Avalon Stoves Wood Burning Stove & Insert, homeappliance

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O l y m p i c ( 1 1 9 0 ) W o o d S t o v e a n d F i r e p l a c e I n s e r t • Residential Freestanding Stove • Mobile-Home Freestanding Stove • Alcove Approved • Hearth-Stove Approved • Masonry Fireplace Insert Save these instructions for future reference 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. Owner's Manual  Copyright 2007, T.I. $10.00 93508061 4050526 Listed Tested to: U.L. 1482\ Report # 028-S-27-2 (June, 1999) 2 Introduction Introduction We welcome you as a new owner of an Avalon Olympic wood-burning stove. In purchasing an Avalon Olympic 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 Avalon Olympic 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 Avalon Olympic appliance has the same serial number as yours. The serial number is stamped onto the label on the back of the appliance. This serial number will be needed in case you require service of any type. Model: Avalon Olympic Serial Number: Purchase Date: Purchased From: Register your warranty online at: traviswarranty.com Or, mail your warranty card to: Travis Industries House of Fire 4800 Harbour Pointe Blvd. SW Mukilteo, WA 98275 Save Your Bill of Sale. To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us. We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur. © Travis Industries 93508061 4050526 Table of Contents 3 General Information Introduction & Important Information...................... 2 Safety Precautions ............................................ 4 Features & Specifications.................................... 6 Stove Installation Planning The Installation..................................... 7 Floor Protection Requirements ............................. 8 Stove Placement Requirements ........................... 8 Clearances ...................................................... 8 Chimney Requirements ...................................... 10 Chimney Termination Requirements...................... 11 Outside Air Requirements ................................... 11 Alcove Installation Requirements .......................... 12 Mobile Home Requirements ................................ 13 INSTALLATION DIAGRAMS Standard Ceiling with a Factory Built Chimney......... 14 Cathedral Ceiling with a Factory Built Chimney........ 14 Exterior Factory Built Chimney ............................. 15 Hearth Stove Positive Connection......................... 15 Hearth Stove Direct Connection ........................... 16 Interior Masonry Chimney ................................... 16 Fireplace Insert Installation Planning The Installation..................................... 17 Preparation for Installation.............................. 17 Additional Accessories Needed for Installation.... 17 Standard vs. Cook-Top Installations ................. 17 Installation Considerations.............................. 17 Top Air Chamber Extension................................. 18 Fireplace Requirements...................................... 19 Insert Placement Requirements............................ 20 Hearth Requirements ......................................... 20 Masonry Fireplace Requirements ......................... 20 Drafting Performance ......................................... 21 Leveling Bolt Installation ..................................... 21 Block-Off Plate Installation .................................. 22 Insert with Positive Connection............................. 23 Insert with Direct Connection (Masonry Fireplace).... 23 Insert with Face Seal Connection.......................... 24 Operating Your Appliance Safety Notice.................................................... 25 Before Your First Fire......................................... 25 Opening the Door.............................................. 25 Bypass Operation.............................................. 26 Starting a Fire................................................... 27 Adjusting the Burn Rate...................................... 28 Ash Removal.................................................... 28 Optional Blower Operation .................................. 29 Re-Loading the Stove......................................... 29 Overnight Burn ................................................. 29 Normal Operating Sounds ................................... 29 Hints for Burning ............................................... 30 Selecting Wood................................................. 30 Troubleshooting ................................................ 31 Maintaining Your Appliance Daily Maintenance............................................. 32 Remove Ash .................................................... 32 Clean The Glass ............................................... 32 Monthly Maintenance ......................................... 33 Door and Glass Inspection .................................. 34 Check For Creosote Buildup................................ 33 Yearly Maintenance ........................................... 34 Touch Up Paint................................................. 34 Blower Cleaning................................................ 34 Firebrick and Baffle Inspection ............................. 34 Door Parts ....................................................... 35 Replacing the Glass........................................... 35 Replacing the Door Gasket.................................. 35 Replacing the Door Handle.................................. 35 Firebox Parts.................................................... 36 Floor & Side Firebrick Removal & Replacement....... 36 Baffle Removal and Replacement......................... 37 Air Tube Removal and Replacement ..................... 37 Warranty............................................................ Listing Information............................................ 39 Optional Equipment Stove Legs....................................................... 40 Pedestal.......................................................... 40 Rear Blower Installation...................................... 42 Outside Air Boot Installation................................. 43 Surround Panels ............................................... 44 Front Blower..................................................... 45 Index ................................................................. 46 © Travis Industries 93508061 4050526 4 Safety Precautions The viewing door must be closed and latched during operation. Never block free airflow through the air vents on this appliance. This appliance is designed and approved for the burning of cord wood only. Do not attempt to burn any other type of fuel other than cord wood in this appliance, it will void all warranties and safety listings. Do not touch the appliance while it is hot and educate all children of the danger of a high temperature 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. Inspect the chimney connector and chimney at least twice monthly and clean if necessary. 36" Gas ASHES 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 front of 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. This appliance must be connected to a listed high Creosote may build up and cause a house fire. Do not connect this appliance to any chimney serving another appliance. Type HT Clay Liner temperature (UL 103 HT) residential type chimney or an approved masonry chimney with a standard clay tile, or stainless steel liner. © Travis Industries 93508061 4050526 Safety Precautions 5 Mobile Home When installed in a mobile home, this appliance must be bolted to the floor, have outside air, and not be installed in the bedroom (Per H.U.D. requirements). Check with local building officials. Never try to repair or replace any part of this appliance unless instructions are given in this manual. All other work must be done by a trained technician. Do not place clothing or other flammable items on or near this appliance. 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. AAAA Allow the appliance to cool before carrying out any maintenance or cleaning. Overfiring the appliance may cause a house fire. If a unit or chimney connector glows, you are overfiring. This Manual Maintain the door and glass seal and keep them in good condition. Avoid placing wood against the glass when loading. Do not slam the door or strike the glass. Do not throw this manual away. This manual has important operating and maintenance instructions that you will need at a later time. Always follow the instructions in this manual. Do not 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). © Travis Industries 93508061 4050526 6 Features & Specifications Installation Options • Freestanding • Freestanding in an Alcove • Freestanding in a Mobile Home • Masonry Fireplace Insert NOTE: This fireplace insert is not approved for Factory Built Z.C. (Metal) Fireplaces Heating Specifications Features • EPA Phase II Approved • 3.1 Cubic Foot Firebox Volume • Single Operating Control • Accepts Logs Up to 24" Long • Steel Plate Construction (1/4" & 3/16") • Heavy Duty Refractory Firebrick • Optional High-Tech Blower Approximate Maximum Heating Capacity (in square feet)* 1,500 to 2,500 Maximum BTU's per Hour (Cord Wood Calculation) 74,300 Overall Efficiency (Oregon Method) 70.0 % Maximum Burn Time Up to 12 Hours * Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is also affected by the quality and moisture level of the fuel. Dimensions Note: Measure side, corner, and back clearances from the stove top.29-3/8" 5-3/4" The flue collar protrudes 1" above the stove top Weight: 510 Lbs. with pedestal * For inserts, add 1" for the flue collar. ** See "Fireplace Requirements" for details on fireplace insert installation. Emissions 21 1/4"* Height: With Legs 29-1/8" Pedestal 32-5/8" 20-1/2"** Figure 1 2.6 Grams Per Hour (EPA Phase II Approved) – Tests conducted by E.E.S.P.C. © Travis Industries 93508061 4050526 Stove Installation (for qualified installers only) 7 SAFETY NOTICE: Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in property damage, bodily injury, or even death. Contact local building or fire officials about restrictions and installation inspection requirements in your area. Planning The Installation We suggest that you have an authorized Travis Industries dealer install your stove. If you install the stove yourself, your authorized dealer should review your installation plans. Check with local building officials for any permits required for installation of this stove and notify your insurance company before