Page 1
SAFETY NOTICE:
Freedom
Bay
Owner's
Manual
- May, 2001 -
¥ Masonry
Fireplace Insert
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.
Freedom Bay Fireplace Insert
10850 117th Place N.E. Kirkland, WA 98033
Part # 93508026 $10.00
Listed
Page 2
Page 3
INTRODUCTION & IMPORTANT INFORMATION PAGE 1
Introduction
We welcome you as a new owner of a Lopi Freedom Bay wood-burning appliance. In purchasing a
Lopi Freedom Bay you have joined the growing ranks of concerned individuals whose selection of an
energy system reflects both a concern for the environment and aesthetics. The Lopi Freedom Bay 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 Lopi Freedom Bay appliance has the
same serial number as yours. The serial number
is stamped onto the label on the right side of the
appliance.
This serial number will be needed in case you
require service of any type.
Model: LOPI Freedom Bay
Serial Number:
Mail your Warranty Card Today, and Save
Your Bill of Sale.
To receive full warranty coverage, you will
need to show evidence of the date you
purchased your appliance. Do not mail your
Bill of Sale to us.
Purchase Date:
Purchased From:
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.
Page 4
PAGE 2 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.
¥ 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.
Gas
Ashes
36"
Minimum
Ok
¥ 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
non-combustible surface
well away from the home
or structure.
¥ Keep furniture, drapes,
curtains, wood, paper, and
other combustibles a
minimum of 36" away
from the appliance.
¥ 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.
¥ 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.
¥ 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.
Type
HT
Clay
Liner
¥ This appliance must be
connected to a listed high
temperature (HT)
residential type chimney
or an approved masonry
chimney with a standard
clay tile, or stainless steel
liner.
¥ Do not place clothing or
other flammable items on
or near this appliance.
Page 5
SAFETY PRECAUTIONS (CONTINUED) PAGE 3
This
Manual
¥ 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.
¥ Allow the appliance to
cool before carrying out
any maintenance or
cleaning.
¥ 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).
Page 6
PAGE 4 TABLE OF CONTENTS
Introduction and Important Information
Introduction and Important Information ...................... 1
Safety Precautions..................................................... 2
Features and Specifications
Features and Specifications ....................................... 5
Insert Installation
Before You Begin....................................................... 6
Planning The Installation............................................ 6
Preparation for Installation.......................................... 6
Insert Installation Considerations............................... 6
Optional Equipment Requirements ............................ 6
Insert Placement Requirements ................................. 7
Hearth Requirements................................................. 7
Insert Size Requirements ........................................... 7
Masonry Fireplace Requirements .............................. 8
Leveling Bolt Installation ............................................. 8
Blower Installation....................................................... 8
Block-Off Plate Installation......................................... 9
INSTALLATION DIAGRAMS
Insert with Positive Connection................................... 10
Insert with Direct Connection...................................... 10
Insert with Face Seal Connection ............................... 11
Maintaining Your Appliance
Maintenance Schedule............................................... 19
Remove Ash From The Firebox (If Necessary).......... 19
Clean The Viewing Glass (If Necessary) ................... 19
Clean The Brass (If Necessary) ................................. 19
Check For Creosote Buildup...................................... 19
Door And Glass Inspection ........................................ 20
Adjusting the Door Cam ....................................... 20
Replacing the Door Gasket .................................. 21
Replacing the Glass or Glass Gasket................... 21
Lubricate The Door Hinge.......................................... 21
Touch-Up Paint .......................................................... 22
Blower Cleaning ......................................................... 22
Firebrick And Baffle Inspection And Cleaning............ 22
Firebrick Removal and Replacement Inst. ........... 23
Baffle Removal and Replacement Instructions..... 23
Secondary Air Tube Replacement Instructions .... 25
Replacement Parts List.............................................. 25
Troubleshooting
Troubleshooting Table ............................................... 26
Warranty
Warranty..................................................................... 27
Listing Information
Operating Your Appliance
Before You Begin....................................................... 12
Paint Curing ............................................................... 12
Location of Controls.................................................... 12
Approximate Air Control Settings ......................... 12
Bypass Control...................................................... 13
Learning to Burn your Appliance................................ 13
How to Start a Hot Fire Quickly ............................ 13
How to Reload Your Appliance ............................ 14
How to Adjust the Heat Output Precisely ............. 14
How to Obtain an Overnight Burn ........................ 15
Good Burning Habits ............................................ 15
Blower Operation ....................................................... 16
A Word about Wood ................................................... 17
Listing Information...................................................... 28
Optional Equipment
Surround Panel Installation........................................ 29
Insulation Installation............................................ 30
Brass Trim Installation (Optional) ......................... 30
Flue Adapter Installation ............................................ 31
Index
Index .......................................................................... 32
Page 7
FEATURES AND SPECIFICATIONS PAGE 5
Installation Options:
¥ Insert into a Masonry Fireplace
Features:
¥ EPA Phase II Approved
¥ 3.1 Cubic Foot Firebox Volume
¥ Single, Push/Pull Operating Control
¥ Accepts Logs Up to 24" Long
Heating Specifications:
Approximate Maximum Heating Capacity (in square feet)* 1,200 to 2,250
Maximum BTU's per Hour (Cord Wood Calculation) 74,300
Overall Efficiency (Oregon Method) 70%
Maximum Burn Time (Hours) 12
* 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:
Flue is centered on the stove and 5 5/8"
from the rear edge of the appliance.
(Use 6" Dia. Pipe)
29 1/4"
¥ Long Burn Time - Up to 12 Hours
¥ 5/16 to 3/16" Steel Construction
¥ Heavy Duty Refractory Firebrick
¥ Optional High-Tech Blower
Weight:
470 Pounds
15 3/4"
4 3/4"
Height*:
21 3/4"
43 3/4"
*Older model panels may use the heightened yoke, adding 7/8" to the height. Furthermore,
allow an additional height to align the pipe on positive and direct connect installations.
Rear edge of
surround panel
Faceplate
Measure all side
clearances from
here.
Emissions: 2.6 Grams Per Hour (EPA Phase II Approved) Ð Tests conducted by E.E.S.P.C. Lab.
Page 8
PAGE 6 INSERT INSTALLATION
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.
¥ Check with local building officials for any permits required for installation of this stove and
notify your insurance company before proceeding with installation.
PLANNING THE INSTALLATION
HINT: We suggest that you have an authorized Travis Industries dealer install your insert. If
you install the insert yourself, your authorized dealer should review your plans for
installation.
This insert is approved for installation into an existing masonry fireplace. Depending upon your
installation concerns, several options are yours to provide the most desirable installation. The sections
that follow detail the requirements that must be met for a safe installation. To further help installation,
the most common types of installations are explained in the section "Insert Installation Considerations".
Prior to installing your insert make a detailed plan with dimensions to double-check them against all of
the requirements listed.
PREPARATION FOR INSTALLATION
¥ Check for damage to the exterior of the insert (dents should be reported, scratches can be fixed
by applying touch up paint).
