BuckMaster AIR-TIGHT ZERO CLEARANCE FIREPLACE, AIR-TIGHT Installation & Operator's Manual

BuckMaster

IMPORTANT: INSTALLATION MUST BE MADE IN
ACCORDANCE WITH STATE AND LOCAL ORDINANCES
WHICH MAY DIFFER FROM THIS INSTALLATION
MANUAL.

CAUTION: READ RULES FOR SAFE
OPERATION AND INSTRUCTIONS

BuckMaster

AIR-TIGHT

ZERO CLEARANCE FIREPLACE

INSTALLATION/OPERATOR’S MANUAL

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

Manufactured by New Buck Corp. Effective April, 2003

Spruce Pine, NC 28777

TABLE OF CONTENTS

INTRODUCTION ............................................................................................................. 3

GENERAL INFORMATION AND SPECIFICATIONS ............................................. 3

PLANNING YOUR FIREPLACE INSTALLATION ................................................ 3-4

LOCATING THE FIREPLACE ......................................................................................... 3

CLEARANCES .................................................................................................................. 3

CHIMNEYS ........................................................................................................................ 4

TYPICAL INSTALLATION .............................................................................................. 4

INSTALLATION ......................................................................................................... 5-20

CHIMNEY ....................................................................................................................... 5-6

COMBUSTION AIR DUCT .............................................................................................. 7

HOT AIR DUCT INSTALLATION ............................................................................. 7-13

FIREPLACE DIMENSIONS ............................................................................................ 14

FRAMING-IN AND FINISHING ............................................................................... 13-17

FAN KIT ........................................................................................................................... 18

WIRING DIAGRAM ................................................................................................... 19-20

OPERATION .................................................................................................................. 20

STARTING A FIRE ......................................................................................................... 21

ASH REMOVAL .............................................................................................................. 21

CARE AND MAINTENANCE ................................................................................. 21-24

CATALYTIC COMBUSTOR REPLACEMENT .................................................. 22-23

BY-PASS DOOR REPLACEMENT ............................................................................. 24

TROUBLE SHOOTING ................................................................................................ 24

CHIMNEY FIRES .......................................................................................................... 24

PARTS LISTS ............................................................................................................ 25-27

WARRANTY ................................................................................................................... 28

1

2

INTRODUCTION

Thank you for your purchase of the BuckMaster Zero­Clearance Fireplace. By following the instructions in
this manual you can be assured of an installation that
will add both beauty and value to your home as well as
provide safe, efficient supplemental heat.

Your BuckMaster dealer can be a valuable source of
information in helping select the proper components for
your installation as well as recommending professionals
who can assist in installation and maintenance.

IMPORTANT INFORMATION

Read these instructions carefully and keep for future
reference.

√ Obtain a building permit and check local codes. This
installation must comply with their rulings.

√ NOTE: When burning any unit or appliance that
combust fuel for heat, such as coal, oil, wood or
natural and (L.P.) liquid petroleum gas. We highly
recommend the use of smoke and carbon monoxide
detectors in your home.

√ To prevent injury or damage, do not allow anyone
unfamiliar with solid fuel to operate this unit.

√ Do not store fuel or other combustible materials
within marked clearances.

√ Do not burn garbage, plastics, “green” wood,
composite wood products or coal. These materials can
produce gases and by-products that may harm the fire
chamber anc himney or produce excessive amounts of
creosote.

√ Never start a fire with gasoline, kerosene, charcoal
lighter fluid, or other flammable liquids.

√ Use only with approved chimney.

√ Black metal on front of unit is HOT - keep children

away.

FIREPLACE SPECIFICATIONS

Emissions 2.7 grams/hr.
Maximum BTU Output/Hr. 54,300
Estimated Heating Capacity 1800 sq. ft.

Height ............................................................. 48"

Width ........................................................ 38-1/4"

Depth ........................................................ 27-3/8"

Flue Size .................................................... 8" I.D.

Hot Air Ducts (Optional) .................................. 8"

Maximum Log Length .................................... 24"

Paint ..................................................... Flat Black

DISCLAIMER NOTICE

The BTU ranges and heating capacity specifications
are provided as guidelines only and in no way guarantee the
output or capacity of the unit. In warmer climates, on average,
the fireplace can be expected to heat a greater area than
indicated.
Other factors which affect the actual area that the unit
will heat include: the conditions of the building, heat loss, type
of construction, amount of insulation, type of air movements,
and location of the unit. The actual BTU output depends on the
type and condition of the wood being burned, draft setting and
the chimney that the fireplace is hooked up to.

NOTE: Your BuckMaster warranty is at the end of this manual.

Be sure to complete and return the warranty registration to the
manufacturer. If you have any problem your local dealer cannot
help you with, please contact the manufacturer direct.

PLANNING YOUR FIREPLACE

INSTALLATION

Before beginning actual installation, it is important to
thoroughly plan out the location of the fireplace and how it will
be used to provide heat to your home. Read the entire manual to
ensure that your installation meets all requirements and that you
have the necessary materials and equipment to complete
installation.

General Guidelines for Locating the Fireplace

1. Consider how it will be framed and its relation to doors,
windows, adjacent walls, and traffic patterns.

2. If possible, locate the fireplace so the chimney can be
installed without cutting through floor joists or roof rafters.

