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• Masonry Fireplace • Factory Built (Metal) Fireplace • Mobile Home Approved Tested and Listed by Omni-Test Laboratories, Inc. Portland, Oregon Report # 028–S–51-2 ASTME-1509 1995, ULCC 1482 Astoria Bay™ Pellet Insert - - Please read this entire manual before installation and use of this pellet fuel-burning room heater. Failure to follow these instructions could result in property damage bodily injury or even death. - - Contact local building or fire officials about restrictions and installation inspection requirements in your area. -- Save these instructions Installer: After installation give this manual to the home owner and explain operation of this stove. $10.00 Copyright 2008, T.I. Part # 100-01144 40807234800 Harbour Pointe Blvd. SW Mukilteo, WA 98275 2 Introduction Introduction We welcome you as a new owner of a Astoria Bay pellet heater. In purchasing a Astoria 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 Astoria Bay is one of the finest home heaters the world over. This manual will explain the installation, operation, and maintenance of this pellet-burning heater. Please familiarize yourself with the Owner's Manual before operating your heater and save the manual for future reference. Included are helpful hints and suggestions which will make the installation and operation of your new heater an easier and more enjoyable experience. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your heater. Important Information No other Astoria Bay heater has the same serial number as yours. On the Astoria Bay the serial number is on the hopper cover. This serial number will be needed in case you require service of any type. Model: Astoria Bay Serial Number: Purchase Date: Purchased From: Mail your Warranty Card Today, and Save Your Bill of Sale. To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us. We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur. Travis Industries 4050525 100-01144 Table of Contents 3 Introduction Introduction......................................................2 Important Information .........................................2 Safety Precautions Safety Precautions ............................................4 Specifications Heating Specifications........................................6 Dimensions.......................................................6 Electrical Specifications......................................6 Fuel.................................................................6 EPA Compliance................................................6 Installation Before you Begin ...............................................7 Packing List......................................................7 Installation Options............................................7 Planning the Installation......................................7 Minimum Fireplace Size.......................................7 Hopper Extension Set-Up ....................................8 Clearances.......................................................10 Mantel Requirements..........................................10 Hearth Requirements..........................................10 Facing Requirements..........................................10 Placing the Insert...............................................10 Venting the Pellet Stove......................................11 Maximum Venting Distance .............................11 Pellet Vent Type............................................11 Installing the Pellet Vent.................................11 Pellet Vent Termination...................................11 Mobile Home Requirements..................................12 Outside Air .......................................................12 Baffle Installation...............................................13 Restrictor Adjustment.........................................13 Surround Panel & Circuit Board Installation .............14 Installation into a Masonry Fireplace......................15 Installation into a Factory Built (Metal) Fireplace.......16 Operation Safety Notice....................................................17 Location of Controls ...........................................17 Starting the Heater for the First Time......................17 Curing the Paint ............................................17 Priming the Auger..........................................17 Loading Pellets..................................................18 The Two Modes of Operation ................................18 Operation (continued) Manual Mode.....................................................19 Auto Mode........................................................20 Restrictor Adjustment.........................................21 Adjusting the Fan Speed......................................21 Start-Up Sequence.............................................22 "AUGER ON" Light..............................................22 "MAINTENANCE REQUIRED" Light........................22 Power Outages..................................................23 Using a Pellet/Corn Mix with This Heater .................23 Maintenance Daily Maintenance (whenever using the heater)........24 Inspect the Burn ...........................................24 Make Sure Pellets are not Piling Up...................24 Check Firepot for Clinkers...............................25 Cleaning the Firepot.......................................25 Opening the Door ..........................................26 Weekly Maintenance (or every 5 bags pellets) .........27 Flyash Removal ............................................27 Clean the Hopper...........................................27 Clean the Heat Exchange Tubes.......................27 Clean the Optional Plated Surfaces...................27 Check Baffles Ashbox and Ashpan, Dispose ......28 Clean the Glass ............................................28 Sweep Ash Into Ashpan..................................29 Yearly Maintenance (or every ton).........................30 Clean the Exhaust Duct..................................30 Clean the Exhaust Blower ...............................31 Clean the Vent..............................................31 Door Seal.....................................................32 Door Alignment .............................................32 Adjusting the Door Hinge and Latch...................33 Check for Air Leaks - Door, Glass and Ashpan ....34 Replacement Parts........................................34 Normal Operating Sounds Normal Operating Sounds....................................35 Safety Label Safety Label .....................................................36 Warranty Warranty..........................................................37 Optional Equipment Thermostat.......................................................38 ZC Kit ..............................................................39 Index Index...............................................................40 Travis Industries 4050525 100-01144 4 Safety Precautions Gas • Do not operate the heater if you smell smoke coming from the heater. Turn the POWER switch to "OFF", monitor your heater, and call your dealer. • Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or 'freshen up' a fire in this heater. Keep all such liquids well away from the heater while it is in use. • Do not unplug the heater if you suspect a malfunction. Turn the MODE SWITCH to "OFF" and monitor the heater (see the "Maintenance" section for details). • Never try to repair or replace any part of the heater unless instructions are given in this manual. All other work should be done by a trained technician. Ok Sealant • Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area. Notify your insurance company of this heater as well. • The exhaust system must be completely airtight and properly installed. The pellet vent joints must be sealed with RTV 500o F. (260o C.) silicone sealant. • This unit 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. • Your heater requires periodic maintenance and cleaning (see "Maintaining Your Heater"). Failure to maintain your heater may lead to smoke spillage in your home. • The viewing door and A • Allow the heater to cool ashpan must be closed and latched during operation. • Never block free airflow through the open vents of the unit. • Do not operate the heater if the flame becomes dark & sooty of if the firepot overfills with pellets. Turn A A A A A AA AA AA AA AA A before carrying out any maintenance or cleaning. 