Avalon Stoves Flush Wood Insert User Manual

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F l u s h W o o d Insert

Owner's Manual

Masonry Fireplace Insert

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SAFETY NOTICE:

If this appliance is not properly installed, a house fire may result. For your safety, follow the installation directions. Contact local building or fire officials about restrictions and installation inspection requirements in your area.

Travis Industries, Inc.

4800 Harbour Pointe Blvd SW

Mukilteo, WA 98275

Industries, Inc.

$10.00 100-01157

4041116

Listed

Tested to: U.L. 1482

2 Introduction

Introduction

We welcome you as a new owner of a Travis Industries Flush Wood wood-burning fireplace insert. In purchasing a Flush Wood 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 Flush Wood is one of the finest appliances the world over. This manual will explain the installation, operation, and maintenance of this appliance. Please familiarize yourself with the Owner's Manual before operating your appliance and save the manual for future reference. Included are helpful hints and suggestions which will make the installation and operation of your new appliance an easier and more enjoyable experience. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your appliance.

Important Information

No other Flush Wood appliance has the same serial number as yours. The serial number is stamped onto the label on the back of the appliance.

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

Model: Flush Wood Insert

Serial Number:

Purchase Date:

Purchased From:

traviswarranty.com

Or, mail your warranty card to:

Travis Industries House of Fire 4800 Harbour Pointe Blvd. SW Mukilteo, WA 98275

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.

Table of Contents 3

General Information

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

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

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

Features & Specifications ....................................6

Fireplace Insert Installation

Planning The Installation .....................................7

Preparation for Installation ..............................7

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

Additional Accessories Needed for Installation ....7

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

Installation Considerations.............................. 8

Masonry Fireplace Requirements..........................8

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

Insert Placement Requirements ............................9

Face Dimensions...............................................9

Drafting Performance .........................................10

Leveling Bolt Installation......................................10

Flue Installation .................................................10

Block-Off Plate Installation...................................11

Surround Panel Installation ..................................12

Face Installation ................................................14

Re-Routing the Electrical Cord to the Left Side ........15

Insert with Positive Connection .............................16

Insert with Direct Connection................................16

Operating Your Appliance

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

Before Your First Fire .........................................17

Door Operation .................................................18

Bypass Operation ..............................................19

Starting a Fire ...................................................19

Adjusting the Burn Rate ......................................21

Ash Removal ....................................................21

Blower Operation ..............................................22

Re-Loading the Stove .........................................22

Overnight Burn..................................................22

Normal Operating Sounds ...................................22

Hints for Burning................................................23

Selecting Wood .................................................23

Troubleshooting ................................................24

Maintaining Your Appliance

Daily Maintenance (while stove is in use) ................25

Remove Ash (if necessary)..............................25

Clean the Glass (if necessary) .........................25

Monthly Maintenance (while appliance is in use).......26

Door and Glass Inspection ..............................26

Creosote - Formation and Need for Removal ......2

Yearly Maintenance............................................27

Touch Up Paint.............................................27

Cleaning the Air Duct and Blower .....................27

Firebrick and Baffle Inspection .........................27

Door Parts ........................................................28

Replacing the Glass.......................................28

Replacing the Door Gasket..............................28

Replacing the Door Handle..............................28

Blower and Electrical Parts ..................................29

Firebox Parts ....................................................29

Baffle Parts..................................................29

Baffle Removal .............................................29

Air Tube Removal & Replacement ....................30

Brick Re mov al & Repl ac emen t ................................. 3 1

Warranty

Warranty ..........................................................32

Listing Information

Listing Label .....................................................33

Index

Index ...............................................................34

4 Safety Precautions

The viewing door must be closed and latched during operation.

Never block free airflow through the air vents on this appliance.

This appliance is designed and approved for the burning of cord wood only. Do not attempt to burn any other type of fuel other than cord wood in this appliance, it will void all warranties and safety listings.

Do not touch the appliance while it is hot and educate all children of the danger of a hightemperature appliance. Young children should be supervised when they are in the same room as the appliance.

36"

Gas

ASHES

Gasoline or other flammable liquids must never be used to start the fire or "Freshen Up" the fire. Do not store or use gasoline or other flammable liquids in the vicinity of this appliance.

Ashes must be disposed in a metal container with a tight lid and placed on a noncombustible surface well away from the home or structure.

Keep furniture, drapes, curtains, wood, paper, and other combustibles a minimum of 36" away from the front of the appliance.

This appliance 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.

Inspect the chimney connector and chimney at least twice monthly and clean if necessary. Creosote may build up and cause a house fire.

Do not connect this appliance to any chimney serving another appliance.

Type

Clay

Liner

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 appliance as well.

This appliance must be connected to a listed high temperature (UL 103 HT) residential type chimney or an approved masonry chimney with a standard clay tile, or stainless steel liner.

Safety Precautions 5

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

Do not place clothing or other flammable items on or near this appliance.

This Manual

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

Maintain the door and glass seal and keep them in good condition.

Avoid placing wood against the glass when loading. Do not slam the door or strike the glass.

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 make any changes or modifications to an existing masonry fireplace or chimney to install this appliance.

Do not make any changes to the appliance to increase combustion air.

Overfiring the appliance may cause a house fire. If a unit or chimney connector glows, you are overfiring.