3. Determine where a duct can be run to provide outside air to
the fireplace for combustion (optional).

CLEARANCES FROM COMBUSTIBLES

Front to Adjacent Wall ........................................................... 8"

Non-combustible Hearth .............................................. 20"x46"

Base of Unit to Overhead Combustible ................................ 49"

Heat Vents to Ceiling ........................................................... 18"

Heat Ducts, Approved Chimney Pipe to Combustibles .......... 2"

Back, Sides, and Top of Unit ........................ Flush to Materials

(Built in Spacers)

3

CLEARANCES TO COMBUSTIBLES

HOT AIR DISTRIBUTION

The high BTU output of the BuckMaster fireplace makes
it an excellent heat source. The diagrams on page 8 and
9 show different duct systems that can be used to heat
one or more rooms in your home.

CHIMNEY CONSIDERATIONS

1. Any UL-103 (HT-2100 degree) type HT, or ULC­S629 (in Canada) factory build chimney system may
be used.

You may connect to a masonry chimney as long as the
conditions in section 8 4.5 of NFPA 211 are met. The
connector from the flue outlet of the BuckMaster and the
masonry chimney must also meet UL 103 type HT
requirements, unless the connector is visible from within
the room and a minimum clearance to combustibles of
18" (460mm) is maintained.

2. Do not vent any other appliance through the
fireplace chimney.

TYPICAL INSTALLATION

IMPORTANT: CAREFULLY REVIEW
COMPLETE INSTALLATION
SECTION BEFORE BEGINNING ANY
ACTUAL WORK.

4

INSTALLATION

PARTS NEEDED CHECKLIST:

1. BuckMaster Fireplace

2. Hot air duct kit

3. 6" wide steel floor safety shield

4. Approved Chimney including:
Anchor Plate
Appropriate number of lengths for proper
height
15
See chimney installation instructions
Firestop radiation shield, Attic radiation shield
Roof flashing
Rain Cap
Supports if necessary

OPTIONAL PARTS

1. Additional hot air ductwork

2. Grill box extension kit

3. Masonry Adapter Kit

4. Temperature probe port extension

5. Non-combustible Face and Hearth

6. Condar temperature probe model 9-85

7. 10" x 10" Grill kit (subject to change)

STRUCTURAL AND FINISHING
MATERIALS OPTIONS

1. Framing and sheathing

2. Facing materials: stone, bricks, tile, etc.

3. Premanufactured fireplace surround and hearth

4. Mantel

PLACING THE FIREPLACE

1. Move fireplace into selected location

2. Hearth preparation:
On combustible flooring, raise the front of the fireplace
enough to slide the 6" wide steel floor safety shield
halfway under the unit. Nail the exposed portion of the
strip to the floor. The safety shied provides added pro­tection against hot embers which could fall in between
the fireplace and the finished hearth. In all installations
consideration must be given to the thickness of the final

hearth material. NOTE: A clearance of 1/2" minimum

must be maintained between the top of the finished
hearth and the bottom of the lower grill to ensure that
the grill can be fully opened for removal of the ash pan.
Elevate the fireplace as required.

o

or 30o elbows if necessary

CHIMNEY GENERAL INFORMATION

1. A minimum of 3' is required from the top of the
chimney to the point where it passes through the
roof. In addition, the top of the chimney must be
at least 2' higher than any wall, roof ridge or
building that is within 10'.

2. Where more than one chimney uses the same
chase, or exits the roof in the same location,
maintain the clearances shown to prevent smoke
being drawn from a warm flue to a cold one.
These are suggested clearances only.

3. Whenever possible the entire run of the chimney
should be within the structure. The use of an
exterior chimney may cause poor draft, excessive
condensation and a faster buildup of creosote.

If it is necessary to use an exterior chimney, it should
be framed in with an insulated enclosure.

Do not fill the enclosure with loose fill. A 2" clearance
must be maintained around the chimney pipe.

4. The fireplace will support a maximum chimney
height of 15'. Additional length should be
supported at 10' intervals using components
specified by the chimney manufacturer.

5

INSTALLING THE CHIMNEY

Follow chimney manufacturer’s instructions for
proper installation. Be sure the chimney is equipped
with the corresponding anchor plate for attachment to
the fireplace.

Whenever possible, the chimney should take a
straight vertical path to the roof. If a bend is required,
use only one angled section with a maximum of two
elbows. Only 15
unit. Consult your dealer for selection of components
and observe required clearances.

1. Cut and frame in holes in ceiling and roof where
chimney will pass with 2" x 4"s. Finished
opening should be 13" x 13" . Use a plumb bob
to line up centers of holes with flue opening on
fireplace.

2. Attach a firestop radiation shield on the underside
of the framing for each floor that the chimney
goes through. At the attic level install an attic
radiation shield.

3. Place bead of hi-temp silicone caulk under
appropriate chimney anchor plate and push plate
collar into fireplace flue. Secure with metal
screws. Connect first chimney section per
manufacturer’s instructions. Continue adding
sections until required height is achieved.

o

or 30o elbows are approved for this

4. If the chimney is not enclosed and passes through
a vented attic space or roof, proceed as follows:

A. Slide roof flashing over chimney and seal

flashing to roof with roofing compound. If
roof is sloped, place top edge of flashing
under shingles and bottom edge on top of
shingles. Secure with roofing nails.