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. • This heater is designed and approved for pelletized wood fuel only. Any other type of fuel the MODE SWITCH to "OFF" and and monitor the heater (see the "Maintenance" section for details). AAAAA AAA A A AA A AAAA AAA AAA AAA A AA AA AA A A burned in this heater will void the warranty and safety listing (see page 6 for details). Travis Industries 4050525 100-01144 Safety Precautions 5 • The heater will not operate during a power outage. If a power outage does occur, check the heater for smoke spillage and open a window if any smoke spills into the room. ? • Keep foreign objects out of the hopper. Mobile Home • Disconnect the power cord before performing any maintenance. NOTE: Turning the Mode Switch to "OFF" does not disconnect all power to the heater. • Do not throw this manual • This heater must be connected to a standard 115 V., 60 Hz grounded electrical outlet. Do not use an adapter plug or sever the grounding plug. Do not route the electrical cord underneath, in front of, or over the heater. • When installed in a mobile home, the heater must have outside air, and NOT BE INSTALLED IN THE BEDROOM. • The exhaust system should be checked twice a year minimum for any build-up of soot or creosote. • Do not touch the hot 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 place clothing or other flammable items on or near the heater. Because this heater can be controlled by a thermostat there is a possibility of the heater turning on and igniting any items placed on or near it. surfaces of the heater. Educate all children of the danger of a high temperature heater. Young children should be supervised when they are in the same room as the heater. • Travis Industries, Inc. grants no warranty, implied or stated, for the installation or maintenance of your heater, and assumes no responsibility of any consequential damage(s). Travis Industries 4050525 100-01144 6 Specifications Heating Specifications: Approximate Maximum Heating Capacity (in square feet)* ........................................800 to 2,250 Burn Rate (Pounds per Hour)**............................................................................1.7 to 5.5 Maximum Burn Time on Low Burn** ......................................................................28 to 52 Hours Hopper Capacity (based upon hopper extension position).........................................48 to 89 Pounds * Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is also affected by the fuel size, quality, and moisture level. ** Small pellets will increase or decrease the stated burn rates and burn times. Differences of plus or minus 20% depending on fuel quality may occur. Dimensions: Center of 4" diameter Flue is 16-7/8" above the baseplate and 7-1/2" left of center 32" 26-1/2" 25-1/2" (allow 36" width for 28" 45" 12" control board installation) 25-3/4" to 20" See "Hopper Extension Set-up" for details. 13-1/4" (allow 14" depth in the Fireplace) Fireplace Opening Door Opening Electrical Specifications: Electrical Rating.........................................................................................115 Volts, 3.6 Amps, 60 Hz Watts During Start-Up Sequence...................................................................400 (approximately) Watts During Operation ...............................................................................180 (approximately) Fuel: • This heater is designed and approved for pelletized wood fuel or a mixture up to 50% corn, 50% pellets. See page 23 for details on using a corn pellet mix. EPA Compliance: This heater is EPA exempt from Phase II requirements, but has been tested for emissions using EPA test methods by OMNI Test Labs. Travis Industries 4050525 100-01144 Installation 7 Before You Begin READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE THIS HEATER. FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH. Check with local building officials for any permits required for installation of this pellet heater and notify your insurance company before proceeding with installation. Packing List • Thermostat & Wire • Scraper Rod Tool • Fuses (2) • Fireplace Installation Sticker • Brush • Leveling Bolts (2) • Control Board Screws • Hopper Screws • Double-Back Tape (for panels) Installation Options: • Masonry Fireplace • Factory Built (Metal) Fireplace • Outside Air Compatible Planning The Installation • Have an authorized Travis Industries dealer install this heater. If you install the heater yourself, have your dealer review your installation plans. • Place the heater outside and load 10 pounds of pellets inside the hopper. Plug the heater in and let it run on HIGH until the pellets run out. This will cure the paint and burn off any oil on the steel, eliminating any smell inside the home. • Inspect the chimney and clean as necessary before installing the heater. NOTE: The convection blower is open to the fireplace cavity and may circulate odors from the fireplace. You may wish to paint the interior of the fireplace with latex paint to prevent odors from entering the home. Minimum Fireplace Size See "Mantel Requirements" for details Min. 32-3/4" (6-1/4" from hopper lid) 25-3/4" - 20" See "Hopper Extension Set-up" Min. 36" Mantel (combustible or non-combustible) Min.42" (7" from hopper lid) Non-Combustible Facing Min. 18" Min. 36" (6" from door opening) Non-Combustible Hearth (includes circuit board) Min. 14" Travis Industries 4050525 100-01144 8 Installation Hopper Extension Set-up This pellet heater has a variable-height hopper. This allows the hopper to be lowered for smaller fireplaces. Follow the instructions below to set the correct hopper extension position. • Determine the correct hopper extension position following the directions below. The unit will extend 14" into the fireplace. For setting the hopper, the maximum fireplace opening measurements have to be taken at 14" into the fireplace. Hopper Extension Position A (highest position) 25-3/4" B (next highest) 24-1/2" C etc... 23-3/8" D etc... 22-1/4" E etc... 21-1/8" F (lowest position) 20" • Remove the hopper top following the directions below. Hopper Top Remove the hopper top by removing the screws holding it in place. 1/4" Nutdriver NOTE: with the hopper top removed, the hopper walls may be removed. • Remove the hopper walls. Travis Industries 4050525 100-01144 Installation 9 • Remove the correct knock-outs in the hopper walls following the directions below. If you are using hopper extension position F, remove the top knock-out. If using position E, remove the second knock-out, (etc...). The second-to-bottom knock-out is position B. Position F Knock-Out Position E Knock-Out Use a center-punch (or other suitable Position D Knock-Out Position C Knock-Out Position B Knock-Out Position A Knock-Out • Re-install the hopper walls following the directions below. tool) to remove the appropriate knock outs in the hopper walls (punch the holes out from the inside). Make sure to support the hopper walls while removing the knock-outs. There are 11 knock-outs for each position. HINT: Attach one screw to each side to align the hopper walls. Then install the remaining screws. NOTE: This hopper extension is in position D. • Attach the hopper top following the directions below. Before installing the hopper top, use a center punch (or other suitable tool) to remove the appropriate knock-outs on the hopper top. Re-attach the hopper top to the hopper walls using the screws included with the insert. Travis Industries 4050525 100-01144 10 Installation Clearances • Insert must be placed so that no combustibles are within, or can swing within (e.g. drapes, doors), 36" of the front of the heater. • Insert must be placed a minimum 8-3/4" from a side wall (or combustible protruding more than 3/4"). Mantel Requirements • The mantel must meet the requirements shown in the illustration to the right. Hearth Requirements The mantel must fall within this shaded area (or above). Maximum mantel depth is 12". 12" AAA AAA AA AAAA AAA AAA AA AA AAA AA AA AA AAA AAA • The non-combustible hearth must extend 6" to the front and sides of the firebox opening (you must open the door to measure). Facing Requirements 3-1/2" 33" AA AA AAAA AAAA 38" • The non-combustible facing must extend 7" to the side and 6" above the hopper lid. Placing the Insert AAA AAAA AAAA AAAA • The insert must be placed within an AA AA AA AA AA AA undamaged masonry or factory built (metal) AA AA AA AA AA AA AA AA AA fireplace. Loose bricks or other damage must be fixed. Clean the fireplace before AA AA AA AA AA AA AA AA installing. Apply the "This fireplace has been AA AA AA AA AA altered..." sticker to the fireplace. You may wish to place it in a location where it Min. 8-3/4" will be covered by the surround panels. Side Wall The vent should be routed to the fireplace prior to installing the insert. See the section "Vent Installation" for details on vent location. Use the leveling bolts for fireplaces with recessed floors (included with the insert). Screw them into the baseplate from below. 13-1/4" Place the insert so the back edge of the baseplete extends 13-1/4" into the fireplace. Run the power cord to the side along the front of the fireplace (do not route it under the insert). Travis Industries 4050525 100-01144 Installation 11 Venting the Pellet Stove • INSTALL VENT AT CLEARANCES SPECIFIED BY THE VENT MANUFACTURER). • DO NOT CONNECT THE PELLET VENT TO A VENT SERVING ANY OTHER APPLIANCE OR STOVE. • DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST VENTING SYSTEM OF THIS UNIT. • USE AN APPROVED WALL THIMBLE WHEN PASSING THE VENT THROUGH WALLS AND A CEILING SUPPORT/FIRE STOP SPACER WHEN PASSING THE VENT THROUGH CEILINGS (MAKE SURE TO MAINTAIN CLEARANCE TO ANY COMBUSTIBLES. Maximum Venting Distance: • Maximum venting height is 33' (maximum horizontal offset is 10') • Use no more than 180° of elbows (two 90° elbows, or two 45° & one 90° elbow, etc.). Pellet Vent Type • Must be Type "L" vent and/or Type "L" chimney liner. • Use 4" diameter vent. Installing the Pellet Vent • Pellet vent connections must be sealed airtight with 500° F. RTV silicone and Seal each vent section (including adapters, elbows, etc...) by injecting a liberal amount of 500° between sections. 