Do not use a grate or other device to elevate the fire off of the firebox floor. Burn the fire directly on the bricks.

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

6 Features & Specifications

Installation Options:

• Masonry Fireplace Insert

WARNING: Do not install this fireplace insert into a factory-built metal (Z.C.) fireplace.

Features:

• EPA Phase II Approved

• 2.9 Cubic Foot Firebox Volume

• Single Operating Control

• Accepts Logs Up to 24" Long

• Steel Plate Construction (5/16" & 1/4")

• Heavy Duty Refractory Firebrick

• Standard High-Tech Blower

• Five Sided Convection Chamber

Heating Specifications:

Approximate Maximum Heating Capacity (in square feet)* 1,200 to 2,000 Maximum BTU's per Hour (Cord Wood Calculation) 73,300 Overall Efficiency (Oregon Method) 71.1 % Maximum Burn Time Up to 12 Hours

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

Dimensions:

6" Diameter Flue Vent

Weight 450 Lbs.

28-7/8"

5-5/8"

21-1/4"

21-1/2"

NOTE:

Clearances are measured from the base of the fireplace insert.

1-1/4”

11-1/8"

20-1/2"

Fireplace Opening

Electrical Line (may be re-routed to opposite side)

Figure 1

Emissions:

4.1 Grams Per Hour (EPA Phase II Approved)

Installation (for qualified installers only) 7

SAFETY NOTICE:

Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in property damage, bodily injury, or even death. Contact local building or fire officials about restrictions and installation inspection requirements in your area.

Planning The Installation

We suggest that you have an authorized Travis Industries dealer install your fireplace insert. If you install the fireplace insert yourself, your authorized dealer should review your installation plans.

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

Preparation for Installation

• Check for damage to the exterior of the fireplace insert (dents should be reported, scratches can be

fixed by applying touch up paint).

• Check the interior of the firebox (replace cracked firebrick and make sure baffle is in place).

The fireplace insert can be lightened by removing the firebricks and baffle (pg 29) - replace before operation.

Packing List

• Touch-Up Paint

• Leveling Bolts

• (3) Chimney Brackets with (6) Tek Self-drilling screws (for attaching the flue to the fireplace insert)

• (6) 10-24 x 1/2" Type F Screws (for surround panels)

• (7) Spring Clips (for surround panels)

• Rheostat (for blower)

• Pull Tool for Bypass

Additional Accessories Needed for Installation

1 Face (see your dealer for details - see pg 14)

2 Surround Panels (see page 12)

Suggested Order of Installation

1 Remove the firebrick and baffle components from the fireplace insert (see pages 29 and 31).

2 Place the fireplace on the hearth 12" from the fireplace (on top of cardboard to prevent

scratching). If power is on the left side, switch the power cord at this time (see page 15).

3 Install the side suround panels (see page 12).

4 Slide the insert into place (it should portrude 1-1/4" from the fireplace opening).

5 Hook up the flue (with the baffle components removed - this allows for access from within the

firebox).

6 Install the top panel and trim. Then replace the firebrick and baffle components.

7 Install the face (see page 14).

8 Installation (for qualified installers only)

Installation Considerations

NOTE: Face Seal Connections are not allowed with this fireplace insert.

Installation Type

Insert with Positive Flue (Full Reline)

(Page 16)

Insert with Direct Connect Flue

(Page 16)

Considerations

• Provides best draft

• Easiest to clean

• Easiest to install

• Provides good draft

• Requires fireplace block-off plate - see page 11

Masonry Fireplace Requirements

• Chimney must have a clay tile liner or a stainless steel liner (positive connection)

• Entire fireplace, including chimney, must be clean and undamaged. Any damage must be repaired

prior to installation of the insert

• Chimney height: 15' minimum; 33' maximum.

• Entire fireplace, including chimney, must meet local building requirements

• Figure 2 shows the minimum size requirements for the type of fireplace used.

Minimum Fireplace Size

Combustible Mantel

Height (front)

Height (rear)

Non-Combustible Facing

Non-Combustible Hearth

Width (front)*

Width (rear)

Depth

Hearth Depth

Hearth Width

Facing Width

Facing Height

Mantel Height

Masonry

Fireplace

21-1/2" 21-1/2" 30-7/8" 21-1/4" 20-1/2" 17-1/4" 44-7/8" 46-7/8" 39" 41-1/2"

* Includes 2" for power cord.

Figure 2

Hearth Requirements

• The fireplace insert must be placed on the masonry hearth built to UBC standards.

• The non-combustible extension in front of the insert must extend 16" in front of the insert and 8" to

both sides.

Installation (for qualified installers only) 9

Insert Placement Requirements

• The insert must be placed so that no combustibles are within, or can swing within (e.g. drapes,

doors), 36" of the front of the insert

• Insert and hearth must be installed on a level, secure floor

• The minimum clearances, facing, and hearth requirements in Figure 3 must be met.

Minimum Clearances

Combustible Mantel

Sidewall to Insert

Side Facing

Top Facing*

Mantel to Insert*

Hearth (Front)

Hearth (Side)

Front of Insert

Side Wall

Combustible Top Facing

Facing

9" 9" 39" 41-1/2" 16" 8" 36"

Face Dimensions

Avalon Victorian Lace

33”

Non-Combustible

Hearth

Extension onto Hearth

1-1/4"

* Measure from the base of the

Fireplace Xtrordinair Arched

33-3/8”

51-1/2” Radius

fireplace insert.