B. Place storm collar over chimney and

flashing. Tighten collar and seal joint with

good quality caulking compound.
C. Install raincap or chimney and secure.
D. Clean flashing with vinegar or solvent and

apply a coat of rustproof paint.

5. If the chimney is enclosed in the attic it must be
fitted with a good radiation shield and vented
flashing.

A. Install radiation shield in roof and attach with

four 3/4" screws or 1" nails.

B. Seal roof flashing to roof with roofing

compound. On sloped roofs, place top edge
of flashing under shingles and bottom edge
on top of shingles. Secure with roofing nails.

C. Place storm collar over chimney and push

down so collar makes contact with flashing.
Seal the collar joint with silicone or high
quality caulking.

D. Install and secure raincap.

6

COMBUSTION AIR DUCT

It is required that a separate source of outside
combustion air be provided for all installations. This
is particularly important in well insulated houses. The
BuckMaster outside air kit assures proper combustion
of the wood. The kit consists of an exterior vent,
flexible vent pipe, and mounting hardware.

The BuckMaster Fireplace is equipped with an
opening on both sides of the unit for connection of the
outside air duct. The actual duct may be run above or
below the floor level.

1. Cut a 4 1/4" hole in the outside wall of the house.
From the outside, install the vent with the vent
openings pointing down.

2. Push one end of the aluminum air duct over the
neck of the outside vent and the other end over
the fireplace connector.

3. Secure duct at each end with clamps supplied (2).

NOTE: Combustion air must be
connected to both sides of the unit and
cannot terminate in attic spaces.

IMPROPER INSTALLATION OF THE AIR INLET DUCT CAN STARVE OTHER

FUEL BURNING APPLIANCES OF COMBUSTION, VENTILATION, AND DILUTION

AIR AS A RESULT OF FIREPLACE OPERATION.

8" WARM AIR OUTLETS

The two 8" heat duct outlets at the unit top are
blocked off during manufacturing so the heat exits the
fixed-open permanent grill at the unit front. If the 8"
heat ducts are installed, however, they cannot be
blocked or have closeable dampers at the heat register
outlet.

CAUTION!

An exception to this would be the self-closing
dampers which are installed when using the booster
fans for extended duct runs over head. Their closure
would only occur in isolated instances, if at all.

7

HOT AIR DUCT INSTALLATION

The BuckMaster Fireplace can be used to heat a single room or an entire house. The diagrams on this and the
following three pages show approved duct configuration.

1) SAME ROOM WITH
DUCT OPTION
United States and
Canada (WIRING
OPTION A)

3) CENTRAL HEATING
United States and Canada (See
complete layout on following
page.)

(WIRING OPTION B,C or D)

2) SAME ROOM AND
SECOND ROOM United
States and Canada (WIRING
OPTION A)

4) TWO ADJACENT ROOMS
United States Only (WIRING
OPTION B or D)

5) BASEMENT, SAME

ROOM AND SECOND
ROOM
United States Only
(WIRING OPTION B)

NOTES:

A. In installations where ductwork is run downward, one

standard hot air vent must also open into the fireplace

room.
B. Booster fans must not be enclosed with a chase.
C. Booster fans on upward ductwork must be equipped

with snap disk, heat sensitive switches. Booster fans

on downward ductwork may be equipped with snap

disk, heat sensitive switches or an on/off switch.
D. All hot air ductwork must be 8" diameter B-Vent

through the initial wall or ceiling penetration. Single

wall pipe may then be used providing booster fans and

self closing dampers are installed on upward ducting.
E. See wiring section for detailed electrical requirements.
F. B-Vent will retain heat much better than single wall

pipe for longer runs.
G. Cut hole in outer skin of B-Vent to install snap disk.

8

TYPICAL DUCTWORK LAYOUT FOR CENTRAL HEATING

Approved for United States and Canada

BuckMaster Fireplace

NOTE:

DUCT WORK MAY
BE RUN OVERHEAD
OR BELOW FLOOR
FOR UNITED
STATES - BELOW
FLOOR ONLY FOR
CANADA.

When running ductwork
down, standard hot air
registers must also open
into room with
fireplace.

CLEARANCE CONSIDERATIONS WHEN INSTALLING HOT AIR DUCTWORK

NOTE: All hot air ductwork must be 8"

diameter B-Vent through the initial wall or
ceiling penetration. Single wall pipe may then
be used providing booster fans and self-closing
dampers are installed on upward ducting.

9

CENTRAL HEATING DUCT SYSTEM
CLEARANCES

All hot air ductwork must be 8" diameter B-Vent
through the initial wall or ceiling penetration.
Single wall pipe may then be used providing
booster fans and backdraft dampers are installed
on upward ducting.

2" clearance to combustibles must be maintained
around the hot air ductwork.

NOTE: When ducting down, attach a 90

of “T” connector for installation of room hot air register.

This is essential to dissipate heat in the event of fan failure.

Attach 90
basement or crawl space.