500° F. RTV screwed together with at least three sheet metal screws. AAAA Silicone F. RTV silicone into the gap AAAAA AAAA AA AA AA AAAAA AAAA AA AA AAAAA AAAA AAAAA AA AA AAAAA AA AAAA AAAAA The exhaust quick AA AA AAA AA AAAAA AAAA AAAAA AAA AA AA AAAAA connect can be removed to allow for installation and cleaning. AA AAA AAAAA AA AAA AAA AA AAAAA AA AAA AA AAAAA AA AA AAAAA AA AA AA AA AA AA AA AA AA AA AA AA AAAA AA AAAA AA AAAA AAAA AA AA AAAA AAAA AA AAAAA AAAA AA AA AA AAAA AAAA AA AAA AA AA AA AA AAA AAAA AAAA AA AAAAA AA AA AA AA AAA AAAA AA AA AA AAAA AAAA Pellet Vent Termination AA AAA AA AA AA • Termination must be a minimum 6" above the top of the chimney (NOTE: the chimney must meet local codes for height above the roof or other obstructions). • Must have an approved cap (to prevent water from entering). • Must not be located where it will become plugged by snow or other material. Travis Industries 4050525 100-01144 12 Installation Mobile Home Requirements • Outside air is required (used for combustion) - see the directions below. WARNING: DO NOT INSTALL IN SLEEPING ROOM. CAUTION: THE STRUCTURAL INTEGRITY OF THE MANUFACTURED HOME FLOOR, WALL, AND CEILING/ROOF MUST BE MAINTAINED. Outside Air (used for combustion) • Outside air is optional (except in mobile homes or when required by local building codes). • Must not be drawn from an enclosed space (garage, unventilated crawl space). • Must not be over 15' long. • Must be made with 1 3/4" diameter or larger metal or aluminum duct with a metal screen attached to the end to keep out rodents (P.V.C. or other combustible materials may not be used). Use the Travis Industries Outside Air Kit (part # 99200136). • Must not terminate above or within 1' of the chimney termination. • Must have a rain cap or down-turned elbow to prevent water from entering. • Must be located so that it will not become plugged by snow or other material. 12" Min. Outside air may be drawn through the chimney (15' maximum length). AAAA Vent Termination AA AAAA AAA AAA AA AA AAAAA AAAA AA AA AAA AA AAAAA AA AAA AAAAA AAAAA AA AAAA AAAAA AA AA AAAA AA AA AA AAAAA AA AA AAAAA AA AAA AA AAAA AAAA AAAAA AAAA AAA AAAAA AAA AA AA AA AAAAA AAAAA AA AAA AAAA AAAA AAAA AAAAA AA AAA AAA AA AAAAA AAA AAA AA AAAAA AA AAA AAAA AAA AAA AAAAA AA AA AAA AA AAA AAAAA AA AA AAAA AAA AAA Outside air may be drawn from the ash cleanout. AAAAA AA AA AA AA AA AA AAA AA AA AAAA AAAA AA AA AA AA AAAA AA AA AA AAA AA AA AA AA AA AA AA AA AAAA AA AA AA AA AA AA AAA AAA AA AA AA AA AA AA AA AA AA AA AAAA AA AA AA AA AA AA AA AA AAA AA AA AA AA AA AA AA AA AAA Travis Industries 4050525 100-01144 Installation 13 Baffle Installation Install the baffles included with the insert (see page 28 for details). Restrictor Adjustment The restrictor is used to adjust airflow to the firepot. It should be adjusted to match the heat output setting and burn the pellets at the appropriate rate. This keeps the firepot as clean as possible. For low heat output settings the restrictor will need to be closed or near closed to limit the amount of air. This prevents the stove from burning the pellet fuel faster than it is fed. For medium heat output settings the restrictor will need to be opened to a medium position. For high heat output settings the restrictor will need to be opened to a high position. This prevents the firepot from over-filling with pellets and becoming clogged with ash clumps. Keeping your firepot clean is the most important step to maintaining a safe and efficient stove. Check and clean your firepot daily until you find the correct restrictor settings and appropriate firepot cleaning interval. Not Enough Air If clinkers (ashes that solidify into a clump) develop or the flame appears lazy and slow to blow the ash out of the firepot, pull the restrictor outward until the flame becomes active and the firepot holes remain clean. NOTE: If the restrictor is fully out, yet the firepot does not remain clean, the stove needs to be cleaned and checked for air leaks (see "Maintenance" section of this manual). Too Much Air If the flames are too active (small, flickering flames) or if burning pellets are expelled from the firepot, move the restrictor rod inwards until the flame slows down and no burning pellets are expelled (note: it is okay to have "glowing embers" jump out of the firepot). Another symptom of too much air is the heater "blowing the fire out" – a condition in which the pellets burn faster than they are fed (this is most common on low). AA Travis Industries 4050525 100-01144 14 Installation Surround Panel & Circuit Board Installation NOTE: Attach the vent prior to installing the surround panels (& circuit board). a e Attach the surround panels to the insert by sliding the slots on each panel over the tabs on the side of the insert. Slot NOTE: When in place, the panels maintain a 3/8" gap around the fireplace. Tab Phillips Screwdriver Remove the circuit board from the rear hopper support. Disconnect the wiring harness from the circuit board (see step "d" below for a detailed view). c Attach the circuit board Back of Side Panel b Bend these block off plates as shown (both sides). When in position, they block the view through the slots. in the surround panels. with the four screws shipped with the insert. Phillips Screwdriver Right Side Surround Run the power cord to the side along the front of the fireplace behind the side panel (do not route it under the insert). Install the top panel so the joggle clips slide over the tabs on top of the side panels and insert. f Tighten the set screws from the back side with a small standard screwdriver Panel AA AA ATop Panel Top Trim "L" Bracket Place the right side surround panel near d the insert and attach the wiring harness to the circuit board. Back Side of Circuit Board Pinch these tabs to remove the wiring harness. If using a thermostat, attach the thermostat wires at this time. A AA AA AA Double-Back Tape Right Side Trim Optional Trim Installation: Insert one leg of each "L" bracket into the top and side trim piece. Align the trim to form a precise corner, then tighten the two set screws with a small standard Wiring Harness (disconnected in step "a") screwdriver. Slide the trim over the panels. Attach the double back tape between the trim and panels at the bottom corners. This keeps the trim tight against Travis Industries 4050525 100-01144 Installation 15 Installation into a Masonry Fireplace Vertical Cap Storm Collar "L" Vent Cover Plate (non-combustible) SiliconeSeal the cover AAAAA AAAAA AAAA plate with silicone. AA AAAA AAAA AAAA AA AA AAAA AA AAAA AA AA AAAA AA AAA AA AAA AA AAA AA AAA AA AAA AAAA AAAA AAAA AA AA AAAA "L" Vent Flex Section AAAA AAAA AA AA AAAA AA AA AA AAAA AAAA AA AAA AAA AAAA AAA AA AAA AAAA AAAA AAA AAAA AAA AAA AAAA AAAA AA AA AAAA AA AAAA AAAAA AA AA HINT: AA AAAA AA Paint the interior of the fireplace with latex paint to prevent fireplace odors AAAAA AA AAAAA AA AAAA AA AAAAA AAAAA from entering the home. AA AA AAA AA AAAA AAAA AA AAA AAAA AAAA AAAAA AAAAA AAA AA AAA AAAA AAAA AAA AAA AA AAAA AA AAAA Outside air may be drawn from the ash cleanout. AAAAA AA AAAAA AA AA AAAA AA AA AA AA AA AA AAAA AA AAAAAAAAAAAAAA AA AA AA AA AA AA AAAA AA AA AAAA AA AAAA AA AA AA AA AA AA AA AA AA AAAA AA AA Travis Industries 4050525 100-01144 16 Installation Installation into a Factory Built (Metal) Fireplace Vertical Cap Storm Collar AAAA A "L" Vent Cover Plate (non-combustible) Silicone Seal the cover AAAA AAAAA AA AAAAA A AA A AAAAAA A A A AA A AAAA A A AAAA A A A AA A AAAAAA A A A AA A A AAAA A A plate with silicone. A A A AAAA AA AAAAA AA AAAAA A AA A AAAA A A AA A A A AAAA AAAA AAAAAA The log grate, AAAAAA "L" Vent Flex Section AA AA AA A AA A A AAAA screen (and rails), and doors (if AAAAAA AAAA AAAA AA present) must be The smoke shelf, shields, AA AA A AA A AA A A AA A A AA AAAAAA removed. AAAAAA damper, and baffles may AAAA AA A A A A AA AA A AA A A AAAAAA A A be removed if attached with mechanical AA AAAA AA AAA A A A A A A AA AA AA AA A A AA AAAA A AAAAAA A A A A A A A fasteners. AAAAAAAA AA AAA A AA AA AA A A AA A A AAAAAA AAAA AAAA AAAA AAAAAAAA AAAA AAAA A A A A A A A A AA AA AA A AAAA AAAAAA A A A A A A A AAAAAAAA AAAA AAAA A AA AA AA A AAA AAAAAA A A A A A A A The firebrick (refractory) AAAA A AAAAAAAA AAAA A AA AA AA A AAAA AAAAAA A A A A A A may be removed. AAAAAAAA A AA AA A A AAAA AAAAAA A A AA AAAAAAAA A AA A A AAAA AAAAAA HINT: Paint the interior of the fireplace with latex paint to AA AA AA AA AAAAAAAA A A AAAAAAAA AAAAAAAA AAAAAAAA A A AAAAAA NOTE: The fixed spacers under the appliance may not prevent fireplace odors from AAAAAAAA be removed. entering the home. AA AAAAAAAA AAAAAAAAAAAAAAAAAAA AA AAAAA AAA AAAAAAAAAAAAAAAAAAA The metal sides, frame members, or