proceeding with installation. Preparation for Installation • Check for damage to the exterior of the stove (dents should be reported, scratches can be fixed by applying touch up paint). • Check the interior of the firebox (replace cracked firebrick and make sure baffle is in place). The stove can be lightened by removing the firebricks and baffle (pg 36) - replace before operation. Additional Accessories Needed for Installation • Legs or Pedestal Packing List • Top Air Chamber Extension (used for inserts only) • (4) Screws (for the Top Air Chamber Extension) • Damper Rod (for the Top Air Chamber Extension) • Pull Tool (used to adjust the damper when hot) Stove Installation Considerations The table below details the six most common types of installations and the considerations for each type. Alternative methods of installation are available if they comply with local building codes. Installation Type Considerations Standard Ceiling with a Factory Built Chimney (Page 14) • Requires ceiling and roof penetration • Provides best draft Cathedral Ceiling with a Factory Built Chimney (Page 14) • Cathedral style chimney support required • Provides best draft Exterior Factory Built Chimney (Page 15) • Uses two elbows to route chimney outside • Exterior chimney is hidden from the room • Elbows reduce draft • Optional exterior chase reduces cold air blockage Hearth Stove Positive Connection (Page 15) • Utilizes existing masonry chimney • Provides good draft due to full reline • Easier to clean than direct or horizontal hearth stove Hearth Stove Direct Connection (Page 16) • Utilizes existing masonry chimney • Requires construction of a "block-off plate" • Draft reduced due to elbows & chimney cross section Interior Masonry Chimney (Page 16) • Utilizes existing masonry chimney © Travis Industries 93508061 4050526 8 Stove Installation (for qualified installers only) Floor Protection Requirements • Stove must be placed on the Travis Industries legs or Pedestal. • Floor protection must extend 6" to the sides and rear of the stove and 16" to the front of the stove (41-3/8" wide by 42-1/2" deep - see Figure 2 and Figure 3). • Floor protection must be non-combustible and at least .018" thick (26 guage). Stove Placement Requirements Clearances may be reduced by methods specified in NFPA 211, listed wall shields, pipe shields, or other means approved by local building or fire officials. • Stove must be placed so that no combustibles are within, or can swing within (e.g. drapes, doors), 36" of the front of the stove • If the stove is placed in a location where the ceiling height is less than 7', it must follow the requirements in the section "Alcove Installation Requirements" • Must maintain the clearances to combustibles listed below (drywall, furniture, etc.): Clearances • The following clearances must be met (see Figure 2 and Figure 3) Minimum Clearance A Sidewall to stove B Backwall to stove C Cornerwall to stove D Connector to sidewall E Connector to backwall F Connector to cornerwall Singlewall Connector Reduced Clearance* 16" 15" 9-1/2" 27-3/4" 17-3/4" 21" 16" 10" 7-1/2" 27-1/4" 12-1/4" 18-1/2" * Reduced clearance installations require one of the chimneys and connectors listed below: AMERI-TEC model DCC connector with AMERI-TEC UL 103 HT chimney DURAVENT model DVL connector with DURAVENT UL 103 HT chimney I.C.C. Excel HP connector with I.C.C. UL 103 HT chimney METALFAB model DW connector with METALFAB UL 103 HT chimney SECURITY model DP connector with SECURITY UL 103 HT chimney Standard Masonry Chimney with any one of the above listed connectors NOTE: Reduced clearance connectors may not connect to the flue collar – an appliance adapter may be required. NOTE: Standard residential installations with reduced clearance connector may use the clearance determined by the manufacturer of the connector for the connector to wall clearance or the clearance listed in this manual. Offsets must be used to maintain the stove to wall clearance. © Travis Industries 93508061 4050526 Stove Installation (for qualified installers only) 9 Top View - Straight Installation Back Wall Clearance B Clearance E l l a W e AAAAAAAAAAAAAA d i 6" Min. S 29-3/8" AAAAAAAAAAAAAA Clearance A A A 5-3/4" AAAAAAAAAAAAAA Clearance D 6" Min. A A 20-1/2" A A AAAAAAAAAAAAAA A A AAAAAAAAAAAAAA AAAAAAAAAAAAAA AAAAAAAAAAAAAA Measure rear and side clearances from the nearest edge of the stove top. NOTE: vent diameter varies depending on brand and model. 16" Min. Floor Protection Measure front clearances from the face of the stove (unibody). Figure 2 Top View - Corner Installation AAAAAAAAAAAAAA AAAAAAAAAAAAAA AAAAAAAAAAAAAA Corner WallCorner Wall Clearance F AAAAAAAAAAAAAA 29-3/8" 6" Min. Clearance C AAAAAAAAAAAAAA AAAAAAAAAAAAAA 5-3/4" AAAAAAAAAAAAAA 6" Min. AAAAAAAAAAAAAA AAAAAAAAAAAAAA 20-1/2" AAAAAAAAAAAAAA AAAAAAAAAAAAAA AAAAAAAAAAAAAA A A AAAAAAAAAAAAAA A A Measure rear and side clearances from the nearest edge of the stove top. NOTE: vent diameter varies depending on brand and model. 16" Min. Floor Protection Measure front clearances from AAAAAAAAAAAAAA AAAAAAAAAAAAAA the face of the stove (unibody). Figure 3 © Travis Industries 93508061 4050526 10 Stove Installation (for qualified installers only) Chimney Requirements • DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE. • Chimney connector must be a minimum 24 MSG black or 26 MSG blued steel (6" diameter). Chimney must be used from the first floor or wall penetration to the chimney cap. • Use 6" diameter type UL 103 HT chimney from one manufacturer (do not mix brands) or code approved masonry chimney with a flue liner. • Chimney connector and chimney must be fastened to the stove and each adjoining section. • Follow the chimney manufacturer's clearances and requirements. • Use the chimney manufacturer's fire stops, attic guards, roof supports, and flashings when passing through a ceiling or thimble when passing through a combustible wall. • No more than 180o of elbows (two 90o elbows, or two 45o & one 90o elbow, etc.). • NOTE: Additional elbows may be allowed if draft is sufficient. Whenever elbows are used the draft is adversely affected. Additional chimney height may be required to boost draft. Chimney Cap (See the section "Chimney Termination Requirements" for more details) AA (Roof Radiation Shield, } Flashing, Storm Collar) Minimum System 15' Maximum System 33' Factory Built Chimney Sections } A A AA AA AA Roof Penetration Equipment Ceiling Penetration AAAA AA AA Minimum Air Space to Equipment (Attic AA Combustibles (See AA} Standard residential installations with Radiation Shield with Chimney Support) Reduced Clearance Chimney Connector Sections Floor Protection AA AA AA AA AA A AA A AA A A AA Chimney Manufacturer's Instructions - usually 2") reduced clearance connector may use the clearance determined by the manufacturer of the connector for the connector to wall clearance or the clearance listed in this manual. Mobile home installations must use the the reduced clearance connector clearances listed in this manual under "Additional Requirements for Mobile Home Installations". AAAAA Stove Clearance (as outlined in this manual) Figure 4 Drafting This appliance relies upon natural draft to operate. External forces, such as wind, Performance 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. • Standard residential installations may use single-wall connector (Mobile-Homes may not) • Standard residential installations with reduced clearance connector may use the clearance determined by the manufacturer of the connector for the connector to wall clearance or the clearance listed in this manual. Offsets must be used to maintain the stove to wall clearance. Mobile homes must use the clearances listed in this manual under "Additional Requirements for Mobile Home Installations". © Travis Industries 93508061 4050526 Stove Installation (for qualified installers only) 11 Chimney Termination Requirements • Must have an approved cap (to prevent water from entering) • Must not be located where it will become plugged by snow or other material • Must terminate at least 3' above the roof and at least 2' above any portion of the roof within 10' (see Figure 5) Slanted Roofs Chimney must extend 2' AA Chimney must extend 3' above the roof A AA above any portion of the roof within 10' of the chimney AA AA Flat Roofs AA Chimney must extend 3' above the roof Chimney must extend 2' above any portion of the roof within 10' of the chimney A A AAAAAAAAAAAAAAA A Outside Air Requirements • Required for mobile homes & in certain localities (check with building officials) • Must not be drawn from an enclosed space (garage, unventilated crawl space) • Requires the optional outside air boot (for legs) or pedestal. When using outside air, find a location where the chimney and outside air hole do not interfere with structural members of the home. Figure 5 Pedestal (with insulation) directs air to the stove. AA A A A A A hole must be cut through the floor protection and floor and the rodent screen nailed in place here (see the optional equipment instructions for exact sizes) Outside Air Boot A A A A A A AAAAA AAAAA A Air may be drawn from a ventilated crawl space or use an air duct. Figure 6 AAAAA AAAAA Optional Air Duct (must not be longer than 15' and at least 16 square inches in cross section) Outside air entrance must be placed so it does not become blocked by snow. © Travis Industries 93508061 4050526 12 Stove Installation (for qualified installers only) Alcove Installation Requirements Whenever the stove is placed in a location where the ceiling height is less than 7' tall, it is considered an alcove installation. Because of the reduced height, the special installation requirements listed below must be met. • Chimney connector and chimney must be one of the following types: AMERI-TEC model DCC connector with AMERI-TEC UL 103 HT chimney DURAVENT model DVL connector with DURAVENT UL 103 HT chimney I.C.C. Excel HP connector with I.C.C. UL 103 HT chimney METALFAB model DW connector with METALFAB UL 103 HT chimney SECURITY model DP connector with SECURITY UL 103 HT chimney Standard Masonry Chimney with any one of the above listed connectors NOTE: Reduced clearance connectors may not connect to the flue collar – an appliance adapter may be required. • Alcoves are classified as combustible or non-combustible. Non-combustible alcoves must have walls and a ceiling that are 3 1/2" thick of a non-combustible material (brick, stone, or concrete - see Figure 7). This non-combustible material must be spaced and ventilated at least 1" off of all combustible materials (walls, ceiling, etc.) to allow air to move around the non-combustible walls and ceiling. All other alcoves are considered combustible. The clearances below must be met: Minimum Clearance (See the Figure 7 below) A Sidewall to stove B Backwall to stove D Connector to sidewall E Connector to backwall G Maximum depth of alcove H Minimum width of alcove J Minimum height of alcove Non-combustible alcove construction (on walls and ceiling) - see the explanation above. Ventilated Combustible Alcove Non-Combustible Alcove 16" 10" 27-1/4" 12-1/4" 48" 61-3/8" 84" 6" 2" 17-1/4" 4-1/4" 48" 41-3/8" 6" above stove top d e a air space 1" Min. A e l A b i t s l s a u i r b A e t m a o C m 3 1/2" thick non combustible material Non-combustible reinforcer b j h g Figure 7 © Travis Industries 93508061 4050526 Stove Installation (for qualified installers only) 13 Mobile Home Requirements • Outside air must be installed - see "Outside Air Requirements" on page 11 • Chimney connector and chimney must be one of the following types: AMERI-TEC model DCC connector with AMERI-TEC UL 103 HT chimney DURAVENT model DVL connector with DURAVENT UL 103 HT chimney I.C.C. Excel HP connector with I.C.C. UL 103 HT chimney METALFAB model DW connector with METALFAB UL 103 HT chimney SECURITY model DP connector with SECURITY UL 103 HT chimney Standard Masonry Chimney with any one of the above listed connectors NOTE: Reduced clearance connectors may not connect to the flue collar – an appliance adapter may be required. • Stove placement must maintain the following clearances to combustibles (drywall, furniture, etc.) Corner Installations Straight Installations d e f a b c NOTE: Measure clearances to the stove top. Figure 8 Minimum Clearance (See the illustration above) A Sidewall to stove B Backwall to stove C Cornerwall to stove D Connector to sidewall E Connector to backwall F Connector to cornerwall • If using offsets, use the connector clearance listed in Figure 9, not the connector manufacturer's clearance. Reduced Clearance Connector 16" 10" 7-1/2" 27-1/4" 12-1/4" 18-1/2" 12-1/4" Min. • The appliance must be secured to the floor (consult your building official). Secure the outside air boot to the floor and stove to insure the stove does not dislocate. • Mobile home installations require a spark arrester at the chimney termination. • The appliance must be grounded to the chassis of the mobile home (consult your building official). • WARNING:DO NOT INSTALL IN SLEEPING ROOM. Minimum Connector Clearance (as outlined above) Minimum Stove Clearance (as outlined above) • CAUTION:THE STRUCTURAL INTEGRITY OF THE MOBILE HOME FLOOR, WALL, AND CEILING/ROOF MUST BE MAINTAINED. AAAAAA AAAAAA Figure 9 © Travis Industries 93508061 4050526 14 Stove Installation (for qualified installers only) Standard Ceiling with a Factory Built Chimney Chimney Cap (See the section "Chimney Termination Requirements" for more details) AA AA A shield). } Follow the chimney manufacturer's instructions and clearances for roof penetrations. A storm collar and flashing are required (some require a radiation Chimney Sections Insulation } A A Follow the chimney manufacturer's instructions and clearances for floor penetrations. A ceiling AA AA A AA AA AA AA Minimum Air Space to Combustibles (See support is required, an attic insulation shield is required where insulation is present. Chimney Connector Sections Floor Protection (See the section "Floor Protection Requirements" for more details) Chimney Manufacturer's Instructions - usually 2") Minimum 15' Maximum 33' Stove Clearances (See the section "Stove Placement Requirements" for more details) Figure 10 Cathedral Ceiling Chimney Cap AAAAA AA AA with a Factory Built Chimney (See the section "Chimney Termination Requirements" for more details) Chimney Sections Minimum Air Space to Combustibles (See Chimney Manufacturer's Instructions - usually 2") Chimney Connector Sections Floor Protection (See the section "Floor Protection Requirements" for more details) A A } A A Follow the chimney manufacturer's instructions and clearances for roof penetrations. A storm collar, flashing, and cathedral-style chimney support are required (some require a radiation shield). Minimum 15' Maximum 33' Stove Clearances (See the section "Stove Placement Requirements" for more details) AAAAA AAAAA Figure 11 © Travis Industries 93508061 4050526 Stove Installation (for qualified installers only) 15 Exterior Factory Built Chimney Chimney Cap AA AA Follow the chimney manufacturer's NOTE: Exterior chimneys are (See the section "Chimney Termination Requirements" for more details) Chimney Sections A require a radiation } instructions and clearances for roof penetrations. A storm collar and flashing are subject to greater moisture and creosote accumulation due to the lower temperatures. An insulated chase will reduce these accumulations (the proper clearances to the chimney must be Minimum Air Space to Combustibles (See Chimney Manufacturer's Instructions - usually 2") Min. 18" clearance to ceiling A Wall Bands and Supports A AA AA AA AA AA required (some shield). Minimum 15' Maximum 33' Insulated Tee (with cleanout ) Follow the chimney maintained). Chimney Connector Sections } AA AA manufacturer's instructions and clearances for wall penetrations. A wall radiation shield Floor Protection (See "Floor Protection Stove Clearances AA AAAA (See the section "Stove (thimble) is required. Optional Requirements" for details) AAAAA Placement Requirements" AAAA for more details) insulated chase Figure 12 Hearth Stove Positive Connection NOTE: Most factory-built chimney manufacturers make stainless steel chimney liners, either flexible or rigid. This provides a wide variety of installation options. Make sure to follow the manufacturer's instructions for installation and support. NOTE: The entire fireplace and chimney must be clean, undamaged, and meet all local building codes (UBC, etc.). Damage must be repaired prior to installation. The chimney must be 15' to 33' tall. Combustible Mantle Min. 18" Floor Protection (See the section "Floor Protection Requirements" for more details) AA A A A A AAAA A AAAA AAAA A A AAAA AAAA AAAA AAAA Cap and flashing prevents water from entering The liner must be stainless steel connector or flexible vent. Follow the liner manufacturer's instructions for installation and support. Airtight Insulated Clean-Out Remove damper or wire it open See the section "Stove Placement Requirements" for minimum clearances required. Figure 13 © Travis Industries 93508061 4050526 16 Stove Installation (for qualified installers only) Hearth Stove Direct Connection NOTE: Direct connections require installation of an airtight, non-combustible block-off plate or damper adapter. Interior or Exterior Masonry Chimney NOTE: This type of installation NOTE: The chimney must have a clay tile liner. If it does not, the installation must use a positive connection (full reline). The entire fireplace and chimney must be clean, undamaged, and meet all local building codes (UBC, etc.). Damage must be repaired prior to installation. The chimney must be 15' to 33' tall. Max. 8" Combustible Mantle Min. 18" Floor Protection (See the section "Floor Protection Requirements" for more details) NOTE: The chimney must have a clay tile liner. If it does not, the installation must use a positive connection (full reline). The entire fireplace and chimney must be clean, undamaged, and meet A A AAA A AAA A AAA A AAA AAA AAA AAA Clay 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 See the section "Stove Placement Requirements" for minimum clearances required. Figure 14 Clay Liner requires a UBC approved masonry connector or a factory built (U.L. Listed) wall thimble. all local building codes (UBC, etc.). Damage must be repaired prior to installation. The chimney must be 15' to 33' tall. See the section "Stove Placement Requirements" for minimum clearances required. Chimney connector sections See the section "Floor Protection Requirements" Min. 18" clearance to ceiling This type of installation requires a UBC approved masonry connector or a factory built (U.L. Listed) wall thimble. Make sure the clean-out seals in place. Figure 15 © Travis Industries 93508061 4050526 Fireplace Insert Installation (for qualified installers only) 17 SAFETY NOTICE: Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in property damage, bodily injury, or even death. Contact local building or fire officials about restrictions and installation inspection requirements in your area. Planning The Installation We suggest that you have an authorized Travis Industries dealer install your fireplace insert. If you install the fireplace insert yourself, your authorized dealer should review your installation plans. Check with local building officials for any permits required for installation of this fireplace insert and notify your insurance company before proceeding with installation. Preparation for Installation • Check for damage to the exterior of the fireplace insert (dents should be reported, scratches can be fixed by applying touch up paint). • Check the interior of the firebox (replace cracked firebrick and make sure baffle is in place). The fireplace insert can be lightened by removing the firebricks and baffle (pg 36) - replace before operation. Additional Accessories Needed for Installation • Surround Panels (see page 44) Standard vs. Cook-Top Installations The top air chamber extension is shipped separately with the heater (see the following page for details). When installed, the unit is considered a "Standard Model" for Insert Placement and Fireplace Requirements. If it is not installed, the unit is considered a "Cook-Top Model" for Insert Placement and Fireplace Requirements. Installation Considerations Installation Type Considerations Insert with Positive Flue (Full Reline) (Page 23) • Utilizes existing masonry fireplace • Provides best draft • Easiest to clean Insert with Direct Connect Flue (Page 23) • Utilizes existing masonry fireplace • Provides good draft • Requires fireplace block-off plate - see page 22 Insert with Face Seal Connection (Page 24) NOTE: Before installing verify with local building officials that this type of installation is approved in your area. • Utilizes existing masonry fireplaces with cross section of 28" to 144" • Provides marginal draft • Easiest to install • Requires the optional surround panels and insulation (see "Surround Panels" on page 44). © Travis Industries 93508061 4050526 18 Fireplace Insert Installation (for qualified installers only) Top Air Chamber Extension The top air chamber extension is shipped separately with the heater and may be installed when the heater is used as an insert (see "Standard Model" under Insert Placement and Fireplace Requirements). Follow the directions below to install. 