¥ Check the interior of the firebox (cracked firebrick should be replaced, displaced baffle
components should be replaced).
¥ Remove the box that contains the blower. Place it aside and install it last (see "Blower
Installation" on page 8
HINT: The insert can be lightened by removing the firebricks and baffle. - see "Firebrick and
Baffle Inspection and Cleaning" on pages 22 - 24.
INSERT INSTALLATION CONSIDERATIONS
The table below details the most common types of installations and the considerations for each type of
insert installation. Alternative methods of installation are available if they comply with local building
codes.
Installation Type Considerations
Insert with Positive Flue (Full Reline)
(Page 10)
Insert with Direct Connect Flue
(Page 10)
Insert with Face Seal Connection
(Page 11)
¥ Utilizes existing masonry fireplace
¥ Provides best draft
¥ Easiest to clean
¥ Utilizes existing masonry fireplace
¥ Provides good draft
¥ Requires fireplace block-off plate - see page 9
¥ Utilizes masonry fireplaces with a cross section of 28" to 144"
¥ Provides okay draft
¥ Easiest to install
¥ Requires insulation (see "Insulation Installation" on page 30
OPTIONAL EQUIPMENT REQUIREMENTS (See the back of this manual for installation instructions)
¥ Must be installed with the surround panels
Page 9
INSERT INSTALLATION (CONT.) PAGE 7
INSERT PLACEMENT REQUIREMENTS (See the illustration below)
¥ 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
¥ Sidewalls must maintain a minimum 15" to the insert
¥ Non-combustible side facing must extend 13 1/2" from the insert
¥ Non-combustible top facing must extend 30" above the insert (17" with mantle shield)
¥ Mantle must be a minimum 32" above the insert (19" with mantle shield)
¥ Hearth must extend 16" in front of the faceplate
¥ Hearth must extend 8" from the sides of the insert
Combustible Mantle
Measure side
clearances
from here.
Sidewall
D
Surround
Panels
A
B
E
F
Non-Combustible
Facing
C
HEARTH REQUIREMENTS (See the illustration above)
¥ Must extend 16" in front of the insert and 8" on both sides (total of 20 3/4" deep by 45 1/4" wide)
¥ Must be non-combustible and at least .018" thick (26 gage)
INSERT SIZE REQUIREMENTS
Minimum
Clearances
A Sidewall to Insert
B Side Facing
C Top Facing
With mantle shield
D Mantle to Insert
With mantle shield
E Hearth (Front)*
F Hearth (Side)**
* Measure from faceplate, does
not include the distance the insert
sticks out on the hearth (4 3/4").
**Total hearth width must be at
least 45 1/4"
Masonry
Fireplace
15"
13 1/2"
30"
17"
32"
19"
16"
8"
A
F
Minimum
Fireplace Size
A Height* (front)
B Height* (rear)
C Width (front)
D Width (rear)
E Depth
F Hearth**
B
E
D
C
* Older model panels may use the
heightened yoke, adding 7/8" to
the height. Furthermore,
additional room is needed to align
the pipe on positive and direct
connect installations.
** Does not include the required
16" of floor protection in front.
Masonry
Fireplace
21 3/4"
21 3/4"
29 1/4"
291/4"
15 3/4"
4 3/4"
Page 10
PAGE 8 INSERT INSTALLATION (CONT.)
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
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
Inside the accessory pack are a pair of leveling bolts used 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. Screw the bolts down 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 the illustration below).
This distance is the
hearth step-up.
The leveling bolts
should stick out
this far from the
base of the insert.
Hearth
Fireplace
The leveling bolts
go into the holes in
the outer rear of the
insert baseplate.
BLOWER INSTALLATION
The included blower is fragile and should be installed last (see directions below).
Remove the two screws
1.
here with a 3/8" nutdriver.
Center the blower
2.
underneath the ashlip. Lift
up on the blower so it tucks
up underneath the ashlip.
Replace the two screws
3.
and tighten.
4.
Plug the
blower
into a
110 volt
grounded
outlet.
Control Box
Page 11
INSERT INSTALLATION (CONT.) PAGE 9
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 provide greater
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 the illustration
below). 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 that is centered in the fireplace and 10 1/4" back
from the fireplace opening. 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 the appropriate screws. Masonry screws must be used for
mounting a block-off plate in a masonry fireplace.
6. Insulate the block-off plate using high-temperature fiberglass insulation (KaowoolÒ 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 hightemperature fiberglass insulation and furnace cement to seal any cracks between the pipe and
block-off plate.
The center of
the flue is 10
1/4" back from
the fireplace
opening.
B
Firebox
Damper
AC
Block-Off Plate Template
2" Flanges
(for attaching
the block-off
plate)
The center of the flue is 10 1/4" back from
the fireplace opening (6 1/4" in diameter).
Measurement
"A"
Measurement "B"
Measurement
"C"
Page 12
PAGE 10 INSERT INSTALLATION (CONT.)
INSERT WITH
POSITIVE
CONNECTION
NOTE:
Most factorybuilt 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
NOTE: This installation may be
used with a masonry fireplace
only. The requirements in the
section "Masonry Fireplace
Requirements" must be fulfilled
prior to installation.
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
Notch the first
connector to
accommodate
the bypass rod.
INSERT WITH
DIRECT
CONNECTION
(MASONRY
FIREPLACE)
NOTE:
Direct
connections
require
installation of
an airtight
block-off plate
or damper
adapter (see
the section
"Block-off
Plate
Construction"
for details on
constructing
and installing a
block-off
plate).
NOTE: This installation may be used
with masonry fireplaces only. The
requirements in the section "Masonry
Fireplace Requirements must be
fulfilled prior to installation.
Combustible Mantle
Surround Panels
See the section
"Insert Placement
Requirements" for
minimum clearances
and hearth required.
Flue Liner
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
Block-off plate or
damper adapter
Notch the connector
to accommodate the
bypass rod.
Page 13
INSERT INSTALLATION (CONT.) PAGE 11
INSERT WITH
FACE SEAL
CONNECTION
NOTE:
Face seal
connections
require
installation of
the surround
panels and
insulation (see
the section
"Surround
Panels
Installation"
on page 29).
NOTE: This installation may be
used with a masonry fireplace
only. The requirements in the
section "Masonry Fireplace
Requirements" must be fulfilled
prior to installation.
Flue Liner
Combustible Mantle
Surround Panels with
insulation (see "Surround
Panels" installation
instructions in the back of
the manual)
See the section "Insert
Placement Requirements"
for minimum clearances
and hearth required.
NOTE: It is
recommended your
chimney have a
minimum 28 and a
maximum of 144
square inch
cross-sectional area
to use a face seal
connection, otherwise
your chimney maynot
have sufficient draw
for the fireplace insert
to operate correctly.
Airtight Insulated
Clean-Out
Remove damper
or wire it open
Page 14
PAGE 12 OPERATING YOUR APPLIANCE
SAFETY NOTICE:
If this appliance is improperly operated , a house fire may result. For your safety,
read the directions below and the Safety Precautions listed on pages 2 and 3 prior
to operating this appliance.