other structural components of the factory built fireplace may not be removed or altered. The metal floor of the firebox may be removed leaving he fireplace floor outer wrap. Use the telescoping legs to support the insert on raised fireplaces. Travis Industries 4050525 100-01144 Operation 17 Safety Notice • Read this entire manual (especially the "Safety Precautions" on pages 4 and 5) before using this heater. Failure to follow the instructions may result in property damage, bodily injury, or even death. • Do not unplug the heater to turn it off. This heater relies upon electricity to push the flue gases out the pellet vent – unplugging it may lead to smoke entering your room. • Failure to maintain your heater will lead to a restricted combustion air system, leading to poor performance and in some cases, smoke spillage into the room. See the "Maintenance" section for details. Location of Controls Control Panel Restrictor The restrictor adjusts the amount of air flowing to the 50 60 70 80 90 Robertshaw 50 60 70 80 90 flame. Thermostat (required for Auto Operation) Pull on this knob to access the control panel. Starting the Heater for the First Time Start the Heater - Let it Burn for 1 Hour - THEN OPEN THE DOOR The stove paint is cured through heat. To prevent it from bonding to the door gasket, you must burn the heater for approximately 1 hour, then open and close the door to break any bonding. Curing the Paint This stove uses a heat-activated paint that will emit some fumes while starting the first fire. Open doors and windows to the room to vent these fumes. You may also notice oil burning 2 to 4 hours AA A Priming the Auger AAAAA off of the interior of the stove. This rust stopping agent will soon dissipate. A Because of its electronic control panel, this stove does not require priming. If you run out of pellets you may notice it will take approximately 5 minutes longer for the stove to start. Travis Industries 4050525 100-01144 18 Operation Loading Pellets Lift the hopper lid to its vertical position. Pour pellets into the hopper until full. NOTE: The hopper holds approximately 48 to 88 pounds of pellets (depending upon hopper set-up). The front edge of the hopper lid becomes very hot, do not touch the area below the handle. The Two Modes of Operation: Manual Manual mode requires the user to turn AA Pellets AA AAAA AAAAAAA AAAAAAA AAAA AAAAAA AAAAA AA AAAAA AAAAAA AAAAAAA AAAAAA AAAAA AA AAAAA AAAAAAA AAAAAA AAAAA AAAA AAAAA Make sure pellets are not left on this heat shield. DISCONNECT POWER BEFORE SERVICE H E the heater on and off manually. A T Auto (requires a thermostat) O Auto mode allows you to use a U HIGH MED AUTO MANUAL These indicator lights T thermostat to control room P temperature. The stove automatically U turns on when the temperature drops T below the thermostat setting. Once the LOWAUGER MAINT. (REQUIRED) AUTO are used to determine which mode you are in. stove reaches operating temperature, UP H the stove then runs at the heat output E setting selected. A OFF MANUAL Use the mode switch to T Switching Modes While in Operation F Whenever the stove is switched from A one mode to another while in N operation, the stove will enter the "start up" sequence for a minimum of 20 minutes. DOWN UP DOWN MANUAL START MANUAL AUGER TM determine the mode. TRAVIS INDUSTRIES HOUSE OF FIRE Travis Industries 4050525 100-01144 Operation 19 Manual Mode Manual mode requires the user to turn the heater on and off manually. UP H E To Start A AUTO OFF MANUAL T Press the "Manual Start" button. That's it. The stove automatically goes to a medium burn rate and high fan while the igniter starts the fire F burning within 10 minutes. During this period A the lowest "HEAT OUTPUT" light will flash. If N the stove does not start in 30 minutes, the stove turns off. Once up to temperature, the stove will then run at the heat output setting selected on the DOWN UP DOWN MANUAL START MANUAL AUGER TM control panel (see "To Adjust the Heat" below). To Shut Down Move the mode switch to "OFF". The exhaust TRAVIS INDUSTRIES HOUSE OF FIRE AUTO UP OFF blower will still run until the heater cools down. MANUAL HE A T F A N DOWN UP DOWN MANUAL START MANUAL AUGER TM H E A T To Adjust the Heat TRAVIS INDUSTRIES HOUSE OF FIRE DISCONNECT POWER BEFORE SERVICE HIGH AUTO O U MED MANUAL Press the "Heat" buttons to adjust the heat T P output. U T LOWAUGER MAINT. (REQUIRED) AUTO These lights indicate the heat output setting. UP H NOTE: During start-up you may adjust the heat E setting. This heat setting will take affect once A OFF MANUAL NOTE: the lights may be difficult to the start-up sequence is complete. T F A N DOWN UP DOWN MANUAL START MANUAL AUGER TM see from an angle. Press the "up" or "down" button to adjust the heat output. TRAVIS INDUSTRIES HOUSE OF FIRE Travis Industries 4050525 100-01144 20 Operation Auto Mode Auto mode allows you to use a thermostat to control room temperature. The stove automatically turns on when the temperature drops below the thermostat setting. Once the stove reaches operating temperature, the stove then runs at the heat output setting selected. To Adjust Room Temperature (or Start the Stove) Move the thermostat to the heat setting desired. If the room is cooler than the setting, the stove will go through the start-up sequence for approximately 10 minutes. During this period the lowest "HEAT OUTPUT" light will flash. Once up to temperature, the stove will then run at the heat output setting selected on the control panel. If the room is too hot, move the thermostat to a lesser setting. DISCONNECT POWER BEFORE SERVICE H To Adjust the Heat E A T Press the "Heat" buttons to adjust the heat output. O U HIGH MED AUTO MANUAL T HINT: P U T If you find that the stove turns on and off repeatedly, you may wish to turn the heat LOWAUGER MAINT. (REQUIRED) AUTO These lights indicate the heat output setting. UP H output to a lesser setting. The lower setting E will provide a more consistent heat output over A OFF MANUAL NOTE: the lights may T time, eliminating the need for the thermostat to repeatedly turn the stove off. NOTE: F A N If the thermostat calls for heat while the stove is still cooling down, the stove will go through the start-up sequence (for a minimum of 20 minutes). DOWN UP DOWN MANUAL START MANUAL AUGER TM be difficult to see from an angle. Press the "up" or "down" button to adjust the heat output. To Shut Down Move the mode switch to "OFF". The exhaust TRAVIS INDUSTRIES HOUSE OF FIRE AUTO UP OFF blower will still run until the heater cools down. MANUAL HE A T F A N DOWN UP DOWN MANUAL START MANUAL AUGER TM TRAVIS INDUSTRIES HOUSE OF FIRE Travis Industries 4050525 100-01144 Operation 21 Restrictor Adjustment The restrictor is used to adjust airflow to the firepot. It should be adjusted to match the heat output setting and burn the pellets at the appropriate rate. This keeps the firepot as clean as possible. For low heat output settings the restrictor will need to be closed or near closed to limit the amount of air. This prevents the stove from burning the pellet fuel faster than it is fed. For medium heat output settings the restrictor will need to be opened to a medium position. For high heat output settings the restrictor will need to be opened to a high position. This prevents the firepot from over-filling with pellets and becoming clogged with ash clumps. Keeping your firepot clean is the most important step to maintaining a safe and efficient stove. Check and clean your firepot daily until you find the correct restrictor settings and appropriate firepot cleaning interval. Not Enough Air If clinkers (ashes that solidify into a clump) develop or the flame appears lazy and slow to blow the ash out of the firepot, pull the restrictor outward until the flame becomes active and the firepot holes remain clean. NOTE: If the restrictor is fully out, yet the firepot does not remain clean, the stove needs to be cleaned and checked for air leaks (see "Maintenance" section of this manual). Too Much Air If the flames are too active (small, flickering flames) or if burning pellets are expelled from the firepot, move the restrictor rod inwards until the flame slows down and no burning pellets are expelled (note: it is okay to have "glowing embers" jump out of the firepot). Another symptom of too much air is the heater "blowing the fire out" – a condition in which the pellets burn faster than they are fed (this is most common on low). Adjusting the Fan Speed AUTO AA UP OFF MANUAL HE A T F A N DOWN UP DOWN MANUAL START MANUAL AUGER TM Press the "up" or "down" button to adjust the fan speed. TRAVIS INDUSTRIES HOUSE OF FIRE Travis Industries 4050525 100-01144 22 Operation Start-Up Sequence This stove utilizes a start-up sequence whenever the mode switch is changed or the heater is started when cold. This is to ensure proper operation through all possible settings and operational states (hot or cold, pellets burning or not burning, etc.). This sequence over-rides all user settings (except the "OFF" position) to set the auger feed rate to medium, the exhaust blower to high, and the igniter on. During this period the lowest "HEAT OUTPUT" light will