Avalon Astoria Bay User Manual

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• Masonry Fireplace

• Factory Built (Metal) Fireplace

• Mobile Home Approved

Tested and Listed by

Omni-Test Laboratories, Inc.

Beaverton, Oregon

Report # 028–S–51-2

ASTME-1509 1995, ULCC

1482

Astoria Bay Pellet Insert

-- Please read this entire manual before installation and use of this pellet fuel-burning room heater. Failure to follow these instructions could result in property damage bodily injury or even death.

-- Contact local building or fire officials about restrictions and installation inspection requirements in your area.

-- Save these instructions

Installer: After installation give this manual to the home-

owner and explain operation of this stove.

4051228

4800 Harbour Pointe Blvd. SW

Mukilteo, WA 98275

2 Introduction

Introduction

We welcome you as a new owner of a Astoria Bay pellet heater. In purchasing a Astoria Bay you have joined the growing ranks of concerned individuals whose selection of an energy system reflects both a concern for the environment and aesthetics. The Astoria Bay is one of the finest home heaters the world over. This manual will explain the installation, operation, and maintenance of this pellet-burning heater. Please familiarize yourself with the Owner's Manual before operating your heater and save the manual for future reference. Included are helpful hints and suggestions which will make the installation and operation of your new heater an easier and more enjoyable experience. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your heater.

Important Information

No other Astoria Bay heater has the same serial number as yours. On the Astoria Bay the serial number is on the hopper cover.

This serial number will be needed in case you require service of any type.

Model: Astoria Bay Serial Number: Purchase Date: Purchased From:

Mail your Warranty Card Today, and Save Your Bill of Sale.

To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us.

We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur.

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Table of Contents 3

Introduction

Introduction ......................................................2

Important Information .........................................2

Safety Precautions

Safety Precautions............................................4

Specifications

Heating Specifications ........................................6

Dimensions.......................................................6

Electrical Specifications......................................6

Fuel.................................................................6

EPA Compliance................................................6

Installation

Before you Begin ...............................................7

Packing List......................................................7

Installation Options ............................................7

Planning the Installation ......................................7

Minimum Fireplace Size.......................................7

Hopper Extension Set-Up ....................................8

Clearances.......................................................10

Mantel Requirements..........................................10

Hearth Requirements..........................................10

Facing Requirements..........................................10

Placing the Insert...............................................10

Venting the Pellet Stove......................................11

Maximum Venting Distance .............................11

Pellet Vent Type............................................11

Installing the Pellet Vent .................................11

Pellet Vent Termination...................................11

Mobile Home Requirements..................................12

Outside Air .......................................................12

Restrictor Adjustment .........................................13

Baffle Installation...............................................13

Surround Panel & Circuit Board Installation .............14

Installation into a Masonry Fireplace......................15

Installation into a Factory Built (Metal) Fireplace.......16

Operation

Safety Notice ....................................................17

Location of Controls ...........................................17

Starting the Heater for the First Time......................17

Curing the Paint ............................................17

Priming the Auger..........................................17

Loading Pellets..................................................18

The Two Modes of Operation ................................18

Operation (continued)

Manual Mode.....................................................19

Auto Mode........................................................20

Restrictor Adjustment .........................................21

Adjusting the Fan Speed......................................21

Start-Up Sequence.............................................21

"AUGER ON" Light..............................................21

"FAULT" Light....................................................22

Power Outages..................................................22

Maintenance

Daily Maintenance (whenever using the heater)........23

Inspect the Burn ...........................................23

Make Sure Pellets are not Piling Up...................23

Check Firepot for Clinkers...............................24

Cleaning the Firepot.......................................24

Bi-Weekly Maintenance (or every 10 bags pellets)....25

Clean the Heat Exchange Tubes.......................25

Vacuum Hopper ............................................25

Clean the Plated Surfaces...............................25

Opening the Door ..........................................26

Check Ashbox and Ashpan, Dispose.................27

Clean the Glass ............................................27

Sweep Ash Into Ashpan..................................28

Yearly Maintenance (or every two tons)..................29

Clean the Exhaust Duct..................................29

Clean the Exhaust Blower ...............................30

Clean the Vent..............................................30

Door Seal.....................................................31

Door Alignment .............................................31

Adjusting the Door Hinge and Latch...................32

Check for Air Leaks - Door, Glass and Ashpan ....33

Replacement Parts........................................33

Normal Operating Sounds

Normal Operating Sounds....................................34

Safety Label

Safety Label .....................................................35

Warranty

Warranty..........................................................36

Optional Equipment

Thermostat.......................................................37

Remote Thermostat............................................38

Optional Log .....................................................38

Optional Door and Grill ........................................38

Z C Kit..............................................................39

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Index

Index...............................................................40

4 Safety Precautions

Gas

• Do not operate the

heater if you smell smoke coming from the heater. Turn the POWER switch to "OFF", monitor your heater, and call your dealer.

• Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or 'freshen up' a fire in this heater. Keep all such liquids well away from the heater while it is in use.

• Do not unplug the heater if you suspect a malfunction. Turn the MODE SWITCH to "OFF" and monitor the heater (see the “Maintenance” section for details).

Sealant

• Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area. Notify your insurance company of this heater as well.

• The exhaust system must be completely airtight and properly installed. The pellet vent joints must be

sealed with RTV 500o F. (260o C.) silicone sealant.

• This unit must be properly installed to prevent the possibility of a house fire. The instructions must be strictly adhered to. Do not use makeshift methods or compromise in the installation.

• Never try to repair or replace any part of the heater unless instructions are given in this manual. All other work should be done by a trained technician.

• The viewing door and ashpan must be closed and latched during operation.

• Never block free airflow through the open vents of the unit.

• Do not operate the heater if the flame becomes dark & sooty of if the firepot overfills with pellets. Turn the MODE SWITCH to "OFF" and and monitor the heater (see the “Maintenance” section for details).

• Your heater requires periodic maintenance and cleaning (see "Maintaining Your Heater"). Failure to maintain your heater may lead to smoke spillage in your home.

• Allow the heater to cool before carrying out any maintenance or cleaning. Ashes must be disposed in a metal container with a tight lid and placed on a non-combustible surface well away from the home or structure.

• This heater is designed and approved for pelletized wood fuel only. Any other type of fuel burned in this heater will void the warranty and safety listing (see page 6 for details).

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Safety Precautions 5

• The heater will not operate during a power outage. If a power outage does occur, check the heater for smoke spillage and open a window if any smoke spills into the room.

• Keep foreign objects out

of the hopper.

Mobile

• This heater must be connected to a standard 115 V., 60 Hz grounded electrical outlet. Do not use an adapter plug or sever the grounding plug. Do not route the electrical cord underneath, in front of, or over the heater.

• When installed in a mobile home, the heater must have outside air, and NOT

BE INSTALLED IN THE BEDROOM.

Home

• Disconnect the power cord before performing any maintenance.

NOTE:

Turning the Mode Switch to "OFF" does not disconnect all power to the heater.

• The exhaust system should be checked twice a year minimum for any build-up of soot or creosote.

This Manual

• Do not throw this manual away. This manual has important operating and maintenance instructions that you will need at a later time. Always follow the instructions in this manual.

• Do not place clothing or other flammable items on or near the heater. Because this heater can be controlled by a thermostat there is a possibility of the heater turning on and igniting any items placed on or near it.

• Do not touch the hot surfaces of the heater. Educate all children of the danger of a hightemperature heater. Young children should be supervised when they are in the same room as the heater.

• Travis Industries, Inc. grants no warranty, implied or stated, for the installation or maintenance of your heater, and assumes no responsibility of any consequential damage(s).