Figure 3

Lopi Wilmington

33-1/2”

2-7/8”

23-1/4”

23-7/8”

Figure 4

23-1/4”

10 Installation (for qualified installers only)

Drafting Performance

This appliance relies upon natural draft to operate. External forces, such as wind, barometric pressure, topography, or factors of the home (negative pressure from exhaust fans, chimneys, air infiltration, etc.), may adversely affect draft. Travis Industries can not be responsible for external forces leading to less than optimal performance.

Leveling Bolt Installation

Two leveling bolts are included to level the insert if the fireplace has a stepped-up hearth. To install, raise the rear of the insert up and insert the leveling bolts into the holes in the rear corners of the insert. Adjust the bolts until they extend the same height as the hearth steps up. After the insert is installed, fine-tune the leveling bolts to level the insert (see Figure 5).

Flue Installation

Included in the owner’s pack are three “flue brackets” and six selfdrilling screws. Use these components to secure the flue to the fireplace insert.

The leveling bolts go into the holes at the rear corners of the insert.

The leveling bolts should stick out this far from the base of the insert.

Fireplace

Hearth

Figure 5

Flue (flexible or rigid)

Flue Bracket

Self-Drilling Screws

Flue Opening

Figure 6

Installation (for qualified installers only) 11

Block-Off Plate Installation

Whenever this appliance is installed with a direct connection a block-off plate, or other non-combustible seal-off device (e.g. damper adapter), will need to be installed. This device is used to seal the chimney, insuring no smoke enters the home and providing the chimney system with a seal to promote draft. The directions below detail the steps for construction and installation of a block-off plate.

1. Determine a location for the block-off plate at the top of the firebox below the damper area (make it high enough to allow installation of the connection pipe). The location should be level and in an area where it can be mounted easily. Measure the width at the rear ("A") and front ("B") of the firebox at the height where the block-off plate will be installed (see Figure 7). Then measure the depth of the location where the block-off plate will be installed ("C").

2. Make a cardboard template of the measurements, but add a 2" flange to each side. This flange will be used to mount the block-off plate to the inside of the firebox. Bend the flanges downwards on the template and place it inside the fireplace. If the template fits correctly in its planned location, go to the next step. If it does not, make a new template with the appropriate corrections until it fits correctly.

3. With the template in place, mark the location of the flue (see “Dimensions” on page 6). This location approximates the center of the flue when the insert is in place (a slight offset may occur based upon insert and block-off plate placement). Remove the template and cut a 6 1/4" diameter hole centered on this mark.

4. Make the block-off plate of 24 gage or thicker steel to match the template. Drill two holes in each flange for mounting the plate.

5. Mount the block-off plate using masonry screws.

6. Insulate the block-off plate using high-temperature fiberglass insulation (Kaowool® or equivalent) and furnace cement (allow the cement to dry for at least 24 hours before burning).

7. After placing the appliance and installing the pipe through the block-off plate, use high-temperature fiberglass insulation and furnace cement to seal any cracks between the pipe and block-off plate.

See the dimensions to

determine the location of the

center of the flue.

Firebox

Damper

Block-Off Plate Template

2" Flanges (for attaching

the block-off plate)

See the dimensions to determine the location of the center of the flue.

Measurement

"A"

Measurement

Measurement "B"

"C"

Figure 7

12 Installation (for qualified installers only)

Surround Panel Installation

The surround panels are available in two sizes shown below.

Width Height Part#

8" Panels 45-1/2" 29-1/2" 99300240

10" Panels 49-1/2" 31-1/2" 99300241

12" Panels 53-1/2" 33-1/2" 99300242

FOR INSIDE FIT PANELS ONLY: the panels may be cut down to fit within the fireplace - see directions below.

Do not cut more than 4" from each side panel.

The rheostat is mounted into the side panel. It requires 1/8" and 3/8" diameter holes to be drilled into the panel. Position the rheostat a minimum 3" away from the insert.

7/16"

4" Min.

1. Before installing the side panels, position the insert over the hearth (not inside the fireplace). You may wish to place something under the insert to prevent scratching (cardboard). Install the side panels following the directions below.

Attach the surround panels with the 6 screws included with the fireplace insert.

HINT: Before installing the panels, pre-thread the holes in the side of the insert (use the selfthreading screws).

Run the rheostat wires behind the surround panel (cut the lock-tie holding them in place).

Run the power cord behind the surround panel

(cut the lock-tie holding it in place).

Installation (for qualified installers only) 13

2. Install the top panel following the directions below.

HINT: Before installing the top panel, position the insert in its final location (1-1/4" from the fireplace opening) and attach the flue to the insert.

Slide the top panel into place. The joggle clips on the back of the panel insert over the tabs on the side panel and the flange on top of the insert.

3. Install the trim and rheostat following the directions below.

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

Spring Clips

tighten the two set screws with a small standard screwdriver. Slide the trim over the panels. Place the spring clips behind the panels at the locations shown. This keeps the trim tight against the panels.

Top Trim

Micro (1/16”) Slotted Screwdriver

Right Side Trim

Attach the rheostat wires (orientation does not matter).

"L" Bracket

Secure the rheostat using the included nut and star washer. The knob presses into place.

