Avalon Firestyles DVL Insert EF-2002 User Manual

DVL EF Insert

Owner's Manual

Featuring the

Burner

Tested and Listed by

OMNI-Test Laboratories, Inc.

Beaverton, Oregon

ANSI Z21.88 1998 CSA 2.33 M 98

CAN/CG A 2.17 M81, U.L. 307b

• Direct Vent Fireplace Insert

• Masonry or Factory Built (Metal)
Fireplace

• Residential or Mobile Home

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause

injury or property damage. Refer to this manual. For assistance or additional
information consult a qualified installer, service agency, or the gas supplier.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.

- Ins tallation mus t be per for m ed by a qualified installer , s er v ic e agenc y or the gas s upplier

IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

Installer: After installation give this manual to the home-owner and

explain operation of this heater.

 Copyright 2005, Travis Industries, Inc. $10.00 100-01151

Travis Industries, Inc.

4800 Harbour Pointe Blvd. SW

Mukilteo, WA 98275

2 Introduction

Introduction

We welcome you as a new owner of a Travis DVL Insert. In purchasing a Travis DVL Insert 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 Travis DVL Insert is one of the finest home
heaters the world over. This manual will explain the installation, operation, and maintenance of this
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 that will make the operation
and maintenance 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 Travis DVL Insert has the same serial number
as yours. The serial number is below and to the left of
the gas control valve.

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

Model: Travis DVL Insert EF
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.

Travis Industries 4041028 100-01151

Table of Contents 3

Introduction & Important Info.

Introduction & Important Information.........................2

Safety Precautions

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

Features & Specifications

Installation Options ...............................................6

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

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

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

Compliance..........................................................6

Insert Installation

Installation Warning...............................................7

Items Required for Installation .................................7

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

Items Packed with Face .........................................7

Order of Installation...............................................7

Insert Placement ..................................................8

Zero Clearance (Metal) Fireplace Requirements...........8

Hearth Requirements.............................................8

Insert Clearances .................................................9

Mantel Requirements.............................................9

Face Sizing..........................................................9

Gas Line Installation..............................................10

Vent Requirements................................................11

Altitude Considerations ..........................................11

Vent Installation ...................................................11

Vent Location.......................................................12

Vent Configurations...............................................13

Installation Without Surround Panels ........................14

Surround Panel Installation.....................................15

Manifold Removal and Installation ............................16

Operating Your Heater

Before You Begin..................................................22

Location of Controls ..............................................22

Starting The Pilot Flame..........................................23

Starting the Heater for the First Time.........................24

Turning the Heater On and Off .................................24

Adjusting the Flame Height......................................24

Adjusting the Blower Speed.....................................25

Normal Operating Sounds.......................................25

Normal Operating Odors.........................................25

Maintaining Your Heater

Maintaining Your Heater's Appearance......................26

Cleaning Your Heater.............................................26

Yearly Service Procedure.......................................26

Troubleshooting Table............................................27

How this Stove Works............................................28

Wiring Diagram .....................................................29

Replacement Parts List..........................................29

Listing Information

Safety Label ........................................................30

Warranty

Warranty.............................................................31

Optional Equipment

LP Conversion Instructions.....................................32

Cast Aluminum Firebacks .......................................34

Ceramic Firebacks ................................................36

Index

Index..................................................................38

Finalizing the Installation

Glass Removal.....................................................17

Log, Twig, and Ember Installation.............................19

Purge and Leak Test the Gas Line............................20

Pilot Flame Inspection............................................20

Air Shutter Adjustment...........................................21

Flame Inspection ..................................................21

Explain Heater Operation to Owner...........................21

Travis Industries 4041028 100-01151

4 Safety Precautions

• IF YOU SMELL GAS:

* Do not light any appliance
* Extinguish any open flame
* Do not touch any electrical switch or plug or unplug anything
* Open windows and vacate building
* Call gas supplier from neighbor's house, if not reached, call fire

department

• This unit must be installed by a qualified installer to prevent the possibility of an
explosion. Your dealer will know the requirements in your area and can inform you of
those people considered qualified. The room heater should be inspected before use
and at least annually by a qualified service person. More frequent cleaning may be
required due to excessive lint from carpeting, bedding material, etc.

• The instructions in this manual must be strictly adhered to. Do not use makeshift
methods or compromise in the installation. Improper installation will void the warranty
and safety listing.