10

o

elbow to side of “T” to run ducting to

o

elbow to the top

OPTIONAL HOT AIR DUCT KIT AND 10" x 10" GRILL KIT

OPTIONAL HOT AIR DUCT KIT

2 - 8" diameter, 12" lengths, B-Vent
2 - 8" diameter 90

OPTIONAL 10" x 10" GRILL KIT (Subject to change)
2 - Hot air grills
2 - Grill Boxes

OPTIONAL PARTS: (from dealer)
8" x 36" length
8" x 18" length
8" x 6" length
8" - 3" - 9" adjustable length

GRILL BOX EXTENSION KIT
2 - Grill Box Extensions

Cut out in drywall for grill box is 11 1/8" square.

o

elbows, B-Vent

HOT AIR DUCT INSTALLATION

The hot air outlets may be vented into the same room as the
fireplace or to an adjacent room or second floor. When going
through a combustible wall or floor, a radiation shield must
be installed in the wall. The required hole size is 13" x 13"
for studs and flooring.

CAUTIONS:

1. Do not install heat registers below the level of the two
hot air outlets on the top of the fireplace.

2. Do not tie the ducts into a central heating system.

3. All hot air ductwork must be 8" diameter B-Vent
through the initial wall or ceiling penetration. Single
wall pipe may then be used providing booster fans and
backdraft dampers are installed on upward ducting.

11

4. Use only outlet registers approved for this unit.
Other registers may restrict air flow causing
overheating.

5. Do not run hot air ducts for a distance greater
than 10' unless system is equipped with booster
fans. (See page 6.)

6. Maintain a 2" minimum clearance from ducts to
combustibles.

NOTE: The grills must exit at least 18" away from

the ceiling and 16" from the side walls.

2" from sidewall if duct booster fans are installed
with snap disks.

FLUSH FIREPLACE INSTRUCTIONS WHEN
INSTALLED WITH 8" DUCT KIT

1. Fit a 90

o

elbow to the to of each duct sections.

Push down firmly to snap lock them together.

2. Attach the duct sections to the hot air outlets on
top of the fireplace. Fasten them in place by
screwing three metal screws through the pipe and
into the fireplace hot air outlets. Be sure face of
each elbow is parallel to the front of the fireplace.

3. The hot air outlet registers are in two parts (grill
and grill box). Put the grills aside for now. Slide
grill boxes over end of 90

o

elbows. Using a
straightedge, check that front of grill boxes are
even with front of fireplace. Secure each grill box
to elbows with two sheet metal screws.

RECESSED FIREPLACE INSTALLATIONS WHEN
INSTALLED WITH 8" DUCT KIT
When the hot air ducts will pass through a masonry
surround built around the fireplace, a grill box
extension kit must be used to make the face of the hot
air registers flush with the brick or stosne. Proceed as
follows:

1. Fit a 90

o

elbow to the top of each duct section.

Push down firmly to snap-lock them together.

2. Attach the duct sections to the hot air outlets on
top of the fireplace. Fasten them in place by
screwing three metal screws through the pipe and
into the fireplace hot air outlets. Be sure the face
of each elbow is parallel to the front of the
fireplace.

3. Screw grill box extensions onto standard grill
boxes using four metal screws. Slide grill box
assemblies over end of 90

o

elbows and adjust so
face of grill boxes will be flush with finished brick
or stone wall. Use two sheet metal screws to
secure each grill box assembly to the 90

o

elbows.

4. Slide 5 1/4" round duct extensions over inner grill
box duct collar.

If you have designed your masonry surround to extend
down over the face of the fireplace, you must also add
a masonry adapter for the front grill. An optional way
to deal with the front grill is to entirely remove it and
construct a soldier course of bricks over the opening.
(See finishing details on page 13.) Depending on the
amount of overlap it may also be necessary to add an
extension tube for the temperature probe access port
and replace the standard by-pass handle with an
extended version. (Consult your dealer.)

INSTALLING EXTENDED BY-PASS ROD AND
ACCESS PORT EXTENSION

1. Pull off top grill and remove set screw from by­pass rod retaining collar.

2. Pull out existing rod, insert extended rod and
replace set screw. If necessary, access door on by

-pass chamber may be removed to facilitate
alignment of rod.

NOTE: When bricking in the access port extension

sleeve (smaller one) and the extended by-pass rod
sleeve, make sure they are aligned properly.

12

INSTALLING MASONRY ADAPTER

1. With the top grill removed, position the masonry
adapter over the opening and mark the position of
the six holes in the adapter’s rear flange.

2. Drill holes into the face of the fireplace and attach
the adapter.

3. When finishing details are complete push grill
into adapter.

FRAMING-IN AND FINISHING
INSTALLATION

The BuckMaster fireplace has been designed so it can
be framed-in using standard combustible building
materials without providing additional fireproofing or
air spaces.

PRECAUTIONS
Do not place unit directly against an exposed vapor
barrier. A vapor barrier should be covered with sheet
rock or similar material.
When installing unit, be sure it is completely wired
during the rough framing stage. (See pages 17-18.)

FRAMING

1. Frame the fireplace using 2" x 4" or heavier
lumber. Use double studs on either side of the
fireplace. The header above the front black fcing
must by 2" x 4" set on edge.

2. Frame-in vertical sides of grill boxes with 2" x 4"s
(when applicable) and secure boxes with corner
nailing strips. See illustrations for general frming
layout.

3. Combustible wall material must be installed flush
with the fireplace facing. It may not project out in
front of the fireplace.

4. When facing the fireplace with brick, etc., the
material must not overlap the front of the unit
more than 2" on the sides to allow proper
operation of the doors.