Knock-Out for Power Cord

A knock-out is provided on both sides the trim. Use pliers to remove the knock-out. This allows the power cord to pass under the trim.

14 Installation (for qualified installers only)

Face Installation

There are several face options available for this fireplace insert. They all install with hooks that allow the face to be hung on the fireplace insert. Follow the directions below to install the face, bypass handle, air control handle, and door handle cover.

Face Installation:

The face has four hooks that hang on the cast-iron tabs near the door hinges. When installing, make sure the hooks insert fully and lock into place.

Air Control Handle

Un-Screw the air control handle (with rod) from the air control.

Install the air control knob, bypass control knob, and handle shield following the directions below.

Bypass Knob

Screw the bypass knob onto the damper control rod.

Handle Shield Installation

Use the two nuts (included with the face) to secure the handle shield and emblem to the right side handle.

NOTE:

There may be a slight gap between the emblem and shield after installation (this is normal).

Air Control Handle

Screw the air control handle (with rod attached) onto the air control.

Installation (for qualified installers only) 15

Re-Routing the Electrical Cord to the Left Side

The power cord is connected to the right side of the insert when it leaves the factory. It may be re-routed to the left side following the directions below. Do this procedure before installing the surround panels.

1. Disconnect the molex connector and remove the power cord following the directions below.

Disconnect the molex connector leading from the power cord.

Rheostat Wires

Power Cord

Use pliers to compress the strain relief from the top and bottom while pulling it out of the hole in the side of the insert.

Make sure the power cord is disconnected prior to conducting these steps.

Remove the power cord.

2. Connect the power cord to the left side following the directions below.

Attach the molex connector on the power cord to the molex connector on the left side of the insert.

Power Cord

Leave the rheostat wires in place.

Re-attach the strain relief to the left side (use pliers to compress the strain relief from the top and bottom while pushing it into the hole).

Remove the button plug from the left side.

16 Installation (for qualified installers only)

Insert with Positive Connection

NOTE:

Most factory-built chimney manufacturers make stainless steel chimney liners, either flexible or rigid. This provides a wide variety of installation options. Make sure to follow the manufacturer's instructions for installation and support.

Install a non-combustible cover plate to prevent water

from entering the chimney

Combustible Mantle

Surround Panels

See the section "Insert Placement Requirements" for

minimum clearances and hearth required.

Cap (prevents water from entering)

Flue Liner

The liner must be stainless steel

connector or flexible vent. Follow the liner

manufacturer's insturctions for

installation and support.

Airtight Insulated Clean-Out

Remove damper or wire it open

Insert with Direct Connection

NOTE:

Direct connections require installation of an airtight block-off plate or damper adapter (see "Block-off Plate Installation" on page 10).

Stainless steel chimney connector must Extend 1' past the block-off plate or to the flue liner

Combustible Mantle

Surround Panels

See the section "Insert Placement Requirements" for minimum clearances and hearth required.

Figure 8

Flue Liner

Airtight Insulated Clean-Out

Remove damper or wire it open

Block-off plate or damper adapter

Operating Your Appliance 17

Safety Notice:

Read and follow all of the warnings on pages 4 and 5 of this manual.

Before Your First Fire

Verify the Installation

Before starting the stove, verify that it is properly installed and all of the requirements in this manual have been followed.

Keep all flammable materials 36" away from the front of the stove (drapes, furniture, clothing, etc.).

Curing the Paint

This heater 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. This typically lasts two to four hours. You may also notice oil burning off of the interior of the heater. This rust-stopping agent will soon dissipate.

Door Gasket - The door gasket might adhere to the paint on the front of the heater. Leave the door slightly ajar for the first fire and be careful when

opening the door after the first fire.

2 to 4 hours

Over-Firing the Stove

This stove was designed to operate at a high temperature. But due to differences in vent configuration, fuel, and draft, this appliance can be operated at an excessive temperature. If the stove starts to glow red (check the faceplate or inner top), you are over-firing the stove. Shut the air control down to low and allow the stove to cool before proceeding.

Over-firing may lead to damage of plated surfaces. If you are uncertain of over-firing conditions, we

suggest placing a stove thermometer (e.g. Rutland® Model 701) directly over the doors - temperatures

exceeding 800° are generally considered over-firing and will void the warranty.

18 Operating Your Appliance

Door Operation

The door becomes hot during use. Use a glove to open the door if the handle is hot.

To prevent smoke from entering the room, open the bypass before opening the door (see following page for directions). You can also open the door a small amount and let air enter the firebox.

Opening the Doors

Rotate the right door

handle down.

Closing the Doors

Shut the left door first.

Swing open the right door. Swing open the left door.

NOTE: Make sure the door latch clears the left side door.

With the door handle pointing

down, swing the right door shut

Rotate the door handle

upwards to secure the

doors.

Operating Your Appliance 19

Bypass Operation

The bypass controls the flow of smoke inside the heater. When pulled out, smoke goes directly up the flue, creating more draft. When pushed in, the smoke goes around the baffle, utilizing the secondary combustion and making the heater more efficient.

• When starting or re-loading, pull the bypass out.

• During normal operation, push the bypass in.