¥ If you have any questions regarding the operation of this appliance, contact your dealer.
! Building a fire in disregard of the information provided in this section can cause permanent damage
to your appliance and void your warranty.
! Never use gasoline, lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start of
"freshen up" a fire in this appliance. Keep these liquids well away from the appliance.
! Keep furnishings and other combustible materials away from the appliance.
PAINT CURING
The paint on this stove cures under heat. Start a small fire and burn at a low rate for the first fire. You
will notice fumes and smoke from the paint curing and oil burning off the steel. This is normal. We
recommend you open windows to vent the room.
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 materials, pending
final disposal. Ashes should be retained in the closed container until all cinders have thoroughly cooled.
LOCATION OF CONTROLS
DOOR HANDLE
Slide in to allow
more air into the
firebox, for a
faster rate of
burn
To open, turn the handle
counter-clockwise and
swing the door forward.
Slide out to close
down the amount
of air into the
firebox, for a
slower rate
of burn
BYPASS
CONTROL
¥ Do not open the door when the air control is closed. This may result in a sudden flash of flames as
the fire ignites with oxygen. However, this appliance has been designed to reduce this possibility.
¥ The controls become hot during operation Ð use a glove or other device if necessary.
¥ Open the door for refueling only, do not operate with the door open or removed.
Pull the bypass out for loading & starting.
Push the bypass in during burning.
2.
1.
AIR CONTROL
Approximate Air Control Settings: Overnight Burn ..................... Fully out to 9/32" open
Medium Burn........................ 9/32" open to 5/16" open
Medium High Burn............... 5/16" open to 7/16" open
High Burn.............................. 7/16" open to pushed fully in
Page 15
OPERATING YOUR APPLIANCE (CONTINUED) PAGE 13
Bypass Control
The bypass control is centered along the top of the appliance and is operated by pushing or pulling the
control in or out. When the control is completely pulled out, the bypass allows the smoke to go directly
up the flue, creating more draft for starting the appliance or reloading. When it is pushed in, the smoke
must go around the baffle which utilizes secondary combustion and makes the appliance more efficient
(see the illustration below).
Bypass Pulled Out-
Used for Starting
and Re-Loading
Bypass Pushed In-
Used for Normal Operation
(Utilizes Secondary
Combustion)
LEARNING TO BURN YOUR APPLIANCE
Using a wood-burning appliance takes some getting used to. Once you become accustomed to operating
your appliance, you will be able to start a hot fire quickly, adjust the heat output precisely, and obtain
overnight burns easier. Experienced wood burners may not need the information below, but may be able
to re-affirm their skills by reading the following. The better you understand your appliance, the more
rewarding you will find it.
How to Start a Hot Fire Quickly
Your wood-burning appliance acts much like an engine - before it will work at its best, it needs to reach
a high temperature. The most common mistake in starting a fire is to use too little kindling, closing the
bypass too soon, or turning the air control down too early. For good results, YOU MUST OBTAIN AN
INTENSE FIRE BEFORE CLOSING THE AIR CONTROL DOWN. The steps below detail one
method for starting a fire.
1. Pile several pieces of kindling on top of newspaper or a fire starter in the center of the firebox (it
is better to have too much kindling than not enough). Place two medium sized pieces of wood on
either side of kindling laying front to back.
2. Make sure the air control is fully open (push all the way in) and the bypass opened (pull all the
way out). Start the newspaper or fire starter. Note: you may want to crack the door during
starting to allow for more air.
3. Allow the kindling to start and burn. Then place another medium size piece of wood on top of
the burning kindling so that it straddles the two medium pieces and close the door. This
arrangement takes advantage of the air inlet located in the center under the door to feed the fire
with adequate oxygen. You may notice the flames burning from the front to the back.
4. Let the fire burn at least 15 minutes before closing the bypass. Wait at least 30 minutes or until
the appliance is fully hot before closing the air control down.
4.1. 2. 3.
Page 16
PAGE 14 OPERATING YOUR APPLIANCE(CONTINUED)
How to Reload Your Appliance
When reloading your appliance, you can avoid smoke entering the room by following the steps below:
1. Push the air control all the way in so the fire starts to burn quickly, helping draft.
2. Pull the bypass out all the way and wait 30 seconds to establish a strong draft.
3. Open the door one inch and let air enter the appliance for a few seconds.
4. Carefully place the new wood on top of the existing fire. Close the door and shut the bypass by
pushing it all the way in. Let the fire burn on high for at least 20 minutes before turning it down
Ð this will reduce creosote build-up.
1.
AIR CONTROL
Open the door 1"
and let air enter
the appliance for
a few seconds
2.
BYPASS
CONTROL
4.3.
How to Adjust the Heat Output Precisely
One complaint from wood-burning appliance owners is controlling the heat output to obtain a consistent
room temperature. The reason for this is the inherent lag time between adjusting the air control and the
change in heat output. Simply put, if you turn a hot appliance down now, it will continue to put off high
amounts of heat for an additional 15 minutes. To obtain consistent room temperature, think ahead.
When the room is starting to warm, and is almost up to the right temperature, turn the appliance down.
If you utilize an optional blower, turn it on and off to increase or decrease room temperature. If you find
the appliance must be turned down often, burn smaller, more intense fires instead. Although this means
more reloadings, it will reduce creosote build-up and give a more consistent heat output.
Page 17
OPERATING YOUR APPLIANCE (CONTINUED) PAGE 15
How to Obtain an Overnight Burn
An overnight burn of 10 hours may be obtained with a small amount of coals left over in the morning if
the right steps are taken.
1. Establish a hot fire.
2. Fill the appliance with large pieces of wood, preferably hardwoods like oak or maple.
3. Let the wood burn on high for 20 to 30 minutes to allow the new pieces of wood to catch fire and
burn off any moisture.
4. Pull the air control out to a low setting. HINT: You want an air control position that is the
farthest in, yet still allows coals to be left in the morning. Experiment using air control positions
that are farther and farther in until a suitable position is found.
5. In the morning, break down the coals and lay kindling and small pieces of wood on top of the
coals to re-establish the fire. NOTE: Even the smallest amount of coals can start a new fire
easily because of all the heat energy stored in the firebrick. If there are no coals left, yet the
appliance is hot, you will find starting a new fire will be much easier and the appliance will start
giving off heat much quicker than if started cold.
Let the appliance burn at least 20 minutes on
high after loading. This allows the appliance to
reach the most efficient operating temperature.
Even the smallest amount of
coals can re-start the appliance.
Good Burning Habits
Increased efficiency, reduced emissions, and less creosote are the rewards of good burning habits.. The
items below list good habits to establish with your new appliance.
¥ Get the appliance hot before turning it down
¥ 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
NOTE: A stove thermometer gives you a good indication of how hot your appliance is burning when
placed directly on top of the appliance. Low burn is approximately 300 degrees F., medium
burn 500 to 600 degrees F., and high burn 700 to 800 degrees F.