flash. "AUGER ON" Light This light comes on when the auger is turning, allowing the operator to know when the auger is turning. "MAINTENANCE REQUIRED" Light NOTE : If the "MAINTENACE REQUIRED" light comes on, check the items below before calling for service . H E A The "MAINTENACE REQUIRED" light is used to T indicate maintenance is required on the heater. It DISCONNECT POWER BEFORE SERVICE HIGH AUTO # 6 Light (red) # 4 Light (yellow) # 2 Light will turn on due to various operating circumstances. MED O U When it turns on, a second light will turn on near MANUAL (green) T "HEAT OUTPUT" (see the illustration to the right). P Determine the maintenance code (2, 4, or 6), then U T use the chart below to diagnose and remedy the situation. LOWAUGER MAINT. (REQUIRED) Light Likely Cause Remedy 2 (green) • Heavy Ash Build-Up in Exhaust Duct • Heavy Ash Build-Up in Exhaust Housing or Plugged Tubing • Heavy Ash Build-Up in Vent • Clean the Firebox (see page 30) • Clean the Exhaust Housing & Tubing (see page 31) • Clean the Vent (see page 31) 4 (yellow) • Heater Ran Out of Pellets • Heater Did Not Start-Up Correctly • Power Outage • Restrictor Not Set Properly • Burnpot Clogged • Air Leak • Heavy Ash Build-Up • Refill the Hopper (see page 18) • Re-Start the Heater and Verify the Pellets Ignite after 10 Minutes • Re-Start the Heater (see page 17) • Re-Start the Heater and Monitor Restrictor Setting (see page 21) • Clean Burnpot (see page 25) • Verify Door, Glass, and Ashpan Seal Correctly (see page 32) • Clean the Firebox (see page 30), Exhaust Housing (see page 31), and Vent (see page 31) 6 (red) • Electrical Input Error (voltage or mhz fluctuation, amp deficiency, etc.) • Components Over-Heated • Faulty Wiring / System Fault • Unplug the Heater then Plug it Back In (this re starts the circuit board) • Clean the Heater and Vent (a plugged heater will slow exhaust flow, increasing temperatures – see pages 30-31) • If this Fault Persists, Contact Your Dealer Travis Industries 4050525 100-01144 Operation 23 "MANUAL AUGER" Button This button turns the auger on. It is used to "prime" the auger after the hopper has run out of pellets. Power Outages If a sustained power outage occurs while in "Manual", the heater will go to a "cool down" mode to vacate smoke once power returns. If the power outage was short, the heater will go to the start-up sequence. If in "Auto", the heater will re-start (if the room is cool). ! Because this heater relies upon a blower to evacuate the smoke, some smoke may enter the home during a power outage. To keep to a minimum, leave the door closed. Using a Pellet/Corn Mix with This Heater This heater may burn a mixture of corn and wood pellets up to a 50% - 50% proportion by volume. Shelled corn burned in Travis pellet appliances must be clean (free of husk and cob residue) and have a moisture content no greater than 15%. DO NOT BURN A MIX WITH MORE THAN 50% CORN TO WOOD PELLETS. THOROUGHLY MIX THE TWO FUELS TOGETHER TO BE SURE OF AN EVEN BURN RATE. • If combustion is slow, if the fire is slow to start, or if clinkers (ashes that solidify into a clump) build up rapidly in the fire pot, decrease the proportion of corn and increase the proportion of wood pellets until you find a proportion that works well in your appliance. • If your stove or insert is operated with a thermostat, you may notice the automatic igniter at times fails to light a 50/50 corn to pellet mix. If you experience this, decrease the proportion of corn and increase the proportion of wood pellets in the mix. For an optimum fire and greatest efficiency, it is important to keep the fire pot free of built up ashes. If you are burning only high quality wood pellets, you should check and clean the fire pot at least every two weeks or after ten bags of pellets. If the pellets you are burning have a high ash content or if you burn a corn/wood pellet mixture, we recommend that you check the fire pot every day and clean it if necessary. Travis Industries 4050525 100-01144 24 Maintenance Daily Maintenance (whenever using the heater) Inspect the Burn When burning on high, the flames should be bright orange with embers jumping from the firepot. NOTE : the optimal restrictor position will vary over time as soot builds up inside the exhaust system. See "Restrictor Adjustment" for details. Make Sure Pellets are Not Piling Up If the pellets pile up over the burn pot, turn the mode switch to "OFF". The most likely causes are: • Restrictor needs adjustment AA AA AA A AA A A A (see "Restrictor Adjustment" in the installation section of this manual) • The door, glass, or ashpan is open or has an air leak • The firepot requires cleaning • The exhaust system requires cleaning AAA AAA AAA AA AA AA A AAA AA AA A AA AA AA AA A A A AA A AA A A AA AA AA A AA AA AA A A A AAA AA AA AA A A AA AAA AA AA Travis Industries 4050525 100-01144 Maintenance 25 Daily Maintenance (whenever using the heater) - Continued Check Firepot for Clinkers If the flames seem to be coming only from the sides, or are orange/black, turn the heater off and check for clinkers. The most likely causes are: • Restrictor needs adjustment (see "Restrictor Adjustment" in A A AA A AAA AAAA AAAA AA AA the installation section of this manual) • Poor pellet quality • The door or glass has an air leak • The exhaust system requires cleaning Cleaning the Firepot WARNING: Make sure the heater has fully cooled (approximately 25 minutes) before opening the door and conducting service. To clean the firepot, open the door (see page AAA AA AA A A A AAA AAA A AA AA A AA 26) and knock away any debris on the firepot with a screwdriver. If severely clogged, remove the firepot to gain better access. A A AA AA Travis Industries 4050525 100-01144 26 Maintenance Daily Maintenance (whenever using the heater) - Continued Opening The Door AAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA Phillips Screwdriver Door Frame Swing open this panel to access the door latch (use Bracket (attached to side of heater) Pawl Lock Nut AAAAAAAAA AAAAAAAA AAAA AAAA AAAAAAAA AAAAAAAA AAAAAAAA With the pawl free of the bracket, the door may be swung open. the tool if necessary). When securing the door, make sure the pawl fits over the bracket before tightening. NOTE: Do not overtighten the pawl. This can permanently damage the latch and prematurely wear out the door gasket. Travis Industries 4050525 100-01144 Maintenance 27 Weekly Maintenance (or every 5 bags of pellets) Flyash Removal This heater was designed to allow for easy flyash removal with the included tools. However, to ease maintenance, several pellet stove owners have purchased vacuums specifically made to remove flyash. Furthermore, some of these vacuums are heat-resistant to allow for flyash removal while it is still warm. Do not use a standard vacuum on this appliance (except to clean the pellet dust out of the hopper). Standard vacuums may spread the fine particles inside the flyash into the home and are not heat-resistant (hot flyash may cause the internal portion of vacuums to ignite). Clean the Hopper Run the stove until the pellets run out. Open the hopper and remove the dust and debris near the bottom of the hopper. Clean the Heat Exchange Tubes WARNING: The front of the heater becomes very hot during operation. Wait until the heater has cooled before cleaning the heat exchange tubes. Keep the door closed so the flyash does not enter the room. Cleaning the Optional Plated Surfaces With the door closed, insert the included tool into the hole on the heat exchanger cleaning rod. Move the heat exchange cleaner up and down several times. Heat Exchanger Cleaning Rod Fingerprints or other marks left on the plated surfaces may become etched in place if they are not wiped clean prior to turning the stove on. Clean the surface with denatured alcohol and a soft cloth (make sure the heater is cool). Other cleaners may leave a film that may dull the finish. Travis Industries 4050525 100-01144 28 Maintenance Weekly Maintenance (or every 5 bags of pellets) - Continued Check Baffles, Ashbox, Ashpan, Dispose Ash If Necessary NOTE: The left baffle is larger than the right baffle. WARNING: The front of the heater becomes very hot during BAFFLE INSTALLATION The firebox baffles install on ledges at the top of the firebox. The two tabs (at the outside back corners) insert into notches at the right and left operation. Let the heater cool completely before conducting service. Cleaning the Baffles Use both hands to lift each baffle up and forward. Then tilt the baffle downwards to remove any flyash that may have accumulated on top of the baffle. NOTE: you do not need to remove the baffle from the firebox. AAAAAAAA AAAA AAAA AAAAAAAA AAAAAAAA AAAAAAAA AAAAAAA AAAAAAA AAA AAA AAAAAAA AAAAAAA AAAAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAAAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA rear corners of the firebox walls. Air Tubes The baffles install on ledges above the firebrick. Ashbox AAAAA AAAAA AAAAA AAAAA Removing the Ashbox Use both hands to lift the ashbox up and away from the insert. AAA Firebrick Removing the Ashpan The ashpan slides out from under the firebox. Ashpan AAAAAAAA AAA AAAAAAAA