Use the included pull tool to operate the bypass rod

Bypass Pulled Out

Used for starting and re-loading

Bypass Pushed In

Used for normal operation

20 Operating Your Appliance

Starting a Fire

Since the dawn of time man has debated the best way to start a fire. Some use the boy-scout "tee-pee", some prefer the "tic-tac-toe" stack. Either way, review the hints and warnings below to ensure proper fire starting.

• Make sure the air control is pushed in and the by-pass pulled out. If additional air is needed, open the

doors 1/4" during the first five minutes of start-up.

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

If using a firestarter, use only products specifically designed for stoves - follow the manufacturer's instructions carefully.

If the smoke does not pass up the chimney, ball up one sheet of newspaper, place it in the center of the firebox and light it. This should start the chimney drafting (this eliminates "cold air blockage").

Use plenty of kindling to ensure the stove reaches a proper temperature. Once the kindling is burning rapidly, place a few larger pieces of wood onto the fire.

Operating Your Appliance 21

Adjusting the Burn Rate

Use the air control slider to control the burn rate of the stove. See the illustration below for details.

Use the air control to change the burn rate.

Low Burn

(air control closed)

High Burn

(air control open)

Approximate Air Control Settings:

Overnight Burn Pulled Fully Out to 1/32" In

Medium Burn 1/32" to 1/16" In

Medium High Burn 1/16" to 3/16" In

High Burn 3/16" to Pushed All the Way In

The air control becomes hot during operation - use gloves or a tool to prevent burns.

The air control may take several minutes to influence the burn rate. When making adjustments, you may wish to let the stove burn for 10 minutes to gauge performance.

Ash Removal

Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, away from all combustible

ASHES

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 thoroughly cooled.

22 Operating Your Appliance

Blower Operation

The blower will turn on once the stove is up to temperature. This is typically 15 to 30 minutes after starting the fire. Follow the directions below to alter the blower speed.

OFF

Turn the dial all the way counter-clockwise until it clicks off.

HIGH

The high position is all the way counter-clockwise, without clicking off.

LOW

Turn the dial all the way clockwise.

The blower may be used to affect heat output (i.e.: to reduce heat output, turn the blower down).

Route the power cord in a location where it will not come in contact with the appliance or become hot.

Re-Loading the Stove

Follow the directions below to minimize smoke spillage while re-loading the stove.

1 Open the air control all the way (push it in). Open the bypass (pull it out).

2 Open the door slightly. Let the airflow inside the firebox to stabilize before opening the doors fully.

3 Load wood onto the fire.

Overnight Burn

This stove is large enough to accommodate burn times up to twelve hours. Follow the steps below to achieve an overnight burn.

1 Move the air control to high burn and let the stove become hot (burn for approximately 15 minutes).

2 Load as much wood as possible. Use large pieces if possible.

3 Let the stove burn on high for 15 minutes to keep the stove hot, then turn the air control to low.

4 In the morning the stove should still be hot, with embers in the coal bed. Stir the coals and load

small pieces of wood to re-ignite the fire, if desired.

Differences if chimney height and draft may lower overall burn times.

Creaks and Clicks:

Normal Operating Sounds

The steel may creak or click when the stove heats up and cools down - this is normal.

Blower Sounds: The blower will make a slight "humm" as it pushes air through the stove.

Operating Your Appliance 23

Hints for Burning

• Get the appliance hot before adjusting to low burn

• Use smaller pieces of wood during start-up and high burns to increase temperature

• Use larger pieces of wood for overnight or sustained burns

• Stack the wood tightly together to establish a longer burn

• Leave a bed of ashes (1/2" deep) to allow for longer burns

• Be considerate of neighbors & the environment: burn dry wood only

• Burn small, intense fires instead of large, slow burning fires when possible

• Learn your appliance's operating characteristics to obtain optimum performance

Selecting Wood

• Dry Wood is Key

• Dry wood burns hot, emits less

smoke and creates less creosote.

Wet Wood

Leads To

Dry Wood

Testing Wood Moisture

• Split wood stored in a dry area will

be fully dry within a year. This insures dry wood. If purchasing wood for immediate use, test the wood with a moisture meter. Some experienced wood burners can measure wood moisture by knocking pieces together and listening for a clear "knock" and not a "thud".

Less Heat

More Smoke and Creostoe

More Heat

Leads To

Less Smoke and Creostoe

Why Dry Wood is Key

Wet wood, when burned, must release water stored within the wood. This cools the fire, creates creosote, and hampers a complete burn. Ask any experienced wood burner and he or she will agree: dry wood is crucial to good performance.

Wood Cutting and Storage

Leads To

Cut wood to length and chop into quarters.

Store the wood off the ground in a covered area. Allow for airflow around the wood to dry the wood.

Air Flow

24 Operating Your Appliance

Troubleshooting

Problem Possible Cause

Smoke Enters Room During Start-Up

Kindling Does Not Start - Fire Smolders

Smoke Enters Room While ReLoading

• Open the bypass (pg. 19).

• Open the air control (pg. 21).

• Cold Air Blockage - burn a piece of newspaper to

establish a draft.

• If the flame is not getting enough air, a small crack in

the door is all that is needed.

• Open the bypass (pg. 19).

• Open the air control (pg. 21).

• Not enough starter paper - use additional newspaper if

necessary.

• If the flame is not getting enough air, a small crack in

the door is all that is needed.

• Open the bypass before opening the door (pg. 19).