5. When the front finish is complete, install the hot
air outlet grills with screws provided. The grills
should point downward to direct the hot air toward
the floor.

WARNINGS

1. Do not build in the area directly above the fireplace.

This area must remain empty.

2. The header should rest on top of the metal spacer.

Do not alter the spacers or notch the header to fit
around them.

3. Do not put wood or combustibles directly on

fireplace.

4. Do not block the rectangular air inlet or outlet, as

this will cause the fireplace to overheat. If installing a
brick soldier course as shown, the top metal grill must
first by removed.

5. A wood mantel, if installed,must be at least 49"

above the base of the fireplace.

6. Do not use a fireplace insert or other products not

specified for use with this furnace.

13

FIREPLACE DIMENSIONS (in inches)

NOTE: Rough opening size:
38 1/2" WIDE x 52" HIGH

14

NON-COMBUSTIBLE FACING CUT-OUT DIMENSIONS

Required for tile or marble facing

SET-BACK FOR FACING OPTIONS

15

ROUGH OPENING DIMENSIONS

ROUGH FRAMED FLOOR LEVEL INSTALLATION

SHOWN WITH OPTIONAL 10" x 10" GRILL KIT

HEADER DETAIL

ROUGH FRAMED RAISED INSTALLATION

SHOWN WITH OPTIONAL 10" x 10" GRILL KIT

16

FINISHING DETAILS AND OPTIONS

PARTIALLY OVERLAPPED NON-COMBUSTIBLE FACING

FINISHING HEARTH:

A non-combustible hearth (e.g. ceramic tiles, stone, bricks, etc.) must extend 24" in front of and 8" beyond the
sides of the fuel loading door. This hearth extension musts be placed on non-combustible flooring. If this unit is to
be installed with a raised hearth, a non-combustible hearth must extend 16" in front of and 8" beyond the sides of
the fuel loading door.

17

STANDARD FORCED AIR FAN

WIRING OF FAN SHOULD BE PERFORMED
BY A QUALIFIED ELECTRICIAN.

The forced air fan comes factory installed and includes the
prewired motor with fan blade and mounting hardware.

The directions below describes how to wire the fan for a
standard duct system equipped with booster fans and/or
snap disks. Refer to the Wiring Diagrams on pages 19 and
20 for further instructions.

1. Mount a 2" x 4" electrical box on the framing near the
fireplace for installing a switch to control the fan kit.

2. On the left side of the fireplace closest to the switch
location, feed a length of flexible conduit through the
7/8" hole in the sidewall of the fireplace.

3. The conduit must have three conductors: hot, neutral,
and ground.

4. Open the electrical box on the fan motor which is
located on the left side of the power conduit.

5. Run power conduit to switch box. Secure with BMX
connector (not supplied).

6. Run grounded electrical cable from a new or existing 15

AMP circuit to the switch box and connect wires and
switch as shown in wiring schematic.

NOTE: If any of the original wire as supplied with the
appliance must be replaced, it must be replaced with
type 16 ga., 105

o

C. rating wire or its equivalent.

NOTE: Installation and repair should be done by a
qualified service person. This 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, pet hair, etc. It is
imperative that control compartments and
circulating air passageways of the heater be kept
clean.

18

DOOR HANDLE INSTALLATION

1. Screw wooden handle onto shank and insert into door.

2. Secure with locking nut.

3. Slide on washer and latch cam and secure with locking nut.

STANDARD WIRING DIAGRAM

WITH WALL SWITCH

Refer to configurations shown on page 8.

STANDARD FANS WITH BOOSTERS

OPTIONAL WIRING

19

C. STANDARD FANS WITH BOOSTERS

ON SEPARATE WALL SWITCH

D. STANDARD FANS WITH BOOSTERS

ON THERMOSTAT

The BuckMaster fireplace is designed for burning
clean, clear wood only. Well dried hardwoods are
recommended for more even combustion, heating and
reduced creosote formation. Small to medium, brisk
fires are recommended.
Extremely hot fires may cause discoloration of gold
doors and are not required to achieve maximum
efficiency.

NEVER BURN COLORED PAPER, PAINTED

WOOD, WOOD WITH NAILS, ETC. THESE

MATERIALS CONTAIN COMPOUNDS THAT

WILL DAMAGE THE UNIT’S CATALYTIC

COMBUSTOR.

Do not overload the fireplace to increase burning
times. If you wish to hold a fire overnight, first close
draft controls tight, then pull approximately 1/4".
This will slow the fire, and leave a bed of hot embers
that will facilitate relighting in the morning. Slow
combustion fires produce more creosote which will
condense on the glass doors and chimney, requiring
more frequent cleaning.

WARNING

DO NOT USE A FIREPLACE INSERT OR

OTHER PRODUCTS NOT SPECIFIED FOR

USE WITH THIS FIREPLACE

20

ST AR TING A FIRE:

1. Pull out the two slide draft controls so they are fully
open.

2. Open the by-pass damper by giving the handle at the top
center of the unit a 1/4 turn to the left.

DRAFT

CONTROLS

BYPASS

DAMPER

OPEN

3. Place a few sheets of crumpled newspaper and some
small pieces of kindling wood directly on the firebrick.
Do not use additional grates or irons. Ignite the paper. Do
not use flammable fluids to start the fire.

4. Once fire is established, add larger pieces of dried natural
seasoned hard wood and close fireplace doors. KEEP
WOOD BEHIND PERMANENT LOG STOP AND DO
NOT LOAD WOOD ABOVE HEIGHT OF
FIREBRICK.

5. Allow 15 to 20 minutes to ensure fire is burning briskly,
then close by-pass damper by turning damper handle to
the right.

6. If necessary, the draft controls can be adjusted inward to
slow the fire and reduce the heat output.

ADDING WOOD TO EXISTING FIRE

Before adding wood, always open by-pass damper first and
close after loading is completed. NEVER OPERATE THE
FIREPLACE WITH THE BY-PASS DAMPER IN THE
OPEN POSITION EXCEPT DURING INITIAL FIRING
AND REFUELING.

For maximum heat production and safety, the fireplace
should ALWAYS be operated with the door completely
closed

CAUTION: Never remove ashes from heater with blower
running.

ASH PAN AND ASH REMOVAL
To remove ashes from the firebox, pull the grate slide plate to
the front with a poker, etc.

CLOSE OPEN

CLOSE

Push the ashes through the opening, into the ash pan.
When the ash pan is approximately two thirds full, remove
and empty.

IMPORTANT: Be sure to close slide plate after cleaning.

CAUTION: Ash pan may be hot, use care in handling.

Ashes should be placed in a metal container with a tight
fitting lid. Keep the container on a non-combustible floor
in a garage or outdoors, since ashes may remain hot for
days and give off toxic fumes. Ensure that ashes are
completely cool before final disposal. Leaving a small
amount of ash in the pan and on the fireplace grate will
help protect the metal from excessive heat and enhance
combustion efficiency.

DO NOT operate the fireplace without the ash pan in
place. Also, the ash pan must be completely closed during
operation to prevent excessive draft which can cause
overheating.

CARE AND MAINTENANCE

CAUTION! DO NOT CLEAN WHILE FIREPLACE IS
HOT.

1. Check the fiber rope gasket around the door periodically
to ensure a tight fit. Replace gaskets if they are not
providing a tight seal.

2. Clean the glass doors. The BuckMaster incorporates an
air wash system that helps keep the glass free of creosote.

If the glass becomes dirty as a result of frequent slow
burning fires, build and maintain a brisk fire. This will
burn off creosote deposits. The glass may also be cleaned
with a hot water/soap solution. Do not use abrasive
cleansers or pads on the glass.

If the glass is ever broken it must be replaced with original
equipment glass only. Consult your fireplace dealer or the
manufacturer. Do not replace with tempered or standard
glass. DO NOT OPERATE THIS FIREPLACE IF
GLASS IS BROKEN OR MISSING.

A. Ensure fireplace is cool.
B. Open door and lift door frame up to disengage

hinge pins.
C. Place door frame face down on a flat surface.
D. Unscrew glass retaining clips along inside edge

of door frame.
E. Lift glass straight up, out of retaining channels. If

glass is broken, use care to avoid sharp edges.

Note that gasket on glass faces front of unit.
F. Insert new glass, ensuring gasket is properly

seated.
G. Reinstall glass retaining clips.
H. Rehang door frame on hinges.

21

3. Door frame - The gold plated frame should be
cleaned with appropriate metal cleaner. Do not
use steel wool or other abrasives.

4. 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
vapor condenses in a relatively cool chimney flue
of a slow burning fire. As a result, creosote
residue accumulates on the flue lining. When
ignited, the creosote makes an extremely hot fire.

The chimney connector and chimney should be
inspected at least once every month during the heating
season to determine if a creosote build-up has
occurred. If creosote has accumulated, it should be
removed to reduce risk of a chimney fire. Your dealer
can recommend a qualified chimney sweep or provide
you with the proper tools to do it yourself. Use only
brushes that are designed for your type of chimney.

After each cleaning, check catalytic combustor to be
sure it is free of creosote or other particles which may
have fallen on it. A plugged combustor will cause the
fireplace to smoke.

CATALYST EQUIPPED

This wood heater contains a catalytic combustor,
which needs periodic inspection and replacement for
proper operation. It is against the law to operate this
wood heater in a manner inconsistent with operating
instructions in this manual or if the catalytic element is
deactivated or removed.

CATALYST WARRANTY

The combustor supplied with this heater is a 3" x 6"
Applied Ceramic catalytic combustor with 16 cells per
sq. in. Consult the catalytic combustor warranty also
supplied with this heater. All warranty claims should
be addressed to:

Applied Ceramics

Customer Service Department

P.O. Box 29664

Atlanta, GA 30359

770-448-6888
See enclosed catalyst warranty for instructions. New
Buck Corporation does not handle catalyst
replacements. Customer can order direct form
Applied Ceramics.

PROPER FUEL SELECTION

For best results, this heater is designed to burn dried
natural seasoned hard wood. Higher efficiencies and lower
emissions generally result when burning air dried natural
seasoned hardwoods, as compared to softwoods or to green
or freshly cut hardwoods. Green or freshly cut hardwoods

(wood with high moisture content) will not product the

BTU’s needed to heat your home. The result will be low
temperature reading on the catalyst probe, thus low BTU
output.

For peak performance, we suggest the use of natural
seasoned hard wood, loading wood length way from
front to rear.

NOTE: Soft woods such as pine, create more creosote,
clogging of chimney, and produce a less efficient burn
performance.

DO NOT BURN: trash or garbage, artificial or paper
logs, cardboard, gift wrapping, treated or painted wood
or any type of coal, or flammable fluids.

Burning treated wood, garbage, solvents, colored paper or
trash may result in release of toxic fumes and may poison
or render the catalytic combustor ineffective.

Burning coal, cardboard, or loose paper can produce soot,
or large flakes of char or fly ash that can coat the
combustor, causing smoke spillage into the room and
rendering the combustor ineffective. (Not covered under
warranty.)

CATALYTIC COMBUSTOR REPLACEMENT

1. Ensure that fireplace is cool.

2. Remove front grill.

3. Remove cast iron access door on front of secondary
heat chamber.

4. Lift out old catalytic combustor and replace with a
new 3" x 6" Applied Ceramic catalytic combustor
with 16 cells per sq. in. (Consult your dealer.)

5. Replace access door and front grill.

REMOVE GRILL

PULL OUT TO

ACCESS DOOR

22

NOTE: If you have installed a brick solder course
over the top grill, the catalytic combustor must be
removed through the firebox.

1. Remove firebrick baffle and supporting angle irons.

2. Slide flame impingement shield to the right and
remove.

3. Open by-pass door.

4. Reach into the firebox and raise catalytic combustor
to top of secondary heat chamber.

5. Remove combustor through open by-pass door. To
install new combustor, follow steps in reverse
order.

FIRE BRICK

SUPPORTING

ANGLE IRONS

INSIDE VIEW OF FIREBOX TOP

FLAME IMPINGEMENT SHIELD

STEEL

BAFFLE PLATE

SIDE VIEW OF FIREBOX

FRONT

TOP VIEW FIREBRICK ARRANGEMENT

CATALYTIC COMBUSTOR

BY-PASS DOOR

23

BY-PASS DOOR REPLACEMENT

All materials subjected to high temperatures will
eventually breakdown. If during regular inspection of
the firebox you discover a hole developing in the cast
iron by-pass door it should be replace.

1. Remove top grill and access door as explained in
catalytic combustor replacement.

2. Remove set screw from by-pass rod collar and jerk
on rod to free it from the by-pass door.

3. Lift out old door and replace with new one. Reinsert
by-pass rod and secure with collar set screw.

4. Replace access door and top grill.

SET

SCREW

TROUBLE SHOOTING

1. Smoke Coming From Fireplace
A. Inadequate Combustion Air - Check that exterior

air duct is not closed or blocked and that draft
controls are properly set.

B. Exhaust Fan - An exhaust fan, particularly in a

tightly build house, may pull smoke back down
the chimney and into the house. Try opening a
window a small amount of avoiding operating
such fans when fireplace is in use.

C. Wet Wood - Use only properly cured woods.

D. Dirty or Blocked Chimney - Check and clean as

necessary.

E. Chimney Too Short - Review chimney specifi-

cations in this manual and see that your install­ation conforms to them.

2. Excessive Creosote
Creosote is a dark brown and black combustion by­product. While deposits in the chimney cannot be
totally eliminated, smaller, hot fires will minimize
formation.

CATALYTIC

COMBUSTOR

TOP VIEW

BY-PASS

DOOR

CHIMNEY FIRES

A chimney that is not regularly cleaned presents a
greater risk of chimney fire. When creosote deposits
are ignited, an extremely hot fire will result.

If you experience a chimney fire:

1. Close the fireplace door and close draft controls.

2. Evacuate all people from the house and notify the
fire department.

3. If possible, discharge a dry chemical fire
extinguisher or throw baking soda or sand on the
fire inside the fireplace to control the fire. DO
NOT USE WATER.

4. Check for smoldering or burning combustibles
next to the fireplace and chimney. Also check
that there are no sparks or hot embers on the roof.

5. Once the fire is out, have the complete system
thoroughly checked over before using again.

24

ITEM DESCRIPTION PART # ITEM DESCRIPTION PART #

1 Top Grill PO CL60-89787 13 Optional 8" Hot Air Duct x 12" N/A*

2 By-pass Handle PO CL60-89780 14 Optional 8" 90

3 Door (Gold) PC CL60-23803 15 Optional Grill Box PS CL60-24033

4 Glass PG CL60-89672 16 Optional 10" x 10" Grill PO CL60-86523

5 Door Handle PO CL60-89712 20 7/32" x 1" Hinge Pin PH 7321LSP

6 Door Handle (wood) PO CL60-89819 24 Door Latch PO CL60-24282

7 Ash Grill PO CL60-89711 67 3/8" Locknut PH 3816HNP5

8 Outer Side PS CL60-24002 68 3/8" Lockwasher PH 38LKWSP5

11 Outer Back PS CL60-23998 69 Grill Clips N/A

12 Outer Top PS CL60-24004

* USE COMMON 8" B-VENT PIPE

o

Elbow N/A*

25

ITEM DESCRIPTION PART # ITEM DESCRIPTION PART #

25 Inner Top PS CL60-24160 42 Glass Rope RP FTV125X1.00GA

26 Back Insulation N/A 43 Door Rope RP 7810863KRP

27 Cast Iron Access Door PC CL60-40347 44 Glass Holders PS CL60-24008

28 Inner Back PS CL60-24005 45 1/4" - 20 x 3/8" Screws N/A

29 Inner Side PS CL60-23999 48 Front Insulation N/A

31 Side Insulation N/A 49 Front Air Duct PS CL60-23996

32 Cast Iron By-pass

Door

33 By-pass Door Rod PO CL60-89707 52 Outer Front PS CL60-24060

34 3/8" x 3/8" Set Screw N/A 53 Top Insulation N/A

35 Catalytic Combustor PO CL60-89786 54 Access Door Gasket RP 7810863KRB

36 Ash Pan MA CL60AP 55 Flame Impingement Shield PS CL60-24053

38 Firebrick PR 900050 56 By-pass Rope RP FR2LD.750G

39 Log Retainer MA CL60-24299 57 Grate Slide Plate N/A

40 Bottom Grill (Black) PO CL60-89711 65 Steel Baffle Plate N/A

66 Angle Iron Supports N/A

N/A = PART NUMBER NOT AVAILABLE AT THIS TIME AND IS SUBJECT TO CHANGE

PC CL60-40346 50 Top Grill (Gold) PO CL60-89797

26

ITEM DESCRIPTION PART #

57 Rear Offset Brackets PS CL60-24040

58 Slide Plate PS CL60-24034

59 Compression Springs PH 141SPRING

60 3/16" Flat Washers PH 316FLW

61 Slide Plate Bracket PS CL60-24010

62 10 - 24 Lock Nuts PH 1024HNP

63 #10 x 1/2 Tek Screws PH 101612TEK

64 Slide Rod MF CL60-22015

65 Phenolic Knob PO BC413

ITEM DESCRIPTION

3 Vent

4 Clamp

5 8' x 4" Flexible Aluminum Vent Pipe

27

NEW BUCK CORPORATION (NBC)

“LIMITED WARRANTY” FOR THE BuckMaster STOVE

PLEASE READ THIS WARRANTY CAREFULLY

PRODUCTS COVERED

This warranty covers the new BuckMaster Stove heating unit, so long as it is owned by the
original purchaser, including optional and standard accessories purchased at the same time,
subject to terms, limitations, and conditions herein set out.

PRODUCTS NOT COVERED
This warranty does not cover the following:
Glass;
Refractory material such as refractory cement or firebrick;
Gaskets.

This Warranty will also not cover any damage and/or failure caused by abuse or improper
installation of the products covered.

WARRANTY TIME PERIODS

(A) Period I

For one year from the date of purchase, NBC will replace or repair, at its option, any part
defective in materials or workmanship. The costs of parts only are included. The customer pays
any labor or transportation charges required.
Thereafter

(B) Period II

For the period after the first year from the date of purchase and extending for 5 years as long as
the BuckMaster Stove is owned by the original purchaser, NBC will repair or replace, at its
option, any part defective in materials or workmanship, with the exception of: electrical motors,
wiring, switches, and components: optional and standard accessories; and all parts not
permanently attached to the heating unit. Parts not permanently attached to the heating unit are
defined as those items designed to be removed from the stove, including those removable with
common hand tools. The costs of parts only are included. The customer pays any labor or
transportation charges required.

PROCEDURE

Should you feel that your BuckMaster Stove is defective, you should contact any Buck Stove
dealer for the name of your nearest authorized Buck Stove service representative, who will
instruct you on the proper procedure, depending on which Warranty Time Period (Period I or
Period II) applies.

28

If for any reason you are dissatisfied with the suggested procedures, you may contact us in writing at:

New Buck Corporation
Customer Service Department
PO Box 69
Spruce Pine, NC 28777

CONDITIONS AND EXCLUSIONS

(A) Replacement of parts may be in the form of new or fully reconditioned parts, at NBC’s option.
(B) There is no other express warranty. All implied warranties of merchantability and fitness for use are limited to

the duration of the Express Warranty.

(C) New Buck Corporation is not liable for indirect, incidental, or consequential damages in connection with the

use of the product including any cost or expense or providing substitute equipment or service during periods of

malfunction or non-use.
Some states do not allow the exclusion of incidental or consequential damages, so the above exclusion may not
apply to you.
(D) All warranty repairs under this warranty must be performed by an authorized Buck Stove service

representative. Repairs or attempted repairs by anyone other than an authorized service representative are not

covered under this warranty. In addition, these unauthorized repairs may result in additional malfunctions, the

correction of which is not covered by warranty.

OTHER RIGHTS

This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

OWNER REGISTRATION CARD

The following Owner Registration Card must be completed in entirety and mailed within 30 days from the date of
purchase or from the date of installation, if installed by a factory certified installer, to New Buck Corporation in
order for warranty coverage to begin.

PLEASE NOTE: The Owner Registration Card must contain the Authorized Buck Stove Dealer Code

Number and the Certified Installer’s number (if applicable) for warranty coverage to begin.

To be completed by selling distributor or dealer for customer:

Name ___________________________________________________________________
(Last) (First)
Address _________________________________________________________________
City ______________________________ State __________________ Zip ___________

Model: BuckMaster

Serial Number _____________________

Date of Installation: Day ____________ Month ___________ Year _______

Installer’s Name _______________________________________________________
Installer’s Certification Number __________________________________________

Dealer’s Name ________________________________________________________

Dealer’s Address ______________________________________________________