AAAAAAAA AAA AAAAAAA AAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA NOTE: When replacing the ash pan make sure it is pushed all the way in. AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA AAAAAAAAAAA Disposal of Ashes – 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, well away from all combustible materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have been thoroughly cooled. Clean the Glass Open the door and clean the glass with a non-abrasive glass cleaner and rag. This will increase the amount of light and heat given off by the heater. Travis Industries 4050525 100-01144 Maintenance 29 Weekly Maintenance (or every 5 bags of pellets) - Continued Sweep Ash Into Ashpan HINT: The more often you clean out the flyash, the more efficient your heater will burn. NOTE: Remove the ashbox prior to conducting the service below. WARNING: The firebox becomes very hot during operation. Let the stove cool completely before conducting service. Swing the side ash trap door up. Lift it up and away from the firebox. a b Ash Trap Door Repeat for the opposite side. Lift the firepot out of its holder. Slide the ash pan trap door forward to expose the ash c d dumps (the door can be removed and cleaned if necessary) Firepot Ash Pan Trap Door Brush all flyash into the ash dumps, including e f the flyash inside the firepot holder. AAA AA Replace the ash trap doors and firepot. Slide the ash pan trap door forward. AAA AA AA HINT: To empty the ashpan, see the instructions on the previous page. Travis Industries 4050525 100-01144 30 Maintenance Yearly Maintenance (or every ton) WARNING: Disconnect the power cord prior to conducting service. The following section details extensive maintenance procedures. We strongly suggest these items be carried out by a trained service technician, possibly by a service agreement set up with your dealer. Soot and Flyash: Formation and Need for Removal – The products of combustion will contain small particles of flyash. The flyash will collect in the exhaust venting system and restrict the flow of the flue gases. Incomplete combustion, such as occurs during startup, shutdown, or incorrect operation of the room heater will lead to some soot formation which will collect in the exhaust venting system The exhaust venting system should be inspected at least once every year to determine if cleaning is necessary. Clean the Vertical Exhaust Duct (the stove must be cool and unplugged) Clean the refractory and the entire area behind it Remove both refractory clips. (both sides). Remove these doors to remove fallen flyash and soot (see "Bi-Weekly Clean the Exhaust Duct (make sure the heater is cool and unplugged) Phillips Screwdriver c Remove the cover plates over the exhaust duct (both sides) Cover Plate d Use a vacuum or bottle brush to remove all flyash from the exhaust duct (if the gasket is damaged, replace). AA AA Swing open this panel to access the door latch (use the tool if necessary). 7/16" Nutdriver Travis Industries 4050525 100-01144 Maintenance 31 Yearly Maintenance (or every ton) - Continued Clean the Exhaust Blower (make sure the heater is cool and unplugged) b a Remove the surround panels and access the left side of the heater. Remove the shroud covering the blower motor. Remove the six screws holding the exhaust blower motor in place. 11/32" Socket c Pull the motor out (be careful not to damage the wiring or blades). Exhaust Box Blower Blades Exhaust Motor Blower Housing Flow Switch Tube Nipple (attached to exhaust box) Cover Plate 7/16" Nutdriver d AAAA AA Clean the blower blades, blower housing, and exhaust box. You may wish to use a vacuum to pull ash out of the vent system. When replacing the motor, take care to align the gasket (if it is damaged, replace). Check the nipple and flow switch tube. Insert a pipe cleaner through the nipple to dislodge any flyash. NOTE: The flow switch will shut off the auger if the tube becomes clogged or dislodged. Make sure it is cleaned out and correctly attached. g Clean the 1/2" air space beneath the unit (use a e f Remove the cover plate over the Use a vacuum or bottle brush to remove all flyash from the exhaust duct (if the gasket on vacuum cleaner or brush). Clean the Vent (make sure the heater and vent is cool) Make sure the cap is free of debris (especially if it has a screen that could become blocked). AA AA Check the vent sections for creosote AA accumulation (indicating a poorly burning stove). Accumulation over 1/4" must be AA removed. AA Warning: Whenever any portion of the pellet vent is disconnected, the joints must be sealed with RTV 500° F. silicone sealant. Travis Industries 4050525 100-01144 32 Maintenance Yearly Maintenance (or every ton) - Continued Door Seal ! Air leaks into the firebox will decrease the stove's performance greatly, leading to excessive sooting, inefficient burning, and perhaps a malfunction. • The door gasket must contact the entire perimeter of the door and create an air tight seal. To verify this, open the door, hold a dollar bill against the body of the heater, close the door, and secure the latch. The dollar bill should be held firmly in place (check the entire perimeter of the door. If it is loose or falls out, the door must be adjusted (see the following page). AA AA AA AA Door Alignment Because the door is three-sided, it is crucial the door is aligned correctly. We recommend that you open the hopper lid and look down upon the door and body of the heater. Use the illustration to the right to determine the correct door alignment. Correctly Aligned Door When properly adjusted, the door should be evenly spaced from the front of the stove (and shut tight, compressing the gasket). Hinge Latch AAAAAAAAAAAAAAAA Top of Stove AAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAA Door Note how both corners are evenly spaced. Latch Too Tight - In the illustration below, the latch is too tight (this is the most common mis alignment). Loosen the latch and tighten the hinge. AAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAA Note how the gasket separates from the body. Hinge Too Tight - In the illustration below, the hinge is too tight. Loosen the hinge and tighten the latch. AAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAA Note how the gasket separates from the body. Travis Industries 4050525 100-01144 Maintenance 33 Yearly Maintenance (or every ton) - Continued Adjusting the Door Hinge and Latch • The door hinge and door latches may be adjusted to pull the door closer to the body. The illustration below details how to adjust these components. NOTE: Make sure to read the section "Door Alignment" on the previous page before adjusting the door. Latch Adjustment Loosen the lock nut and twist the pawl (clockwise to tighten, counter-clockwise to loosen). Tighten the lock nut to secure in place. Bracket (attached to side of heater) Door Pawl Lock Nut Hinge Adjustment Door Hinge Bracket Dimple (used to monitor hinge bracket position) (1) With the door closed, loosen the two bolts going through the door hinge bracket. (2) Loosen the four nuts used to move the hinge adjusting plate. Tighten or loosen these nuts to adjust the door hinge bracket. Adjust the upper and lower nuts equally to insure the door remains level. Tighten the four nuts. (3) Tighten the two bolts loosened in step 1. Door Hinge Adjusting Plate Travis Industries 4050525 100-01144 34 Maintenance Yearly Maintenance (or every ton) - Continued Check for Air Leaks Around the Door, Glass, and Ashpan ! Air leaks into the firebox will decrease the stove's performance greatly, leading to excessive sooting, inefficient burning, and perhaps a malfunction. • Inspect the door gasket to make sure it is fully attached. Use stove gasket cement to re-attach if necessary. If the door gasket is worn or flattened, replace. • If the glass is cracked, replace. The glass is held in place by glass clips that are underneath the airwash brackets. See the illustration below for details. • Remove the ashpan and inspect the gasket around the perimeter of the ashpan. Re-attach, or replace the gasket if necessary. Door Trim Door Gasket AAAAA Attachment AAAAA Door Frame AAAAAAAA AAA AAAAAAAA AAA AAAAAAAA AAAAA AAAAA Nuts AAA AAAAAAAA AAA AAAAAAAA AAAAAAAA AAA AA A AA AAA AAAAAAAA A AA AA A AAAAA AAAAAAAA AAA A AAAAA 5/16" A AAA AAAAAAAA A AAAAAAAA A AAA AA A Nutdriver AAAAAAAA AA A AAAAAAAA AA A AA AA A AA AAAAAAAA AAAAAAAA A AAAAAAAA A AA A AA A A AAAAAAAA A A AA AA A AAA Glass Clip A A AA A AAAAAAAA A AAAAAAAA AA A Door A AAAAAAAA A Gasket Airwash Bracket AA Glass (with channel gasket) Replacement Parts A Glass Clips AAAAAAAA AA A AA A AA A Airwash Brackets ASH DUMP PLATE, LARGE PS/PI 91002022 GASKET, DOOR 7/8" x 85" WHITE ROPE 99900431 ASHTRAP DOORS 93005054 GASKET, GLASS 5/8"x137" BLACK 99900398 AUGER BEARING PLT, LOWER, LRG 91002024 GLASS, FRONT, P12/14, P13 91002004 AUGER BUSHING PLATE, UPPER 93005093 GLASS, SIDE, P12/14, P13 91002005 AUGER DRIVE COLLAR, 1997 & UP 91002021 GROMMET, IGNITOR WIRE BLACK RUBBER 100-02811 AUGER FLIGHT INSPECTION COVER 210-02702 GSKT, CLEAN-OUT CVR, 3.250 x 2.750 100-03235 AUGER FLIGHT, 2000+ LRG PEL 91002013 GSKT, COMB BLOWER (BODY) 100-03206 AUGER MOTOR STOP, P11-P15 93005096 GSKT, COMB BLOWER(MOTOR) 7" dia 100-03231 AUGER MOTOR, ALL PS/PI 90-0191 GSKT, EXHAUST PLATE 5"x 5" 100-03239 AUGER SUB-ASS'Y - LARGE PEL 91002020 HANDLE, HOPPER LID 100-04312 BLOWER, COMB, PELLET 93005535 HANDLE, PEL CNTRL BOARD 97 99300094 BLOWER, CONV, P2-8/11-15/G1 98900755 HINGE PLATE ASS'Y 91002017 BRUSH, BROOM STYLE - PELLET 100-04301 HOSE NIPPLE, BARBED 100-04307 BURNPOT ASSY, FIREPOT 99300171 IGNITER, LG PS/PI 99300149 CABLE HANGER CLIP 100-04310 KNOB (PHENOLIC), 3/4" dia 100-04241 CNTRL BRD, LG PEL (P13-15) 100-00203 LBL, EXHAUST DAMPER 112-00505 CORD RESTRAINER 100-00112 MAGNET w/OUT SHEATH 1x.75" 1/4" THICK 100-02801 DAMPER PLATE S-ASS'Y - LRG PS 221-22089 OIL PAN, COMB BLOWER - LG PEL 210-03216 DRAFT (FLOW) SWITCH 93005060 POWER CORD, PS/PI 93005015 DRAFT FLOW TUBING 99300164 REFRACTORY SIDE CLIP, LEFT 210-03831L FIRE-BACK, CAST IRON, 93005059 REFRACTORY SIDE CLIP, RIGHT 210-03831R FIREBOX BAFFLE, LEFT 210-05199 SCRAPER ROD (P12/13/14) 211-01660 FIREBOX BAFFLE, RIGHT 210-05198 SNAP-DISC - 120deg CERAMIC NO 100-00232 FUSE HOLDER (IN-LINE) 100-00210 SNAP-DISC - 120deg NO # NO 100-00231 FUSE, 5AMP, 5 - FOR INLINE 93-0695 SNAP-DISC - 200deg NC # NC 100-00233 FUSE, 6AMP, 5 - CONTROL BOARD 93005019 TOOL, GLASS LATCH/RESTRICT0R 100-02302 GASKET CEMENT (WHITE), 4oz. 99900409 WIRE HRNS, PEL, JUMPER, LRGPELLET 100-00390 GASKET, ASHPAN 70" BLK 1/2"x1/8" ADH 99900428 WIRE HRNS, PEL, PS/PI 97 & UPLARGE OR SMALL 100-00391 Travis Industries 4050525 100-01144 Normal Operating Sounds 35 Exhaust Blower The blower may create a low-pitched hum. This sound will change as the FEED RATE is altered. Heat Exchanger Tubes You may hear the heated air being forced through these tubes by the convection fan. Firepot As pellets are fed into the firepot, a light clicking sound may be heard. Auger Motor When feeding pellets, you may hear the intermittent buzz of this motor running. Covection Fan The modern high efficiency fan may produce a low hum, particularly on "HIGH". This sound will change as the FAN dial is turned. Travis Industries 4050525 100-01144 36 Safety Label WARNING - DO NOT REMOVE OR COVER THIS LABEL Listed Pelletized Solid Fuel Burning Appliance For use in masonry or factory built (ZC) fireplaces. INSERT CLEARANCE DIAGRAM AAAAAAAAAA AAAAAAAAAA MANTEL AAAAAAAAAA B M I Travis Industries, Inc. A A AAAAAAAA AA AAAA AA AA AA A AAAAAAAAAAAA L R L T A R C AAAAAAAAAA AAAAAAAA AAAAAA AA AA AA AA A W O E A D I I AAAAAAAAAA AA AAAAAAAA AAAAAA AA C S 10850 117th Pl. NE A Pellet D AF Serial No. Kirkland, WA 98033 AAAAAAAAAA AAAAAAAA AA AAAAAA Model: Astoria Bay PI (Avanti PI) Electrical Rating: 115 V., 60 Hz., Insert FE AA Report No.: 028-S-51-2 Start 3 Amps, Tested to: ASTM E1509-95 Run 1.5 Amps Maximum Input Rating: 5.5 lbs (2.50 kg)/hr This pellet appliance has been tested and listed for use in manufactured homes in accordance with Oregon Administrative Rules 814-23-900 through 814-23-909. Install and use only in accordance with the installation and operating instructions. Contact local building or fire officials about restrictions and installation inspection in your area. Do not remove bricks or mortar from masonry fireplace or alter factory built fireplace. HEARTH EXTENSION Minimum Clearance to Combustible Materials (Measured from insert top) Adjacent Sidewall A 8.75 in Mantel B 11.5 in Top Facing C 6.25 in Side Facing D 7 in Combustible floor beyond hearth extension must be protected by a non-combustible material, extending 6 in/150 mm (E) to the front and 6 in/150 mm (F) to the sides of door opening. Do Not Connect This Unit to a Chimney Flue Serving Another Appliance. Components Required for Masonry Fireplace and Factory Built Fireplace Installation: Listed 4 in diameter flue liner. For use with 1/4 in/6 mm to 5/16 in/7 mm diameter pelletized wood fuels that comply with premium grade standards set by Association of Pellet Fuel Industries. Replace glass only with 5 mm ceramic glass available from your dealer. DANGER: Risk of electric shock. Disconnect power before servicing unit. Do not route power cord beneath heater. The space beneath the heater must not be obstructed. Do not obstruct combustion air openings. Operate only with viewing door closed and with ashbox and ashpan in place. Keep all furnishings well away from heater. Do Not Overfire – If Heater or Chimney Connector Glows, You Are Overfiring. Inspect And Clean Chimney Frequently – Under Certain Conditions of Use, Creosote Buildup May Occur Rapidly. HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP CHILDREN, CAUTION CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN DATE OF MANUFACTURE BURNS. SEE THE NAMEPLATE AND INSTRUCTIONS. OPERATE THIS UNIT ONLY WITH THE FUEL HOPPER LID CLOSED. FAILURE TO DO SO MAY RESULT IN EMISSION OF PRODUCTS OF COMBUSTION FROM THE HOPPER UNDER CERTAIN CONDITIONS. MAINTAIN HOPPER SEAL IN GOOD CONDITION. DO NOT OVERFILL HOPPER. 2003 2004 2005 2006 Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. 0468 (IGN) Travis Industries 4050525 100-01144 Limited 7 Year Warranty 37 To register your TRAVIS INDUSTRIES, INC. 7 Year Warranty, complete the enclosed warranty card and mail it within ten (10) days of the appliance purchase date to: TRAVIS INDUSTRIES, INC., 4800 Harbour Pointe Blvd. SW, Mukilteo, WA 98275. TRAVIS INDUSTRIES, INC. warrants this gas appliance (appliance is defined as the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows: Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store. Years 1 & 2 - COVERAGE: PARTS & LABOR Firebox Assembly: Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box Door Assembly: Door Frame, Latch Assembly, Glass Retainers Auger Assembly Auger Flight, Auger Tube, Auger Bushings Exclusions: Paint, Gasketing Ceramic Glass Glass (breakage from thermal shock) Igniter System Igniter, Igniter Leads Electrical System Auger Motor, Convection Blower, Exhaust Blower, Circuit Board, Snap Disks, Wiring Harness, Vacuum Switch Accessories Panels, Legs, Pedestal, Gold Trim, Ceramic Log with Log Shelf, Gold Door (See # 9 below) 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. Years 3 Through 5 - COVERAGE: PARTS & LABOR Firebox Assembly: Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box Door Assembly: Door Frame, Latch Assembly, Glass Retainers Auger Assembly Auger Flight, Auger Tube, Auger Bushings One-Way Freight Allowance One-way freight allowance on pre-authorized repair done at factory is covered. Exclusions: Paint, Gasketing, Ceramic Glass, Igniter System, Electrical System, Accessories (panels, legs, pedestal, gold trim, ceramic log, gold door), Re-Installation Allowance Years 6 & 7 - COVERAGE: PARTS ONLY Firebox Assembly: Firepot, Firepot Holder, Ash Cleanout Doors, Ashbox or Ash Dump, Cast Fireback, Heat Exchanger Tubes, Exhaust Manifold, Exhaust Box Door Assembly: Door Frame, Latch Assembly, Glass Retainers Exclusions: Paint, Gasketing, Ceramic Glass, Igniter System, Electrical System, Accessories (panels, legs, pedestal, gold trim, ceramic log, gold door), Auger Assembly, Re-Installation Allowance, One-Way Freight Allowance, Labor CONDITIONS & EXCLUSIONS 1. This new appliance must be installed by a qualified installer. It must be installed, operated, and maintained at all times in accordance with the instructions in the Owner's Manual. Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty. 2. This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized Travis dealer. 3. Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty. 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 chimney/venting installation. 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 manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God. • 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 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. • Damage to gold or nickel surfaces caused by fingerprints, scratches, melted items, or other external sources left on the gold or nickel from the use of cleaners other than denatured alcohol is not covered in this warranty. 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 not covered by this warranty. In some states, the exclusion of incidental or consequential damage may not apply. 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 permission of TRAVIS INDUSTRIES, INC. and bearing a TRAVIS INDUSTRIES, INC. label of approval. 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 appliance's serial number has been removed or altered in any way. If the appliance is used for commercial purposes, it is excluded from this warranty. 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. assumes no liability for such warranties or representations. 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 expressly disclaimed and purchaser's recourse is expressly limited to the warranties set forth herein. IF WARRANTY SERVICE IS NEEDED: 1. If you discover a problem that you believe is covered by this warranty, you MUST REPORT it to your Travis dealer WITHIN 30 DAYS, giving them proof of purchase, the purchase date, and the model name and serial number. 2. Travis Industries has the option of either repairing or replacing the defective component. 3. If your dealer is unable to repair your appliance's defect, he may process a warranty claim through TRAVIS INDUSTRIES, INC., including the name of the dealership where you purchased the appliance, a copy of your receipt showing the date of the appliance's purchase, and the serial number on your appliance. At that time, you may be asked to ship your appliance, freight charges prepaid, to TRAVIS INDUSTRIES, INC. TRAVIS INDUSTRIES, INC., at its option, will repair or replace, free of charge, your appliance if it is found to be defective in material or workmanship within the time frame stated within this 7 year warranty. TRAVIS INDUSTRIES, INC. will return your appliance, freight charges (years 1 to 5) prepaid by TRAVIS INDUSTRIES, INC., to your regional distributor, or dealership. 4. Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store. Travis Industries 4050525 100-01144 38 Optional Equipment Thermostat (Part # 99300650) ! Do not connect 120 VAC to the thermostat circuit of this heater (do not use a household thermostat used for a wall-board or other electical heater). 1 Attach the thermostat wire to the circuit board (see the illustration to the right). Route the wire through the back of the heater (away from any hot or moving components). 2 Determine a location for the thermostat that is within range of the 20' length of thermostat wire. It should be centralized in Attach the quick-connects to the two posts near the molex connector on the circuit board (orientation does not mater). Pull the cover off the thermostat the room and away from the heater. The wire may be routed externally on the wall or behind the wall (preferred). 3 Follow the directions to the right to attach the thermostat and thermostat wires. 50 60 70 80 90 Robertshaw 50 60 70 80 90 Run the thermostat wires through the wall (cut off excess wire, leaving 6" of slack). Expose 1/2" of wire and attach to these two posts. Standard Screwdriver Attach the thermostat to the wall through these two holes. Travis Industries 4050525 100-01144 Optional Equipment 39 ZC Kit (99200149) The optional zc kit allows this insert to be directly into the framing of a house or mobile home. See the kit for installation details. A AAA A AA AAA AA AA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAA A A AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA A Floor Protection AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA A A AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAA Rear Vent Shield (used only on inserts venting directly to the rear - note how it is slid back until it contacts the wall thimble) A A A AA AA A A A A A A Vent Clearances (make sure all vent maintains 3" clearance to any combustible) 12" Minimum House Shield (prevents soot discoloration) HIGHLY RECOMMENDED A A A A A A A A A AAA A AAAA A AAAA A AAAA A AAAA A AAAA A AAAA A AAAA AA Enclosure Height (measure from top of floor protection) Floor Protection Outside Air AAAAAAAAAAAAAA A AAAAAAAAAAA A AAAAAA AAAA Connection (recommended) Wall Thimble (note 3" clearance between vent and combustibles) Vent Latch (used to connect and disconnect the vent ) Travis Industries 4050525 100-01144 40 Index Adjusting the Fan Speed......................................21 Air Leaks..........................................................32 Ashpan (Opening and Disposing Ashes).................28 AUGER ON Light................................................22 Auto Mode........................................................20 Blower (Exhaust Blower Cleaning) .........................31 Blower Speed Adjustment....................................21 Cap (Pellet Vent Termination) ...............................11 Check for Air Leaks - Door, Glass and Ashpan.........32 Clean the Exhaust Blower....................................31 Clean the Exhaust Duct.......................................30 Clean the Glass.................................................28 Clean the Heat Exchange Tubes ...........................27 Clean the Vent...................................................31 Cleaning Ashpan (Opening and Disposing Ashes).....28 Cleaning the Firebox (Sweep Ash Into Ashpan) ........29 Cleaning the Firepot...........................................25 Cleaning the Hopper (Vacuum Hopper) ...................26 Clearances.......................................................10 Clinkers (Check Firepot for Clinkers)......................25 Controls...........................................................17 Curing the Paint.................................................17 Daily Maintenance (whenever using the heater)........24 Dimensions.......................................................6 Door (cleaning the gold).......................................26 Door (Opening)..................................................26 Door Gasket (inspection, removal) ........................32 Electrical Specifications......................................6 Emissions (EPA Compliance) ...............................6 EPA Compliance................................................6 Exhaust Blower (Cleaning)...................................31 Exhaust Duct (Cleaning)......................................30 Factory Built (Metal) Fireplace Requirements...........16 Fan (Adjusting the Fan Speed)..............................21 Firebox (Cleaning)..............................................28 Fireplace Sizing.................................................7 Fireplace Preparation..........................................7 Firepot Cleaning.................................................25 Firepot Inspection (Inspect the Burn).....................24 Flames (Inspect the Burn)....................................24 Floor Protection Requirements (Hearth)..................7 Fuel.................................................................10 Gasket (door, glass - inspection & removal) ............34 Glass (Cleaning)................................................28 Glass Removal..................................................34 Gold (cleaning).................................................. 27 Hearth Requirements.......................................... 10 Heat Exchange Tubes (cleaning) .......................... 27 Heating Specifications........................................6 Hopper Cleaning (Vacuum Hopper)........................ 27 Important Information.........................................2 Installation Options............................................7 Installation Warnings (Before you Begin)................7 Introduction......................................................2 Listing Label..................................................... 36 Loading Pellets ................................................. 18 MAINTENANCE REQUIRED Light.......................... 22 Mantel Requirements.......................................... 10 Manual Mode .................................................... 19 Masonry Fireplace Requirements.......................... 15 Metal (Factory Built) Fireplace Requirements........... 16 Mobile Home Requirements.................................. 12 Modes of Operation............................................ 18 Noise (Normal Operating Sounds) ......................... 35 Normal Operating Sounds.................................... 35 Opening the Door............................................... 26 Outside Air....................................................... 12 Parts List......................................................... 34 Pellet Vent Termination....................................... 11 Pellets (Fuel) ....................................................6 Pellets (loading) ................................................ 18 Pellets Piling Up ................................................ 24 Placing the Stove ..............................................7 Planning the Installation......................................7 Power Outages ................................................. 23 Priming the Auger .............................................. 17 Restrictor Adjustment......................................... 21 Safety Label..................................................... 36 Safety Precautions............................................ 4, 5 Serial Number Label ........................................... 36 Smell in Home (Starting Heater for the First Time) ..... 17 Start-Up Sequence ............................................ 22 Thermostat Operation (Auto Mode)........................ 20 Vent (Cleaning) ................................................. 31 Vent Type ........................................................ 11 Venting Distance............................................... 11 Venting the Pellet Stove...................................... 11 Warnings ......................................................... 4, 5 Warranty.......................................................... 37 Weekly Maintenance (or every 5 bags pellets)......... 27 Yearly Maintenance (or every ton)......................... 30 Zero-Clearance (Metal) Fireplaces......................... 16 Travis Industries 4050525 100-01144
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