1. Remove the grill. Remove and discard the bypass extension rod (keep the pull ring). Remove the grill. Phillips Screwdriver Remove and discard the bypass extension rod attached to the stove (keep the pull ring). 2. Install the top air chamber extension following the directions below. Attach the top air chamber extension using the screws included in the owner's pack. Phillips Screwdriver 3. Attach the grill to the air chamber top. Attach the bypass extension rod included in the owner's kit to the damper yoke. Attach the bypass pull ring to the extension rod to complete the installation. © Travis Industries 93508061 4050526 Fireplace Insert Installation (for qualified installers only) 19 Fireplace Requirements Figure 16 shows the minimum size requirements. Combustible Mantel a b c j d Non-Combustible Facing h e f i g b a h d i c e j Non-Combustible Hearth Minimum Fireplace Size Height (front) Height (rear) Width (front) Width (rear) Depth Hearth Depth* Hearth Width Facing Width Facing Height with Mantel Shield Mantel Height with Mantel Shield Standard Model 22-1/4" 22-1/4" 29-3/8" 29-3/8" 14-1/8" 22-3/8" 45-3/8" 56-3/8" 51-1/4" 38-1/4" 53-1/4" 40-1/4" Cook-Top Model 22-1/4" 22-1/4" 29-3/8" 29-3/8" 11-5/8" 24-7/8" 45-3/8" 56-3/8" 52-1/4" 39-1/4" 54-1/4" 41-1/4" g f * This is the distance the insert protrudes from the fireplace opening plus the required 16" of hearth extension. Figure 16 © Travis Industries 93508061 4050526 20 Fireplace Insert Installation (for qualified installers only) Insert Placement Requirements • The insert must be placed so that no combustibles are within, or can swing within (e.g. drapes, doors), 36" of the front of the insert • Insert and hearth must be installed on a level, secure floor • The minimum clearances, facing, and hearth requirements in Figure 17 must be met. AAAAAAAAAAAAA Combustible Mantel Minimum Clearances Standard Model Cook-Top Model Side Wall AAAAAAAA k l AAAAAAAAAAAAA Combustible Top Facing m AAAAAAAAAAAAA n AAAAAAAAAAAAA AAAAAAAAAAAAA n Sidewall to Insert Side Facing Top Facing with Mantel Shield Mantel to Insert 15" 13-1/2" 30" 17" 32" 15" 13-1/2" 31" 18" 33" m Facing with Mantel Shield 19" 20" AAAAAAAAAAAAA o AAAAAAAAAAAAA AAAAAAAAAAAAA p k l AAAAAAAAAAAAA q AAAAAAAAAAAAA p AAAAAAAAAAAAA Non-Combustible x AAAAAAAAAAAAA q x Hearth Hearth (Front)* Hearth (Side) Front of Insert Extension onto Hearth 16" 8" 36" 6-3/8" 16" 8" 36" 8-7/8" AAAAAAAAAAAAA o AAAAAAAAAAAAA Hearth Requirements * Does not include the distance the insert extends onto the hearth (dimension "x"). Figure 17 • Must extend 16" in front of the insert and 8" on both sides (min. 19" deep by 39-5/8" wide) • Must be non-combustible and at least .018" thick (26 gauge) 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 © Travis Industries 93508061 4050526 Fireplace Insert Installation (for qualified installers only) 21 Drafting Performance This appliance relies upon natural draft to operate. External forces, such as wind, barometric pressure, topography, or factors of the home (negative pressure from exhaust fans, chimneys, air infiltration, etc.), may adversely affect draft. Travis Industries can not be responsible for external forces leading to less than optimal performance. Leveling Bolt Installation Two leveling bolts are included to level the insert if the fireplace has a stepped-up hearth. To install, raise the rear of the insert up and insert the leveling bolts into the holes in the rear corners of the insert. Adjust the bolts until they extend the same height as the hearth steps up. After the insert is installed, fine-tune the leveling bolts to level the insert (see Figure 18). This distance is the AAA The leveling bolts go into the holes at the hearth step-up. The leveling bolts should stick out this far from the base of the insert. Hearth AAA AAA Fireplace AAA AAA AAA rear corners of the insert. Figure 18 © Travis Industries 93508061 4050526 22 Fireplace Insert Installation (for qualified installers only) Block-Off Plate Installation Whenever this appliance is installed with a direct connection a block-off plate, or other non-combustible seal-off device (e.g. damper adapter), will need to be installed. This device is used to seal the chimney, insuring no smoke enters the home and providing the chimney system with a seal to promote draft. The directions below detail the steps for construction and installation of a block-off plate. • Determine a location for the block-off plate at the top of the firebox below the damper area (make it high enough to allow installation of the connection pipe). The location should be level and in an area where it can be mounted easily. Measure the width at the rear ("A") and front ("B") of the firebox at the height where the block-off plate will be installed (see Figure 19). Then measure the depth of the location where the block-off plate will be installed ("C"). • 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. • With the template in place, mark the location of the flue (see "Dimensions" on page 6). This location approximates the center of the flue when the insert is in place (a slight offset may occur based upon insert and block-off plate placement). Remove the template and cut a 6 1/4" diameter hole centered on this mark. • 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. • Mount the block-off plate using masonry screws. • Insulate the block-off plate using high-temperature fiberglass insulation (Kaowool® or equivalent) and furnace cement (allow the cement to dry for at least 24 hours before burning). • After placing the appliance and installing the pipe through the block-off plate, use high-temperature fiberglass insulation and furnace cement to seal any cracks between the pipe and block-off plate. AA Block-Off Plate Template B See the dimensions to determine the AAAA Damper AAA AA AAA AA AAA AAA AA 2" Flanges (for attaching the block-off plate) Measurement "C" Measurement "A" location of the center of the flue. C A AAA Firebox AAA AAA Measurement "B" See the dimensions to determine the location of the center of the flue. Figure 19 © Travis Industries 93508061 4050526 Fireplace Insert Installation (for qualified installers only) 23 Insert with Positive Connection NOTE: Most factory-built Install a non-combustible cover plate to prevent water from entering the chimney NOTE: This installation may be used with a masonry or zero clearance fireplace. The requirements in the section AA Cap (prevents water from entering) Flue Liner AA The liner must be 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. Insert with Direct Connection (Masonry Fireplace) NOTE: Direct connections require installation of an airtight block-off plate or damper adapter (see "Block-off Plate Installation" on page 22). "Masonry Fireplace Requirements" or "Zero Clearance Fireplaace Requirements" must be fulfilled prior to installation. Combustible Mantle Surround Panels See the section "Insert Placement Requirements" for minimum clearances and hearth required. NOTE: This installation may be used with a masonry or zero clearance fireplace. This illustration depicts a masonry insert, all 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. AA AA AA AAA AA AAA AA AAA AA AAA AA AAA AAA AAA AAA A A A A A AAA AAAA A A AAA AAA AAA AAA AAA 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 Figure 20 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 © Travis Industries 93508061 4050526 24 Fireplace Insert Installation (for qualified installers only) Insert with Face Seal Connection NOTE: Face seal connections require installation of the surround panels and insulation (see the "Surround Panel Installation" on page 44). 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) A See the section "Insert Placement Requirements" for minimum clearances and hearth required. A A A A AAA A AAA A AAA A AAA AAA AAA AAA 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 © Travis Industries 93508061 4050526 Operating Your Appliance 25 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. Read and follow all of the warnings on pages 4 and 5 of this manual. Before Your First Fire Verify the Installation Before starting the stove, verify that the stove is properly installed and all of the requirements in this manual have been followed. Keep all flammable materials 36" away from the front of the stove (drapes, furniture, clothing, etc.). Curing the Paint This heater uses a heat-activated paint that will emit some fumes while starting the first fire. Open doors and windows to the room to vent these fumes. This typically lasts two to four hours. You may also notice oil burning off of the interior of the heater. This rust-stopping agent will soon dissipate. Door Gasket - The door gasket might adhere to the paint on the front of the heater. Leave the door slightly ajar for the first fire and be careful when opening the door after the first fire. Over-Firing the Stove 2 to 4 hours AA A AA A AA A This stove was designed to operate at a high temperature. But due to differences in vent configuration, fuel, and draft, this appliance can be operated at an excessive temperature. If the stove top or other area starts to glow red, you are over-firing the stove. Shut the air control down to low and allow the stove to cool before proceeding. Over-firing may lead to damage of plated surfaces. If you are uncertain of over-firing conditions, we suggest placing a stove thermometer (e.g. Rutland® Model 710) directly over the door on the stove top - temperatures exceeding 800° are generally considered over-firing and will void the warranty. Opening the Door Turn the handle clockwise to un-latch. Swing the door open. The door becomes hot during use. Use a glove to open the door if the handle is hot. To prevent smoke from entering the room, open the bypass before opening the door (see following page for directions). You can also open the door a small amount and let air enter the firebox. © Travis Industries 93508061 4050526 26 Operating Your Appliance Bypass Operation The bypass controls the flow of smoke inside the heater. When pulled out, smoke goes directly up the flue, creating more draft. When pushed in, the smoke goes around the baffle, utilizing the secondary combustion and making the heater more efficient. • When starting or re-loading, pull the bypass out. • During normal operation, push the bypass in. Bypass Pulled Out Used for starting and re-loading Use the included pull tool to operate the bypass rod Bypass Pushed In AA AA AA AA AA Used for normal operation AAAAA AAAAA AAAAA AAAAA AAAAA © Travis Industries 93508061 4050526 Operating Your Appliance 27 Starting a Fire Since the dawn of time man has debated the best way to start a fire. Some use the boy-scout "tee-pee", some prefer the "tic-tac-toe" stack. Either way, review the hints and warnings below to ensure proper fire starting. • Make sure the air control is pushed in. If additional air is needed, open the doors 1/4" during the first five minutes of start-up. The bypass may be opened if the heater needs more draft. Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start or "freshen up" a fire in this stove. Keep all such liquids well away from the stove while it is in use. If using a firestarter, use only products specifically designed for stoves - follow the manufacturer's instructions carefully. If the smoke does not pass up the chimney, ball up one sheet of newspaper, place it in the center of the firebox and light it. This should start the chimney drafting (this eliminates "cold air blockage"). Use plenty of kindling to ensure the stove reaches a proper temperature. Once the kindling is burning rapidly, place a few larger pieces of wood onto the fire. © Travis Industries 93508061 4050526 28 Operating Your Appliance Adjusting the Burn Rate Use the air control slider to control the burn rate of the stove. See the illustration below for details. Use the air control to change the burn rate. AA AA Low Burn (air control closed) High Burn (air control open) Approximate Air Control Settings Overnight Burn Fully out to 9/32" open Medium Burn 9/32" to 5/16" open Medium High Burn 5/16" to 7/16" open High Burn 7/16" open to pushed fully in The air control becomes hot during operation - use gloves or a tool to prevent burns. The air control may take several minutes to influence the burn rate. When making adjustments, you may wish to let the stove burn for 10 minutes to gauge performance. Ash Removal Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, away from all combustible ASHES materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until all cinders have thoroughly cooled. © Travis Industries 93508061 4050526 Operating Your Appliance 29 Optional Blower Operation The blower will turn on once the stove is up to temperature. This is typically 15 to 30 minutes after starting the fire. Follow the directions below to alter the blower speed. OFF Turn the dial all the way counter clockwise until it clicks off. AA A OFF HI A AA LO CONTROL AA A HIGH The high position is all the way counter clockwise, without clicking off. AA A OFF HI A AA LO CONTROL AA A LOW Turn the dial all the way clockwise. AAA A OFF HI AA LO CONTROL AA BLOWER BLOWER BLOWER A The blower may be used to affect heat output (i.e.: to reduce heat output, turn the blower down). Route the power cord in a location where it will not come in contact with the appliance or become hot. Re-Loading the Stove Follow the directions below to minimize smoke spillage while re-loading the stove. 1. Open the air control all the way (push it in). Open the bypass (pull it out). 2. Open the door slightly. Let the airflow inside the firebox to stabilize before opening the door fully. 3. Load wood onto the fire. Overnight Burn This stove is large enough to accommodate burn times up to eight hours. Follow the steps below to achieve an overnight burn. 1. Move the air control to high burn and let the stove become hot (burn for approximately 15 minutes). 2. Load as much wood as possible. Use large pieces if possible. 3. Let the stove burn on high for 15 minutes to keep the stove hot, then turn the air control to low. 4. In the morning the stove should still be hot, with embers in the coal bed. Stir the coals and load small pieces of wood to re-ignite the fire, if desired. Differences if chimney height and draft may lower overall burn times. Normal Operating Sounds Creaks and Clicks: The 3/16" and 1/4" steel may creak or click when the stove heats up and cools down - this is normal. Blower Sounds: The blower will make a slight "humm" as it pushes air through the stove. Hint: Make sure the leveling bolts on legs are extended - preventing the hearth from amplifying any vibrations. © Travis Industries 93508061 4050526 30 Operating Your Appliance Hints for Burning • Get the appliance hot before adjusting to low burn • Use smaller pieces of wood during start-up and high burns to increase temperature • Use larger pieces of wood for overnight or sustained burns • Stack the wood tightly together to establish a longer burn • Leave a bed of ashes (1/2" deep) to allow for longer burns • Be considerate of neighbors & the environment: burn dry wood only • Burn small, intense fires instead of large, slow burning fires when possible • Learn your appliance's operating characteristics to obtain optimum performance Selecting Wood • Dry Wood is Key • Dry wood burns hot, emits less smoke and creates less creosote. • Testing Wood Moisture • Split wood stored in a dry area will be fully dry within a year. This insures dry wood. If purchasing wood for immediate use, test the wood with a moisture meter. Some experienced wood burners can measure wood moisture by Wet Wood Leads To Less Heat Leads To Dry Wood More Heat Leads To Leads To knocking pieces together and listening for a clear "knock" and not a "thud". Why Dry Wood is Key More Smoke and Creostoe Less Smoke and Creostoe Wet wood, when burned, must release water stored within the wood. This cools the fire, creates creosote, and hampers a complete burn. Ask any experienced wood burner and he or she will agree: dry wood is crucial to good performance. Wood Cutting and Storage Cut wood to length and chop into quarters. Store the wood off the ground in a covered area. Allow for airflow around the wood to dry the wood. Air Flow Air Flow Air Flow © Travis Industries 93508061 4050526 Operating Your Appliance 31 Troubleshooting Problem Possible Cause Smoke Enters Room During Start-Up • Open the bypass (pg. 26). • Open the air control (pg. 28). • Cold Air Blockage - burn a piece of newspaper to establish a draft. • If the flame is not getting enough air, a small crack in the door is all that is needed. Kindling Does Not Start - Fire Smolders • Open the bypass (pg. 26). • Open the air control (pg. 28). • Not enough starter paper - use additional newspaper if necessary. • If the flame is not getting enough air, a small crack in the door is all that is needed. Smoke Enters Room While Re Loading • Open the bypass (pg. 26) before opening the door. • Let the air stabilize before fully opening the door. Then open the door approximately 1 inch. Let air go into the firebox for a few seconds. Once the smoke appears to be flowing up the chimney consistently, open the door. • Insufficient Draft - Chimney height and outside conditions can negatively affect draft. In these cases a small amount of smoke may enter the home. Adding more pipe or a draft-inducing cap may help. Stove Does Not Burn Hot Enough • Wood is Wet - see the section "Selecting Wood" on page 30 for details on wood. • Make sure the air control is all the way open. Slide the control back and forth to insure the control is not stuck. • Insufficient Draft - Chimney height and outside conditions can negatively affect draft. In these cases the fire may burn slowly. Adding more pipe or a draft inducing cap may help. Blower Does Not Run • Stove is Not Up to Temperature - This is normal. The blower will come on when the stove is hot - usually 15 to 30 minutes. • Electricity is Cut to the Blower - Check the household breaker or fuse to make sure it is operable. Stove Does Not Burn Long Enough • Depending upon wood, draft, and other factors, the burn time may be shorter then stated. Make sure the doors are sealing and not allowing air into the firebox - See the section "Door and Glass Inspection" on page 33 for details. • Check the ash bed for coals. Often, coals are still glowing under a slight bed of flyash. By raking these into a pile you can re-start your stove quickly. © Travis Industries 93508061 4050526 32 Maintaining Your Appliance Failure to properly maintain and inspect your appliance may reduce the performance and life of the appliance, void your warranty, and create a fire hazard. Daily Maintenance (while stove is in use) Remove Ash (if necessary) • Ash removal is not required once it builds up. 1/2" to 1" of ash may be desirable because it slows the burn rate. Generally, remove ash once it has built up over 1". Follow the directions below to remove ash. • Let the stove cool completely (at least two hours after the last coal has extinguished). • Place a cloth or cardboard protector over the hearth to catch ash and protect against scratching. • Open the doors and scoop the ash into a metal container with a tight fitting lid. The closed container of ashes should be placed on a noncombustible floor or on the ground, away from all combustible materials, pending final disposal. ASHES Improperly disposed ashes lead to fires. Hot ashes placed in cardboard boxes, dumped in back yards, or stored in garages, are recipes for disaster. Wood-burning stoves are inherently dirty. During cleaning have a vacuum ready to catch spilled ash (make sure ash is entirely extinguished). There are vacuum cleaners specifically made to remove ash (even if the ash is warm). Contact your dealer for details. Clean the Glass (if necessary) This appliance has an airwash to keep the glass clean. However, burning un-seasoned wood or burning on lower burn rates leads to dirtier glass (especially on the sides). Clean the glass by following the directions below. Allow the stove to fully cool. Apply glass cleaner or soapy water to the inside of the glass. Wipe with newspaper or a paper towel. AA AA For Stubborn Creosote: Dip newspaper or a paper towel in cool ashes and wipe it on the glass. The ash acts as a light abrasive. AAAA The glass will develop a very slight haze over time. This is normal and will not affect viewing of the fire. © Travis Industries 93508061 4050526 Maintaining Your Appliance 33 Monthly Maintenance (while appliance is in use) Make sure the appliance has fully cooled prior to conducting service. Door and Glass Inspection The door must form an air-tight seal to the firebox for the stove to work correctly. Inspect the door gasket to make sure it forms an air-tight seal to the firebox. The door can be lifted off the hinges if extensive repairs are conducted. High-Temperature anti-sieze may be used on the door hinges to eliminate squeaks. If the glass is damaged, replace it - see "Replacement Parts" for details. AA AA AA AA Use wood stove gasket cement to re-adhere loose gasket. Severely frayed or thread-bare gasket should be replaced. The door latch should pull the door against the face of the stove (but not so tight as to not allow full handle rotation). If the latch requires adjustment, follow the directions below. Side View of Door Handle Door Cam Door Handle Washers Use a 9/16" Exploded View Door Cam Adjustment: To tighten, remove a washer from the inside of the door frame. To loosen, Door Frame socket wrench to remove this nut. place an additional washers on the inside of the door frame or loosen the nut 1/2 turn. Creosote - Formation and Need for Removal When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow burning fire. As a result, creosote residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire. The chimney and chimney connector should be inspected at least once every two months during the heating season to determine if a creosote buildup has occurred. If creosote has accumulated, it should be removed to reduce the risk of a chimney fire. If you are not certain of creosote inspection, contact your dealer or local chimney sweep for a full inspection. Excess creosote buildup may cause a chimney fire, that may result in property damage, injury, or death. © Travis Industries 93508061 4050526 34 Maintaining Your Appliance Yearly Maintenance Make sure the appliance has fully cooled prior to conducting service. Touch Up Paint Included with the owner's pack of this appliance is a can of Stove-Brite® paint. To touch up nicks or dulled paint, apply the paint while the appliance is cool. Sand rusted or damaged areas before preparation (use 120 grit sandpaper). Clean and dry the area to prepare the surface. Wait at least one hour before starting the appliance. The touched up area will appear darker than the surrounding paint until it cures from heat. Curing will give off some fumes while curing – open windows to ventilate. Cleaning the Air Duct and Blower (if applicable) Touch-Up P a i n t Use a vacuum to clean the air ducts (channels). This prevents dust from burning and creating odors. The optional blower should be vacuumed every year to remove any buildup of dust, lint, etc. BOTTOM OF STOVE Firebrick and Baffle Inspection Use a vacuum cleaner to remove any buildup on the screens of the blower. Use the illustration on page 36 as a reference for checking the following items. Make sure the appliance is cool before proceeding. Baffle Firebricks - check the bricks along the ceiling of the firebox to make sure they are intact and have no gaps between them. Slide the bricks to eliminate any gaps. Baffle Supports - make sure the front and back baffle supports in are place and not degraded. Slight scaling or rusting of the metal is normal. Secondary Air Tubes - Check the two air tubes and collars to make sure they are intact and not severely deteriorated. Slight scaling or rusting of the metal is normal. Make sure the push pins hold the air tubes in place. Floor and Wall Firebricks - replace any severely damaged firebrick along the side or floor of the firebox. © Travis Industries 93508061 4050526 Maintaining Your Appliance 35 Door Parts 9 Cross Section Door Gasket - Adhere with gasket cement. Glass Clip Screw AA AA AAAA Door Frame Make sure there is a the edge of AA 8 1 2 Glass Clip Glass Clip A A A gap around the glass AAAAA AAAAA AAAAA 3 AA Gasket Glass 4 Glass Gasket 6 AAAA AAAAAA 7 AAAAA AAAAA AAAAAA AAAAAA 11 10 AA AA 12 AAAAA AAAAAA AA AA AAAAAA 5 5/16" Nutdriver AAAAAA AAAAAA AA 9/16" Wrench ID # DESCRIPTION QTY PART # ID # AAAAAA DESCRIPTION QTY PART # 1 DOOR SHELL - BLACK Door Shell - Brass 1 99300505 99300502 2 GLASS GASKET - 3/8" 1 99900403 3 GLASS 1 99400302 4 GLASS CLIP WITH GASKET 4 91001250 5 GLASS CLIP SCREWS (10) 4 91001249 6 DOOR GASKET CEMENT 1 99900409 7 DOOR GASKET - 7/8" X 120" 1 99900406 8-12 DOOR HANDLE ASBLY. 1 99900415 9 DOOR HANDLE, WOOD 1 99300600 11 DOOR CAM, BRASS 1 99900416 Replacing the Glass The glass must not contact the door shell or glass clips directly. The glass gasket and glass clip gaskets insulate the glass to prevent cracking. Do not over-tighten the glass clips. Remove the door and place it on a suitable work surface. Remove the door gasket. Remove the glass clips (the glass clip gaskets adhere to the glass clips). Remove the glass. Place the glass gasket in the inner channel of the door shell then place the glass on top of the gasket. Replace the clips to secure. Replacing the Door Gasket The door gasket inserts into the outer groove of the door shell. Stove gasket cement holds it in place. Before installing, remove any residual cement. Lay the gasket in place (start at the lower left corner) and cut off any excess gasket (do not stretch the gasket. The cement fully cures with heat from the stove. You may need to open and close the door repeatedly to get the gasket to seat fully. Replacing the Door Handle See the illustration above for a component list (see pg. 33 for details on adjusting the door). © Travis Industries 93508061 4050526 36 Maintaining Your Appliance Firebox Parts 1 7 10 8 AA 9 2 6 3 10 4 AA 10 5 10 10 12 10 11 12 10 10 10 10 10 10 11 10 10 ID # Description Qty Part # ID # Description Qty Part # 1 Air Tubes & Sleeve 1 98900210 2 Air Tube Roll Pins 6 98900357 3 Air Tube Retainer Sleeve 3 100-11001 4 Baffle Support, Front "Y" 1 99900277 5 Baffle Support, Rear "T" 1 99900278 6 Damper Plate 1 98900320 7 Damper Slider 1 98900338 8 Damper Yoke 1 98900326 9 Damper Extension Rod with Pull Ring 1 98900334 10 Brick - 9" x 4.5" un-cut 15 175-00001 (1) 99900102 (8) 11 Brick - Cut (8.25" x 4.5") 2 251-00010 12 Brick - Cut (6.25" x 4.5") 2 251-00011 Floor and Side Firebrick Removal & Replacement Do not pry firebrick - they chip and crack easily. Remove the floor firebricks first. The side firebrick are removed later because they are pinned in place by the floor firebrick. Clean the firebox prior to replacing the firebrick. © Travis Industries 93508061 4050526 Maintaining Your Appliance 37 Baffle Removal & Replacement The baffle is held up by the front air tube. Make sure to support the baffle after removing the air tubes. 1. Lift up on the front portion of the front three firebricks. 2. Lift the front baffle support "Y" 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. 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 damper plate will come to rest on the rear secondary air tube and rear air channel. 6. Slide the damper slider all the way forward. 7. Reach into the firebox and push up on the damper yoke until the damper yoke separates from the damper slider. Remove both the damper slider and damper plate by sliding them between the front two secondary air tubes. REPLACEMENT INSTRUCTIONS: 1. Place the damper plate above the secondary air tubes in the rear center of the firebox. 2. Position the damper slider so the damper yoke inserts into the two tubes on the damper slider (make sure to have correct orientation). Then slide the damper slider over the damper plate until both are centered in the firebox. 3. Follow the instructions above in reverse order, starting with step number 5. Air Tube Removal & Replacement Air Tube Collar Air Tube Remove the left pin on the air tube collar a Roll Pinb Slide the air tube to the left, swing it down and remove from the firebox. © Travis Industries 93508061 4050526 38 Limited 7 Year Warranty To register your TRAVIS INDUSTRIES, INC. 7 Year Warranty, complete the enclosed warranty card and mail it within ten (10) days of the appliance purchase date to: TRAVIS INDUSTRIES, INC., 4800 Harbour Pointe Blvd. SW, Mukilteo, WA 98275. TRAVIS INDUSTRIES, INC. warrants this gas appliance (appliance is defined as the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows: Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store. Years 1 & 2 - COVERAGE: PARTS & LABOR Firebox Assembly: Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber Door Assembly: Solid Brass or Cast Door, Latch Assembly, Glass Retainers Plated Finish Plated Door, Legs, etc… See "Conditions & Exclusions" # 9 below. Air Control Assembly Slider Plate, Pressure Plate Exclusions: Paint, Gasketing Ceramic Glass Glass (breakage from thermal shock) Firebrick Breakage from thermal shock Accessories Legs, Pedestal, Panels, Blower 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: Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber Air Control Assembly Slider Plate, Pressure Plate Door Assembly: Solid Brass or Cast Door, Latch Assembly, Glass Retainers One-Way Freight Allowance One-way freight allowance on pre-authorized repair done at factory is covered. Exclusions: Paint, Gasketing, Plated Finish, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance Years 6 & 7 - COVERAGE: PARTS ONLY Firebox Assembly: Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber Door Assembly: Solid Brass or Cast Door, Latch Assembly, Glass Retainers Air Control Assembly Slider Plate, Pressure Plate Exclusions: Paint, Gasketing, Plated Finish, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance, One Way Freight Allowance, Labor CONDITIONS & EXCLUSIONS 1. This new appliance must be installed by a qualified installer. It must be installed, operated, and maintained at all times in accordance with the instructions in the Owner's Manual. Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty. 2. This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized Travis dealer. 3. Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty. Over-firing (operation where the steel may glow red) of this appliance can cause serious damage and will nullify this warranty. 4. The warranty, as outlined within this document, does not apply to the chimney components or other Non-Travis accessories used in conjunction with the installation of this product. If in doubt as to the extent of this warranty, contact your authorized Travis retailer before installation. 5. Travis Industries will not be responsible for inadequate performance caused by environmental conditions such as nearby trees, buildings, roof tops, wind, hills or mountains or negative pressure or other influences from mechanical systems such as furnaces, fans, clothes dryers, etc. 6. This Warranty is void if: a. The unit has been operated in atmospheres contaminated by chlorine, fluorine or other damaging chemicals. b. The unit is subject to submersion in water or prolonged periods of dampness or condensation. c. Any damage to the unit, combustion chamber, heat exchanger or other components due to water, or weather damage which is the result of, but not 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. 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 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). 9. Damage to brass or plated surfaces caused by fingerprints, scratches, melted items, or other external sources left on the surfaces from the use of abrasive cleaners is not covered in this warranty. Damage to the surfaces from over-firing (operation where the steel may glow red) is not covered in this warranty. 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 93508061 4050526 Listing Information 39 Listing Label Report #028-S-27-2 (June, 1999) DO NOT REMOVE THIS LABEL LISTED SOLID FUEL BURNING APPLIANCE SUITABLE FOR USE IN RESIDENTIAL, ALCOVE, MOBILE HOME, OR MASONRY INSERT INSTALLATIONS. TM MODEL: Olympic (1190) TESTED TO RELEVANT PORTIONS OF UL 1482, 737 AND 907. SERIAL NUMBER PREVENT HOUSE FIRES - Install and use only in accordance with the Avalon 1190 owner's manual. Contact your local building or fire officials about restrictions and installation inspection in your area. Refer to local building codes and the chimney manufacturer's instructions for precautions required for passing a chimney through a combustible wall or ceiling. Do not run a chimney connector through a combustible wall or ceiling. Do not connect this unit to a chimney flue serving another appliance. Clearances may be reduced by methods specified in NFPA 211, listed wall shields, pipe shields, or other means approved by local building or fire officials. FREESTANDING INSTALLATION STANDARD RESIDENTIAL FREESTANDING INSTALLATIONS REQUIRE: 6" diameter, minimum 24 MSG black or 25 MSG blued steel connector, with listed (type HT) factory-built chimney, suitable for use with solid fuels or masonry chimney. Pedestal or legs are required. ALCOVE INSTALLATIONS REQUIRE: One of the listed doublewall connectors shown below. Pedestal or legs are required. Maximum alcove depth 48", minimum alcove height 84". MOBILE HOME AND REDUCED CLEARANCE INSTALLATIONS REQUIRE: One of the listed doublewall connectors shown below. In addition, mobile home installations require outside air - use the optional pedestal or outside air boot. Pedestal or legs are required. • DURAVENT model DVL with DURA-PLUS chimney • AMERI-TEC model DCC with model HS chimney • SECURITY model DP with SECURITY model ASHT or S2100 chimney • METALFAB model DW connector with TG chimney • Standard Masonry Chimney with any one of the above listed connectors CLEARANCES AND FLOOR PROTECTION REQUIREMENTS: A. SIDEWALL TO UNIT B. BACKWALL TO UNIT C. CORNER TO UNIT D. SIDEWALL TO CONNECTOR E. BACKWALL TO CONNECTOR F. CORNERWALL TO CONNECTOR STANDARD RESIDENTIAL INSTALLATION (SINGLEWALL CONNECTOR) 16" 15" 9.5" 27.5" 17.5" 20.5" MOBILE HOME, ALCOVE AND REDUCED CLEARANCE INSTALLATIONS (REQUIRES DOUBLE WALL CONNECTOR) 16" 10" 7.5" 27" 12" 18" MINIMUM CLEARANCES TO COMBUSTIBLES: FLOOR PROTECTOR OPTIONAL EQUIPMENT: Front or rear blower (electrical rating: 115V, 60 Hz., 1.8 Amps) BACKWALL E D B ADJACENT WALL A D 6" MIN. 6" Replace glass only with AVALON supplied NEOCERAM ceramic glass (5mm). L L AW 45˚ STOVE F JA C EN MIN. STOVE For use with solid wood fuels only (cord wood). Operate with E DI S C STOVE T A W A L L 16" MIN. feed door closed - open to feed fire only. Do not use a grate or elevate fire - build fire directly on the hearth. MASONRY INSERT INSTALLATION MINIMUM CLEARANCES MANTLE TO COMBUSTIBLES AND HEARTH REQUIREMENTS: A. SIDEWALL TO INSERT B. SIDE FACING TO INSERT C. TOP FACING TO INSERT WITH MANTLE SHIELD D. MANTLE TO INSERT WITH MANTLE SHIELD *E. HEARTH EXTENSION IN FRONT STANDARD MODEL 15" 13.5" 30" 17" 32" 19" 16" COOK TOP MODEL 15" 13.5" 31" 18" 33" 20" 16" * L L A WE DI S EL BI TS UB MO E DI S EL BI TS UB M OC D G N I C A F B A COMBUSTIBLE TOP FACING C G N I C A F E C A L P E R I F F. HEARTH EXTENSION TO SIDES 8" C 8" E F HEARTH EXTENSION *NOTE: The Cook Top Model must be installed on a code conforming masonry hearth. If the fireplace hearth extension is raised 4.5" above a combustible floor, the hearth extension 16" in front of the fireplace insert must be of non-combustible material and at least .018" (26 gauge) thick. If the fireplace hearth extension is not raised 4.5", the hearth extension 16" in front of the fireplace insert must be constructed of 3.5" thick clay brick or equivalent. See installation manual for further information. REQUIRED EQUIPMENT: Surround Panels DO NOT remove firebricks or mortar from masonry fireplace. Manufactured by: U.S. ENVIRONMENTAL PROTECTION AGENCY Certified to comply with July 1990 particulate emission standards. DATE OF MANUFACTURE 1999 2000 2001 Jan. Feb. Mar. Apr. May June July Aug. Sep. Oct. Nov. Dec. © Travis Industries 93508061 4050526 40 Optional Equipment Stove Leg Installation (Brass # 99200500, Cast Black # 99200800, Sculptured # 99200105) Raise the stove 8" (use lumber). Attach each leg following the instructions below. Attach each leg to the stove by inserting a bolt and washer through the hole or slot in the leg and into the threaded hole on the stove. These rubber-tipped bolts are for leveling the stove. Make sure they contact the floor. Do not adjust with weight on the legs, the rubber tips may tear. Pedestal (Part # 99200200) 9/16" Socket Wrench If using outside air with the pedestal, follow the directions on the following page under "Outside Air Installation" prior to installing the pedestal. Mobile Home installations require the pedestal to be attached to the floor (use the lag bolts). • Place the pedestal into position on the floor protection. Lift the pedestal up and insert the two dowels included with this kit onto the forward and rear edge of the pedestal base. • Lift the stove onto the pedestal base. Line up the press-nuts on the bottom of the stove with the two attachment brackets on the pedestal. Insert the two bolts, with washers, through the brackets on the pedestal and into the stove. Tighten the bolts with a 9/16" wrench. The two pedestal bolts attach the pedestal to the bottom of the stove. Stove Early models mount to the pedestal through these holes. hThe lag bolts and washers may be c n e r W " 6 1/ 9 inserted through these holes to anchor the pedestal to the floor. Pedestal The dowels insert onto the front and back edge of the pedestal base. AAAA AAAA If using outside air, tuck the insulation under the sides of the pedestal. © Travis Industries 93508061 4050526 Optional Equipment 41 Outside Air Installation (for wood stoves only) This pedestal has an internal air duct that may be used to direct air to the combustion chamber. Follow the directions below prior to installing the stove or attaching the pedestal. Outside air is required for mobile home installations and in certain localities. Read the section "Outside Air Requirements" on page 11 prior to installing outside air. • Before placing the stove on the pedestal, determine the location of the hole that is cut through the floor protection and floor. The illustration to the right details the location where this hole may be cut in relation to the faceplate of the stove. Cut a hole at least 16 square inches in area that does not interfere with structural members of the home. Size of Pedestal Base 19-3/4" 26" The hole for outside air must fall underneath the pedestal base. The faceplate of the 1190 is 3/4" in front of the front edge of the pedestal • Place the included screen (or other screen) over the hole to act as a rodent barrier. It may be attached above or below the floor. Secure the screen with the included staples. OUTSIDE AIR EQUIPMENT Cover plate is used to AAA Insulation is used to seal the side AAA block off room air . Screen is used to prevent rodents from entering. Staples are used to attach the screen to the floor. edges of the pedestal . AAA • Prop the front of the stove up 12" and pry out the outside air knockout with a large screwdriver. • The cover plate seals the area around the air control rod. Remove the two screws and bridge from the cover plate. Slide the cover plate underneath the air control rod and re-attach the bridge. FRONT OF STOVE Drop Chute Outside Air Knock-Out Knock-Out Ashpan Pedestal/Air Boot Outside Air Knock-Out DO NOT REMOVE Rear Blower Knock-Outs Bridge Phillips Screwdriver Remove the two screws that hold the bridge to the cover plate. Then replace the bridge when the cover plate is in place. Air Control Rod The cover plate has a clip which attaches it underneath the air control. © Travis Industries 93508061 4050526 42 Optional Equipment Rear Blower Installation (Part number 99000138) The rear blower improves heat transfer by pushing heated air through the convection channel. Operating instructions are described in the section "Blower Operation" on page 29. 1. The stove should be in place with the legs installed prior to installing the rear blower. 2. Follow the directions below to install the thermodisk. These wires pass through the left side convection channel. Thermodisk Assembly Bend metal up or down here to create a snug fit Air Control Rod Insert the thermodisk assembly 4" to 5" inside the convection channel. 3. Install the wire clip following the directions below. Use a screwdriver to pry out the knock-out. Slide the wire clip over the edge of the strip of metal between the two knock-outs. Wire Clip Snap Disk Wires 4. Attach the blower following the directions below. Feed the two snap disk wires into the eye of the wire clip. Remove all slack from the wire, making sure not to dislodge the snap disk. Pinch the eye of the wire clip to secure the wires. WARNING: To prevent electrical shock, the wires must be secured so they do not contact the firebox above the convection channel. The blower attaches to the stove with the three b included screws. Use a 3/8" socket driver or wrench. 3/8" Nutdriver a Attach the quick-connects leading from the snap disk to the AAAA NOTE: Prior to attaching the blower, tuck all excess wire into the area inside the blower. quick-connects from the blower (orientation does not matter). Plug the power cord into a 110 V. outlet after installing the c blower. © Travis Industries 93508061 4050526 Optional Equipment 43 Outside Air Boot Installation (Part number 99200134) The outside air boot routes outside air to the stove for combustion. Refer to the section "Outside Air Requirements" on page 11 for installation concerns. The directions below detail installation. 1. Install the cover plate following the directions below (use the correct cover plate). Remove the two screws on the cover plate to remove the piece that fits over the air control rod. Then replace the piece when the cover plate is in place. Air Control Rod The cover plate has a clip which attaches it underneath the air control. 2. Refer to the illustration below to determine the location and size of the hole penetrating the floor. Cut the hole prior to locating the stove. 3. Attach gasket to the bottom edge of the lower air boot section (near the screen). Attach gasket on top of the flanges on the upper air boot section. Slide the two sections together with both seams facing the rear (do not attach the two sections at this time). 4. Follow the directions below for attaching the upper section of the air boot (with gasket) to the stove. 5. Slide the lower section down until it contacts the hearth. Attach the two sections together following the directions below Use a Attach the included gasket to all four top edges of the air boot. Bottom of Stove AAAA screwdriver to pry out the knock-out. Attach the air boot with AA AA 8-7/8" Attach gasket to the bottom edge of the air boot. A A 5-1/8" the two screws included with the kit. 1/4" Nutdriver Use the included screws to attach the two telescoping portions of air boot together. The included drill bit should be used to drill the hole. Make sure the air boot is expanded to the correct size before drilling. 9/64" Drill Bit 5/16" Nutdriver AAAAAAAAAA AAAAAAAAAA AAAA AAAAAAAAAA AAAA AAAAAAAAAA Floor (and hearth) The hole in the floor (and hearth) must be a minimum 16 square inches. It should be 1/2" smaller than the footprint of the air boot in each dimension to allow for the gasket to seal. © Travis Industries 93508061 4050526 44 Optional Equipment Surround Panels (see part #'s below) Size Size on Insert (w trim) PART # 8" 45 1/4" wide by 28 7/8" high 99300312 10" 49 1/4" wide by 30 7/8" high 99300313 12" 53 1/4" wide by 32 7/8" high 99300314 INSTALLATION INSTRUCTIONS 1. With the insert 12" from the fireplace, install the side surround panels (see the directions to the right). 2. Adjust the position of the side panels so they are: 1) aligned with the top of the insert; 2) both the same distance back from the front of the insert; 3) Avalon Pendleton-45 and Rainier-45: Remove the brass trim along the top of the stove. Attach the side panels with perpendicular to the floor (use the top panel, if necessary, to judge alignment). Tighten the screws that hold the side panels in place. 3. Install the top panel and trim following the directions to the right. Insulation Installation (required for face seal installations only) 1. With the insert drawn 6" Button Plugs (pry out with a screwdriver) Spring AA Side Panel 5/16" Nutdriver the included screws (hint: pre-thread the holes prior to installing the panels). 5/16" Nutdriver A Micro (1/16") Standard Screwdriver Top Trim 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, allowing the insulation to form a seal between the panels and the fireplace. Use a screwdriver to tuck any exposed insulation behind the panels. Clips Top Trim AA AAAA Top Panel AAAA Install the top panel so the tabs insert into the joggle clips on the top panel "L" Bracket 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 screwdriver. Slide the trim over the panels. Place the spring clips behind the panels at the locations shown. This keeps the trim tight against the panel. Optional Knock-Out An optional knock-out is provided on both sides if the power cord is routed behind the surround panel. © Travis Industries 93508061 4050526 Optional Equipment 45 Front Blower (part # 99000190) TO SWITCH THE POWER CORD TO THE LEFT SIDE: Follow the directions below to switch the power cord. Make sure the power cord, wires, or molex assembly do not protrude into the opening of the blower. The wires tuck in here, directly behind the blower cage. Left Side of Blower Remove the strain relief by squeezing it from the top and bottom with a pair of slip-joint pliers. INSTALLATION INSTRUCTIONS Disconnect the molex plug inside the blower assembly. Remove the power cord by pulling it out of the hole exposed by removing the strain relief. Assembly Remove the button plug from the left side and insert it into the hole on the right side. The Olympic (1190), requires removal of the button plug below the blower knob and installation of the air control rod extention (see illustration below). Install the snap disk (see the illustration below. The round disc must be facing upwards and come in contact with the bottom of the firebox for the blower to operate correctly. Ashlip of Appliance Bend these legs on the snap disk if it does not fit tightly Wedge the snap disk in back of the stiffener on the left side The air control extender allows the air control rod to pass through the blower assembly on the Rainier (945/990) and Button Plug for Air Control Rod (For the Rainier (945/990) and Olympic (1190) Olympic (1190). Wood Air Control Handle Make sure the wires leading to the snap disk are routed above the left side blower outlet (to prevent damage to the wires during installation). Install the blower following the directions below. ake sure the wires run over he top of the blower housing nd are not damaged when the lower is installed. his clip aligns the blower nside the convection channel. Insert the baseplate of the appliance into this gap. This clip slips over the edge of the appliance unibody and locks the blower in place. Baseplate of Appliance (Below Ashlip) Front of Appliance © Travis Industries 93508061 4050526 46 Index Air Control ...................................................28 Air Tube Part Number ....................................36 Air Tube Removal & Replacement ....................37 Alcove.........................................................12 Ash Disposal ................................................32 Baffle Parts ..................................................36 Baffle Removal and Replacement.....................37 Blower Cleaning............................................34 Blower Does Not Run (Troubleshooting) ............31 Blower Installation (rear) .................................42 Blower Operation (optional) .............................29 Burn Rate ....................................................28 Cathedral Ceiling...........................................14 Ceiling Penetration ........................................10 Chimney Cleaning .........................................33 Chimney Inspection (Creosote) ........................33 Chimney Requirements ..................................10 Chimney Termination Requirements..................11 Cleaning the Ash...........................................32 Cleaning the Glass ........................................32 Clearances (stove) ........................................8 Close Clearance Connectors ...........................8 Connector Requirements ................................10 Creosote Check ............................................33 Daily Maintenance.........................................32 Dimensions ..................................................6 Door and Glass Inspection ..............................33 Door Assembly .............................................35 Door Gasket Replacement ..............................35 Door Handle Replacement ..............................35 Door Opening...............................................25 Door Parts ...................................................35 Draft Performance .........................................10 Elbows (Chimney) .........................................10 Emissions ....................................................6 EPA Approval...............................................6 Exterior Chimney...........................................11 Features......................................................6 Fire Starting .................................................26 Firebox Assembly..........................................36 Firebox Parts................................................36 Firebrick and Baffle Inspection .........................34 Firebrick Removal & Replacement ....................36 Floor Protection Requirements (stove)...............8 Glass Cleaning .............................................32 Glass Replacement .......................................35 Hearth (Floor Protection - Stove) ......................8 Hearth Stove ................................................16 Heating Specifications ....................................6 Hints for Burns..............................................30 Installation Options ........................................6 Installation (stove) .........................................7 Leg Installation .............................................40 Listing Label.................................................39 Maintenance ................................................32 Mobile Home Requirements ............................13 Monthly Maintenance .....................................33 Noise (Normal Operating Sounds) ....................29 Non-Combustible Alcove.................................12 Opening the Door..........................................25 Operation ....................................................17 Outside Air Boot Installation.............................43 Outside Air...................................................11 Over-Firing the Stove .....................................25 Overnight Burn .............................................29 Paint (Touch-Up Paint) ...................................34 Paint Curing .................................................25 Rear Blower Installation..................................42 Re-Loading the Stove.....................................29 Safety Label.................................................39 Safety Precautions ........................................4 Smell (from paint curing).................................25 Smoke Enters Room (Troubleshooting)..............31 Sounds (Normal Operating Sounds)..................29 Starting a Fire...............................................26 Stove Does Not Burn Long Enough...................31 Stove is Not Hot Enough (Troubleshooting) ........31 Table of Contents ..........................................3 Touch-Up Paint.............................................34 Troubleshooting (Operation) ............................31 Warranty Card ..............................................2 Warranty .....................................................37 Wood..........................................................30 Yearly Maintenance .......................................34 © Travis Industries 93508061 4050526