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6 Specifications

Heating Specifications:

Approximate Maximum Heating Capacity (in square feet)* ........................................800 to 2,250

Burn Rate (Pounds per Hour)**............................................................................1.7 to 5.5

Maximum Burn Time on Low Burn** ......................................................................28 t o 52 Hours

Hopper Capacity (based upon hopper extension position).........................................48 to 89 Pounds

* Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is also

affected by the fuel size, quality, and moisture level.

** Small pellets will increase or decrease the stated burn rates and burn times. Differences of plus or minus 20% depending

on fuel quality may occur.

Dimensions:

Center of 4” diameter Flue is 16-7/8” above the baseplate and 7-1/2” left of center

32”

26-1/2”

25-1/2” (allow 36” width for

28”

control board installation)

25-3/4” to 20” See “Hopper Extension Set-up”

for details.

45”

12"

13-1/4” (allow 14” depth in the Fireplace)

Fireplace Opening

Door Opening

Electrical Specifications:

Electrical Rating.........................................................................................115 Volts, 3.6 Amps, 60 Hz

Watts During Start-Up Sequence...................................................................400 (approximately)

Watts During Operation ...............................................................................180 (approximately)

Fuel:

The unit is designed for wood pellets that comply with the standards set by the Association of Pellet Fuel Industry (density of at least 40 lbs. per cubic foot, 1/4" to 5/16" diameter, length no greater than 1–1/2", 8200 BTU's/lb., moisture under 8% by weight, ash under 1% by weight, and salt under 300 parts per million). If the fuel does not comply to this standard, the unit may not operate as designed.

NOTE : This heater may use alternative fuel if equipped with the multi-fuel fire pot and properly maintained. See the

publication “Multi-Fuel Pellet Fire Pot” for requirements (available from your Travis Industries, Inc. dealer).

EPA Compliance:

This heater is EPA exempt from Phase II requirements, but has been tested for emissions using EPA test methods by OMNI Test Labs.

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Installation 7

Before You Begin

READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE THIS HEATER. FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.

Check with local building officials for any permits required for installation of this pellet heater and notify your insurance company before proceeding with installation.

Packing List

• Thermostat & Wire • Scraper Rod Tool • Fuses (2) • Fireplace Installation Sticker • Brush

• Leveling Bolts (2) • Control Board Screws • Hopper Screws • Double-Back Tape (for panels)

Installation Options:

• Masonry Fireplace • Factory Built (Metal) Fireplace • Outside Air Compatible

Planning The Installation

• Have an authorized Travis Industries dealer install this heater. If you install the heater yourself, have your dealer review your installation plans.

• Place the heater outside and load 10 pounds of pellets inside the hopper. Plug the heater in and let it run on HIGH until the pellets run out. This will cure the paint and burn off any oil on the steel, eliminating any smell inside the home.

• Inspect the chimney and clean as necessary before installing the heater. NOTE: The convection blower is open to the fireplace cavity and may circulate odors from the fireplace. You may wish to paint the interior of the fireplace with latex paint to prevent odors from entering the home.

Minimum Fireplace Size

See "Mantel

Requirements" for

details

Min. 32-3/4" (6-1/4" from

hopper lid)

25-3/4” - 20” See “Hopper Extension Set-up”

Min. 18"

Min. 36"

(6" from door

opening)

Non-Combustible Hearth

Mantel (combustible or non-combustible)

Min.42"

(7" from hopper

lid)

Min. 36" (includes circuit board)

Min. 14"

Non-Combustible

Facing

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8 Installation

Hopper Extension Set-up

This pellet heater has a variable-height hopper. This allows the hopper to be lowered for smaller fireplaces. Follow the instructions below to set the correct hopper extension position.

• Determine the correct hopper extension position following the directions below.

The unit will extend 14” into the fireplace. For setting the hopper, the maximum fireplace opening measurements have to be taken at 14” into the fireplace.

Hopper Extension Position

A (highest position) 25-3/4” B (next highest) 24-1/2” C etc... 23-3/8” D etc... 22-1/4” E etc... 21-1/8” F (lowest position) 20”

• Remove the hopper top following the directions below.

Remove the hopper top by removing the screws holding it in place.

1/4" Nutdriver

NOTE: with the hopper top removed, the hopper walls may be removed.

Hopper Top

• Remove the hopper walls.

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Installation 9

• Remove the correct knock-outs in the hopper walls following the directions below.

If you are using hopper extension position F, remove the top knock-out. If using position E, remove the second knock-out, (etc...). The second-to-bottom knock-out is position B.

Position F Knock-Out Position E Knock-Out Position D Knock-Out Position C Knock-Out Position B Knock-Out Position A Knock-Out

• Re-install the hopper walls following the directions below.

Use a center-punch (or other suitable tool) to remove the appropriate knockouts in the hopper walls (punch the holes out from the inside). Make sure to support the hopper walls while removing the knock-outs. There are 11 knock-outs for each position.

NOTE: This hopper extension is in position D.

• Attach the hopper top following the directions below.

Before installing the hopper top, use a centerpunch (or other suitable tool) to remove the appropriate knock-outs on the hopper top.

Re-attach the hopper top to the hopper walls using the screws included with the insert.

HINT: Attach one screw to each side to align the hopper walls. Then install the remaining screws.

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10 Installation

Clearances

• Insert must be placed so that no combustibles are within, or can swing within (e.g. drapes, doors),

36" of the front of the heater.

• Insert must be placed a minimum 8-3/4" from

a side wall (or combustible protruding more than 3/4").

Mantel Requirements

• The mantel must meet the requirements

shown in the illustration to the right.

The mantel must fall within this shaded area (or above). Maximum mantel depth is 12”.

12”

Hearth Requirements

• The non-combustible hearth must extend 6”

to the front and sides of the firebox opening (you must open the door to measure).

Facing Requirements

• The non-combustible facing must extend 7"

to the side and 6" above the hopper lid.

Placing the Insert

• The insert must be placed within an

undamaged masonry or factory built (metal) fireplace. Loose bricks or other damage must be fixed. Clean the fireplace before installing.

Side Wall

Min. 8-3/4"

3-1/2”

33”

38”

Apply the "This fireplace has been altered..." sticker to the fireplace. You may wish to place it in a location where it will be covered by the surround panels.

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The vent should be routed to the fireplace prior to installing the insert. See the section "Vent Installation" for details on vent location.

Use the leveling bolts for fireplaces with recessed floors (included with the insert). Screw them into the baseplate from below.

13-1/4"

Place the insert so the back edge of the baseplete extends 13-1/4" into the fireplace.

Run the power cord to the side along the front of the fireplace (do not route it under the insert).

Installation 11

Venting the Pellet Stove

• PELLET VENT MUST MAINTAIN A MINIMUM 3" CLEARANCE TO ANY

COMBUSTIBLE (INSTALL VENT AT CLEARANCES SPECIFIED BY THE VENT MANUFACTURER).

• DO NOT CONNECT THE PELLET VENT TO A VENT SERVING ANY

OTHER APPLIANCE OR STOVE.

• DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM

OF THIS UNIT.

Maximum Venting Distance:

• Maximum venting height is 33' (maximum horizontal offset is 10')

• Use no more than 180° of elbows (two 90° elbows, or two 45° & one 90° elbow, etc.).

Pellet Vent Type

• Must be Type "L" vent and/or Type "L" chimney liner.

• Use 4" diameter vent.

Installing the Pellet Vent

• Pellet vent connections must

be sealed airtight with 500° F. RTV silicone and screwed together with at least three sheet metal screws.