• Open the air control before opening the door (pg. 21).

• Let the air stabilize before fully opening the door. Then

open the door approximately 1 inch. Let air go into the firebox for a few seconds. Once the smoke appears to be flowing up the chimney consistently, open the door.

• Insufficient Draft - Chimney height and outside

conditions can negatively affect draft. In these cases a small amount of smoke may enter the home. Adding more pipe or a draft-inducing cap may help.

Stove Does Not Burn Hot Enough

Blower Does Not Run

Stove Does Not Burn Long Enough

• Wood is Wet - see the section "Selecting Wood" on

page 23 for details on wood.

• Make sure the air control is all the way open. Slide the

control back and forth to insure the control is not stuck.

• Insufficient Draft - Chimney height and outside

conditions can negatively affect draft. In these cases the fire may burn slowly. Adding more pipe or a draftinducing cap may help.

• Stove is Not Up to Temperature - This is normal. The

blower will come on when the stove is hot - usually 15 to 30 minutes.

• Electricity is Cut to the Blower - Check the household

breaker or fuse to make sure it is operable.

• Depending upon wood, draft, and other factors, the

burn time may be shorter then stated. Make sure the doors are sealing and not allowing air into the firebox See the section "Door and Glass Inspection" on page 26 for details.

• Check the ash bed for coals. Often, coals are still

glowing under a slight bed of flyash. By raking these into a pile you can re-start your stove quickly.

Maintaining Your Appliance 25

Failure to properly maintain and inspect your appliance may reduce the performance and life of the appliance, void your warranty, and create a fire hazard.

Daily Maintenance (while stove is in use)

Remove Ash (if necessary)

• Ash removal is not required once it builds up. 1/2" to 1" of ash may be desirable because it slows the

burn rate. Generally, remove ash once it has built up over 1". Follow the directions below to remove ash.

• Let the stove cool completely (at least two hours after the last coal has extinguished).

• Place a cloth or cardboard protector over the hearth to catch ash and protect against

scratching.

• Open the doors and scoop the ash into a metal container with a tight fitting lid. The

closed container of ashes should be placed on a noncombustible floor or on the ground, away from all combustible materials, pending final disposal.

Improperly disposed ashes lead to fires. Hot ashes placed in cardboard boxes, dumped in back yards, or stored in garages, are recipes for disaster.

Wood-burning stoves are inherently dirty. During cleaning have a vacuum ready to catch spilled ash (make sure ash is entirely extinguished).

There are vacuum cleaners specifically made to remove ash (even if the ash is warm). Contact your dealer for details.

ASHES

Clean the Glass (if necessary)

This appliance has an airwash to keep the glass clean. However, burning un-seasoned wood or burning on lower burn rates leads to dirtier glass (especially on the sides). Clean the glass by following the directions below.

Allow the stove to fully cool. Apply glass cleaner or soapy water to the inside of the glass. Wipe with newspaper or a paper towel.

For Stubborn Creosote:

Dip newspaper or a paper towel in cool ashes and wipe it on the glass. The ash acts as a light abrasive.

The glass will develop a very slight haze over time. This is normal and will not affect viewing of the fire.

26 Maintaining Your Appliance

Monthly Maintenance (while appliance is in use)

Make sure the appliance has fully cooled prior to conducting service.

Door and Glass Inspection

The door can be lifted off the hinges if extensive repairs are conducted.

Use wood stove gasket cement to re-adhere loose gasket.

The door must form an air-tight seal to the firebox for the stove to work correctly. Inspect the door gasket to make sure it forms an air-tight seal to the firebox.

The door latch should pull the door against the face of the stove (but not so tight as to not allow full handle rotation). If the latch requires tightening, remove a washer between the door cam and door frame. If the latch is too tight, add a washer between the door cam and door frame.

Severely frayed or thread-bare gasket should be replaced.

If the glass is damaged, replace it - see “Replacement Parts” for details.

Door Cam

Nut

Washers

High-Temperature anti-sieze may be used on the door hinges to eliminate squeaks.

Door Frame

Door Handle

Note flat portion on bottom of door handle shaft.

Creosote - Formation and Need for Removal

When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slowburning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire. The chimney and chimney connector should be inspected at least once every two months during the heating season to determine if a creosote buildup has occurred. If creosote has accumulated, it should be removed to reduce the risk of a chimney fire.

If you are not certain of creosote inspection, contact your dealer or local chimney sweep for a full inspection. Excess creosote buildup may cause a chimney fire, that may result in property damage, injury, or death.

Maintaining Your Appliance 27

Yearly Maintenance

Make sure the appliance has fully cooled prior to conducting service.

Touch Up Paint

Included with the owner's pack of this appliance is a can of Stove-Brite® paint. To touch up nicks or dulled paint, apply the paint while the appliance is cool. Sand rusted or damaged areas before preparation (use 120 grit sandpaper). Clean and dry the area to prepare the surface. Wait at least one hour before starting the appliance. The touched up area will appear darker than the surrounding paint until it cures from heat. Curing will give off some fumes while curing – open windows to ventilate.

Cleaning the Air Duct and Blower

Use a vacuum to clean the air ducts (channels). This prevents dust from burning and creating odors.

The blower (including blades) should be vacuumed every year to remove any buildup of dust, lint, etc.