Ok

Look for this label:

For LPG only | Pout 11” W.C.

If the label is present, the
heater is equipped for LP
(propane). If the label is
absent, the heater is equipped
for NG (natural gas).

• 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.

• It is imperative that control
compartments, screens, or
circulating air passageways
of the heater be kept clean
and free of obstructions.
These areas provide the air
necessary for safe
operation.

• This heater is either approved for natural
gas (NG) or for propane (LP). Burning
the incorrect fuel will void the warranty
and safety listing and may cause an
extreme safety hazard. Direct questions
about the type of fuel used to your
dealer. Check the label and flame adjust
knob on the gas control valve.

• If the flame becomes sooty,
dark orange in color, or
extremely tall, do not
operate the heater. Call
your dealer and arrange for
proper servicing.

• Do not operate the heater if
it is not operating properly in
any fashion or if you are
uncertain. Call your dealer
for a full explanation of your

?

heater and what to expect.

• Do not store or use gasoline
or other flammable liquids in
the vicinity of this heater.

Gas

• Do not operate if any portion
of the heater was
submerged in water or if any
corrosion occurs.

Travis Industries 4041028 100-01151

Safety Precautions 5

• 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.

• The viewing glass should be
opened only for lighting the
pilot or conducting service.

• Any safety screen or guard
removed for servicing must
be replaced prior to
operating the heater.

• Operate the heater
according to the instructions
included in this manual.

• If the main burners do not
start correctly turn the gas
off at the gas control valve
and call your dealer for
service.

• Light the heater using the
built-in piezo igniter. Do not
use matches or any other
external device to light your
heater.

• Never remove, replace,
modify or substitute any part
of the heater unless

instructions are given in this
manual. All other work must
be done by a trained
technician. Don't modify or
replace orifices.

• Allow the heater to cool
before carrying out any
maintenance or cleaning.

• The pilot flame must contact
the thermopile and
thermocouple (see the
illustration to the left). If it
does not, turn the gas
control valve to "OFF" and
call your dealer.

• This unit is not for use with
solid fuel

• Do not place anything inside
the firebox (except the
included fiber logs).

• If the fiber logs become
damaged, replace with
Travis Industries log set.

• Children and adults should

be alerted to the hazards of
high surface temperature
and should stay away to
avoid burns or clothing
ignition. Young children
should be supervised when
they are in the same room as
the heater.

• Instruct everyone in the
house how to shut gas off to
the appliance and at the gas
main shutoff valve. The gas
main shutoff valve is usually
next to the gas meter or
propane tank and requires a
wrench to shut off.

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.

• Plug the heater into a 120V
grounded electrical outlet.
Do not remove the
grounding plug.

• Don’t route the electrical
cord in front of, over, or
under 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).

Travis Industries 4041028 100-01151

6 Installation (for qualified installers only)

Features:

Installation Options:

- Works During Power Outages (millivolt system)

- High Efficiency

- Residential or Mobile Home

- Optional Thermostat or Remote Control

- Ember Fyre™ Burner for "Wood Fire" Look

- Quiet Blower for Effective Heat Distribution

- Convenient Operating Controls

- Variable-Rate Heat Output

- Fireplace Insert

- Masonry or Zero Clearance
(Metal) Fireplace

- Low Maintenance

Heating Specifications:

Natural Gas Propane

Approximate Heating Capacity (in square feet)* 600 to 2,000 600 to 2,000
BTU Input Per Hour (on high) 40,000 40,000
BTU Output on Low 20,700 17,900
Efficiency** (with blowers on) 78.9 % 81.0 %
AFUE (Annual Fuel Utilization Efficiency) 71.0 % 73.7 %

* Heating capacity will vary with floor plan, insulation, use of power heat vent, and outside temperature.
** Efficiency rating is a product thermal efficiency rating determined under continuous operation

independent of installed system.

23-3/4"

See the section "Vent Requirements"
for vent location.

33-3/8"* 8x10

Arch/Rect.

36-3/8"* 10x13

Rect. Panels

Fuel:
Compliance:

Panels

32-1/4"

17-3/8"

44-3/16"* 8x10 Arch/Rect. Panels

48-3/16"* 10x13 Rect. Panels

* Includes trim & standoffs

This heater is designed either for natural gas or for propane. Check the sticker on top of
the gas control valve or check with the installer to verify gas use.

This unit has passed the ANSI Z21.88 – 1998, CSA 2.33 M98 Vented Gas Fireplace
Heater Standard as tested by OMNI-Test Laboratories, Inc. Beaverton, Oregon.

16"*

1-5/8"*

Travis Industries 4041028 100-01151

Installation (for qualified installers only) 7

Installation Warnings:

! Failure to follow all of the requirements may result in property damage, bodily

injury, or even death.

! This heater must be installed by a qualified installer who has gone through a

training program for the installation of direct vent gas appliances.

! This appliance must be installed in accordance with all local codes, if any; if not,

follow ANSI Z223.1 and NFPA 54(88) in the USA and B-149 in Canada.

! In Manufactured or Mobile Homes must confirm with: In USA, Manufactured Home

Construction and Safety Standard, Title 24 CFR, Part 3280; In Canada, CSA Z240.4
and Gas-Equipped Recreational Vehicles and Mobile Housing. This appliance may

be installed in Manufactured Housing only after the home is site located.
! The DVL Insert is designed to operate on natural gas (NG) or propane (LP).
! All exhaust gases must be vented outside the structure of the living-area.

Combustion air is drawn from outside the living-area structure.
! Notify your insurance company before hooking up this heater.
! The requirements listed below are divided into sections. All requirements must be

met simultaneously. The order of installation is not rigid – the qualified installer

should follow the procedure best suited for the installation.

Additional Items Required for Installation

• 6-5/8” to 3” & 4” Co-Linear Adapter – W/ Flashing (Travis Part # 98900124)

• Face

• Gas Hookup Equipment

• Surround Panels (Optional - see “Installation without Surround Panels”)

• 3” and 4” Diameter Gas Liner

• Direct Vent Cap (Simpson Duravent Part # 991)

Packing List

• DVL Insert

• Log Set (Log Set, Coals, and Embers)

• Owner's Manual

• Two Leveling Bolts

• Propane Conversion Kit

• "Fireplace Altered" tag (attach to the fireplace)

• 8" Pipe Inlet (3/8" dia.)

• Door Latch Key

• Block Off Plate

• (2) Fireback Clips (for ceramic firebacks only)

Items Packed with the Face

• Face (with attachment hardware) • Face Installation Instructions

Order of Installation

1 If the heater is to use propane, install the propane conversion kit (see page 32)
2 Install gas line into the fireplace (do not connect to unit)
3 Position the heater (see "Insert Placement")
4 Connect the gas line and gas vent to the appliance.
5 Install the optional surround panels and trim. Attach the on/off switch.
6 Follow the instructions under "Finalizing the Installation" on pages 17 through 21.

Travis Industries 4041028 100-01151

8 Installation (for qualified installers only)

Insert Placement

• Insert must be placed within a code-conforming masonry fireplace or tested and listed zero-clearance

(metal) fireplace. Fix any fireplace damage prior to installation.

• Because the insert uses a circulation blower, clean the fireplace, smoke shelf, and chimney prior to

installation. We recommend painting the interior surface of the fireplace with latex paint to further

eliminate dust.

• This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance

produces when determining a location.

For tight fits (under 28"), you may remove the manifold. See the
section "Removing the Manifold"

Min. 38-1/4" - Includes 6" for gas line installation

Attach the "This fireplace has been altered..." plate
to the fireplace (use two screws or other suitable

Min. 23-3/4"

method). You may wish to place it in a location
where it will be covered by the surround panels.

The DVL inserts 16" into the
fireplace.

Use the leveling bolts for
fireplaces with recessed floors.

The gas line and shutoff
valve should be installed
prior to insert placement.

Run the on/off switch wires to the
right, behind the surround panels.

Run the power cord to either
side of the insert along the face.

Zero-Clearance (Metal) Fireplace Requirements:

• The damper ("A") and grate (with log set) ("B") must be removed (see the illustration below)

• The smoke shelf ("C"), internal baffles ("D"), screen ("E"),

masonry lining or refractory ("G" & "I"), and metal or glass doors

("F") may be removed (if applicable)

NOTE: If any internal baffle is cut, bent, or removed, the

fireplace must be permanently marked to indicate
that it has been altered and is no longer suitable
for burning solid fuel (wood).

• The insulation ("H"), and any structured rigid frame members

(metal sides, floor, door frame, face of the fireplace, etc.) must

not be removed or altered.

H

F

E

C

I

B

A

D

G

Hearth Requirements

• The heater must be installed on a non-combustible hearth extending a minimum 12" from the fireplace

opening (local codes may require a larger hearth). The hearth must also extend to both sides of the

face (see page 9 for face sizing).

Travis Industries 4041028 100-01151

Installation (for qualified installers only) 9

Insert Clearances

• Due to the high temperature of the fireplace, it should be located out of traffic and away from furniture

and draperies.

Side

Combustible or Non-Combustible Mantel

Min. 10”

Combustible Top Facing

Wall

Max. 8”

Min. 8-1/2”

See “Face
Sizing” Below

Min. 6”

Side Facing

The non-combustible hearth
must be as wide as the face
and extend to both sides.

Min. 6”

See “Face
Sizing” Below

12” Min. (from fireplace opening)

Mantel Clearances

The mantel must be a minimum 10” above the face and a maximum 8” deep.

NOTE: The combustible area above the facing must not protrude more than 3/4" from the facing. If it

does, it is considered a mantel and must meet the mantel requirements listed in this manual.

Face Sizing

Avalon Rosario DVL

26”

Lopi Discovery DVL

35-3/4”

25-7/8”

2”

Avalon
Cambridge

37-5/8”

DVL

FPX Arched
FPX Artisan

NOTE: Artisan faces
vary in size.

36-3/4”

Avalon

Craftsman

16-1/2”

* The decorative braces protrude 1/4”

FPX 34
Rectangular
Bevel

2-3/8”

2-1/4”

27-1/2”

27-1/2”

36”

Avalon
Rawhide

27”

35-3/4”

FPX 34
Architectural
Faces

Avalon
Victorian DVL

27”

35-3/4”

3-1/2"

Radius = 45”

26”

35-3/4”

26-1/2”

34-3/4”

Access
Door

26-1/2”

34-3/4”

Access
Door

27-7/8”

33-5/8”

Access
Door

Travis Industries 4041028 100-01151

10 Installation (for qualified installers only)

Gas Line Installation

! This appliance must be installed in accordance with all local codes, if any; if not, follow ANSI Z223.1

and NFPA 54(88) in the USA and B-149 in Canada.
! The heater and gas control valve must be disconnected from the gas supply piping during any

pressure testing of that system at test pressures in excess of 1/2 psig (3.45 kPA). For pressures

under 1/2 psig (3.45 kPA), isolate the gas supply piping by closing the manual shutoff valve.

• Leak test all gas line joints and the gas control valve prior to and after starting the heater.

Gas Line Connection

• The location of the gas inlet is shown below

• A manual shutoff valve is required within 3’ of the fireplace. It should be placed upstream of

the flex line (if used) and may be installed behind the access door inside the heater. ). T-

Handle gas cocks are required in Massachusetts in compliance with code 248CMR.

A 6" wide opening is provided on the left side, 3" behind the fireplace opening. It is 3" tall.

Shutoff Valve

With the 8" pipe nipple installed,
the inlet is approximately 15"
from the center of the
appliance.

Shutoff Valve

8" Gas Inlet Pipe (shipped with the

insert in the accessory pack)

The gas inlet on the gas control valve is
located 3-5/8" behind the fireplace
opening, 7-3/4" to the left of the center,
and 1-7/8" above the base of the
appliance.

Apply thread sealant to
both ends of the pipe prior
to installation.

Gas Control Valve

Fuel

• This heater is designed for natural gas but can be converted to propane. Check the sticker on the top

of the gas control valve to make sure the correct fuel is used.

Gas Inlet Pressure

Standard Input Pressure
Natural Gas 7" W.C. (1.74 kPA)
Propane 13" W.C. (2.73 kPA)

• If the pressure is not sufficient, make sure the piping used is large enough and the total gas load for
the residence does not exceed the amount supplied.

• The supply regulator (the regulator that attaches directly to the residence inlet or to the propane tank)
should supply gas at the suggested input pressure listed above. Contact the local gas supplier if the
regulator is at an improper pressure.

Travis Industries 4041028 100-01151

Installation (for qualified installers only) 11

Vent Requirements

! The gas appliance and vent system must be vented directly to the outside of the building, and never

be attached to a chimney serving a separate solid fuel or gas-burning appliance. Each direct vent gas
appliance must use it's own separate vent system.

! Make sure the exhaust pipe on the heater connects to the exhaust portion of the cap. The

illustrations below show how the flex liners should be attached.

• The exhaust vent must reline the entire length of the chimney and terminate above the chimney top

! Be careful not to crimp or rupture the liner when bending it into chimney offsets

• When installed, the vent must meet all of the vent
manufacturer's requirements

• Make sure to order the following:

-4” UL 441 Gas Liner for Exhaust, 3” UL 441 Gas Liner

for Air Inlet

- 6-5/8” to 3” & 4” Co-Linear Adapter & Flashing

(Travis Part # 98900124).

- Vertical Termination Cap (Dura-Vent pt # 991)

Altitude Considerations

Max. Ht. 35'
Min. Ht. 8'

Exhaust
(4" dia.)

Inlet
(3" dia.)

This heater has been tested at altitudes ranging from sea
level to 8,000 feet (2,400 M). In this testing we have
found that the heater, with its standard orifice, burns
correctly with just an air shutter adjustment. If local codes
require resizing the orifice, in the U.S.A. refer to ANSI

223.1, Appendix P, in Canada B-149.1 or B-149.2

! Failure to adjust the air shutter properly may lead to

improper combustion which can create a safety hazard.
Consult your dealer or installer if you suspect an
improperly adjusted air shutter.

Vent Restrictor

WARNING: Restrictor adjustment should

only be done by a qualified installer.
Only those installations determined to

be over-drafting require this
adjustment. The best indication of
over-drafting is a hyper-active flame
pattern (flames that move too quickly).
If the air shutter is constricted, the
flames become short and yellow, yet
still very active. Over-drafting may
affect the pilot, but this is not the best
way to determine over-drafting. Over­drafting is most likely in tall venting
configurations (especially if using an
“Exhaust Only Re-Line”). Do not
over-restrict the vent (this leads to
ghosting or lifting flames - reduce
restrictor setting).

To Adjust the Restrictor:

1

Determine a restrictor position. Start low(move
the restrictor a maximum two positions at a time)
and thoroughly test the heater before adjusting further.

2

Remove the screw with a 1/4" nutdriver (or screwdriver).

3

Rotate the adjustment plate clockwise until the correct index hole is below the pivot point.

4

Insert the screw into the correct index hole and tighten.

Rotate the
adjustment
plate to change
the restrictor
position.

9

Index Holes

This restrictor is in

Position #3.

10
11

3

4

5

6

7

8

NOTE:

Position #1 is the
fully open position

Max. 1'
offset

2

1

1/4" Nutdriver

Screw

Adjustment
Plate

Pivot Point

Travis Industries 4041028 100-01151

12 Installation (for qualified installers only)

Vent Installation

Exhaust (4”)

Vent Location

Inlet (3”)

High-Temp.

Silicone

4” dia. Gas

Liner

3” dia. Gas

Liner

Exhaust

Exhaust (4” Dia.)

13-1/4”

2-1/4”

Termination Cap
(Simpson Part # 991)

6-5/8” to 3” & 4” Co-
Linear Adapter (Travis
Part # 98900124)

Inlet

Center Line

2”

Inlet (3” Dia.)

13-7/8”

Apply high-temperature
silicone to the liners on
both ends and secure
with 2 screws.

High-Temp.

Silicone

16”

Fireplace

Opening

Vent
Configurations

Inlet & Exhaust Re-Line

Exhaust

4" dia.

Gas Liner

Suggestion:
Paint the fireplace cavity
with latex paint to eliminate
the possibility of odors from
the fireplace circulating into
the room.

Direct Vent Cap

(part # 991)

6-5/8" to 3" & 4" Colinear

Adapter & Flashing

(Travis Part # 98900124)

Inlet

3" dia. Gas Liner

Recommended Block-Off
Plate (non-combustible
metal and/or insulation).
Prevents odors from
chimney entering room.

Exhaust Only Re-Line

(recommended)

Exhaust

4" dia. Gas Liner

Any cracks or
damage inside the
chimney must be
repaired.

The block-off plate mus
seal the intake to the
chimney space. This
way air is drawn down
the chimney for
combustion air.

Block-Off Plate
(non-combustible
materials)

Inlet

Z.C. (Metal) firebox

NOTE: You may use either re-line configuration with a masonry or zero-clearance fireplace.

Masonry Fireplace

Travis Industries 4041028 100-01151