AA AA

The exhaust quickconnect can be removed to allow for installation and cleaning.

500° F. RTV

Silicone

Seal each vent section (including adapters, elbows, etc...) by injecting a liberal amount of 500° F. RTV silicone into the gap between sections.

AAA AAA

Pellet Vent Termination

• Termination must be a minimum 6" above the top of the chimney (NOTE: the chimney

must meet local codes for height above the roof or other obstructions).

• Must have an approved cap (to prevent water from entering).

• Must not be located where it will become plugged by snow or other material.

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12 Installation

Mobile Home Requirements

• Outside air is required (used for combustion) - see the directions below.

WARNING: DO NOT INSTALL IN SLEEPING ROOM. CAUTION: THE STRUCTURAL INTEGRITY OF THE MANUFACTURED HOME

FLOOR, WALL, AND CEILING/ROOF MUST BE MAINTAINED.

Outside Air (used for combustion)

• Outside air is optional (except in mobile homes or when required by local building codes).

• Must not be drawn from an enclosed space (garage, unventilated crawl space).

• Must not be over 15' long.

• Must be made with 1 3/4" diameter or larger metal or aluminum duct with a metal screen

attached to the end to keep out rodents (P.V.C. or other combustible materials may not be used). Use the Travis Industries Outside Air Kit (part # 99200136).

• Must not terminate above or within 1' of the chimney termination.

• Must have a rain cap or down-turned elbow to prevent water from entering.

• Must be located so that it will not become plugged by snow or other material.

Outside air may be drawn through the chimney (15’ maximum length).

AAA AAA

Outside air may be drawn from the ash cleanout.

12” Min.

Vent Termination

AAA

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Installation 13

Baffle Installation

Install the baffles included with the insert (see page 27 for details).

Restrictor Adjustment

The exhaust restrictor “fine tunes” your appliance, ensuring it pulls the correct amount of air through the firebox. Altitude, vent configuration, and other factors make restrictor adjustment necessary for every installation.

NOTE : the optimal restrictor position will vary over time as soot builds up inside the exhaust system – make sure the homeowner knows how to visually inspect the flame and adjust the restrictor.

Not Enough Air:

If clinkers develop or the flame appears lazy and slow to blow the ash out of the firepot, pull the restrictor outward until the flame becomes active and the firepot holes remain clean. NOTE: If the restrictor is fully out (“5”), yet the firepot does not remain clean, the stove needs to be cleaned and checked for air leaks (see “Maintenance” section of this manual).

Too Much Air:

If the flames are too active (small, flickering flames) or if burning pellets are expelled from the firepot, move the restrictor rod inwards until the flame slows down and no burning pellets are expelled. Another symptom of too much air is the heater “blowing the fire out” – a condition in which the pellets burn faster than they are fed (this is most common on low).

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14 Installation

Surround Panel & Circuit Board Installation

NOTE: Attach the vent prior to installing the surround panels (& circuit board).

Back of

Side Panel

Bend these blockoff plates as shown (both sides). When in position, they block the view through the slots. in the surround panels.

NOTE: When in place, the panels maintain a 3/8” gap around the fireplace.

Phillips Screwdriver

Remove the circuit board from the rear hopper support. Disconnect the wiring harness from the circuit board (see step “d” below for a detailed view).

Attach the circuit board with the four screws shipped with the insert.

Phillips Screwdriver

Right Side Surround Panel

Attach the surround panels to the insert by sliding the slots

on each panel over the tabs on the side of the insert.

Run the power cord to the side along the front of the fireplace behind the side panel (do not route it under the insert).

Slot

Tab

Install the top panel so the joggle clips slide over the tabs on top of the side panels and insert.

Tighten the set screws from the back side with a small standard screwdriver

Top Trim

"L" Bracket

Right Side Trim

Optional Trim Installation:

Insert one leg of each "L" bracket into the top and side trim piece. Align the trim to form a precise corner, then tighten the two set screws with a small standard screwdriver. Slide the trim over the panels. Attach the doubleback tape between the trim and panels at the bottom corners. This keeps the trim tight against

Place the right side surround panel near the insert and attach the wiring harness

to the circuit board.

Back Side of Circuit Board

Pinch these tabs to remove the wiring harness.

Wiring Harness (disconnected in step “a”)

If using a thermostat, attach the thermostat wires at this time.

Top Panel

Double-Back Tape

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Installation 15

A A

Installation into a Masonry Fireplace

AA AA

“L” Vent Flex Section

Vertical Cap

Storm Collar

“L” Vent

Cover Plate (non-combustible)

Silicone

Seal the cover plate with silicone.

HINT: Paint the interior of the fireplace with latex paint to prevent fireplace odors from entering the home.

Outside air may be drawn from the ash cleanout.

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16 Installation

Installation into a Factory Built (Metal) Fireplace

AA AA

“L” Vent Flex Section

The smoke shelf, shields, damper, and baffles may be removed with mechanical fasteners.

if attached

Vertical Cap

Storm Collar

“L” Vent

Cover Plate (non-combustible)

Silicone

Seal the cover plate with silicone.

AA AA

The log grate,

screen (and rails),

AAAA

and doors (if

present) must be

AAAA

removed.

AAAA AAAA AAAA

The firebrick (refractory) may be removed.

HINT: Paint the interior of the fireplace with latex paint to prevent fireplace odors from entering the home.

The metal sides, frame members, or other structural components of the factory built fireplace may not be removed or altered.

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The metal floor of the firebox may be removed floor outer wrap.

leaving the fireplace

AAAA AAAA AAAA AAAA AAAA

NOTE: The fixed spacers under the appliance may not be removed.

Use the telescoping legs to support the insert on raised fireplaces.

Operation 17

Safety Notice

• Read this entire manual (especially the "Safety Precautions" on pages 4 and 5)

before using this heater. Failure to follow the instructions may result in property damage, bodily injury, or even death.

• Do not unplug the heater to turn it off. This heater relies upon electricity to push the flue gases out the pellet vent – unplugging it may lead to smoke entering your room.

• Failure to maintain your heater will lead to a restricted combustion air system, leading to poor performance and in some cases, smoke spillage into the room. See the "Maintenance" section for details.

Location of Controls

Control Panel

Restrictor

The restrictor adjusts the amount of air flowing to the flame.

50 60 70 80 90

Robertshaw

50 60 70 80 90

Thermostat

(required for

Auto Operation)

Pull on this knob to access the control panel.

Starting the Heater for the First Time

Start the Heater - Let it Burn for 1 Hour - THEN OPEN THE DOOR

The stove paint is cured through heat. To prevent it from bonding to the door gasket, you must burn the heater for approximately 1 hour, then open and close the door to break any bonding.

Curing the Paint

This stove uses a heat-activated paint that will emit some fumes while starting the first fire. Open doors and windows to the room to vent these fumes. You may also notice oil burning off of the interior of the stove. This ruststopping agent will soon dissipate.

Priming the Auger

Because of its electronic control panel, this stove does not require priming. If you run out of pellets you may notice it will take approximately 5 minutes longer for the stove to start.

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2 to 4 hours

18 Operation

Loading Pellets

Lift the hopper lid to its vertical position. Pour pellets into the hopper until full. NOTE: The hopper holds approximately 48 to 88 pounds of pellets (depending upon hopper set-up).

The front edge of the hopper lid becomes very hot, do not touch the area below the handle.

Make sure pellets are not left on this heat shield.

The Two Modes of Operation:

Manual

Manual mode requires the user to turn the heater on and off manually.

Auto (requires a thermostat)

Auto mode allows you to use a thermostat to control room temperature. The stove automatically turns on when the temperature drops below the thermostat setting. Once the stove reaches operating temperature, the stove then runs at the heat output setting selected.

Switching Modes While in Operation

Whenever the stove is switched from one mode to another while in operation, the stove will enter the "startup" sequence for a minimum of 20 minutes.

DISCONNECT POWER BEFORE SERVICE

H E A T

O U T P U T

H E A T

F A N

HIGH

MED

LOW

DOWN

REMOTE

AUTO

MANUAL

AUGER

FAULT

AUTO

OFF

MANUAL

START

MANUAL

AUGER

NOTE: if using a modulating remote, this light will come on to indicate the remote is controlling the heater.

These indicator lights are used to determine which mode you are in.

Use the mode switch to determine the mode.

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TRAVIS INDUSTRIES

HOUSE OF FIRE

Manual Mode

Operation 19

Manual mode requires the user to turn the heater on and off manually.

To Start

Press the "Manual Start" button. That's it. The stove automatically goes to a medium burn rate and high fan while the igniter starts the fire burning within 10 minutes. During this period the lowest “HEAT OUTPUT” light will flash. If the stove does not start in 30 minutes, the stove turns off.

Once up to temperature, the stove will then run at the heat output setting selected on the control panel (see “To Adjust the Heat” below).

To Shut Down

Move the mode switch to "OFF". The exhaust blower will still run until the heater cools down.

H E A T

F A N

H E A T

F A N

DOWN

TRAVIS INDUSTRIES

HOUSE OF FIRE

MANUAL

DOWN

AUTO

OFF

MANUAL

AUTO

OFF

MANUAL

START

MANUAL

AUGER

START

AUGER

To Adjust the Heat

Press the "Heat” buttons to adjust the heat output.

NOTE: During start-up you may adjust the heat setting. This heat setting will take affect once the start-up sequence is complete.

TRAVIS INDUSTRIES

HOUSE OF FIRE

DISCONNECT POWER BEFORE SERVICE

H E A T

O U T P U T

H E A T

F A N

REMOTE

HIGH

AUTO

MANUAL

MED

AUGER

LOW

FAULT

AUTO

MANUAL

DOWN

TRAVIS INDUSTRIES

HOUSE OF FIRE

OFF

MANUAL

START

MANUAL

AUGER

These lights indicate the heat output setting.

NOTE: the lights may be difficult to see from an angle.

Press the

“up” or “down”

button to adjust the heat output.

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20 Operation

Auto Mode

To Adjust Room Temperature (or Start the Stove)

Move the thermostat to the heat setting desired. If the room is cooler than the setting, the stove will go through the start-up sequence for approximately 10 minutes. During this period the lowest “HEAT OUTPUT” light will flash. Once up to temperature, the stove will then run at the heat output setting selected on the control panel. If the room is too hot, move the thermostat to a lesser setting.

To Adjust the Heat

Press the "Heat” buttons to adjust the heat output.

HINT:

If you find that the stove turns on and off repeatedly, you may wish to turn the heat output to a lesser setting. The lower setting will provide a more consistent heat output over time, eliminating the need for the thermostat to repeatedly turn the stove off.

NOTE:

If the thermostat calls for heat while the stove is still cooling down, the stove will go through the start-up sequence (for a minimum of 20 minutes).

E A T

O U T P U T

H E A T

F A N

DISCONNECT POWER BEFORE SERVICE

REMOTE

HIGH

MED

LOW

TRAVIS INDUSTRIES

HOUSE OF FIRE

DOWN

AUTO

MANUAL

AUGER

FAULT

AUTO

OFF

MANUAL

START

AUGER

These lights indicate the heat output setting.

NOTE: the lights may be difficult to see from an angle.

Press the

“up” or “down”

button to adjust the heat output.

To Shut Down

Move the mode switch to "OFF". The exhaust blower will still run until the heater cools down.

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H E A T

DOWN

F A N

DOWN

TRAVIS INDUSTRIES

HOUSE OF FIRE

AUTO

OFF

MANUAL

START

MANUAL

AUGER

Operation 21

Restrictor Adjustment

The exhaust restrictor “fine tunes” your appliance, adjusting the amount of air flowing to the flame. NOTE : the optimal restrictor position will vary over time as soot builds up inside the exhaust system.

Not Enough Air:

Too Much Air:

Adjusting the Fan Speed

H E A T

F A N

AUTO

DOWN

TRAVIS INDUSTRIES

HOUSE OF FIRE

OFF

MANUAL

START

MANUAL

AUGER

Press the

“up” or “down”

button to adjust the fan speed.

Travis Industries 4050525 100-01144

22 Operation

Start-Up Sequence

This stove utilizes a start-up sequence whenever the mode switch is changed or the heater is started when cold. This is to ensure proper operation through all possible settings and operational states (hot or cold, pellets burning or not burning, etc.). This sequence over-rides all user settings (except the "OFF" position) to set the auger feed rate to medium, the exhaust blower to high, and the igniter on. During this period the lowest “HEAT OUTPUT” light will flash.

"MANUAL AUGER" Button

This button turns the auger on. It is used to “prime” the auger after the hopper has run out of pellets.

"AUGER ON" Light

This light comes on when the auger is turning. This allows the operator to determine when the auger is turning.

"FAULT" Light

This light comes on when an error occurs:

• The stove runs out of pellets

• During initial start-up (for a split

second) or for improper electrical frequency

• A start-up sequence that does not

result in the heater coming up to temperature

To reset the fault light, turn the mode switch to off and re-start the stove.

DISCONNECT POWER BEFORE SERVICE

H E

HIGH

A T

MED

O U T P

LOW

U T

REMOTE

AUTO

MANUAL

AUGER

FAULT

Fault Codes (for qualified service personnel only)

Fault and #2 (LOW) Light Flash = Flow Switch Fault Fault and # 4 (MID) Light Flash = System Snap Disk Fault (pellets run out & stove goes cold) Fault and # 6 (HIGH) Light Flash = Safety Snap Disk Fault

Power Outages

If a sustained power outage occurs while in "Manual", the heater will go to a "cool down" mode to vacate smoke once power returns. If the power outage was short, the heater will go to the start-up sequence. If in "Auto", the heater will re-start (if the room is cool).

! Because this heater relies upon a blower to evacuate the smoke, some smoke may enter

the home during a power outage. To keep to a minimum, leave the door closed.

Travis Industries 4050525 100-01144

Maintenance 23

Daily Maintenance (whenever using the heater)

Inspect the Burn

When burning on high, the flames should be bright orange with embers jumping from the firepot.

NOTE : the optimal restrictor position will vary over time as soot

builds up inside the exhaust system. See "Restrictor Adjustment" for details.

Make Sure Pellets are Not Piling Up

If the pellets pile up over the burn pot, turn the mode switch to "OFF".

The most likely causes are:

• Restrictor needs adjustment

(see “Restrictor Adjustment” in the installation section of this manual)

• The door, glass, or ashpan is

open or has an air leak

• The firepot requires cleaning

• The exhaust system requires

cleaning

Travis Industries 4050525 100-01144

24 Maintenance

Daily Maintenance (whenever using the heater) - Continued

Check Firepot for Clinkers

If the flames seem to be coming only from the sides, or are orange/black, turn the heater off and check for clinkers.

The most likely causes are:

• Restrictor needs adjustment

(see “Restrictor Adjustment” in the installation section of this manual)

• Poor pellet quality

• The door or glass has an air leak

• The exhaust system requires

cleaning

Cleaning the Firepot

WARNING:

Make sure the heater has fully cooled (approximately 25 minutes) before opening the door and conducting service.

To clean the firepot, open the door (see page

26) and knock away any debris on the firepot with a screwdriver. If severely clogged, remove the firepot to gain better access.

Travis Industries 4050525 100-01144

Maintenance 25

Bi-Weekly Maintenance (or every 10 bags of pellets)

Clean the Heat Exchange Tubes

WARNING:

The front of the heater becomes very hot during operation. Wait until the heater has cooled before cleaning the heat exchange tubes.

With the door closed, insert the included tool into the hole on the heat exchanger cleaning rod. Move the heat exchange cleaner up and down several times.

Heat Exchanger

Cleaning Rod

Keep the door closed so the flyash does not enter the room.

Vacuum Hopper

Run the heater until the pellets run out. Open the hopper and vacuum out the entire hopper. The dust and any other debris near the bottom should be removed to prevent excessive build-up.

Cleaning the Optional Plated Surfaces

Fingerprints or other marks left on the plated surfaces may become etched in place if they are not wiped clean prior to turning the stove on. Clean the surface with denatured alcohol and a soft cloth (make sure the heater is cool). Other cleaners may leave a film that may dull the finish.

Travis Industries 4050525 100-01144

26 Maintenance

Bi-Weekly Maintenance (or every 10 bags of pellets) - Continued

Opening The Door

Phillips Screwdriver

Swing open this panel to access the door latch (use the tool if necessary).

Door Frame

Bracket (attached to side of

heater)

Pawl

Lock Nut

When securing the door, make sure the pawl fits over the bracket before tightening.

With the pawl free of the bracket, the door may be swung open.

Travis Industries 4050525 100-01144

NOTE: Do not overtighten the pawl. This can permanently damage the latch and prematurely wear out the door gasket.

Maintenance 27

AAA

Bi-Weekly Maintenance (or every 10 bags of pellets) - Continued

Check Baffles, Ashbox, Ashpan, Dispose Ash If Necessary

NOTE: The left baffle is larger than

the right baffle.

WARNING:

The front of the heater becomes very hot during operation. Let the heater cool completely before conducting service.

Cleaning the Baffles

Use both hands to lift each baffle up and forward. Then tilt the baffle downwards to remove any flyash that may have accumulated on top of the baffle. NOTE: you do not need to remove the baffle from the firebox.

Ashbox

Removing the Ashbox

Use both hands to lift the ashbox up and away from the insert.

BAFFLE INSTALLATION

The firebox baffles install on ledges at the top of the firebox. The two tabs (at the outside back corners) insert into notches at the right and left rear corners of the firebox walls.

Air Tubes

The baffles install on ledges above the firebrick.

Firebrick

Removing the Ashpan

The ashpan slides out from under the firebox.

Ashpan

NOTE: When replacing the ash pan make sure it is pushed all the way in.

Disposal of Ashes – Ashes should be placed in a metal container with a tight fitting lid. The closed

container of ashes should be placed on a non-combustible floor or on the ground, well away from all combustible materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have been thoroughly cooled.

Clean the Glass

Open the door and clean the glass with a non-abrasive glass cleaner and rag. This will increase the amount of light and heat given off by the heater.

Travis Industries 4050525 100-01144

28 Maintenance

Bi-Weekly Maintenance (or every 10 bags of pellets) - Continued

Sweep Ash Into Ashpan

HINT: The more often you clean out the flyash, the more efficient your heater will burn. NOTE: Remove the ashbox prior to conducting the service below.

WARNING:

The firebox becomes very hot during operation. Let the stove cool completely before conducting service.

Swing the side ash trap door up.

Ash Trap Door

Lift the firepot out of its holder.

Firepot

Lift it up and away from the firebox.

Repeat for the opposite side.

Slide the ash pan trap door forward to expose the ash

dumps (the door can be removed and cleaned if necessary)

Ash Pan Trap Door

Brush all flyash into the ash dumps, including

the flyash inside the firepot holder.

HINT: To empty the ashpan, see the instructions on the previous page.

Travis Industries 4050525 100-01144

Replace the ash trap doors and firepot.

Slide the ash pan trap door forward.

Maintenance 29

Yearly Maintenance (or every two tons)

WARNING: Disconnect the power cord prior to conducting service.

The following section details extensive maintenance procedures. We strongly suggest these items be carried out by a trained service technician, possibly by a service agreement set up with your dealer.

Soot and Flyash: Formation and Need for Removal – The products of combustion will contain small particles of flyash. The flyash will collect in the exhaust venting system and restrict the flow of the flue gases. Incomplete combustion, such as occurs during startup, shutdown, or incorrect operation of the room heater will lead to some soot formation which will collect in the exhaust venting system The exhaust venting system should be inspected at least once every year to determine if cleaning is necessary.

Clean the Vertical Exhaust Duct (the stove must be cool and unplugged)

Clean the refractory and

the entire area behind it Remove both refractory clips.

(both sides).

Remove these doors to remove fallen flyash and soot (see “Bi-Weekly

Clean the Exhaust Duct (make sure the heater is cool and unplugged)

Use a vacuum or bottle brush to remove all flyash from the exhaust duct (if the gasket is damaged, replace).

Phillips Screwdriver

Swing open this panel to access the door latch (use the tool if necessary).

Remove the cover plates over the exhaust duct (both sides)

Cover Plate

7/16" Nutdriver

Travis Industries 4050525 100-01144

30 Maintenance

Yearly Maintenance (or every two tons) - Continued

Clean the Exhaust Blower (make sure the heater is cool and unplugged)

Remove the six screws holding the

Remove the surround panels and access

the left side of the heater. Remove the shroud covering the blower motor.

exhaust blower motor in place.

11/32" Socket

Pull the motor out (be careful not

to damage the wiring or blades).

Blower Blades

Exhaust Motor

Exhaust Box

Blower Housing

Clean the blower blades, blower housing, and exhaust box. You may wish to use a

vacuum to pull ash out of the vent system. When replacing the motor, take care to

Cover

Plate

Remove the cover

plate over the exhaust duct.

7/16" Nutdriver

Use a vacuum or bottle brush to remove all flyash from the exhaust duct (if the gasket on the cover plate is damaged, replace).

align the gasket (if it is damaged, replace).

Clean the 1/2” air space beneath the unit (use a vacuum cleaner or brush).

Clean the Vent (make sure the heater and vent is cool)

Make sure the cap is free of debris (especially if it has a screen that could become blocked).

Check the vent sections for creosote accumulation (indicating a poorly burning stove). Accumulation over 1/4” must be removed.

Warning: Whenever any portion of the pellet vent is disconnected, the joints must be sealed with

RTV 500° F. silicone sealant.

Travis Industries 4050525 100-01144

Maintenance 31

Yearly Maintenance (or every two tons) - Continued

Door Seal

! Air leaks into the firebox will decrease the

stove's performance greatly, leading to excessive sooting, inefficient burning, and perhaps a malfunction.

• The door gasket must contact the entire perimeter of the door and create an airtight seal. To verify this, open the door, hold a dollar bill against the body of the heater, close the door, and secure the latch. The dollar bill should be held firmly in place (check the entire perimeter of the door. If it is loose or falls out, the door must be adjusted (see the following page).

Correctly Aligned Door

When properly adjusted, the door should be evenly spaced from the front of the stove (and shut tight,

Door Alignment

compressing the gasket).

Because the door is three-sided, it is crucial the door is aligned correctly. We recommend that you open the hopper lid and look down upon the door and body of the heater. Use the illustration to the right to determine the correct door alignment.

Hinge

Top of Stove

Door

Note how both corners are evenly spaced.

Latch Too Tight - In the illustration below, the latch is too tight (this is the most common misalignment). Loosen the latch and tighten the hinge.

Note how the gasket separates from the body.

Hinge Too Tight - In the illustration below, the hinge is too tight. Loosen the hinge and tighten the latch.

Latch

Travis Industries 4050525 100-01144

Note how the gasket separates from the body.

32 Maintenance

Adjusting the Door Hinge and Latch

• The door hinge and door latches may be adjusted to pull the door closer to the body. The illustration below details how to adjust these components. NOTE: Make sure to read the section "Door Alignment" on the previous page before adjusting the door.

Latch Adjustment

Loosen the lock nut and twist the pawl (clockwise to tighten, counter-clockwise to loosen). Tighten the lock nut to secure in place.

Hinge Adjustment

Door Hinge Bracket

Bracket (attached to side of

heater)

Door

Pawl

Lock Nut

Dimple (used to monitor hinge

bracket position)

(1) With the door closed, loosen the two bolts going through the door hinge bracket.

(2) Loosen the four nuts used to move the hinge adjusting plate. Tighten or loosen these nuts to adjust the door hinge bracket. Adjust the upper and lower nuts equally to insure the door remains level. Tighten the four nuts.

(3) Tighten the two bolts loosened in step 1.

Travis Industries 4050525 100-01144

Door

Hinge Adjusting Plate

Maintenance 33

Check for Air Leaks Around the Door, Glass, and Ashpan

! Air leaks into the firebox will decrease the stove's performance greatly, leading to excessive

sooting, inefficient burning, and perhaps a malfunction.

• Inspect the door gasket to make sure it is fully attached. Use stove gasket cement to re-attach if necessary. If the door gasket is worn or flattened, replace.

• If the glass is cracked, replace. The glass is held in place by glass clips that are underneath the airwash brackets. See the illustration below for details.

• Remove the ashpan and inspect the gasket around the perimeter of the ashpan. Re-attach, or replace the gasket if necessary.

Door Trim

Door Gasket

Attachment

Nuts

5/16"

Nutdriver

Door Frame

Glass Clip

Airwash Bracket

Glass (with

channel gasket)

Glass Clips

Airwash Brackets

Replacement Parts

ASH DUMP PLATE, LARGE PS/PI 91002022 GASKET, DOOR 7/8" x 85" WHITE ROPE 99900431 ASHTRAP DOORS 93005054 GASKET, GLASS 5/8"x137" BLACK 99900398 AUGER BEARING PLT, LOWER, LRG 91002024 GLASS, FRONT, P12/14, P13 91002004 AUGER BUSHING PLATE, UPPER 93005093 GLASS, SIDE, P12/14, P13 91002005 AUGER DRIVE COLLAR, 1997 & UP 91002021 GROMMET, IGNITOR WIRE BLACK RUBBER 100-02811 AUGER FLIGHT INSPECTION COVER 210-02702 GSKT, CLEAN-OUT CVR, 3.250 x 2.750 100-03235 AUGER FLIGHT, 2000+ LRG PEL 91002013 GSKT, COMB BLOWER (BODY) 100-03206 AUGER MOTOR STOP, P11-P15 93005096 GSKT, COMB BLOWER(MOTOR) 7" dia 100-03231 AUGER MOTOR, ALL PS/PI 90-0191 GSKT, EXHAUST PLATE 5.00"x5.00" 100-03239 AUGER SUB-ASS'Y - LARGE PEL 91002020 HANDLE, HOPPER LID 100-04312 BLOWER, COMB, PELLET 93005535 HANDLE, PEL CNTRL BOARD 97 99300094 BLOWER, CONV, P2-8/11-15/G1 98900755 HINGE PLATE ASS'Y 91002017 BRUSH, BROOM STYLE - PELLET 100-04301 HOSE NIPPLE, BARBED 100-04307 BURNPOT ASSY, FIREPOT 99300171 IGNITER, LG PS/PI 99300149 CABLE HANGER CLIP 100-04310 KNOB (PHENOLIC), 3/4" dia 100-04241 CNTRL BRD, LG PEL (P13-15) 100-00203 LBL, EXHAUST DAMPER 112-00505 CORD RESTRAINER 100-00112 MAGNET w/OUT SHEATH 1x.75" 1/4" THICK 100-02801 DAMPER PLATE S-ASS'Y - LRG PS 221-22089 OIL PAN, COMB BLOWER - LG PEL 210-03216 DRAFT (FLOW) SWITCH 93005060 POWER CORD, PS/PI 93005015 DRAFT FLOW TUBING 99300164 REFRACTORY SIDE CLIP, LEFT 210-03831L FIRE-BACK, CAST IRON, 93005059 REFRACTORY SIDE CLIP, RIGHT 210-03831R FIREBOX BAFFLE, LEFT 210-05199 SCRAPER ROD (P12/13/14) 211-01660 FIREBOX BAFFLE, RIGHT 210-05198 SNAP-DISC - 120deg CERAMIC NO 100-00232 FUSE HOLDER (IN-LINE) 100-00210 SNAP-DISC - 120deg NO # NO 100-00231 FUSE, 5AMP, 5 - FOR INLINE 93-0695 SNAP-DISC - 200deg NC # NC 100-00233 FUSE, 6AMP, 5 - CONTROL BOARD 93005019 TOOL, GLASS LATCH/RESTRICT0R 100-02302 GASKET CEMENT (WHITE), 4oz. 99900409 WIRE HRNS, PEL, JUMPER, LRGPELLET 100-00390 GASKET, ASHPAN 70" BLK 1/2"x1/8" ADH 99900428 WIRE HRNS, PEL, PS/PI 97 & UPLARGE OR SMALL 100-00391

Door Gasket

Travis Industries 4050525 100-01144

34 Normal Operating Sounds

Auger Motor

Exhaust Blower

The blower may create a low-pitched hum. This sound will change as the FEED RATE is altered.

When feeding pellets, you may hear the intermittent buzz of this motor running.

Heat Exchanger Tubes

You may hear the heated air being forced through these tubes by the convection fan.

Firepot

As pellets are fed into the firepot, a light clicking sound may be heard.

Convection Fan

The modern high efficiency fan may produce a low hum, particularly on "HIGH". This sound will change as the FAN dial is turned.

Travis Industries 4050525 100-01144

Safety Label 35

Minimum Clearance to Combustible Materials

(Measured from insert top)

Adjacent Sidewall A 8.75 in Mantel B 11.5 in Top Facing C 6.25 in Side Facing D 7 in

WARNING - DO NOT REMOVE OR COVER THIS LABEL

Listed Pelletized Solid Fuel Burning Appliance

For use in masonry or factory built (ZC) fireplaces.

Model: Astoria Bay PI

(Avanti PI)

Electrical Rating: 115 V., 60 Hz., Report No.: 028-S-51-2 Start 3 Amps, Tested to: ASTM E1509-95 Run 1.5 Amps Maximum Input Rating: 5.5 lbs (2.50 kg)/hr

This pellet appliance has been tested and listed for use in manufactured homes in accordance with Oregon Administrative Rules 814-23-900 through 814-23-909.

Install and use only in accordance with the installation and operating instructions. Contact local building or fire officials about restrictions and installation inspection in your area. Do not remove bricks or mortar from masonry fireplace or alter factory built fireplace.

Combustible floor beyond hearth extension must be protected by a non-combustible material, extending 6 in/150 mm (E) to the front and 6 in/150 mm (F) to the sides of door opening. Do Not Connect This Unit to a Chimney Flue Serving Another Appliance. Components Required for Masonry Fireplace and Factory Built Fireplace Installation: Listed 4 in diameter flue liner.

For use with 1/4 in/6 mm to 5/16 in/7 mm diameter pelletized wood fuels that comply with premium grade standards set by Association of Pellet Fuel Industries. Replace glass only with 5 mm ceramic glass available from your dealer.

DANGER: Risk of electric shock. Disconnect power before servicing unit. Do not route power cord beneath heater. The space beneath the heater must not be obstructed. Do not obstruct combustion air openings. Operate only with viewing door closed and with ashbox and ashpan in place. Keep all furnishings well away from heater. Do Not Overfire – If Heater or Chimney Connector Glows, You Are Overfiring. Inspect And Clean Chimney Frequently – Under Certain Conditions of Use, Creosote Buildup May Occur Rapidly.

HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP CHILDREN,

CAUTION

CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS. SEE THE NAMEPLATE AND INSTRUCTIONS. OPERATE THIS UNIT ONLY WITH THE FUEL HOPPER LID CLOSED. FAILURE TO DO SO MAY RESULT IN EMISSION OF PRODUCTS OF COMBUSTION FROM THE HOPPER UNDER CERTAIN CONDITIONS. MAINTAIN HOPPER SEAL IN GOOD CONDITION. DO NOT OVERFILL HOPPER.

Serial No.

2003 2004 2005 2006

Jan. Feb. Mar. Apr.

May Jun. Jul. Aug.

Sep. Oct. Nov. Dec.

DATE OF MANUFACTURE

Travis Industries, Inc.

10850 117th Pl. NE

Kirkland, WA98033

INSERT CLEARANCE DIAGRAM

MANTEL

FACIAOR TRIM

SIDEWALL

HEARTH EXTENSION

Pellet Insert

0468 (IGN)

AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAAA

AAAAAA

AAAAAAAA

AAAAAA

AAAA

Travis Industries 4050525 100-01144

36 Limited 7 Year Warranty

To register your TRAVIS INDUSTRIES, INC. 7 Year Warranty, complete the enclosed warranty card and mail it within ten (10) days of the appliance purchase date to: TRAVIS INDUSTRIES, INC., 4800 Harbour Pointe Blvd. SW, Mukilteo, WA 98275. TRAVIS INDUSTRIES, INC. warrants this gas appliance (appliance is defined as the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows:

Check with your dealer in advance for any costs to you when arranging a warranty call.

Mileage or service charges are not covered by this warranty. This charge can vary from store to store.

Years 1 & 2 - COVERAGE: PARTS & LABOR

Firebox Assembly:

Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box

Door Assembly:

Door Frame, Latch Assembly, Glass Retainers

Auger Assembly

Auger Flight, Auger Tube, Auger Bushings

Ceramic Glass

Glass (breakage from thermal shock)

Igniter System

Igniter, Igniter Leads

Electrical System

Auger Motor, Convection Blower, Exhaust Blower, Circuit Board, Snap Disks, Wiring Harness, Vacuum Switch

Exclusions: Paint, Gasketing

Years 3 Through 5 - COVERAGE: PARTS & LABOR

Firebox Assembly:

Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box

Exclusions: Paint, Gasketing, Ceramic Glass, Igniter System, Electrical System, Accessories (panels, legs, pedestal, gold trim, ceramic log, gold

door), Re-Installation Allowance

Door Assembly:

Door Frame, Latch Assembly, Glass Retainers

Auger Assembly

Auger Flight, Auger Tube, Auger Bushings

Years 6 & 7 - COVERAGE: PARTS ONLY

Firebox Assembly:

Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box

Exclusions: Paint, Gasketing, Ceramic Glass, Igniter System, Electrical System, Accessories (panels, legs, pedestal, gold trim, ceramic log, gold

door), Auger Assembly, Re-Installation Allowance, One-Way Freight Allowance, Labor

Door Assembly:

Door Frame, Latch Assembly, Glass Retainers

CONDITIONS & EXCLUSIONS

1. This new appliance must be installed by a qualified installer. It must be installed, operated, and maintained at all times in accordance with the instructions in the Owner’s Manual. Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty.

2. This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized Travis dealer.

3. Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty.

4. The warranty, as outlined within this document, does not apply to the chimney components or other Non-Travis accessories used in conjunction with the installation of this product. If in doubt as to the extent of this warranty, contact your authorized Travis retailer before installation.

5. Travis Industries will not be responsible for inadequate performance caused by environmental conditions such as nearby trees, buildings, roof tops, wind, hills or mountains or negative pressure or other influences from mechanical systems such as furnaces, fans, clothes dryers, etc.

6. This Warranty is void if: a. The unit has been operated in atmospheres contaminated by chlorine, fluorine or other damaging chemicals. b. The unit is subject to submersion in water or prolonged periods of dampness or condensation. c. Any damage to the unit, combustion chamber, heat exchanger or other components due to water, or weather damage which is the result of, but not limited

7. Exclusions to this 7 Year Warranty include: injury, loss of use, damage, failure to function due to accident, negligence, misuse, improper installation,

1. This 7 Year warranty excludes damage caused by normal wear and tear, such as paint discoloration or chipping, worn or torn gasketing, chipped or

1. Damage to gold or nickel surfaces caused by fingerprints, scratches, melted items, or other external sources left on the gold or nickel from the use of

10. TRAVIS INDUSTRIES, INC. is free of liability for any damages caused by the appliance, as well as inconvenience expenses and materials. Incidental or

11. This warranty does not cover any loss or damage incurred by the use or removal of any component or apparatus to or from the Travis appliance without the

12. Any statement or representation of Travis products and their performance contained in Travis advertising, packaging literature, or printed material is not part of

13. This warranty is automatically voided if the appliance’s serial number has been removed or altered in any way. If the appliance is used for commercial

14. No dealer, distributor, or similar person has the authority to represent or warrant Travis products beyond the terms contained within this warranty. TRAVIS

15. Travis Industries will not cover the cost of the removal or re-installation of hearths, facing, mantels, venting or other components.

1. If for any reason any section of this warranty is declared invalid, the balance of the warranty remains in effect and all other clauses shall remain in effect.

17. This 7 year warranty is the only warranty supplied by Travis Industries, Inc., the manufacturer of the appliance. All other warranties, whether express or

to, improper chimney/venting installation.

alteration or adjustment of the manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God.

cracked firebrick, etc. Also excluded is damage to the unit caused by abuse, improper installation, modification of the unit, or the use of fuel other than that for which the unit is configured.

cleaners other than denatured alcohol is not covered in this warranty. consequential damages are not covered by this warranty. In some states, the exclusion of incidental or consequential damage may not apply. express written permission of TRAVIS INDUSTRIES, INC. and bearing a TRAVIS INDUSTRIES, INC. label of approval. this 7 year warranty. purposes, it is excluded from this warranty. INDUSTRIES, INC. assumes no liability for such warranties or representations.

implied, are hereby expressly disclaimed and purchaser’s recourse is expressly limited to the warranties set forth herein.

IF WARRANTY SERVICE IS NEEDED:

1. If you discover a problem that you believe is covered by this warranty, you MUST REPORT it to your Travis dealer WITHIN 30 DAYS, giving them proof of purchase, the purchase date, and the model name and serial number.

2. Travis Industries has the option of either repairing or replacing the defective component.

3. If your dealer is unable to repair your appliance’s defect, he may process a warranty claim through TRAVIS INDUSTRIES, INC., including the name of the dealership where you purchased the appliance, a copy of your receipt showing the date of the appliance’s purchase, and the serial number on your appliance. At that time, you may be asked to ship your appliance, freight charges prepaid, to TRAVIS INDUSTRIES, INC. TRAVIS INDUSTRIES, INC., at its option, will repair or replace, free of charge, your appliance if it is found to be defective in material or workmanship within the time frame stated within this 7 year warranty. TRAVIS INDUSTRIES, INC. will return your appliance, freight charges (years 1 to 5) prepaid by TRAVIS INDUSTRIES, INC., to your regional distributor, or dealership.

4. Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store.

Accessories

Panels, Legs, Pedestal, Gold Trim, Ceramic Log with Log Shelf, Gold Door (See # 9 below)

Re-Installation Allowance

In cases where heater must be removed from home for repairs, a partial cost of re-installation is covered (pre-authorization required)

One-Way Freight Allowance

One-way freight allowance on pre-authorized repair done at factory is covered.

One-Way Freight Allowance

One-way freight allowance on pre-authorized repair done at factory is covered.

Travis Industries 4050525 100-01144

Optional Equipment 37

Thermostat (Part # 99300650)

! Do not connect 120 VAC

to the thermostat circuit of this heater (do not use a household thermostat used for a wall-board or other electical heater).

1 Attach the thermostat wire to

the circuit board (see the illustration to the right). Route the wire through the back of the heater (away from any hot or moving components).

2 Determine a location for the

thermostat that is within range of the 20' length of thermostat wire. It should be centralized in the room and away from the heater. The wire may be routed externally on the wall or behind the wall (preferred).

3 Follow the directions to the right

to attach the thermostat and thermostat wires.

50 60 70 80 90

Robertshaw

Attach the quick-connects to the two posts near the molex connector on the circuit board (orientation does not mater).

50 60 70 80 90

Pull the cover off the thermostat

Run the thermostat wires through the wall (cut off excess wire, leaving 6” of slack).

Expose 1/2” of wire and attach to these two posts.

Standard Screwdriver

Attach the thermostat to the wall through these two holes.

Travis Industries 4050525 100-01144

38 Optional Equipment

Remote Thermostat (Part # 99300653)

• Follow the instructions included with the remote thermostat for installation and operation.

Optional Log (Part # 98900126)

! Make sure the heater has fully

cooled before installation.

1 Open the door (see the instructions

included with the owner’s manual.

2 Attach the two log shelf legs to the

cross brace with the four included nuts. Make sure to use the correct leg for each side.

• Install the log shelf assembly and log following the directions below.

Center the log on the log shelf and

push it back so it rests against these two tabs.

NOTE: On inserts, the ash box must be installed before placing the log shelf assembly.

Left Log Shelf Leg

Log Shelf Cross Brace

Right Log Shelf Leg

Nuts

3/8" Nutdriver

Place the log shelf assembly so the

back edge contacts the cast firebrick in the rear of the firebox. Note how the taper on the assembly matches the taper on the cast firebrick.

When in place, the log should appear as shown in the photograph to the right.

Travis Industries 4050525 100-01144

Optional Equipment 39

ZC Kit (99200149)

The optional zc kit allows this insert to be directly into the framing of a house or mobile home. See the kit for installation details.

Rear Vent Shield (used only on inserts venting directly to the rear - note how it is slid back until it contacts the wall thimble)

12”

Minimum

House Shield

(prevents soot discoloration)

HIGHLY RECOMMENDED

Floor Protection

Vent Clearances (make sure all vent maintains 3” clearance to any combustible)

Enclosure Height

(measure from top of floor protection)

Floor Protection

Outside Air

Connection

(recommended)

Travis Industries 4050525 100-01144

Wall Thimble (note 3” clearance between vent and combustibles)

Vent Latch (used to connect and disconnect the vent )

40 Index

Adjusting the Fan Speed......................................21

Air Leaks..........................................................33

Ashpan (Opening and Disposing Ashes).................27

AUGER ON Light................................................21

Auto Mode........................................................20

Bi-Weekly Maintenance (or every 10 bags pellets)....25

Blower (Exhaust Blower Cleaning) .........................30

Blower Speed Adjustment....................................21

Cap (Pellet Vent Termination) ...............................11

Check for Air Leaks - Door, Glass and Ashpan.........33

Clean the Exhaust Blower....................................30

Clean the Exhaust Duct.......................................29

Clean the Glass.................................................27

Clean the Heat Exchange Tubes ...........................25

Clean the Vent...................................................30

Cleaning Ashpan (Opening and Disposing Ashes).....27

Cleaning the Firebox (Sweep Ash Into Ashpan) ........28

Cleaning the Firepot...........................................24

Cleaning the Hopper (Vacuum Hopper) ...................25

Clearances.......................................................10

Clinkers (Check Firepot for Clinkers)......................24

Controls...........................................................17

Curing the Paint.................................................17

Daily Maintenance (whenever using the heater)........23

Dimensions.......................................................6

Door (cleaning the gold).......................................25

Door (Opening)..................................................26

Door Gasket (inspection, removal) ........................33

Electrical Specifications......................................6

Emissions (EPA Compliance) ...............................6

EPA Compliance................................................6

Exhaust Blower (Cleaning)...................................30

Exhaust Duct (Cleaning)......................................29

Factory Built (Metal) Fireplace Requirements...........16

Fan (Adjusting the Fan Speed)..............................21

FAULT Light......................................................22

Firebox (Cleaning)..............................................25

Fireplace Sizing.................................................7

Fireplace Preparation..........................................7

Firepot Cleaning.................................................24

Firepot Inspection (Inspect the Burn) .....................23

Flames (Inspect the Burn)....................................23

Floor Protection Requirements (Hearth)..................7

Fuel.................................................................10

Gasket (door, glass - inspection & removal) ............33

Glass (Cleaning)................................................27

Glass Removal..................................................33

Gold (cleaning).................................................. 25

Hearth Requirements.......................................... 10

Heat Exchange Tubes (cleaning) ..........................25

Heating Specifications........................................ 6

Hopper Cleaning (Vacuum Hopper)........................ 25

Important Information .........................................2

Index.............................................................. 40

Installation Options............................................ 7

Installation Warnings (Before you Begin)................ 7

Introduction...................................................... 2

Listing Label..................................................... 35

Loading Pellets .................................................18

Mantel Requirements.......................................... 10

Manual Mode ....................................................19

Masonry Fireplace Requirements.......................... 15

Metal (Factory Built) Fireplace Requirements........... 16

Mobile Home Requirements.................................. 12

Modes of Operation............................................ 18

Noise (Normal Operating Sounds) .........................34

Normal Operating Sounds.................................... 34

Opening the Door............................................... 26

Outside Air....................................................... 12

Parts List ......................................................... 33

Pellet Vent Termination....................................... 11

Pellets (Fuel) ....................................................6

Pellets (loading) ................................................18

Pellets Piling Up ................................................23

Placing the Stove ..............................................7

Planning the Installation...................................... 7

Power Outages .................................................22

Priming the Auger ..............................................17

Remote Thermostat............................................ 38

Restrictor Adjustment......................................... 21

Safety Label .....................................................35

Safety Precautions ............................................4, 5

Serial Number Label ...........................................35

Smell in Home (Starting Heater for the First Time) .....17

Start-Up Sequence ............................................21

Thermostat Operation (Auto Mode)........................ 20

Vent (Cleaning) .................................................30

Vent Type ........................................................11

Venting Distance ...............................................11

Venting the Pellet Stove...................................... 11

Warnings .........................................................4, 5

Warranty.......................................................... 36

Yearly Maintenance (or every two tons).................. 29

Zero-Clearance (Metal) Fireplaces......................... 16

Travis Industries 4050525 100-01144

Avalon Astoria Bay User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual