000 Section 2 Chimneys amp Dampers FACTORY BUILT CHIMNEYS We do not recommend exterior chimneys see Sec 4 of the Temp Cast Planning Guide but if a chimney on the outside of the house is unavoidable then an insulated factory built e g HT or 2100 F chimney is the better choice When a factory built chimney is started at the floor level there will not be sufficient space to access the clean out cap under it In order to provide a clean out access the following method is suggested The preferred method is to make a masonry connection to the fireplace with 8 200mm round flue tile A short section of vertical masonry chimney is then constructed with 8
36. leanout door Align this hole with the centre of the cross manifold part 3 If a rear chimney connection has been made the second soot door may be installed on the opposite side channel to simplify inspection and cleaning from both sides Both soot doors should align with the centre of the cross manifold A third cleanout door will be needed for the base of the chimney The transition from fireplace to flue connector should be as smooth and rounded as possible so that the smoke does not encounter any corners or ledges as it enters the flue connector Refer to Fig 8 page 9 Ensure that the ceramic fibre strips have been applied to the core walls Now position the first 2 heat exchange channels using refractory mortar on their bottom edges only Weights Use a tie down or web clamp around the 2 channels to slightly compress 30 amp 31 95 Ibs the ceramic fibre Secure the channels with 2 bands of packing tape then remove the tie down es Part 30 or 31 Using A Masonry Saw Cut Around Perimeters Of The Opening Slightly Past The Corners As Ilustrated Also Cut An X Through The Center To Ensure That The Pieces Are Easily Removed Without Breaking 9 The Remaining Section WARNING Ensure that the saw cuts extend slightly beyond the corners before attempting to break out the center pieces cu pr Fiberglass tape Tie down
37. nd text on page 39 amp 40 7 IF HOLLOW MASONRY UNITS ARE USED FILL THEM WITH MASONRY But avoid perfectly flat amp smooth solid bricks which could move under thermal expansion 8 BACKFILL SPACES BETWEEN MASONRY FACING AND CORRUGATED SPACER To eliminate air spaces amp therefore optimize heat radiation Hefer to Pg 45 9 PROVIDE AN EXPANSION JOINT ON TOP BETWEEN MASONRY CAP AND MASONRY FACADE So that vertical expansion of the core will not cause thermal cracks in the masonry facing Refer to Pg 45 amp 46 10 AMASONRY FACADE MUST BE INSTALLED ON ALL 4 SIDES AND TOP OF THE HEATER EVEN IF SOME AREAS WILL NOT BE VISIBLE FAILURE TO HAVE A CONTINUOUS MASONRY FACADE OF AT LEAST 4 ON ALL SIDES amp TOP OF THE HEATER WILL CREATE A FIRE HAZARD WHICH COULD CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Temp Cast 2000 Installation Manual November 2000 48 Note Using a measuring tape amp marker transfer all dimensions and piece numbers onto the ceramic fiber supplied before starting to make any cuts This will ensure that there will be sufficient ceramic fibre in the required shapes Ceramic Wool Cutting Plan Standard Fireplace Standard Bake Oven Standard See through November 2000 Section 6 Ceramic Wool Cutting Plan 3 x 2 e 3 x30 Front K 3 04 3 x18 See Through Door Ke 39240 S xI8 Side Channel 24 x 150 cop Side kio r BI Top Side ON Side
38. of a rear chimney connection a third clean out door will be required for the chimney itself Standard chimney clean outs are available at brick supply yards or a third Temp Cast clean out can be ordered Cover all door frames immediately after installation to keep them clean INSTALLING See Through DOORS The installation of a second set of fire doors for a See Through Fireplace will follow the same steps as previously detailed However the finished height of the rear doors will be about 1 5 380mm higher than the front doors Refer to Fig 16 This dimension can be adjusted down a little but care must be taken so that the door frame is sealed against the ceramic gasket on all four sides of the firebox opening and a reasonably smooth transition from the door sill to Part 7ST results It is important that air enters the firebox only from the slots in the top of the door frame In addition the installer must ensure that half of the 8 dia combustion air supply is fed to the second door and that an identical air slot is created behind the facade under the door frame on the rear side of the fireplace Without this provision the rear doors will not have an air wash and will become dirty November 2000 Section 4 Installation of Door Frames amp Fig 16 Fireplace Rear Side 24 NOTE Rear Do
39. on Manual November 2000 Section 3 Step By Step Assembly 21 STEP 12 Mortar and place the lower rear wall of the secondary combustion chamber part 424 Note that the bottom edges of the parts on this course are not keyed Weights 24 66 Ibs WA step 12 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 22 STEP 13 Install the 2 short side walls of the secondary combustion chamber parts 25 amp 26 These parts are not keyed and may have to be checked periodically to ensure they don t get out of position while the refractory is drying Weights 25 amp 26 36 Ibs Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 23 STEP 14 Install the lower front wall of the secondary combustion chamber part 27 Seat this part with the mallet amp double check the position of the side walls adjust with the rubber mallet as required Weights 27 66 lbs step 14 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 24 STEP 15 Install part 28 the upper rear secondary combustion wall This is also a heavy part and may require 2 people so that the previous course does get disturbed Installation is easiest if the bottom of the module is placed first into position and then raised upright So this part does not tilt inwards a lit
40. or a le Located 1 to 2 Higher Than Front Door Tx Firegrate Temp Cast 2000 Installation Manual 8 Diameter Fresh Air Supply November 2000 Section 4 Installation of Door Frames amp Facade 43 INSTALLING BAKE OVEN DOORS We recommend that the Bake Oven door be installed directly on the core with a gasket and or optional Trim Plate in contrast to the fire doors Without the benefit of an air wash the door glass will tend to stay cleaner if it is as close as possible to the fire In this case the door frame is installed before the facade reaches this level Some installers may want to install it on the facade without a Trim Plate which may be acceptable only if the appearance of the glass is not a consideration To make the installation simpler tap the hinge pin out of the hinge and remove the door from the frame WITHOUT THE TRIM PLATE OPTION If not already done use the frame as a template amp cut out the cardboard spacer from around the bake oven allowing an extra 1 2 12 5mm Glue a 1 25mm wide strip of ceramic wool to the door sill Also glue 1 strips of ceramic Fig 18 wool around the opening so that a gasket is formed between the door frame and the core Use ceramic wool pcs K17 amp K18 See Fig 17 Spacer is cut 4 larger than door frame BE lt
41. ous course In the See Through fireplace there is no part 11 Seat with the rubber mallet and ensure that joints are tight Remember to keep the front edges of the modules aligned and use a 48 level to ensure that the four sides are plumb Leveling the courses is not critical it is sufficient if the courses are approximately level Weights 10 12 lbs 11 52 lbs 12 amp 13 68 Ibs 12ST amp 13ST 68 lbs Note Part 11 is eliminated in the See Through Step 5 See Through Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly STEP 6 Install the lintel course parts 14 15 amp 16 in order using a small 3 8 bead of refractory mortar on the outside edges of the adjoining parts Weights 14 amp 14 ST 86 lbs 15 amp 16 64 Ibs p See Through Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 16 STEP 7 Complete the lintel course with part 17 Ensure that it aligns with the front edges of the previous course Seat firmly with the rubber mallet to ensure thin strong joints and stable support for the next course If necessary this course can be clamped with a tie down until the refractory mortar sets Weights Refractory 17 84 lbs Mortar RD 17 17 step 7 Step 7 See Through
42. rebox Opening Fermanent Bolts x hme Door Frame Chip out or cut masonry from area of bolte inetall frame with bolte inserted and mortar completely around the bolte Alternate attachment Drill slightly smaller hole on 5 to 10 degree angle in finished masonry amp install bolts dfap f Temp Cast 2000 Installation Manual November 2000 Section 4 Installation of Door Frames amp Facade 41 FIRE DOORS Step Four When the facade is complete and the masonry has fully set remove the 2 temporary bolts from the frame 1f the 2 small brackets were used this will detach the frame from them The door frame is now independent of the fireplace core and will not be affected by the thermal expansion of the core Replace the doors on the frame and check for proper fit and operation ALTERNATE ATTACHMENT METHOD If cutting or chipping masonry around the bolts is not advisable an alternate but more difficult attachment method can be used See Fig 15 Remove the 4 permanent bolts from the door frame Build the facade around the door frame or around the flange as the case may be and complete the masonry work When the masonry work is fully set i e after 1 or 2 days make a mark on the masonry where the 4 bolts will go using the bolt holes as a guide Care must be taken at this point so that the threaded holes on the outside of the frame are not damaged
43. rt 3 is cut to receive the flue connector This joint must also be smoke tight base with a tight fitting metal door for chimney cleaning e have a cross sectional area of at least 50 sq inches 320 sq cm NOT BE CONNECTED TO ANOTHER APPLIANCE OR TO ANY AIR DUCTS FLUE CONNECTIONS The chimney connection is made at the bottom of the fireplace in the first course The connection can be made on either side of the fireplace or through the back wall into the cross manifold Refer to Fig 2 The flue connection can be up to 5 ft long creating heated benches amp allowing additional flexibility in chimney locations For a side connection the side channel Part 30 or 31 is cut to receive the connector see step 18 Make this cut carefully so that a smooth transition from the fireplace to the Temp Cast 2000 Installation Manual See also Section 3 Step 3 MASONRY CHIMNEYS Due to the thermal mass storage capability of masonry chimneys we recommend them over factory built chimneys provided they are completely inside the home Masonry chimneys should have carefully aligned flue liners with joints that are smoke tight and joined with refractory mortar The inside surface of the liner should be smooth with all excess mortar removed Refractory clay and UL ULC listed stainless steel are all acceptable liners An access for a chimney cleanout can be cut in the first vertical flue ti
44. ry Heater O Decorative Fireplace 0 OPTIONS Bake Oven n Corner Model See Through O Arched Door 0 24K Plating Air Intake Damper Roof top Damper O Thermotect Board Air Supply Door INSTALLATION DETAILS Facade Material Facade Thickness HOUSE CONSTRUCTION Conventional Frame Log O Timber Frame R2000 n Other HOUSE SIZE Total Sq Ft ____ _ Area Being Heated HOUSE STYLE Bungalow 2 Storey 3 Storey Split Level O Other wc 9401 Temp Cast 2000 Installation Manual November 2000
45. t 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 Fig 1a Full Brick EN Fireplace Core Corrugated Spacer Door Frame Ceramic Wool Gasket Combustion Air Brick Facade Firebox Cut or etepped out N Bi Air Space Behind Facing Air Intake Slot Hearth SU de iq A e dea VIRES M pcs PO Se tt aN ee 929 T 20 57 ae eh Oe Temp Cast 2000 Installation Manual 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 cus
46. tle extra refractory mortar can be used on the inside edge of the part Weights 28 126 lbs f LL Step 15 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 25 STEP 16 Part 29 is installed to complete the secondary combustion chamber forming the front wall These 2 upper walls may have a tendency to lean inward while the mortar is setting Adding a little extra mortar to the inside edges of this part will help to keep it from leaning in Leaning can also be prevented by making a simple wood jig Cut a length of 2x4 11 7 8 long This piece will be the spacer Nail this piece to a longer piece of wood Place the jig on top of the walls so that the spacer hangs down and prevents the two walls from leaning inward This jig can be left in place until Step 22 Weights 29 126 lbs Step 16 Temp Cast 2000 Installation Manual November 2000 Section 3 Step By Step Assembly 26 STEPS 11 THRU 16 Bake Oven Installation Assemble the Bake Oven parts in numerical order as illustrated below Parts 22B and 23B are laid with a bead of refractory mortar around the outside edges of the parts and seated with the rubber mallet Use refractory mortar wherever one part joins another as indicated by shaded areas Weights 22B 23B amp 24B 48 Ibs 25B amp 26B 51 Ibs 27B 126 lbs 28B 100 lbs 29
47. tom 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 Fig 1b Brick Facade Door amp Glass Note This air slot must not be obstructed Firebox Skew Firegrate Door Frame Bi Air Intake Slot Module oy eek 5 Combustion Air Optional Air Supply Door CAR Nooo November 2000 SECTION 2 CHIMNEYS amp DAMPERS GENERAL REQUIREMENTS Temp Cast fireplaces require an approved chimney system for safe and satisfactory chimney results free of obstructions to the flow of the escaping smoke Use joint sealing mortar to make it completely smoke Fig 2 tight The connector piece penetrates the performance Approved masonry and factory built chimney systems are both acceptable In addition to building code m requirements every fireplace side channel about 1 25mm but care must be taken to ensure that it does not protrude past the inner p edge of the side channel 7 See Figs 3 and 4 chimney system should e extend straight up from the base of the fireplace be at least 18 ft 5 5m in height e have an access at the If the connection is made at the back of the fireplace the cross manifold Pa
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