New Buck Corporation 91 Bay User Manual

Model 91 Bay Heater

Fireplace Insert & Freestanding

FEATURES

PREPARATION INSTALLATION

OPERATION MAINTENANCE SAFETY

Contact your insurance company for coverage and installation inspection

SAFETY NOTICE

If this heater 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.

This product is listed by Warnock-Hersey International, Inc. to the UL Standard No. 1482.

Manufactured by New Buck Corporation - Spruce Pine, NC 28777 - Revised 5/2001

Tested by ITS

PN-PI-9100660

TABLE OF CONTENTS

SECTION I

Room Heater Features................................................................................................... 3

Important Statements .................................................................................................... 3-6

SECTION II

Masonry Insert Installation ........................................................................................... 7-11

SECTION III

Residential Freestanding Heater Installation............................................................... 12-18

SECTION IV

Wood Heater Safety .................................................................................................... 19

SECTION V

Operation..................................................................................................................... 20-21

SECTION VI

Preventive Maintenance / Parts Replacement ............................................................. 22-25

SECTION VII

Troubleshooting .......................................................................................................... 26-27

WARRANTY...............................................................................................Rear Cover

SECTION I

The New Buck Corporation room heater Model 91 Bay is one of the safest and most efficient heating systems
available when installed and operated as specified in these instructions and as stipulated on the operation and
installation labels affixed to the unit. The unit is designed to burn wood fuel only.
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.

Throughout the manual, you will see this symbol. This indicates areas of importance regarding safety.
Please make a special note of these areas.

Install and use only in accordance with the manufacturer’s installation and operating instructions. Do not connect
this unit to a chimney flue serving another appliance. This unit is not designed for installation into Mobile Home.
This unit has been safety tested by ITS (Warnock-Hersey) to UL Standards 737 and 1482.

ROOM HEATER FEATURES

Before attempting to install or operate your heater, it is a good idea to familiarize yourself with the features and
operating controls of the unit.

OPERATING CONTROLS

WARNING: Model 91 Bay Heater was not designed for fire grates.

1. Bypass Damper: The bypass damper control is located in the top center of the heater front just under the top.

It is operated by pushing or pulling the rod. The damper is fully open when the handle is pulled out and fully
closed when it is pushed in. The damper must by OPEN before the door is opened.

2. Blower Control: The blower control (Rheostat) is located on the side of the unit. The rheostat is used to
vary the speed of the blower. It can be set at any position. It must be turned on to activate the automatic
thermostat on the stove.

3. Primary Air Controls: The primary air intake draft controls are located at the left and right bottom side of
the hearth. They are operated by moving the handle out to open (to allow air into the firebox) or in (to
control or close off) the air into the firebox. Right side primary air and air wash control (3A). Left side, (3),
also called shot gun air control, allows air to the center of the firebox of the stove.

4. Warm Air Outlets: Provides heat extraction from the top of the firebox.

5. Baffles: Directs air flow around the unit for maximum heat transfer.

6. Air Inlet: Allows cool air near the floor to be circulated through the blower and back into the warm air
chamber of the heater.

7. Door: Provides an “airtight” feature. The door allows a much higher burning efficiency than can be
obtained with an open firebox.

8. Hearth Extension: Offers protection from spilled ashes and cinders.

9. Power Cord: Provides electrical power to operate the blower.

10. Catalyst: Enables the unit to burn cleanly and efficiently.

11. Catalyst Probe: Probe is located to the right of the bypass damper rod. It is used to determine (catalyst)
temperature.

12. Automatic/Off/Manual Switch: Located at the bottom right corner of stove. In the “Manual” position, the

blower operates continuously. In the “Automatic” position, the blower is controlled by the internal
thermostat which reacts to the temperature of the air between the stove walls. (Not the same as the
temperature showing on the Catalyst Probe.)

SAFETY STANDARD COMPLIANCE

The Model 91 Bay catalytic solid fuel (wood) burning combination room heater/fireplace stove manufactured by
New Buck Corporation complies with US 1482-1994 and UL 737-1995 for residential freestanding and masonry
fireplace insert installations when constructed and installed in accordance with ITS approved documentation.

EPA COMPLIANCE STATUS

This manual describes the installation and operation of the New Buck Corporation Model 91 Bay wood heater.
These heaters meet the U.S. Environmental Protection Agency’s Emission limits for wood heaters sold after July
1, 1992. Under specific test conditions this heater has been shown to deliver heat at rates ranging from
approximately 10,000 to 54,500 BTU/hr for the Model 91 Bay.

MODEL 91 WOOD STOVE IDENTIFICATION

40

33

13

5

10

14

18

8

39

1

11

41

4

20

32

16

31

7

15

37 & 38

21

19

3A

29

35

36

6

28

1. Bypass Damper & Brass Spring Handle

2. Blower Control (Rheostat)

3. Primary Air Control Air Wash Rod for Both
Sides

3a. Shot Gun Air Control

4. Warm Air Outlets

5. Baffles (Interior of Stove)

6. Air Inlet

7. Door

8. Hearth Extension

9. Power Cord

10. Catalyst (Interior Firebox)

11. Catalyst Probe

12. Automatic / Off / Manual Switch

13. Brass Cap

14. Hinge Block

15. Brass Overlays

16. Brass Overlay Mounting Screws

17. Door Glass & Logo

18. Glass Clips

19. Hearth Brass

34

2

25

26

30

24

23

20. Door Gasket

21. Side Glass

22. Leveling Screws

23. Firebrick

24. Motor

25. Motor Mount Bracket

26. Cover Door

27. Cover Door Screws

28. Shot Gun Air Box

29. Ash Pan

30. Disc Thermostat

31. Door Handle & Brass Spring Handle

32. Air Wash Screen

33. Glass Gasket

34. Cover Door Hinge

35. Magnet Holder

36. Cover Door Magnet

37. Door Latch

38. Door Latch Screw

39. Lower Heat Shield

40. Hinge Pins

41. 8" Flue Exit

22

3

12

9

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 set of (3) (2"x3-1/2"x6"x25" cells). 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 (dry), natural wood. Higher efficiencies and lower emissions
generally result when burning air dried 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.

DO NOT BURN:

1) Treated Wood 3) Garbage 5) Solvents 7) Trash

2) Coal 4) Cardboard 6) Colored Paper
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.)

ACHIEVING CATALYTIC LIGHT-OFF

The temperature in the stove and the gases entering the combustor must be raised to between 700
catalytic activity to be initiated. The temperature can be determined by the Catalyst Monitor Probe. During the
start up of a cold stove a medium to high firing rate must be maintained for about 20 minutes. This can be
achieved by starting the fire with dry kindling, paper, and small split wood. Have the Bypass Damper fully open
(pulled out). This ensures that the stove, catalyst, and fuel are all stabilized at proper operating temperatures.
Even though it is possible (and likely) to have gas temperatures reach 600
fire is started, if the fire is allowed to die down immediately it may go out or the combustor may stop working.
Once the combustor starts working, heat generated in it by burning the smoke will keep it working.

ACHIEVING CATALYTIC LIGHT-OFF WHEN REFUELING

During the refueling and rekindling of a cool fire, or a fire that has burned down to the charcoal phase, operate the
stove at a medium to high firing rate for about 10 minutes to ensure that the catalyst reaches approximately 800
F.

o

F to 900o F for

o

F within two to three minutes after a

o

CATALYST MONITORING

It is important to periodically monitor the operation of the catalytic combustor to ensure that it is functioning
properly, and to determine when it needs to be replaced. A non-functioning combustor will result in a loss of
heating efficiency, and an increase in creosote and emissions. See Troubleshooting section for detailed
instructions BEFORE attempting to remove catalyst.

This catalytic heater is equipped with the means to monitor catalyst operation. Properly functioning combustors
typically maintain temperatures in excess of 1000
Catalyst Troubleshooting section of this owner’s manual.

o

F. If catalyst temperatures are not in excess of 500o refer to

CAUTION AGAINST OVER-FIRING

Do Not Over-fire This Heater.

Attempts to achieve heat output rates that exceed heater design specifications can result in permanent damage to
the heater and to the catalytic combustor.

ASH REMOVAL

Whenever ashes build up in the firebox and when the fire has burned down and cooled, remove excess ashes.
Leave an ash bed approximately 1 inch deep on the firebox bottom to help maintain a hot charcoal bed. To
remove ashes the dump is located at the left inner bottom. By lifting the dump door, place the ashes through the
dump opening. The ashes fall directly into the ash pan. The ash pan is located at the left side under the hearth
behind the cover door.

NOTE: Be sure to turn the room air blower off before removing ashes. Open cover door and slide ash pan out.
NOTE: Fueling and ash removal door (s) must remain closed when in operation.

Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be
placed on a non-combustible floor or on the ground, away from all combustible materials, pending final disposal.
The ashes should be retained in the closed container until all cinders have thoroughly cooled.

NOTE: Be sure to turn room air blower back on when job is completed.
NOTE: The room heater is not to be connected to any air distribution duct.

CREOSOTE - FORMATION AND NEED FOR REMOVAL

When wood is burned slowly, it produces tar and other organic vapor, which combined with expelled moisture
forms creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a
result, creosote residue accumulates on the flue lining. When ignited this creosote makes an extremely hot fire.

NOTE: SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

SECTION II

MASONRY INSERT INSTALLATION

INSTALLATION OPTIONS

This unit (appliance) may be installed into an all masonry fireplace, built in accordance with the Uniform Building Code
and the National Fire Protection Association (NFPA 211).

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

A. At a minimum, a starter pipe reaching from the stove flue exit to the base of the existing code approved masonry

chimney (flue-liner) and an airtight face seal.

B. Direct connection: In accordance with NFPA-211-9-4.5, Connection to Masonry Fireplaces. A solid fuel-burning

appliance such as a stove or insert shall be permitted to use a masonry fireplace flue where the following conditions
are met:

Exception: Listed fireplace accessories shall be permitted to use a masonry fireplace flue.

1) There is a connector that extends from the appliance to the flue liner.

2) The cross-sectional area of the flue is no more than three times the cross-sectional area of the flue collar of the appli­ance.

3) If the appliance vents directly through the chimney wall above the smoke chamber, there shall be a noncombustible
seal below the entry point of the connector.

4) The installation shall be such that the chimney system can be inspected and cleaned.

5) Means shall be provided to prevent dilution of combustible products in the chimney flue with air from the habitable
space.

. It may be necessary to positive connect this unit to enhance the performance, if any of the following conditions ex-

C
ists:

1) Poor Drawing Flue 3) Double Flues 5) Stone Front Fireplace/ or damaged flue liner

2) Oversized Flue (17” x 7) 4) Ash Dump 6) Chimney that does not exceed 12’

Check with your dealer if any of the above conditions exist, before installing your stove. Proper installation is critical to
the performance of the Model 91.
Use Fireplace Kit PA FP91 for installation. An optional oversized fireplace kit is available for larger fireplaces. Check
with dealer.

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.

OPTION (A)

STARTER PIPE

SEAL TRIM PANELS WITH INSULA­TION / AND OR HIGH TEMPERATURE
CAULK

NOTE: New Buck Corporation grants no
warranty, implied or stated, for the installation
or maintenance of your appliance, and assumes
no responsibility of any consequential damage

AIRTIGHT INSU­LATED CLEAN­OUT

REMOVE
DAMPER
OR WIRE
IT OPEN

OPTION (B) OPTION (C)

NOTE: Follow installation

instruction with Positive
Connection Kit.

NOTE: Follow installation instruction
with Direct Connection Kit.
(Kit sold separately)

SEAL TRIM PANELS
WITH INSULATION /
AND OR HIGH TEM­PERATURE CAULK

STAINLESS
STEEL
CHIMNEY
CONNEC­TOR MUST
EXTEND 1’
PAST THE
BLOCK-OFF
PLATE OR
TO THE
FLUE LINER

AIRTIGHT
INSULATED
CLEAN-OUT

REMOVE
DAMPER
OR WIRE IT
OPEN

(Kit sold separately)

INSTALL A NON-COMBUSTIBLE
COVER PLATE TO PREVENT
WATER FROM ENTERING THE
CHIMNEY

TRIM PANELS

CAP(PREVENTS
WATER FROM
ENTERING)

FLUE
LINER

THE LINER MUST
BE STAINLESS
STEEL CONNEC­TOR OR FLEXIBLE
VENT. FOLLOW
THE LINER MANU­FACTURE’S IN­STRUCTIONS FOR
INSTALLATION
AND SUPPORT.

AIRTIGHT
INSULATED
CLEAN-OUT

REMOVE
DAMPER
OR WIRE
IT OPEN

BLOCK-OFF PLATE
OR DAMPER
ADAPTER

INSTALLATION (Fireplace Insert)

Minimum Clearances to Combustible Materials (in inches)

MANTEL

30"

20"

24"
HEARTH EXTENSION

FIGURE 1
FIREPLACE INSERT

8"

20"

15"