Page 18
PAGE 16 OPERATING YOUR APPLIANCE(CONTINUED)
BLOWER OPERATION
The blower assists the convection chamber in distributing heat to your home. The directions below
detail the options you have with the blower and the best method for operation.
What turns the blower on
The blower includes a heat-sensing device that does not allow the blower to turn on until the appliance is
up to temperature. Once up to temperature, the blower will operate at the speed determined by the
position of the blower knob (see the illustration below). The blower shuts off once the appliance cools.
BLOWER KNOB
OFF
Turn the knob all the
way counter-clockwise
to turn off.
HIGH
Turn the knob
clockwise from the off
position until it clicks.
LOW
Turn the knob all
the way clockwise
to turn to low.
How to Use the Blower to Regulate Heat
Turn the blower to high if the room needs heat and the appliance is up to temperature. When the room
has reached a high enough temperature, turn the blower off to stop the heat transfer. Used in
conjunction with the air control, a steady temperature can be achieved.
Page 19
OPERATING YOUR APPLIANCE (CONTINUED) PAGE 17
A WORD ABOUT WOOD
This appliance is designed to burn natural cord wood with high efficiencies and low emissions. With
properly dried wood, you will fully realize the heating and clean-burning potential of our hightechnology appliance. With poor wood, this high-technology appliance will become much less efficient
and produce more emissions. Read on to find out more about the type of fuel you should use.
The Drier the Better
The most common mistake made by
wood-burners is using wet, green, or
un-seasoned fuel. Ask any
experienced wood-burner, and he or
she will tell you the importance of
dry wood. The reason is this: wet,
green, or un-seasoned wood still has
water in it. When the wood burns it
must use its heat energy to evaporate
the water. This robs your home of
heat (it also leads to greater smoke
and creosote due to lesser firebox
temperatures). Dry wood usually has
cracks in the grain. It will also be
lighter and when two pieces are
knocked together a crisp "knock" will
be heard, not a dull "thud". When
burning green, wet, or unseasoned
wood you may notice difficulty in
lighting, and water bubbling out of
the grain when it becomes hot.
Wet Wood
Leads
To
Less Heat
Leads
To
More Smoke
& Creosote
Dry Wood
More Heat
Less Smoke
& Creosote
Leads
To
Leads
To
How to Dry and Store Wood
Aging is the only economical method for drying wood. Follow the steps below to dry and store wood:
1. Make sure the wood is split into quarters and is no longer than 18" long (Hint: if you cut trees in
summer, leave the leaves on for a week, this will draw moisture from the wood to dry it quicker).
2. Stack the wood in loose piles that are covered and off the ground (this is to allow air to pass over
each piece of wood Ð promoting faster drying) If no shelter is built, place clear polyethylene
plastic over the wood (at an angle to allow moisture to run off). Let dry for at least one year.
3. Store the wood in a dry location, preferably outside to prevent insects and dirt from entering the
home. When needed, move small loads inside where the added heat will promote further drying.
Cover with 4 mil
Cut the wood to 18"
or less lengths and
chop into quarters
before stacking
Prevailing
Winds
Keep the
wood off
the ground
to increase
air flow
Air Flow
Polyethylene
Air Flow
Stack the
wood
loosely to
allow for
air flow
between
the
pieces
Air Flow
Page 20
PAGE 18 OPERATING YOUR APPLIANCE(CONTINUED)
A WORD ABOUT WOOD (CONTINUED)
Constructing a Wood Shed
The drawing to the right details the
construction of an inexpensive wood shed
Sheet Metal Roofing
2x6x12 Rafter
2x8x8' Girder
4x4x2 Posts Spaced 8' Apart
2x4 Purlins
Siding and Girts
(Optional)
that will promote drying, increasing the
heat output from your wood.
8' Width
3' Depth
What Type of Wood is Best
Choosing the kind of firewood to burn in your appliance depends on what is available to you.
Softwoods, such as pine or fir ignite and burn quicker, but require more frequent loadings and are less
suited for overnight burns. For longer burns, with less frequent loadings, we recommend harder woods
such as oak or maple. The chart below details the BTU (heat) output of the various species. Note the
higher BTU output of the harder woods. The best arrangement is to have softwoods for starting and
immediate heating and hardwoods for overnight and sustained burns.
SPECIES
(20% moisture)
ALDER 2540 19,050,000 476
APPLE 4400 33,000,000 825
ASH 3440 25,800,000 645
BIRCH 3040 22,800,000 705
CEDAR 2060 15,450,000 386
COTTONWOOD 2160 16,200,000 405
DOGWOOD 4320 31,725,000 793
ELM 2260 16,950,000 423
FIR, DOUGLAS 2970 22,275,000 556
HEMLOCK 2700 20,250,000 506
MAPLE 3200 24,000,000 600
OAK, RED 3680 27,600,000 690
OAK, WHITE 4200 31,500,000 787
PINE 2250 16,875,000 421
REDWOOD 2400 18,000,000 450
SPRUCE 2240 16,800,000 420
LBS./CORD
(Approximate)
BTU's/CORD
(Approximate)
Hours per Cord at 40,000 BTU's per Hour
(Approximate)
How to Buy Wood
Wood is sold by the cord (4' wide by 4' high by 8' long). Buy wood in the spring and summer, when
prices are lower and it will have plenty of time to dry. If buying in winter, have the wood moisture
tested (test several pieces). You will receive up to 25% more heat from a cord of dry wood than from
wet or green wood. Rotate your wood so as to allow for the maximum drying time for all pieces.
Don't Burn Wood Scraps, Garbage, Paper, Wax Logs, Coal, Etc.
Wood scraps from construction are typically chemically treated, making them difficult to burn and
dangerous due to emitting chemicals. The same holds true for garbage, solvents, driftwood containing
salt, cardboard, and colored paper. Coal and wax impregnated logs burn especially hot, creating a
possible safety hazard. In addition, all the aforementioned items may create excessive creosote.
Page 21
MAINTAINING YOUR APPLIANCE PAGE 19
MAINTENANCE SCHEDULE
Your appliance requires periodic maintenance to work correctly. The steps involved with maintenance
are usually quick and easy. Look through this maintenance schedule and plan accordingly.
WARNING: 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.
PERIODIC MAINTENANCE (every week when appliance is in use):
¥ Remove ash from the firebox (if necessary)
¥ Clean the viewing glass (if necessary)
¥ Clean the brass (if necessary)
¥ Check for creosote buildup in the chimney and connector
BI-MONTHLY MAINTENANCE (every two months during the heating season):
¥ Door and glass inspection
¥ Lubricate the door hinge
YEARLY MAINTENANCE (before every heating season):
¥ Touch-up paint
¥ Blower cleaning
¥ Firebrick and baffle inspection and cleaning
REMOVE ASH FROM THE FIREBOX (IF NECESSARY)
At least once a week while the appliance is in use, check the level of ash on the floor of the firebox. If
1" or more of ash has accumulated, let the appliance cool and place the excess ash into an airtight
container away from any structure. After the ash is fully extinguished it may be disposed. A 1/2" to 1"
bed of ash is desirable, for it allows the appliance to burn at a slightly lower speed.
WARNING: Ashes removed from the appliance must be stored in an airtight container away
from any structure until fully extinguished before disposing.
CLEAN THE VIEWING 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. For especially dirty glass, use fine steel wool to remove build-up.
Apply glass
cleaner to the
inside of the
glass when it
is cool
Then take a piece of newspaper
or paper towel, dip it in cool
ashes, and wipe the glass
CLEAN THE BRASS (IF NECESSARY)
If your insert has a brass door, it may be cleaned using a non-abrasive polish (such as FLITZÒ) when
the appliance is cool. The brass trim and ashlip is anodized, and should be cleaned with soap and water.
CHECK FOR CREOSOTE BUILDUP
Creosote buildup should be checked twice monthly during the heating season. Either look down the
chimney from the top or remove a chimney connector section. Any more than 1/4" of buildup requires
chimney cleaning. Creosote develops quickest when burning at a low temperature or when burning unseasoned wood. When wood is burned slowly, it produces tar and other vapors which combine with
moisture to form creosote. Creosote vapors condense in the relatively cool chimney flue and creosote
residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire.
Page 22
PAGE 20 MAINTAINING YOUR APPLIANCE (CONTINUED)
DOOR AND GLASS INSPECTION
The door must seal air-tight for the appliance to work correctly. Check the two items below and follow
the appropriate remedy to fix any problems.
¥ Check the door cam operation. When closed, the door cam should pull the door against the face
of the appliance, but not be so tight as to not allow the handle to point downwards. If the
operation is not correct, see the section "Adjusting the Door Cam" below.
¥ Remove the door by opening it and lifting it off the hinges. Place the door face down and check
the door gasket (see the illustration below). If the door gasket requires replacement, see the
section "Replacing the Door Gasket" on the following page. Check the glass and glass gasket. If
the glass or gasket require replacement, see the section "Replacing the Glass or Glass Gasket" on
the following page.
The door gasket should
be unbroken, have
enough bulge to contact
the face of the unit, and
be firmly attached to the
door frame.
The glass gasket
should form an
airtight seal
between the glass
and the door frame.
Check the
glass for any
cracking.
Door Cam
Adjusting the Door Cam
If the door cam does not pull the door against the face of the appliance, the door cam will need to be
tightened (see the illustration below for details). If the door handle does not turn down all the way, it is
too tight and will need to be loosened (see the illustration below for details). Before adjusting, remove
the door by opening the door and lifting it off the hinges.
Side View of Door Handle
Door Cam
Washers
Door Frame
Door
Handle
Use a 9/16"
socket wrench to
remove this nut.
Exploded View
Door Cam
Adjustment:
To tighten, remove
a washer from the
inside of the door
frame. To loosen,
place an additional
washers on the
inside of the door
frame or loosen
the nut 1/2 turn.
Page 23
MAINTAINING YOUR APPLIANCE (CONTINUED) PAGE 21
Replacing the Door Gasket
Remove the door by opening it and lifting it off the hinges. Remove the old gasket by stripping it away
with a screwdriver or other tool (see the illustration below). Apply a line of gasket cement (available
from your dealer) in the groove that follows the perimeter of the door. Insert the gasket into the groove.
Do not stretch the gasket as you place it into the groove. Cut off any excess gasket when done. Allow 2
hours for the cement to dry. When re-installing the door, the gasket may need to be flattened by
repeatedly opening and closing the door.
Replacing the Glass or Glass Gasket
Remove the door by opening it and lifting it off the hinges. Remove the door handle from the door.
Then remove the glass retainer by unscrewing the ten screws that hold it in place with a 5/16" nutdriver
(see the illustration below). Carefully remove the glass. Make sure the 3/4" black channel tape (new or
old) runs around the perimeter of the glass. If using a new gasket, trim off any excess. Place the glass
(new or old) in place so there is a small gap between the edge of the glass and the door frame. Make
sure the gasket is tucked underneath the glass so the glass does not touch the door frame. Place the glass
retainer in place and secure it with the screws removed earlier. Make sure the white gasket stays in
place and seals the window. Tighten the glass retainer until the gaskets start to flatten.
The glass is held in place
with the glass retainer
and ten screws
The door gasket is 7/8" white rope gasketing
and is held in place with gasket cement.
Use a 5/16" nutdriver for
the glass retainer screws.
Glass Retainer
CCrroossss SSeeccttiioonn
Glass
3/4" Black Channel Tape
Door Frame
Make sure
there is a
small space
around the
edge of the
glass.
LUBRICATE THE DOOR HINGE
Periodically lubricate the door hinges with a high temperature lubricant (such as Permatex Industrial Ò
Anti-Seize). Lubricating the door involves removing the door by opening it and lifting it off the hinges,
and placing lubricant on the hinge pins.
Page 24
PAGE 22 MAINTAINING YOUR APPLIANCE (CONTINUED)
TOUCH-UP PAINT
Included with the owner's pack of this appliance is a can of
Stove-BriteÒ paint. To touch up nicks or dulled paint, apply
the paint while the appliance is cool. Use 120 grit sandpaper
(clean with water and dry with a piece of cloth) if the surface
requires smoothing. 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
Touc h-U p
P a i nt
some fumes while curing Ð open windows to ventilate the
fumes.
BLOWER CLEANING
The blower for this appliance will gather dust as it circulates air. Before cleaning, remove the blower
from the appliance (see "Blower Installation" on page 8). Remove all dust and debris from the blower
grill and around the interior of the blower.
FIREBRICK AND BAFFLE INSPECTION AND CLEANING
With the appliance cool, remove all ash from the firebox and scrape away any scale that may have built
up on the surface of the firebrick with a wire brush or scraper. Any of the firebrick on the floor or walls
of the firebrick that is cracked must be replaced (see the section "Firebrick Removal and Replacement
Instructions"). Next, inspect the baffle components. The illustration below details the areas that must be
inspected. If any of the components need to be replaced, see the section "Baffle Removal and
Replacement Instructions".
BYPASS ASSEMBLY
Entire assembly must be
properly aligned and correctly
oriented.
BAFFLE FIREBRICKS
Must not be cracked or have
gaps between them. Cracked
bricks must be replaced. Gaps
are eliminated by pushing the
bricks closer together.
SECONDARY AIR TUBES
Must be intact without any
cracks. Scaling and a slight
amount of bending is normal
for this component.
BAFFLE SUPPORTS
Must be snug against the baffle
firebricks and resting on the
secondary air collars.
SECONDARY AIR TUBE COLLARS
Must have the two push pins inserted into them.
This keeps the secondary air tubes aligned.
FLOOR & WALL FIREBRICKS
Must not be cracked or severely
chipped (damaged bricks must be
replaced). Remove any scaling or
buildup with a scraper or wire brush.
Page 25
MAINTAINING YOUR APPLIANCE (CONTINUED) PAGE 23
Firebrick Removal and Replacement Instructions
With the appliance cool, remove all ash from the firebox. Only the firebrick that is damaged must be
replaced. If the damaged firebrick is on the floor, it can be replaced by simply removing the firebrick in
front of it. NOTE: Do not pry firebrick to remove, this will chip or crack the firebrick. If a
firebrick on the wall of the firebox needs replacement, the floor firebrick near it will need to be removed
first. The wall firebrick is held upright by a clip on the walls of the firebox. To remove, pivot it out
from the bottom. See the illustration below.
WALL FIREBRICKS
First remove the firebricks
on the floor in front of the
firebrick needing
replacement. Then pivot it
out from the bottom to clear
the clip that holds it in place.
FLOOR FIREBRICKS
Remove the firebricks in
front of the firebrick
needing replacement.
CLIPS -
Hold the wall firebrick in place.
FIREBRICK SIZES -
All firebrick is 1 1/4" x 4 1/2"
x 9" except those labeled.
Firebrick labeled are
1 1/4" x 4 1/2" x 6 3/8".
Firebrick labeled are
1 1/4" x 4 1/2" x 8 1/4".
A
B
A
B
A
Baffle Removal and Replacement Instructions
The view below details the baffle components. Instructions for removal are on the following page.
Bypass Rod - threaded in two locations for easy removal
Bypass Handle
Bypass
Damper
Baffle
Firebrick
Center
Baffle
Support
Bypass Support - note
its orientation and how
it rests on the rear
baffle firebrick
Forward
Baffle
Support
Baffle supports rest on these tabs
Page 26
PAGE 24 MAINTAINING YOUR APPLIANCE (CONTINUED)
Baffle Removal and Replacement Instructions (continued)
All of the baffle components are removable to facilitate easy cleaning and repairs. Make sure the
appliance is cool before removing any of the components. See the instructions on the following page for
removing the secondary air tubes.
REMOVING BAFFLE COMPONENTS
1. Lift up on the
front portion of
the front three
firebricks.
2. Lift the front
baffle support
and rotate it
forward until it
can be removed.
3. Slide the center front firebrick
forward and out the door opening. Then
slide the side front firebricks towards
the middle then out in the same manner.
SIDE VIEW
Front
Firebrick
Front
Baffle
Support
2.
1.
Tab
Welded to
Firebox
3.
4. Slide the center baffle support
forward and out of the firebox.
5. Slide the rear firebrick forward and
out of the firebox. NOTE: When the
center rear firebrick are slid forward the
baffle support will come to rest on the
rear secondary air tube and rear air
channel.
6. Slide the bypass all the way forward.
7. Reach into the firebox and push up
on the bypass rod until the bypass
damper seperates from the bypass rod.
Remove both the bypass damper and
bypass assembly by sliding them
between the front two secondary air
tubes.
7.
4.
6.
5.5.
7.
7.
REPLACEMENT INSTRUCTIONS:
A. Place the bypass support above the secondary air tubes in the rear center of the firebox.
B. Position the bypass damper so the bypass rod inserts into the two tubes on the bypass damper (make sure to have
correct orientation). Then slide the bypass damper over the bypass support until both are centerd in the firebox.
C. Follow the instructions above in reverse order, starting with step number 5.
Page 27
MAINTAINING YOUR APPLIANCE (CONTINUED) PAGE 25
Secondary Air Tube Replacement Instructions
REMOVING THE
SECONDARY AIR TUBES
Follow the directions to the right
to remove any of the three
seconary air tubes.
NOTE: When replacing, make sure the
two holes on the secondary air tube
sleeve line up with the hole on the
secondary air tube and the hole on the
air tube stub welded to the side air
channel.
Pry out both pins on the secondary
air tube sleeve (use a screwdriver).
Slide the secondary air tube to the right
until it disengages from the left side.
Slide the secondary air
tube sleeve to the left.
Side Air Channel
(Welded to side of Firebox)
Secondary Air
Tube Sleeve
1.
Pin
2.
Air Tube Stub
(welded to the
side air channel)
3.
4.
REPLACEMENT PARTS LIST
PART PART DESCRIPTION
Door Gasket Black 7/8" dia. Fiberglass rope 64" long
Glass Gasket Black 3/4" x 1/8" fiberglass channel tape 60" long
Door Glass 5 mm neoceram, 11 7/8" tall @ center, 19 1/4" wide
Retainer for Door Glass Cast steel retainer attaches to door with ten screws (included)
Handle for Door Brass spring (1/2")
Door Handle Steel shaft with threaded end (includes spring handle)
Door Cam Cast brass
Air Control Handle Brass spring (3/8")
Firebrick 1 1/4" x 4 1/2" x 9" silicon based refractory - some firebrick will require cutting
Secondary Air Tube 22 7/8" long with 3/16" holes every 3/4", includes two pins
Front Baffle Support 23 5/8" long, 1 1/2" angle iron welded to 21 1/8" long 1" deflector at 45° angle
Center Baffle Support 23 5/8" long, 1 1/2" angle iron welded to 23 5/8" long 1" strip to form a "t"
Bypass Support 9" by 9" square 5/16" thick with two 7 1/4" x 1" guides top & bottom, stop
Bypass Damper 6 11/16" dia. Circle of 5/16" thick steel, two 1" tubes welded to top for yoke
Bypass Yoke and Bypass Extender All 3/8" dia. Rod, 6" (before bending) yoke welded to 7" rod, + 7" extender
Bypass Handle Cast iron eye bolt
Owner's Manual This document
Air Control Slider Steel plate with air control rod
Air Control Floating Plate with Springs 8 springs and the floating plate used to guide air control slider
Bypass Pull Tool Tool used to adjust bypass
Page 28
PAGE 26 TROUBLESHOOTING
Problem: Possible Cause: Remedy:
Smoke Spills From
Door When
Loading
Kindling Does Not
Start
Appliance Does Not
Put Off Much
Heat
Appliance Does Not
Burn Overnight
Appliance Does Not
Burn Fast On
High
Blower Does Not
Turn On
Smoke Is Dirty
From Chimney
¥ Door was opened before the air
control was pushed in
¥ Door was opened before the
bypass was pulled out
¥ Door was opened too quick
¥ Draft is not adequate
¥ Cold air block in chimney
¥ Kindling is wet or too large to
light
¥ Bypass was closed
¥ Wood is wet, unseasoned, or
green
¥ Appliance requires time to
warm up
¥ Bypass was open
¥ Wood is fast burning
¥ Wood is in small pieces
¥ Check for coals - there may be
some there
¥ Draft is low
¥ Wood is wet
¥ Appliance is cool
¥ Appliance is not hot enough yet
¥ Blower is not plugged in or
circuit is off
¥ When reloading or starting,
smoke is higher than normal
¥ Wood is wet
Pull the air control all the way out a few seconds before
opening the door.
Pull the bypass all the way out before opening the door
(see "Bypass Control" on page 13)
Door should be opened a crack to allow air to enter
before opening all the way (see "How to Reload your
Appliance" on page 14).
Your installer or dealer can give you more information
on draft. The most common causes of low draft are a
short, offset, or small chimney, an external down draft
due to wind, an extremely air-tight home with exhaust
fans, or a thermal down draft due to appliance placement.
A cold air block keeps the appliance from establishing a
draft. First ignite a piece of newspaper in the appliance
before starting the kindling.
Kindling must ignite quickly to be effective. Wet or
large kindling will make starting very difficult.
Pull the bypass all the way out before starting the
appliance (see "Bypass Control" on page 13).
Wet wood will give off much less heat than dry, seasoned
wood (see "A Word about Wood" on page 17).
The appliance will not give off heat until it has been
burning on high for at least one half hour (see "Learning
to Burn your Appliance" on page 13).
The bypass should be closed once the fire is established
to increase the appliance's efficiency (see "Bypass
Control" on page 13).
Lighter, faster burning woods (e.g. alder, pine) are less
suited for overnight burns (see "A Word about Wood" on
page 17)
Wood should be large to facilitate a slower burn (see
"How to Achieve an Overnight Burn" on page 15).
Even a small amount of coals are enough to start a new
fire if kindling is placed on top.
Your installer or dealer can give you more information
on draft. The most common causes of low draft are a
short, offset, or small chimney, an external down draft
due to wind, an extremely air-tight home with exhaust
fans, or a thermal down draft due to appliance placement.
Wet wood will give off much less heat than dry, seasoned
wood (see "A Word about Wood" on page 17).
New high-tech. appliances have a lag time between
adjusting the air control and the fire speeding up.
Appliance must be up to temperature for the blower to
turn on if it is turned to "AUTO" (see "Blower
Operation" on page 16).
Check the outlet that the blower is plugged into with a
lamp to see if it has power.
The fire is evaporating the water from the wood, giving
off more visible smoke.
Wet wood will give off much more smoke than dry,
seasoned wood (see "A Word about Wood" on page 17).
Page 29
WARRANTY PAGE 27
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., 10850 117th Place N.E., Kirkland, Washington 98033. TRAVIS INDUSTRIES, INC. warrants this 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:
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
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, 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, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance, One-Way Freight Allowance, Labor
Door Assembly:
Solid Brass or Cast Door, Latch Assembly, Glass Retainers
CONDITIONS & EXCLUSIONS
1. This new appliance must be installed by a qualified installer. It must be installed, operated, and maintained at all times in accordance with the instructions in the OwnerÕs 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. Overfiring (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 limited to, improper
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 adjustment of the
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 firebrick, etc. Also
9. Damage to brass surfaces caused by fingerprints, scratches, melted items, or other external sources left on the brass surfaces from the use of abrasive cleaners is not covered in this
10. TRAVIS INDUSTRIES, INC. is free of liability for any damages caused by the appliance, as well as inconvenience expenses and materials. Incidental or consequential damages are
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 express written
12. Any statement or representation of Travis products and their performance contained in Travis advertising, packaging literature, or printed material is not part of this 7 year warranty.
13. This warranty is automatically voided if the applianceÕs serial number has been removed or altered in any way. If the appliance is used for commercial purposes, it is excluded from
14. No dealer, distributor, or similar person has the authority to represent or warrant Travis products beyond the terms contained within this warranty. TRAVIS INDUSTRIES, INC.
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 Industries, Inc., the manufacturer of the appliance. All other warranties, whether express or implied, are hereby
chimney/venting installation.
manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God.
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).
warranty.
not covered by this warranty. In some states, the exclusion of incidental or consequential damage may not apply.
permission of TRAVIS INDUSTRIES, INC. and bearing a TRAVIS INDUSTRIES, INC. label of approval.
this warranty.
assumes no liability for such warranties or representations.
expressly disclaimed and purchaserÕs recourse is expressly limited to the warranties set forth herein.
Ceramic Glass
Glass (breakage from thermal shock)
Firebrick
Breakage from thermal shock
Accessories
Legs, Pedestal, Panels, Blower
Door Assembly:
Solid Brass or Cast Door, Latch
Assembly, Glass Retainers
RE-INSTALLATION ALLOWANCE
In cases where heater must be removed from
home for repairs, a partial cost of re-installation is
covered (pre-authorization required)
ONE-WAY FREIGHT ALLOWANCE
One-Way Freight Allowance On Pre-Authorized
Repair Done At Factory Is Covered.
ONE-WAY FREIGHT ALLOWANCE
ONE-Way Freight Allowance On Pre-Authorized
Repair Done At Factory Is Covered.
Air Control Assembly
Slider Plate, Pressure Plate
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 applianceÕs 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 applianceÕs 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. Dealers may require you to pay a service or trip charges for any warranty work. This charge
can vary from store to store.
Page 30
PAGE 28 PRODUCT LISTING INFORMATION
The data on the label below matches the data on the label attached to the side of your insert.
Page 31
OPTIONAL EQUIPMENT PAGE 29
SURROUND PANEL INSTALLATION (SEE TABLE BELOW FOR PART NUMBER)
Surround panel size is determined by the type of installation and the size of the fireplace opening.
Direct and positive connections do not require insulation or panels that overlap the fireplace opening
(panels that overlap the fireplace opening are usually more attractive). Face seal connections require
surround panels that overlap the fireplace opening on the top and sides at least 2" (2 1/2" for rough
surfaces). This overlap is needed for the insulation that forms the airtight seal between the surround
panels and the fireplace. Any questions on selection of the surround panels should be directed towards
your dealer. The table below details the size of the surround panels when installed.
SURROUND PANEL SIZE SIZE ON APPLIANCE (Including Trim) PART #
8" 45 3/8" width by 29 1/2" height 99300104
10" 49 3/8" width by 31 1/2" height 99300105
12" 53 3/8" width by 33 1/2" height 99300111
The surround panels should be installed prior to installing the insert. Place the insert 12" from the
fireplace opening before installing the surround panels.
1. Follow the directions in the illustration below to install the side panels.
Place two clips
1.
(included in the
owner's pack) over
one of the surround
panels (flat side in).
Cook Top
Top of Insert
Rotate the panel
2.
back and place it so
the inside flange fits
inside the side
convection jacket.
Note how the cook
top fits into the
notch.
Side
Convection
Jacket
Inside
Flange
Insert the two screws
3.
(included with the panels)
through the convection
jacket and into the two
clips installed in step one.
Turn a couple of times but
do not tighten.
4.
Repeat for the opposite side.
Back
of
Insert
Page 32
PAGE 30 OPTIONAL EQUIPMENT (CONTINUED)
SURROUND PANEL INSTALLATION (CONTINUED)
3. Install the top panel (see the illustration below). Adjust the top panel so its edges are flush with
the side edges of the side panels.
Top Panel
The joggle clips on the
top panel slide over the
offset portion on top of
the side panels and over
the mounting flange.
Mounting Flange
4. Adjust the position of the side panels so they are: 1) flush with the bottom of the insert; 2) both
the same distance back from the front of the insert; 3) perpendicular to the floor. Tighten the
nuts that hold the side panels in place.
Insulation Installation
The installation of the insulation is required only for face seal connections. Direct and positive
connections do not require the insulation to be installed.
1. With the insert drawn 12" away from the fireplace, glue the insulation strip included with the
surround panel kit to the back of the panels using RTV silicon or stove gasket cement. The
insulation should be installed so it overlaps the fireplace opening to form a seal between the
panels and the fireplace face. Let the silicon or cement dry.
2. Push the insert into the fireplace, insuring a seal is made with the insulation between the panels
and the fireplace face. Use a screwdriver to tuck any exposed insulation behind the panels.
Brass Trim Installation (Optional)
The optional surround panel brass trim greatly enhances the appearance of your insert and is easy to
install. Follow the directions below to install.
1. Lay the three pieces of brass trim on the floor in front of the insert. Arrange the brass trim so
that it resembles the illustration below. The rounded edge of the trim that will be facing
outwards when installed should be facing down.
2. Insert each "L" bracket leg into the groove in the 45° cut end of each side piece. Slide the other
leg of each "L" bracket into the groove in each end of the top piece. Tighten the four set screws
with a screwdriver into the "L" brackets, insuring that the 45° cuts are butted together to form a
neat joint. Pick up the brass trim and slide it over the top panel until the trim is flush with the
bottom edge of the top panel.
CROSS SECTION OF BRASS TRIM
Set screw that holds the
"L" bracket in place
Groove where the "L"
bracket fits into
Groove Where Top
Panel Fits Into
Front Side
Left Trim
Insert
Lay the trim on the
floor in front of the
insert with the rounded
portion facing down.
"L" Brackets
Top Trim
Right Trim
Page 33
OPTIONAL EQUIPMENT (CONTINUED) PAGE 31
SURROUND PANEL INSTALLATION (CONTINUED)
3. Some kits include double-back tape. For those kits, follow the instructions below.
Attach a square of double-back tape to each of the bottom corners of the surround
panels before installing the trim. This will keep the panels from flaring at the bottom.
Surround
Panel
Surround Panel
Brass Trim
FLUE ADAPTER INSTALLATION (PART NUMBER 98900120)
The flue adapter has a built in flue collar with pre-drilled holes designed to make flue attachment easier.
It may also be used to adjust the position of the flue exit, up to 2 1/2" forward or 1 5/8" back.
1. Determine the position of the flue adapter that best suits the installation. Mark the location of the
four mounting holes on the top of the insert (NOTE: the position is variable Ð see the illustration
below for details). Remove the flue adapter and drill four 5/32" holes into the top.
2. Adhere the self-adhesive gasket included with the flue adapter along the bottom perimeter of the
adapter. Cut off any excess gasket.
3. Place the flue adapter in place. Use a 5/16" nutdriver to attach the four screws that secure it to
the insert.
Attach the adapter to the insert
with the four screws included with
the kit (use a 5/16" nutdriver).
Make sure the cover plate is in
place. If it is not, place something
over this hole (Kaowool or other
high-termperature insulation will
work).
Flue
Adapter
Place the
self-adhesive
gasket along
the bottom
perimeter of
the adapter.
Flue Exit
The flue adapter may offset
the flue location up to 1 5/8"
back. On models with
surround panels, the adapter
may offset the flue location up
to 2 1/2" forward.
Center
of Flue
Exit
Place the adapter like this
to offset the flue backward.
Drill 5/32"
diameter
holes for
the screws.
Center
of Flue
Exit
Place the adapter like this
to offset the flue forward.
Page 34
Page 35
Page 36
PAGE 32 INDEX
Adjusting the Heat Output............................................ 14
Air Control Settings ...................................................... 12
Ash Removal................................................................ 19
Baffle (removal and replacement)................................ 23
Block-Off Plate Installation ........................................... 9
Blower (cleaning) ......................................................... 22
Blower (installation)...................................................... 8
Blower (operation)........................................................ 16
Brass Cleaning............................................................. 19
Brass Trim Installation (for panels)............................... 30
BTU Output .................................................................. 5
Bypass Control............................................................. 13
Chimney Inspection (Creosote Inspection) .................. 19
Chimney Requirements (Masonry Fireplace Req.)...... 8
Clearances ................................................................... 7
Creosote Inspection ..................................................... 19
Dimensions................................................................... 5
Direct Connection......................................................... 10
Door (Inspection) ......................................................... 20
Door Cam..................................................................... 20
Door Gasket ................................................................. 21
Door Hinge (lubricating) ............................................... 21
Efficiency...................................................................... 5
Emissions..................................................................... 5
EPA Emission .............................................................. 5
Face Seal Connection.................................................. 11
Fan Cleaning (Blower) ................................................. 22
Fan Installation (Blower) .............................................. 8
Fan Operation (Blower)................................................ 16
Firebox Size ................................................................. 5
Firebrick (inspection and cleaning) ............................. 22
Firebrick (removal and replacement) ........................... 23
Fireplace Requirements ............................................... 8
Fireplace Sizing ........................................................... 7
Floor Protection (see Hearth Requirements) ............... 7
Flue Adapter Installation .............................................. 31
Flue Size (6") ............................................................... 5
Fuel to Use (cord wood only) ....................................... 17
Glass (Inspection) ........................................................ 20
Glass Cleaning............................................................. 19
Glass or Glass Gasket ................................................. 21
Hearth Requirements ................................................... 7
Heating Capacity.......................................................... 5
Insert Placement Requirements................................... 7
Insert Size Requirements............................................. 7
Insulation Installation (for panels) ................................ 30
Leveling Bolt Installation .............................................. 8
Listing Information........................................................ 28
Location of Controls ..................................................... 12
Log Length (Up to 24") ................................................. 5
Maintenance Schedule................................................. 19
Masonry Fireplace Requirements ................................ 8
Offset (Flue Adapter) ................................................... 31
Optional Equipment Requirements .............................. 6
Overnight Burn ............................................................. 15
Paint (touch-up) ........................................................... 22
Paint Curing ................................................................. 12
Panels .......................................................................... 29
Parts List ...................................................................... 25
Positive Connection ..................................................... 10
Reloading Your Appliance ........................................... 14
Replacement Parts List................................................ 25
Safety Label ................................................................. 28
Safety Precautions ....................................................... 2
Secondary Air Tube (replacement) .............................. 25
Secondary Air Tube (warranty - 5 yrs) ......................... 27
Specifications ............................................................... 5
Starting the Fire ........................................................... 13
Surround Panel Installation.......................................... 29
Table of Contents......................................................... 4
Troubleshooting Table ................................................. 26
Warranty....................................................................... 27
Weight (Dimensions).................................................... 5
Wood Types ................................................................. 17
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