Touch-Up

Paint

Remove the face. Use a vacuum cleaner to remove any debris or dust in the convection chamber or near the blower (

WARNING: do not touch the

blower blades).

Firebrick and Baffle Inspection

Use the illustration on page 29 as a reference for checking the following items. Make sure the appliance is cool before proceeding.

Baffle Firebricks - check the bricks along the ceiling of the firebox to make sure they are intact and have no gaps between them. Slide the bricks to eliminate any gaps.

Baffle Supports - make sure the front and back baffle supports in are place and not degraded. Slight scaling or rusting of the metal is normal.

Secondary Air Tubes - Check the two air tubes and collars to make sure they are intact and not severely deteriorated. Slight scaling or rusting of the metal is normal. Make sure the pins hold the air tubes in

place.

Floor and Wall Firebricks - replace any severely damaged firebrick along the side or floor of the firebox.

28 Maintaining Your Appliance

Door Parts

ID # Description Qty Part # ID # Description Qty Part #

1 Door Gasket (3/8" Rope) 99900429 2 Door Gasket Cement 1 220-00147 3 Door Hinge Asbly - Lower Left

Door Hinge Asbly - Lower Right Door Hinge Asbly - Upper Left

Door Hinge Asbly - Upper Right 5 Right Side Door (w gasket) 1 224-11101 6 Left Side Door (w gasket) 1 224-11100 7 Glass (either side) 2 173-01042 8 Glass Gasket (1/4" Rope) 224-11086 9 Wood Door Handle 2 224-14062 10 Left Door Handle Assembly 1 224-14055 11 Right Door Handle Assembly 1 224-14057 12 Door Cam 1 150-07108 13 Door Shield (included with face)

1 1 1 1

224-11096 224-11097 224-11098 224-11099

4 Upper Glass Clip

(with screws & gasket) Lower Glass Clip (with screws & gasket)

224-23026

224-23025

Replacing the Glass

The glass must not contact the door or glass clips directly. The glass gasket and glass clip gaskets isolate the glass to prevent contact with the metal components. Do not over-tighten the glass clips.

Lay the glass gasket in the door frame (cut off excess gasket). Place the glass on the gasket. Secure the glass clips to hold the glass in place (make sure the glass clip gaskets are in place).

Replacing the Door Gasket

The door gasket is attached to the outer groove of the door using stove gasket cement. Before installing, remove any residual cement. Lay the gasket in place (start at the lower outside corner) and cut off any excess gasket (do not stretch the gasket). The cement fully cures with heat from the stove. You may need to open and close the door repeatedly to get the gasket to seat fully.

Replacing the Door Handle

See the illustration above for a component list (see pg. 26 for details on adjusting the door).

Maintaining Your Appliance 29

Blower and Electrical Parts

Description Qty Part # Description Qty Part #

Left Blower 1 228-10069 Right Blower 1 228-10070 Blower Grommet and Spacer (4) 2 93005017 Rheostat 1 100-00122 Rheostat Knob 1 100-04111 Power Cord 1 100-00260

Firebox Parts

Baffle Parts

ID # Description Qty Part # ID # Description Qty Part #

1 Sec. Air Tubes w Pins (all 4) 1 98900742 2 Air Tube Pin (w Screw) 4 3 Baffle Front 1 210-05342 4 Baffle Rear 1 210-05343 5 Baffle Brick (see page 31) 6 Bypass Plate 1 221-12120 7 Damper Plate Assembly 1 221-12122 8 Damper Yoke 1 221-12123 9 Damper Rod Extension 1 100-11508

Baffle Removal

1 Remove the face to prevent damage. Open the doors.

2 Remove the front two air tubes (see "Air Tube Removal & Replacement" on the following page).

3 Remove front baffle support (rotate it forward to disengage it from the rear baffle).

4 Remove front row of six bricks.

5 Unscrew the damper rod extension from damper yoke and slide it forward to remove (you may

need to use pliers to unscrew the rod).

6 Lift the damper yoke up to disengage it from the damper plate. Remove the yoke from the stove

(this requires some angling and rotation to remove).

7 Remove the bypass plate and damper assembly by pulling forward and leaning the front edge

down.

8 Remove the four rear bricks.

9 Remove rear baffle by angling one side down and then removing at an angle through the firebox

opening.

30 Maintaining Your Appliance

Air Tube Removal & Replacement

VIEW FROM THE FRONT VIEW FROM THE REAR

Air Tube

Air Tube Bolt

3/8" Wrench

Air Channel

AIR TUBE REMOVAL

Air Tube Bolt

Note how the center of the air tube pin inserts into a hole on the air tube.

Air Tube Pin

Loosen this bolt 2 or 3 turns (do not remove).

Air Channel

With the bolt loosened the air tube can be slid out of the air channel.

The pin will then disengage from the air tube (you may wish to rotate the tube slightly).

Pivot the air tube downwards and slide it out of the air channel on the opposite side.

Maintaining Your Appliance 31

Brick Removal & Replacement

Floor and Side Brick Baffle Brick

Do not pry the brick - they chip and crack easily.

Remove the floor bricks first. The side bricks are pinned in place by the floor firebrick. Clean the firebox prior to replacing the brick.

Refer to the section "Baffle Removal" on page 29 for details on removing the baffle bricks.

ID # Description Qty Part # ID # Description Qty Part #

1 Brick - Uncut

(4-1/2" x 9" x 1-1/4")

Brick - Box of 9

10 175-00001

(qty = 1) 99900102

2.823”

(box of 9)

3.625”

0.826”

1.688”

3.125”

9”

2.688”

9”

1-1/4" thick

3”

1-1/4" thick

9 Set of Three (3) Notched Bricks

8.486”

8.83”

5.25”

2.5” Thick

4.25”

2 251-00049 4

2 251-00046 6

1 251-00048

3 251-00044

3.125”

1.625”

7.385”

8.882”

9”

6.691”

9”

2.75”

0.65”

4.5”

1-1/4" thick

4-1/2”

1-1/4" thick

2 251-00050

1-1/4" thick

1 251-00051

1-1/4" thick

2 251-00047

2 251-00043

32 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:

Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber

Door Assembly:

Solid Brass or Cast Door, Latch Assembly, Glass Retainers

Plated Finish

Plated Door, Legs, etc… See "Conditions & Exclusions" # 9 below.

Air Control Assembly

Slider Plate, Pressure Plate

Exclusions: Paint, Gasketing

Years 3 Through 5 - COVERAGE: PARTS & LABOR

Firebox Assembly:

Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber

Air Control Assembly

Slider Plate, Pressure Plate

Exclusions: Paint, Gasketing, Plated Finish, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance

Years 6 & 7 - COVERAGE: PARTS ONLY

Firebox Assembly:

Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber

Exclusions: Paint, Gasketing, Plated Finish, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance, One-

Way Freight Allowance, Labor

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. Over-firing (operation where the steel may glow red) of this appliance can cause serious damage and will nullify this 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

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

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

9. Damage to brass or plated surfaces caused by fingerprints, scratches, melted items, or other external sources left on the surfaces from the use of abrasive

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 purposes,

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.

16. 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 Indu stries, Inc., the manufacturer of the appliance. All other warranties, whether express or implied,

limited to, improper chimney/venting installation.

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.

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 (use cord wood only).

cleaners is not covered in this warranty. Damage to the surfaces from over-firing (operation where the steel may glow red) 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.

it is excluded from this warranty.

INDUSTRIES, INC. assumes no liability for such warranties or representations.

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.

Ceramic Glass

Glass (breakage from thermal shock)

Re-Installation Allowance

Firebrick

Breakage from thermal shock

One-Way Freight Allowance

Accessories

Legs, Pedestal, Panels, Blower

Door Assembly:

Solid Brass or Cast Door, Latch Assembly, Glass Retainers

Door Assembly:

Solid Brass or Cast Door, Latch Assembly, Glass Retainers

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 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.

Air Control Assembly

Slider Plate, Pressure Plate

Listing Label

MANTEL

HEARTH EXTENSION

FACIAOR TRIM

INSERT

SIDEWALL

INSERT CLEARANCE DIAGRAM

Listing Information 33

Air Control (Burn Rate) ...................................21

Air Tube Part Number ....................................29

Air Tube Removal & Replacement ....................30

Ash Disposal ................................................25

Baffle Parts ..................................................29

Baffle Removal and Replacement .....................29

Blower Cleaning............................................27

Blower Does Not Run (Troubleshooting) ............24

Blower Operation ..........................................22

Burn Rate ....................................................21

Chimney Cleaning .........................................26

Chimney Inspection (Creosote) ........................26

Cleaning the Ash...........................................25

Cleaning the Glass ........................................25

Clearances ..................................................9

Creosote Check ............................................26

Daily Maintenance .........................................25

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

Door and Glass Inspection ..............................26

Door Assembly .............................................28

Door Gasket Replacement ..............................28

Door Handle Replacement ..............................28

Door Opening ...............................................18

Door Parts ...................................................28

Draft Performance .........................................10

Emissions ....................................................6

EPA Approval ...............................................6

Face Dimensions ..........................................9

Features......................................................6

Fire Starting .................................................20

Firebox Assembly..........................................29

Firebox Parts................................................29

Firebrick and Baffle Inspection .........................27

Firebrick Removal & Replacement ....................29

Floor Protection Requirements (Hearth) .............9

Glass Cleaning .............................................25

Glass Replacement .......................................28

Hearth (Floor Protection).................................9

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

Hints for Burning ...........................................23

Installation (planning) .....................................7

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

Installation ...................................................7

Listing Label.................................................33

Maintenance ................................................25

Monthly Maintenance .....................................26

Noise (Normal Operating Sounds) ....................22

Opening the Door ..........................................18

Operation ....................................................17

Over-Firing the Stove .....................................17

Overnight Burn .............................................22

Paint (Touch-Up Paint) ...................................27

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

Re-Loading the Stove.....................................22

Safety Label .................................................33

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

Smell ..........................................................17

Smoke Enters Room (Troubleshooting)..............24

Sounds (Normal Operating Sounds) ..................22

Starting a Fire...............................................20

Stove Does Not Burn Long Enough...................24

Stove is Not Hot Enough (Troubleshooting) ........24

Table of Contents ..........................................3

Touch-Up Paint.............................................27

Troubleshooting (Operation) ............................24

Warranty Card ..............................................2

Warranty .....................................................32

Wood..........................................................23

Yearly Maintenance .......................................27

Avalon Stoves Flush Wood Insert User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual