Freedom
Bay
Owner's
Manual- May, 2001 ¥ Masonry
Fireplace Insert

SAFETY NOTICE:
If this appliance is not properly installed, a housefire may result. For your safety, follow the
installation directions. Contact local building or
fire officials about restrictions and installation
inspection requirements in your area.

Freedom Bay Fireplace Insert
10850 117th Place N.E. Kirkland, WA 98033

Part # 93508026$10.00ListedINTRODUCTION & IMPORTANT INFORMATIONPAGE 1Introduction
We welcome you as a new owner of a Lopi Freedom Bay wood-burning appliance. In purchasing a
Lopi Freedom Bay you have joined the growing ranks of concerned individuals whose selection of anenergy system reflects both a concern for the environment and aesthetics. The Lopi Freedom Bay is oneof the finest appliances the world over. This manual will explain the installation, operation, andmaintenance 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 andenjoyment from your appliance.

Important Information
No other Lopi Freedom Bay appliance has thesame serial number as yours. The serial number
is stamped onto the label on the right side of theappliance.
This serial number will be needed in case you
require service of any type.
Model:
Serial Number:
Purchase Date:
Purchased From:

LOPI Freedom Bay

Mail your Warranty Card Today, and Save
Your Bill of Sale.

To receive full warranty coverage, you willneed to show evidence of the date youpurchased your appliance. Do not mail yourBill of Sale to us.

We suggest that you attach your Bill of Sale tothis page so that you will have all theinformation you need in one place should theneed for service or information occur.

PAGE 2

SAFETY PRECAUTIONS¥

The viewing door must be
closed and latched during
operation.

¥

Never block free airflow
through the air vents on
this appliance.

¥

This appliance is designed
and approved for theburning of cord woodonly. Do not attempt toburn any other type offuel other than cord woodin this appliance, it willvoid all warranties andsafety listings.

¥

¥

¥

¥

¥

¥

Do not touch theappliance while it is hot
and educate all children of
the danger of a hightemperature appliance.
Young children should besupervised when they arein the same room as theappliance.
This appliance must be
properly installed toprevent the possibility ofa house fire. The
instructions must be
strictly adhered to. Do
not use makeshiftmethods or compromisein the installation.
Inspect the chimney
connector and chimney atleast twice monthly andclean if necessary.
Creosote may build up
and cause a house fire.
Do not connect thisappliance to any chimney
serving another appliance.
Maintain the door andglass seal and keep themin good condition.
Avoid placing woodagainst the glass whenloading. Do not slam thedoor or strike the glass.

¥Gasoline or otherflammable liquids mustnever be used to start thefire or "Freshen Up" thefire. Do not store or use
gasoline or otherflammable liquids in thevicinity of this appliance.

¥

Ashes must be disposed ina metal container with atight lid and placed on a
non-combustible surface
well away from the homeor structure.

¥

Keep furniture, drapes,
curtains, wood, paper, andother combustibles aminimum of 36" awayfrom the appliance.

¥

Contact your local
building officials to
obtain a permit andinformation on any
installation restrictions orinspection requirements inyour area. Notify yourinsurance company of thisappliance as well.

¥This appliance must beconnected to a listed hightemperature (HT)residential type chimney
or an approved masonrychimney with a standard
clay tile, or stainless steel
liner.

¥Do not place clothing orother flammable items onor near this appliance.

Gas

Ashes

36"
Minimum

Ok

Type
HT

Clay
Liner

SAFETY PRECAUTIONS (CONTINUED)
¥

¥

¥
This
ManualNever try to repair or
replace any part of thisappliance unless
instructions are given inthis manual. All otherwork must be done by atrained technician.

Allow the appliance tocool before carrying out
any maintenance or
cleaning.

Do not throw this manualaway. This manual has
important operating andmaintenance instructions
that you will need at alater time. Always follow
the instructions in thismanual.

PAGE 3¥

Do not make any changes
or modifications to an
existing masonry fireplaceor chimney to install thisappliance.

¥

Do not make any changes
to the appliance toincrease combustion air.

¥Overfiring the appliance
may cause a house fire. If
a unit or chimney
connector glows, you are
overfiring.

¥

Do not use a grate orother device to elevate thefire 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 yourappliance, and assumes
no responsibility of any
consequential
damage(s).

PAGE 4

TABLE OF CONTENTS

Introduction and Important Information

Maintaining Your Appliance

Introduction and Important Information ...................... 1

Maintenance Schedule............................................... 19

Safety Precautions..................................................... 2

Remove Ash From The Firebox (If Necessary).......... 19
Clean The Viewing Glass (If Necessary) ................... 19

Features and Specifications
Features and Specifications ....................................... 5

Insert Installation

Clean The Brass (If Necessary) ................................. 19
Check For Creosote Buildup ...................................... 19
Door And Glass Inspection ........................................ 20
Adjusting the Door Cam ....................................... 20
Replacing the Door Gasket .................................. 21
Replacing the Glass or Glass Gasket................... 21

Before You Begin....................................................... 6

Lubricate The Door Hinge .......................................... 21

Planning The Installation............................................ 6

Touch-Up Paint .......................................................... 22

Preparation for Installation .......................................... 6

Blower Cleaning ......................................................... 22

Insert Installation Considerations............................... 6

Firebrick And Baffle Inspection And Cleaning............ 22
Firebrick Removal and Replacement Inst. ........... 23
Baffle Removal and Replacement Instructions..... 23
Secondary Air Tube Replacement Instructions .... 25

Optional Equipment Requirements ............................ 6
Insert Placement Requirements ................................. 7
Hearth Requirements................................................. 7
Insert Size Requirements ........................................... 7

Replacement Parts List .............................................. 25

Masonry Fireplace Requirements .............................. 8
Leveling Bolt Installation ............................................. 8
Blower Installation ....................................................... 8

Troubleshooting
Troubleshooting Table ............................................... 26

Block-Off Plate Installation......................................... 9
INSTALLATION DIAGRAMS
Insert with Positive Connection ................................... 10
Insert with Direct Connection ...................................... 10

Warranty
Warranty..................................................................... 27

Insert with Face Seal Connection ............................... 11

Listing Information
Operating Your Appliance

Listing Information...................................................... 28

Before You Begin....................................................... 12
Paint Curing ............................................................... 12

Optional Equipment

Location of Controls .................................................... 12
Approximate Air Control Settings ......................... 12
Bypass Control ...................................................... 13

Surround Panel Installation ........................................ 29
Insulation Installation ............................................ 30
Brass Trim Installation (Optional) ......................... 30

Learning to Burn your Appliance................................ 13
How to Start a Hot Fire Quickly ............................ 13
How to Reload Your Appliance ............................ 14
How to Adjust the Heat Output Precisely ............. 14
How to Obtain an Overnight Burn ........................ 15
Good Burning Habits ............................................ 15

Flue Adapter Installation ............................................ 31

Blower Operation ....................................................... 16
A Word about Wood ................................................... 17

Index
Index .......................................................................... 32

FEATURES AND SPECIFICATIONSPAGE 5

Installation Options:¥ Insert into a Masonry Fireplace
Features:¥¥¥¥

EPA Phase II Approved
3.1 Cubic Foot Firebox Volume
Single, Push/Pull Operating Control
Accepts Logs Up to 24" Long

¥
¥
¥
¥

Long Burn Time - Up to 12 Hours
5/16 to 3/16" Steel Construction
Heavy Duty Refractory Firebrick
Optional High-Tech Blower

Heating Specifications:
Approximate Maximum Heating Capacity (in square feet)*
Maximum BTU's per Hour (Cord Wood Calculation)
Overall Efficiency (Oregon Method)
Maximum Burn Time (Hours)*

1,200 to 2,250
74,30070%
12Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside temperature. It is also
affected by the quality and moisture level of the fuel.

Dimensions:
Flue is centered on the stove and 5 5/8"
from the rear edge of the appliance.
(Use 6" Dia. Pipe)

Weight:
470 Pounds

29 1/4"15 3/4"4 3/4"

Rear edge ofsurround panel
Faceplate

Height*:21 3/4"

Measure all sideclearances fromhere.

43 3/4"*Older model panels may use the heightened yoke, adding 7/8" to the height. Furthermore,allow an additional height to align the pipe on positive and direct connect installations.

Emissions: 2.6 Grams Per Hour (EPA Phase II Approved) Ð Tests conducted by E.E.S.P.C. Lab.

INSERT INSTALLATIONPAGE 6

SAFETY NOTICE:
If this appliance is not properly installed, a house fire may result. For your safety,
follow the installation directions. Contact local building or fire officials about
restrictions and installation inspection requirements in your area.
¥

Check with local building officials for any permits required for installation of this stove andnotify your insurance company before proceeding with installation.

PLANNING THE INSTALLATIONHINT: We suggest that you have an authorized Travis Industries dealer install your insert. If
you install the insert yourself, your authorized dealer should review your plans for
installation.
This insert is approved for installation into an existing masonry fireplace. Depending upon yourinstallation concerns, several options are yours to provide the most desirable installation. The sections
that follow detail the requirements that must be met for a safe installation. To further help installation,
the most common types of installations are explained in the section "Insert Installation Considerations".
Prior to installing your insert make a detailed plan with dimensions to double-check them against all of
the requirements listed.

PREPARATION FOR INSTALLATION¥¥¥

Check for damage to the exterior of the insert (dents should be reported, scratches can be fixedby applying touch up paint).
Check the interior of the firebox (cracked firebrick should be replaced, displaced baffle
components should be replaced).
Remove the box that contains the blower. Place it aside and install it last (see "Blower
Installation" on page 8
HINT: The insert can be lightened by removing the firebricks and baffle. - see "Firebrick and
Baffle Inspection and Cleaning" on pages 22 - 24.

INSERT INSTALLATION CONSIDERATIONS
The table below details the most common types of installations and the considerations for each type of
insert installation. Alternative methods of installation are available if they comply with local building
codes.
Installation TypeConsiderations¥ Utilizes existing masonry fireplace
Insert with Positive Flue (Full Reline)¥ Provides best draft(Page 10)¥ Easiest to clean

Insert with Direct Connect Flue
(Page 10)

¥ Utilizes existing masonry fireplace¥ Provides good draft¥ Requires fireplace block-off plate - see page 9

Insert with Face Seal Connection(Page 11)

¥ Utilizes masonry fireplaces with a cross section of 28" to 144"
¥ Provides okay draft¥ Easiest to install¥ Requires insulation (see "Insulation Installation" on page 30

OPTIONAL EQUIPMENT REQUIREMENTS (See the back of this manual for installation instructions)¥Must be installed with the surround panels

INSERT INSTALLATION (CONT.)

PAGE 7INSERT PLACEMENT REQUIREMENTS (See the illustration below)
¥
¥
¥
¥
¥
¥
¥
¥

The insert must be placed so that no combustibles are within, or can swing within (e.g. drapes,
doors), 36" of the front of the insert
Insert and hearth must be installed on a level, secure floor
Sidewalls must maintain a minimum 15" to the insert
Non-combustible side facing must extend 13 1/2" from the insert
Non-combustible top facing must extend 30" above the insert (17" with mantle shield)
Mantle must be a minimum 32" above the insert (19" with mantle shield)
Hearth must extend 16" in front of the faceplate
Hearth must extend 8" from the sides of the insert
Combustible Mantle
Measure sideclearancesfrom here.

Non-Combustible
FacingD
C

SurroundPanelsSidewall

Minimum
Clearances

Masonry
Fireplace

A Sidewall to Insert
B Side Facing
C Top Facing
With mantle shield
D Mantle to Insert
With mantle shield
E Hearth (Front)*
F Hearth (Side)**15"
13 1/2"
30"
17"
32"
19"
16"
8"

A

B
E
F

* Measure from faceplate, does
not include the distance the insert
sticks out on the hearth (4 3/4").
**Total hearth width must be atleast 45 1/4"

HEARTH REQUIREMENTS (See the illustration above)¥ Must extend 16" in front of the insert and 8" on both sides (total of 20 3/4" deep by 45 1/4" wide)¥ Must be non-combustible and at least .018" thick (26 gage)
INSERT SIZE REQUIREMENTS

B
A
E
D
C
F

Minimum
Fireplace Size

Masonry
Fireplace

A Height* (front)
B Height* (rear)
C Width (front)
D Width (rear)
E DepthF Hearth**

21 3/4"
21 3/4"29 1/4"291/4"
15 3/4"4 3/4"* Older model panels may use theheightened yoke, adding 7/8" tothe height. Furthermore,
additional room is needed to alignthe pipe on positive and directconnect installations.
** Does not include the required
16" of floor protection in front.

INSERT INSTALLATION (CONT.)

PAGE 8MASONRY FIREPLACE REQUIREMENTS¥¥

Chimney must have a clay tile liner or a stainless steel liner (positive connection)
Entire fireplace, including chimney, must be clean and undamaged. Any damage must be
repaired prior to installation of the insert¥ Chimney height: 15' minimum; 33' maximum.
¥ Entire fireplace, including chimney, must meet local building requirements
Drafting
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.
LEVELING BOLT INSTALLATION
Inside the accessory pack are a pair of leveling bolts used to level the insert if the fireplace has a
stepped-up hearth. To install, raise the rear of the insert up and insert the leveling bolts into the holes in
the rear corners of the insert. Screw the bolts down until they extend the same height as the hearth steps
up. After the insert is installed, fine-tune the leveling bolts to level the insert (see the illustration below).

This distance is thehearth step-up.
The leveling bolts
should stick out
this far from thebase of the insert.
HearthFireplace
The leveling bolts
go into the holes in
the outer rear of theinsert baseplate.

BLOWER INSTALLATION
The included blower is fragile and should be installed last (see directions below).
1. Remove the two screws
here with a 3/8" nutdriver.
4.
2.

3.

Center the blower
underneath the ashlip. Liftup on the blower so it tucks
up underneath the ashlip.

Plug theblowerinto a110 volt
groundedoutlet.

Replace the two screws
and tighten.

Control Box

INSERT INSTALLATION (CONT.)

PAGE 9BLOCK-OFF PLATE INSTALLATION
Whenever this appliance is installed with a direct connection a block-off plate, or other non-combustible
seal-off device (e.g. damper adapter), will need to be installed. This device is used to seal the chimney,
insuring no smoke enters the home and providing the chimney system with a seal to provide greater
draft. The directions below detail the steps for construction and installation of a block-off plate.
1. Determine a location for the block-off plate at the top of the firebox below the damper area
(make it high enough to allow installation of the connection pipe). The location should be level
and in an area where it can be mounted easily. Measure the width at the rear ("A") and front("B") of the firebox at the height where the block-off plate will be installed (see the illustration
below). Then measure the depth of the location where the block-off plate will be installed ("C").
2. Make a cardboard template of the measurements, but add a 2" flange to each side. This flange
will be used to mount the block-off plate to the inside of the firebox. Bend the flanges
downwards on the template and place it inside the fireplace. If the template fits correctly in its
planned location, go to the next step. If it does not, make a new template with the appropriate
corrections until it fits correctly.
3. With the template in place, mark the location that is centered in the fireplace and 10 1/4" backfrom the fireplace opening. This location approximates the center of the flue when the insert isin place (a slight offset may occur based upon insert and block-off plate placement). Remove thetemplate and cut a 6 1/4" diameter hole centered on this mark.
4. Make the block-off plate of 24 gage or thicker steel to match the template. Drill two holes ineach flange for mounting the plate.
5. Mount the block-off plate using the appropriate screws. Masonry screws must be used for
mounting a block-off plate in a masonry fireplace.
6. Insulate the block-off plate using high-temperature fiberglass insulation (KaowoolÒ orequivalent) and furnace cement (allow the cement to dry for at least 24 hours before burning).
7. After placing the appliance and installing the pipe through the block-off plate, use hightemperature fiberglass insulation and furnace cement to seal any cracks between the pipe andblock-off plate.
Block-Off Plate Template

Damper2" Flanges(for attaching
the block-off
plate)

Measurement"A"

Measurement"C"
The center ofthe flue is 10
1/4" back fromthe fireplace
opening.

B

C

A

Measurement "B"

Firebox
The center of the flue is 10 1/4" back fromthe fireplace opening (6 1/4" in diameter).

PAGE 10INSERT INSTALLATION (CONT.)

INSERT WITH
POSITIVE
CONNECTIONNOTE:
Most factorybuilt chimney
manufacturers
make stainlesssteel chimney
liners, either
flexible orrigid. This
provides awide variety of
installation
options. Make
sure to follow
themanufacturer's
instructions for
installationand support.

INSERT WITH
DIRECT
CONNECTION(MASONRY
FIREPLACE)
NOTE:
Directconnections
requireinstallation ofan airtightblock-off plateor damper
adapter (seethe section"Block-off
Plate
Construction"
for details on
constructing
and installing a
block-offplate).

Install a non-combustible
cover plate to prevent waterfrom entering the chimney
NOTE: This installation may be
used with a masonry fireplace
only. The requirements in thesection "Masonry Fireplace
Requirements" must be fulfilled
prior to installation.

Combustible Mantle

Surround Panels

See the section "Insert
Placement Requirements" forminimum clearances andhearth required.

NOTE: This installation may be usedwith masonry fireplaces only. The
requirements in the section "Masonry
Fireplace Requirements must be
fulfilled prior to installation.

Cap (prevents waterfrom entering)

Flue Liner
The liner must be
stainless steel
connector or flexible
vent. Follow the liner
manufacturer's
insturctions for
installation andsupport.
Airtight Insulated
Clean-Out
Remove damper
or wire it open
Notch the firstconnector toaccommodate
the bypass rod.

Flue Liner
Stainless steel
chimney connector
must Extend 1' past
the block-off plateor to the flue liner

Combustible Mantle
Airtight
Insulated
Clean-Out

Surround Panels

See the section"Insert Placement
Requirements" forminimum clearancesand hearth required.

Remove damper
or wire it open
Block-off plate or
damper adapter
Notch the connector
to accommodate thebypass rod.

INSERT INSTALLATION (CONT.)
INSERT WITH
FACE SEALCONNECTION
NOTE:
Face sealconnections
requireinstallation of
the surround
panels andinsulation (seethe section"Surround
PanelsInstallation"
on page 29).

NOTE: This installation may be
used with a masonry fireplace
only. The requirements in thesection "Masonry Fireplace
Requirements" must be fulfilled
prior to installation.
Flue Liner

Combustible Mantle
Surround Panels withinsulation (see "Surround
Panels" installation
instructions in the back of
the manual)

NOTE: It is
recommended yourchimney have aminimum 28 and amaximum of 144
square inchcross-sectional area
to use a face sealconnection, otherwise
your chimney maynot
have sufficient draw
for the fireplace insert
to operate correctly.

Airtight Insulated
Clean-Out
See the section "Insert
Placement Requirements"
for minimum clearancesand hearth required.

PAGE 11

Remove damper
or wire it open

PAGE 12OPERATING YOUR APPLIANCE

SAFETY NOTICE:
If this appliance is improperly operated , a house fire may result. For your safety,
read the directions below and the Safety Precautions listed on pages 2 and 3 prior
to operating this appliance.
¥!
!
!

If you have any questions regarding the operation of this appliance, contact your dealer.
Building a fire in disregard of the information provided in this section can cause permanent damage
to your appliance and void your warranty.
Never use gasoline, lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start of"freshen up" a fire in this appliance. Keep these liquids well away from the appliance.
Keep furnishings and other combustible materials away from the appliance.

PAINT CURING
The paint on this stove cures under heat. Start a small fire and burn at a low rate for the first fire. You
will notice fumes and smoke from the paint curing and oil burning off the steel. This is normal. We
recommend you open windows to vent the room.

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

LOCATION OF CONTROLSDOOR HANDLE

Slide in to allow
more air into thefirebox, for afaster rate ofburn

To open, turn the handle
counter-clockwise andswing the door forward.

BYPASSCONTROL

Pull the bypass out for loading & starting.
Push the bypass in during burning.

Slide out to close
down the amountof air into thefirebox, for aslower rateof burn

2.
1.

AIR CONTROL¥¥¥Do not open the door when the air control is closed. This may result in a sudden flash of flames as
the fire ignites with oxygen. However, this appliance has been designed to reduce this possibility.
The controls become hot during operation Ð use a glove or other device if necessary.
Open the door for refueling only, do not operate with the door open or removed.

Approximate Air Control Settings:

Overnight Burn ..................... Fully out to 9/32" open
Medium Burn ........................ 9/32" open to 5/16" open
Medium High Burn ............... 5/16" open to 7/16" open
High Burn.............................. 7/16" open to pushed fully inOPERATING YOUR APPLIANCE (CONTINUED)

PAGE 13

Bypass Control
The bypass control is centered along the top of the appliance and is operated by pushing or pulling thecontrol in or out. When the control is completely pulled out, the bypass allows the smoke to go directly
up the flue, creating more draft for starting the appliance or reloading. When it is pushed in, the smokemust go around the baffle which utilizes secondary combustion and makes the appliance more efficient(see the illustration below).
Bypass Pushed InUsed for Normal Operation(Utilizes Secondary
Combustion)

Bypass Pulled OutUsed for Starting
and Re-Loading

LEARNING TO BURN YOUR APPLIANCE
Using a wood-burning appliance takes some getting used to. Once you become accustomed to operating
your appliance, you will be able to start a hot fire quickly, adjust the heat output precisely, and obtainovernight burns easier. Experienced wood burners may not need the information below, but may be able
to re-affirm their skills by reading the following. The better you understand your appliance, the more
rewarding you will find it.
How to Start a Hot Fire QuicklyYour wood-burning appliance acts much like an engine - before it will work at its best, it needs to reacha high temperature. The most common mistake in starting a fire is to use too little kindling, closing thebypass too soon, or turning the air control down too early. For good results, YOU MUST OBTAIN AN
INTENSE FIRE BEFORE CLOSING THE AIR CONTROL DOWN. The steps below detail one
method for starting a fire.
1. Pile several pieces of kindling on top of newspaper or a fire starter in the center of the firebox (itis better to have too much kindling than not enough). Place two medium sized pieces of wood oneither side of kindling laying front to back.
2. Make sure the air control is fully open (push all the way in) and the bypass opened (pull all theway out). Start the newspaper or fire starter. Note: you may want to crack the door during
starting to allow for more air.
3. Allow the kindling to start and burn. Then place another medium size piece of wood on top of
the burning kindling so that it straddles the two medium pieces and close the door. This
arrangement takes advantage of the air inlet located in the center under the door to feed the firewith adequate oxygen. You may notice the flames burning from the front to the back.
4. Let the fire burn at least 15 minutes before closing the bypass. Wait at least 30 minutes or until
the appliance is fully hot before closing the air control down.
1.

2.

3.

4.

PAGE 14

OPERATING YOUR APPLIANCE(CONTINUED)

How to Reload Your Appliance
When reloading your appliance, you can avoid smoke entering the room by following the steps below:
1. Push the air control all the way in so the fire starts to burn quickly, helping draft.
2. Pull the bypass out all the way and wait 30 seconds to establish a strong draft.
3. Open the door one inch and let air enter the appliance for a few seconds.
4. Carefully place the new wood on top of the existing fire. Close the door and shut the bypass bypushing it all the way in. Let the fire burn on high for at least 20 minutes before turning it downÐ this will reduce creosote build-up.
1.

2. BYPASSCONTROL

AIR CONTROLOpen the door 1"
and let air enter
the appliance fora few seconds
3.

4.

How to Adjust the Heat Output Precisely
One complaint from wood-burning appliance owners is controlling the heat output to obtain a consistentroom temperature. The reason for this is the inherent lag time between adjusting the air control and thechange in heat output. Simply put, if you turn a hot appliance down now, it will continue to put off highamounts of heat for an additional 15 minutes. To obtain consistent room temperature, think ahead.
When the room is starting to warm, and is almost up to the right temperature, turn the appliance down.
If you utilize an optional blower, turn it on and off to increase or decrease room temperature. If you findthe appliance must be turned down often, burn smaller, more intense fires instead. Although this means
more reloadings, it will reduce creosote build-up and give a more consistent heat output.

OPERATING YOUR APPLIANCE (CONTINUED)

PAGE 15

How to Obtain an Overnight Burn
An overnight burn of 10 hours may be obtained with a small amount of coals left over in the morning if
the right steps are taken.
1. Establish a hot fire.
2. Fill the appliance with large pieces of wood, preferably hardwoods like oak or maple.
3. Let the wood burn on high for 20 to 30 minutes to allow the new pieces of wood to catch fire andburn off any moisture.
4. Pull the air control out to a low setting. HINT: You want an air control position that is thefarthest in, yet still allows coals to be left in the morning. Experiment using air control positions
that are farther and farther in until a suitable position is found.
5. In the morning, break down the coals and lay kindling and small pieces of wood on top of thecoals to re-establish the fire. NOTE: Even the smallest amount of coals can start a new fireeasily because of all the heat energy stored in the firebrick. If there are no coals left, yet theappliance is hot, you will find starting a new fire will be much easier and the appliance will startgiving off heat much quicker than if started cold.
Let the appliance burn at least 20 minutes onhigh after loading. This allows the appliance toreach the most efficient operating temperature.

Even the smallest amount ofcoals can re-start the appliance.

Good Burning Habits
Increased efficiency, reduced emissions, and less creosote are the rewards of good burning habits.. The
items below list good habits to establish with your new appliance.
¥ Get the appliance hot before turning it down
¥ Use smaller pieces of wood during start-up and high burns to increase temperature¥ Use larger pieces of wood for overnight or sustained burns¥ Stack the wood tightly together to establish a longer burn¥ Leave a bed of ashes (1/2" deep) to allow for longer burns¥ Be considerate of neighbors & the environment: burn dry wood only
¥ Burn small, intense fires instead of large, slow burning fires when possible¥ Learn your appliance's operating characteristics to obtain optimum performance
NOTE: A stove thermometer gives you a good indication of how hot your appliance is burning whenplaced directly on top of the appliance. Low burn is approximately 300 degrees F., medium
burn 500 to 600 degrees F., and high burn 700 to 800 degrees F.

PAGE 16OPERATING YOUR APPLIANCE(CONTINUED)BLOWER OPERATIONThe blower assists the convection chamber in distributing heat to your home. The directions below
detail the options you have with the blower and the best method for operation.
What turns the blower on
The blower includes a heat-sensing device that does not allow the blower to turn on until the appliance is
up to temperature. Once up to temperature, the blower will operate at the speed determined by the
position of the blower knob (see the illustration below). The blower shuts off once the appliance cools.

BLOWER KNOBOFFTurn the knob all theway counter-clockwise
to turn off.

HIGH
Turn the knob
clockwise from the off
position until it clicks.

LOW
Turn the knob all
the way clockwise
to turn to low.

How to Use the Blower to Regulate Heat
Turn the blower to high if the room needs heat and the appliance is up to temperature. When the roomhas reached a high enough temperature, turn the blower off to stop the heat transfer. Used inconjunction with the air control, a steady temperature can be achieved.

OPERATING YOUR APPLIANCE (CONTINUED)

PAGE 17

A WORD ABOUT WOOD
This appliance is designed to burn natural cord wood with high efficiencies and low emissions. With
properly dried wood, you will fully realize the heating and clean-burning potential of our hightechnology appliance. With poor wood, this high-technology appliance will become much less efficientand produce more emissions. Read on to find out more about the type of fuel you should use.
The Drier the Better
The most common mistake made by
Dry Wood
Wet Wood
wood-burners is using wet, green, or
un-seasoned fuel. Ask any
experienced wood-burner, and he or
Leads
Leads
she will tell you the importance ofToTo
dry wood. The reason is this: wet,green, or un-seasoned wood still has
water in it. When the wood burns it
must use its heat energy to evaporate
More HeatLess Heat
the water. This robs your home ofheat (it also leads to greater smoke
and creosote due to lesser firebox
Leads
Leads
temperatures). Dry wood usually has
ToTo
cracks in the grain. It will also belighter and when two pieces areknocked together a crisp "knock" willMore Smoke
Less Smokebe heard, not a dull "thud". When
& Creosote& Creosoteburning green, wet, or unseasoned
wood you may notice difficulty inlighting, and water bubbling out of
the grain when it becomes hot.
How to Dry and Store Wood
Aging is the only economical method for drying wood. Follow the steps below to dry and store wood:
1. Make sure the wood is split into quarters and is no longer than 18" long (Hint: if you cut trees insummer, leave the leaves on for a week, this will draw moisture from the wood to dry it quicker).
2. Stack the wood in loose piles that are covered and off the ground (this is to allow air to pass overeach piece of wood Ð promoting faster drying) If no shelter is built, place clear polyethylene
plastic over the wood (at an angle to allow moisture to run off). Let dry for at least one year.
3. Store the wood in a dry location, preferably outside to prevent insects and dirt from entering thehome. When needed, move small loads inside where the added heat will promote further drying.

Cut the wood to 18"
or less lengths andchop into quarters
before stacking

Cover with 4 mil
Polyethylene

Air Flow

Prevailing
Winds

Stack thewood
loosely toallow forair flow
betweenthepiecesKeep thewood off
the groundto increase
air flow

Air Flow
Air FlowPAGE 18

OPERATING YOUR APPLIANCE(CONTINUED)

A WORD ABOUT WOOD (CONTINUED)

Sheet Metal Roofing

2x4 Purlins
2x6x12 RafterConstructing a Wood Shed

2x8x8' Girder

The drawing to the right details theconstruction of an inexpensive wood shedthat will promote drying, increasing theheat output from your wood.

4x4x2 Posts Spaced 8' Apart
Siding and Girts(Optional)

8' Width
3' Depth

What Type of Wood is Best
Choosing the kind of firewood to burn in your appliance depends on what is available to you.
Softwoods, such as pine or fir ignite and burn quicker, but require more frequent loadings and are lesssuited for overnight burns. For longer burns, with less frequent loadings, we recommend harder woods
such as oak or maple. The chart below details the BTU (heat) output of the various species. Note thehigher BTU output of the harder woods. The best arrangement is to have softwoods for starting and
immediate heating and hardwoods for overnight and sustained burns.
SPECIES(20% moisture)

LBS./CORD(Approximate)

BTU's/CORD(Approximate)

Hours per Cord at 40,000 BTU's per Hour
(Approximate)

ALDER
APPLE
ASH
BIRCH
CEDAR
COTTONWOOD
DOGWOOD
ELM
FIR, DOUGLASHEMLOCK
MAPLE
OAK, RED
OAK, WHITEPINE
REDWOODSPRUCE

2540
4400
3440
3040
2060
2160
4320
2260
2970
2700
3200
3680
4200
2250
2400
2240

19,050,000
33,000,000
25,800,000
22,800,000
15,450,000
16,200,000
31,725,000
16,950,000
22,275,000
20,250,000
24,000,000
27,600,000
31,500,000
16,875,000
18,000,000
16,800,000

476
825
645
705
386
405
793
423
556
506
600
690
787
421
450
420

How to Buy Wood
Wood is sold by the cord (4' wide by 4' high by 8' long). Buy wood in the spring and summer, when
prices are lower and it will have plenty of time to dry. If buying in winter, have the wood moisturetested (test several pieces). You will receive up to 25% more heat from a cord of dry wood than fromwet or green wood. Rotate your wood so as to allow for the maximum drying time for all pieces.
Don't Burn Wood Scraps, Garbage, Paper, Wax Logs, Coal, Etc.
Wood scraps from construction are typically chemically treated, making them difficult to burn anddangerous due to emitting chemicals. The same holds true for garbage, solvents, driftwood containing
salt, cardboard, and colored paper. Coal and wax impregnated logs burn especially hot, creating a
possible safety hazard. In addition, all the aforementioned items may create excessive creosote.

MAINTAINING YOUR APPLIANCE

PAGE 19

MAINTENANCE SCHEDULEYour appliance requires periodic maintenance to work correctly. The steps involved with maintenanceare usually quick and easy. Look through this maintenance schedule and plan accordingly.
WARNING: Failure to properly maintain and inspect your appliance may reduce theperformance and life of the appliance, void your warranty, and create a fire hazard.
PERIODIC MAINTENANCE (every week when appliance is in use):¥ Remove ash from the firebox (if necessary)¥ Clean the viewing glass (if necessary)¥ Clean the brass (if necessary)¥ Check for creosote buildup in the chimney and connector
BI-MONTHLY MAINTENANCE (every two months during the heating season):¥ Door and glass inspection¥ Lubricate the door hinge
YEARLY MAINTENANCE (before every heating season):¥ Touch-up paint¥ Blower cleaning¥ Firebrick and baffle inspection and cleaning
REMOVE ASH FROM THE FIREBOX (IF NECESSARY)At least once a week while the appliance is in use, check the level of ash on the floor of the firebox. If
1" or more of ash has accumulated, let the appliance cool and place the excess ash into an airtightcontainer away from any structure. After the ash is fully extinguished it may be disposed. A 1/2" to 1"
bed of ash is desirable, for it allows the appliance to burn at a slightly lower speed.
WARNING: Ashes removed from the appliance must be stored in an airtight container awayfrom any structure until fully extinguished before disposing.

CLEAN THE VIEWING GLASS (IF NECESSARY)This appliance has an airwash to keep the glass clean. However, burning un-seasoned wood or burning
on lower burn rates leads to dirtier glass (especially on the sides). Clean the glass by following thedirections below. For especially dirty glass, use fine steel wool to remove build-up.
Apply glasscleaner to theinside of theglass when it
is cool

Then take a piece of newspaperor paper towel, dip it in coolashes, and wipe the glass

CLEAN THE BRASS (IF NECESSARY)
If your insert has a brass door, it may be cleaned using a non-abrasive polish (such as FLITZÒ) when
the appliance is cool. The brass trim and ashlip is anodized, and should be cleaned with soap and water.
CHECK FOR CREOSOTE BUILDUP
Creosote buildup should be checked twice monthly during the heating season. Either look down thechimney from the top or remove a chimney connector section. Any more than 1/4" of buildup requires
chimney cleaning. Creosote develops quickest when burning at a low temperature or when burning unseasoned wood. When wood is burned slowly, it produces tar and other vapors which combine withmoisture to form creosote. Creosote vapors condense in the relatively cool chimney flue and creosote
residue accumulates on the flue lining. When ignited, this creosote makes an extremely hot fire.

PAGE 20MAINTAINING YOUR APPLIANCE (CONTINUED)

DOOR AND GLASS INSPECTION
The door must seal air-tight for the appliance to work correctly. Check the two items below and follow
the appropriate remedy to fix any problems.
¥ Check the door cam operation. When closed, the door cam should pull the door against the faceof the appliance, but not be so tight as to not allow the handle to point downwards. If theoperation is not correct, see the section "Adjusting the Door Cam" below.
¥ Remove the door by opening it and lifting it off the hinges. Place the door face down and checkthe door gasket (see the illustration below). If the door gasket requires replacement, see thesection "Replacing the Door Gasket" on the following page. Check the glass and glass gasket. If
the glass or gasket require replacement, see the section "Replacing the Glass or Glass Gasket" on
the following page.
The door gasket should
be unbroken, haveenough bulge to contact
the face of the unit, andbe firmly attached to thedoor frame.

Check theglass for any
cracking.

The glass gasket
should form an
airtight seal
between the glassand the door frame.

Door Cam

Adjusting the Door Cam
If the door cam does not pull the door against the face of the appliance, the door cam will need to betightened (see the illustration below for details). If the door handle does not turn down all the way, it is
too tight and will need to be loosened (see the illustration below for details). Before adjusting, remove
the door by opening the door and lifting it off the hinges.
Side View of Door Handle

Exploded View

Door Cam
Door
HandleWashers

Door Frame

Use a 9/16"
socket wrench to
remove this nut.

Door Cam
Adjustment:
To tighten, remove
a washer from theinside of the door
frame. To loosen,
place an additional
washers on theinside of the door
frame or loosen
the nut 1/2 turn.

MAINTAINING YOUR APPLIANCE (CONTINUED)

PAGE 21

Replacing the Door Gasket
Remove the door by opening it and lifting it off the hinges. Remove the old gasket by stripping it awaywith a screwdriver or other tool (see the illustration below). Apply a line of gasket cement (available
from your dealer) in the groove that follows the perimeter of the door. Insert the gasket into the groove.
Do not stretch the gasket as you place it into the groove. Cut off any excess gasket when done. Allow 2hours for the cement to dry. When re-installing the door, the gasket may need to be flattened byrepeatedly opening and closing the door.
Replacing the Glass or Glass Gasket
Remove the door by opening it and lifting it off the hinges. Remove the door handle from the door.
Then remove the glass retainer by unscrewing the ten screws that hold it in place with a 5/16" nutdriver(see the illustration below). Carefully remove the glass. Make sure the 3/4" black channel tape (new orold) runs around the perimeter of the glass. If using a new gasket, trim off any excess. Place the glass(new or old) in place so there is a small gap between the edge of the glass and the door frame. Make
sure the gasket is tucked underneath the glass so the glass does not touch the door frame. Place the glass
retainer in place and secure it with the screws removed earlier. Make sure the white gasket stays inplace and seals the window. Tighten the glass retainer until the gaskets start to flatten.

The glass is held in placewith the glass retainer
and ten screws

Cross Section
Door Frame
The door gasket is 7/8" white rope gasketingand is held in place with gasket cement.
Make surethere is asmall spacearound theedge of theglass.

Use a 5/16" nutdriver forthe glass retainer screws.

Glass Retainer
Glass

3/4" Black Channel Tape

LUBRICATE THE DOOR HINGE
Periodically lubricate the door hinges with a high temperature lubricant (such as Permatex Industrial Ò
Anti-Seize). Lubricating the door involves removing the door by opening it and lifting it off the hinges,
and placing lubricant on the hinge pins.

PAGE 22

MAINTAINING YOUR APPLIANCE (CONTINUED)TOUCH-UP PAINT
Included with the owner's pack of this appliance is a can ofStove-BriteÒ paint. To touch up nicks or dulled paint, apply
the paint while the appliance is cool. Use 120 grit sandpaper(clean with water and dry with a piece of cloth) if the surface
requires smoothing. Wait at least one hour before starting theappliance. The touched up area will appear darker than thesurrounding paint until it cures from heat. Curing will give offsome fumes while curing Ð open windows to ventilate thefumes.

Touch-Up
Paint

BLOWER CLEANINGThe blower for this appliance will gather dust as it circulates air. Before cleaning, remove the blower
from the appliance (see "Blower Installation" on page 8). Remove all dust and debris from the blower
grill and around the interior of the blower.

FIREBRICK AND BAFFLE INSPECTION AND CLEANING
With the appliance cool, remove all ash from the firebox and scrape away any scale that may have built
up on the surface of the firebrick with a wire brush or scraper. Any of the firebrick on the floor or wallsof the firebrick that is cracked must be replaced (see the section "Firebrick Removal and Replacement
Instructions"). Next, inspect the baffle components. The illustration below details the areas that must be
inspected. If any of the components need to be replaced, see the section "Baffle Removal andReplacement Instructions".
BYPASS ASSEMBLY
Entire assembly must be
properly aligned and correctly
oriented.
BAFFLE FIREBRICKS
Must not be cracked or havegaps between them. Cracked
bricks must be replaced. Gaps
are eliminated by pushing thebricks closer together.
SECONDARY AIR TUBES
Must be intact without any
cracks. Scaling and a slightamount of bending is normal
for this component.
BAFFLE SUPPORTS
Must be snug against the baffle
firebricks and resting on thesecondary air collars.
SECONDARY AIR TUBE COLLARS
Must have the two push pins inserted into them.
This keeps the secondary air tubes aligned.

FLOOR & WALL FIREBRICKS
Must not be cracked or severely
chipped (damaged bricks must be
replaced). Remove any scaling orbuildup with a scraper or wire brush.

MAINTAINING YOUR APPLIANCE (CONTINUED)

PAGE 23

Firebrick Removal and Replacement Instructions
With the appliance cool, remove all ash from the firebox. Only the firebrick that is damaged must be
replaced. If the damaged firebrick is on the floor, it can be replaced by simply removing the firebrick infront of it. NOTE: Do not pry firebrick to remove, this will chip or crack the firebrick. If a
firebrick on the wall of the firebox needs replacement, the floor firebrick near it will need to be removed
first. The wall firebrick is held upright by a clip on the walls of the firebox. To remove, pivot it out
from the bottom. See the illustration below.
WALL FIREBRICKSFirst remove the firebricks
on the floor in front of thefirebrick needing
replacement. Then pivot it
out from the bottom to clear
the clip that holds it in place.

CLIPS Hold the wall firebrick in place.

FLOOR FIREBRICKS
Remove the firebricks infront of the firebrickneeding replacement.

FIREBRICK SIZES All firebrick is 1 1/4" x 4 1/2"
x 9" except those labeled.

B
A
A

Firebrick labeled A are
1 1/4" x 4 1/2" x 6 3/8".
Firebrick labeled B are
1 1/4" x 4 1/2" x 8 1/4".

Baffle Removal and Replacement Instructions
The view below details the baffle components. Instructions for removal are on the following page.
Bypass Rod - threaded in two locations for easy removal
Bypass Handle
BypassDamperBaffleFirebrickCenterBaffleSupportForwardBaffleSupportBypass Support - note
its orientation and how
it rests on the rear
baffle firebrick
Baffle supports rest on these tabs

PAGE 24

MAINTAINING YOUR APPLIANCE (CONTINUED)

Baffle Removal and Replacement Instructions (continued)
All of the baffle components are removable to facilitate easy cleaning and repairs. Make sure theappliance is cool before removing any of the components. See the instructions on the following page forremoving the secondary air tubes.
REMOVING BAFFLE COMPONENTS
1. Lift up on thefront portion of
the front threefirebricks.
2. Lift the front
baffle supportand rotate it
forward until it
can be removed.

SIDE VIEW
Front
Firebrick

2.
1.

Front
BaffleSupportTab
Welded toFirebox3. Slide the center front firebrickforward and out the door opening. Thenslide the side front firebricks towards
the middle then out in the same manner.

3.

4. Slide the center baffle support
forward and out of the firebox.

4.

5. Slide the rear firebrick forward andout of the firebox. NOTE: When thecenter rear firebrick are slid forward thebaffle support will come to rest on therear secondary air tube and rear air
channel.

6.

6. Slide the bypass all the way forward.
5.

7. Reach into the firebox and push up
on the bypass rod until the bypass
damper seperates from the bypass rod.
Remove both the bypass damper andbypass assembly by sliding thembetween the front two secondary air
tubes.

5.

7.

7.

7.

REPLACEMENT INSTRUCTIONS:
A. Place the bypass support above the secondary air tubes in the rear center of the firebox.
B. Position the bypass damper so the bypass rod inserts into the two tubes on the bypass damper (make sure to havecorrect orientation). Then slide the bypass damper over the bypass support until both are centerd in the firebox.
C. Follow the instructions above in reverse order, starting with step number 5.

MAINTAINING YOUR APPLIANCE (CONTINUED)

PAGE 25

Secondary Air Tube Replacement Instructions
REMOVING THE
SECONDARY AIR TUBES
Follow the directions to the rightto remove any of the threeseconary air tubes.

Secondary Air
Tube Sleeve

Pry out both pins on the secondary
air tube sleeve (use a screwdriver).

1.
Pin

Slide the secondary air
tube sleeve to the left.

NOTE: When replacing, make sure thetwo holes on the secondary air tube
sleeve line up with the hole on thesecondary air tube and the hole on the
air tube stub welded to the side air
channel.

2.

Side Air Channel(Welded to side of Firebox)
Air Tube Stub(welded to theside air channel)

Slide the secondary air tube to the right
until it disengages from the left side.
3.

4.

REPLACEMENT PARTS LIST
PART

PART DESCRIPTION

Door Gasket
Glass Gasket
Door Glass
Retainer for Door Glass
Handle for Door
Door Handle
Door Cam
Air Control Handle
FirebrickSecondary Air Tube
Front Baffle Support
Center Baffle Support
Bypass Support
Bypass Damper
Bypass Yoke and Bypass Extender
Bypass Handle
Owner's Manual
Air Control Slider
Air Control Floating Plate with Springs
Bypass Pull Tool

Black 7/8" dia. Fiberglass rope 64" longBlack 3/4" x 1/8" fiberglass channel tape 60" long
5 mm neoceram, 11 7/8" tall @ center, 19 1/4" wide
Cast steel retainer attaches to door with ten screws (included)
Brass spring (1/2")
Steel shaft with threaded end (includes spring handle)
Cast brass
Brass spring (3/8")
1 1/4" x 4 1/2" x 9" silicon based refractory - some firebrick will require cutting
22 7/8" long with 3/16" holes every 3/4", includes two pins
23 5/8" long, 1 1/2" angle iron welded to 21 1/8" long 1" deflector at 45° angle
23 5/8" long, 1 1/2" angle iron welded to 23 5/8" long 1" strip to form a "t"
9" by 9" square 5/16" thick with two 7 1/4" x 1" guides top & bottom, stop
6 11/16" dia. Circle of 5/16" thick steel, two 1" tubes welded to top for yoke
All 3/8" dia. Rod, 6" (before bending) yoke welded to 7" rod, + 7" extenderCast iron eye bolt
This document
Steel plate with air control rod
8 springs and the floating plate used to guide air control slider
Tool used to adjust bypass

PAGE 26

TROUBLESHOOTING
Problem:

Smoke Spills From
Door When
Loading

Kindling Does Not
Start

Possible Cause:¥¥

Door was opened before the aircontrol was pushed in
Door was opened before thebypass was pulled out
Door was opened too quick¥

Draft is not adequate¥

Cold air block in chimney¥

Kindling is wet or too large tolight
Bypass was closed¥¥
Appliance Does Not ¥Put Off Much
Heat¥¥
Appliance Does Not ¥Burn Overnight

Smoke Is Dirty
From Chimney

Bypass was open
Wood is fast burning¥

Wood is in small pieces¥

Check for coals - there may besome there
Draft is low

Appliance Does Not ¥Burn Fast On
High

Blower Does Not
Turn On

Wood is wet, unseasoned, orgreen
Appliance requires time towarm up¥

Wood is wet¥

Appliance is cool¥

Appliance is not hot enough yet¥

Blower is not plugged in or
circuit is off
When reloading or starting,smoke is higher than normal
Wood is wet¥¥

Remedy:Pull the air control all the way out a few seconds before
opening the door.
Pull the bypass all the way out before opening the door
(see "Bypass Control" on page 13)
Door should be opened a crack to allow air to enter
before opening all the way (see "How to Reload your
Appliance" on page 14).
Your installer or dealer can give you more information
on draft. The most common causes of low draft are a
short, offset, or small chimney, an external down draft
due to wind, an extremely air-tight home with exhaust
fans, or a thermal down draft due to appliance placement.
A cold air block keeps the appliance from establishing a
draft. First ignite a piece of newspaper in the appliance
before starting the kindling.
Kindling must ignite quickly to be effective. Wet or
large kindling will make starting very difficult.
Pull the bypass all the way out before starting theappliance (see "Bypass Control" on page 13).
Wet wood will give off much less heat than dry, seasoned
wood (see "A Word about Wood" on page 17).
The appliance will not give off heat until it has beenburning on high for at least one half hour (see "Learning
to Burn your Appliance" on page 13).
The bypass should be closed once the fire is establishedto increase the appliance's efficiency (see "Bypass
Control" on page 13).
Lighter, faster burning woods (e.g. alder, pine) are lesssuited for overnight burns (see "A Word about Wood" onpage 17)
Wood should be large to facilitate a slower burn (see"How to Achieve an Overnight Burn" on page 15).
Even a small amount of coals are enough to start a newfire if kindling is placed on top.
Your installer or dealer can give you more information
on draft. The most common causes of low draft are a
short, offset, or small chimney, an external down draft
due to wind, an extremely air-tight home with exhaust
fans, or a thermal down draft due to appliance placement.
Wet wood will give off much less heat than dry, seasoned
wood (see "A Word about Wood" on page 17).
New high-tech. appliances have a lag time between
adjusting the air control and the fire speeding up.
Appliance must be up to temperature for the blower toturn on if it is turned to "AUTO" (see "Blower
Operation" on page 16).
Check the outlet that the blower is plugged into with alamp to see if it has power.
The fire is evaporating the water from the wood, giving
off more visible smoke.
Wet wood will give off much more smoke than dry,seasoned wood (see "A Word about Wood" on page 17).

WARRANTY

PAGE 27

To register your TRAVIS INDUSTRIES, INC. 7 Year Warranty, complete the enclosed warranty card and mail it within ten (10) days of the appliance purchase date
to: TRAVIS INDUSTRIES, INC., 10850 117th Place N.E., Kirkland, Washington 98033. TRAVIS INDUSTRIES, INC. warrants this appliance (appliance is definedas the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows:

Years 1 & 2 - COVERAGE: PARTS & LABOR
Firebox Assembly:

Ceramic Glass

Firebox, Baffle Supports, Air Tubes, Air Channels, Convection
ChamberGlass (breakage from thermal shock)

Door Assembly:

Breakage from thermal shock

Solid Brass or Cast Door, Latch Assembly, Glass Retainers

Air Control AssemblyFirebrickAccessories
Legs, Pedestal, Panels, Blower

Slider Plate, Pressure Plate

Exclusions:

RE-INSTALLATION ALLOWANCE
In cases where heater must be removed fromhome for repairs, a partial cost of re-installation iscovered (pre-authorization required)
ONE-WAY FREIGHT ALLOWANCE
One-Way Freight Allowance On Pre-Authorized
Repair Done At Factory Is Covered.

Paint, Gasketing

Years 3 Through 5 - COVERAGE: PARTS & LABOR
Firebox Assembly:

Door Assembly:

ONE-WAY FREIGHT ALLOWANCE

Firebox, Baffle Supports, Air Tubes, Air Channels, Convection Chamber

Solid Brass or Cast Door, Latch
Assembly, Glass Retainers

ONE-Way Freight Allowance On Pre-Authorized
Repair Done At Factory Is Covered.

Air Control Assembly
Slider Plate, Pressure Plate

Exclusions:

Paint, Gasketing, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance

Years 6 & 7 - COVERAGE: PARTS ONLY
Firebox Assembly:

Door Assembly:

Air Control AssemblyFirebox, Baffle Supports, Air Tubes, Air Channels,
Convection Chamber

Solid Brass or Cast Door, Latch Assembly, Glass Retainers

Slider Plate, Pressure Plate

Exclusions:

Paint, Gasketing, Accessories (Legs, Pedestal, Panels, Blower), Glass, Firebrick, Re-Installation Allowance, One-Way Freight Allowance, Labor

CONDITIONS & EXCLUSIONS
1.
2.
3.
4.
5.
6.

7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

This new appliance must be installed by a qualified installer. It must be installed, operated, and maintained at all times in accordance with the instructions in the OwnerÕs Manual.
Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty.
This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized Travis dealer.
Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty. Overfiring (operation where the steel may glow red) of this appliance can cause serious damage and will nullify this warranty.
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.
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.
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, improperchimney/venting installation.
Exclusions to this 7 Year Warranty include: injury, loss of use, damage, failure to function due to accident, negligence, misuse, improper installation, alteration or adjustment of the
manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God.
This 7 Year warranty excludes damage caused by normal wear and tear, such as paint discoloration or chipping, worn or torn gasketing, chipped or cracked firebrick, etc. Also
excluded is damage to the unit caused by abuse, improper installation, modification of the unit, or the use of fuel other than that for which the unit is configured (use cord wood only).
Damage to brass surfaces caused by fingerprints, scratches, melted items, or other external sources left on the brass surfaces from the use of abrasive cleaners is not covered in thiswarranty.
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.
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.
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.
This warranty is automatically voided if the applianceÕs serial number has been removed or altered in any way. If the appliance is used for commercial purposes, it is excluded fromthis warranty.
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.
Travis Industries will not cover the cost of the removal or re-installation of hearths, facing, mantels, venting or other components.
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.
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 purchaserÕs recourse is expressly limited to the warranties set forth herein.

IF WARRANTY SERVICE IS NEEDED:
1.
2.
3.

4.

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 purchasedate, and the model name and serial number.
Travis Industries has the option of either repairing or replacing the defective component.
If your dealer is unable to repair your applianceÕs defect, he may process a warranty claim through TRAVIS INDUSTRIES, INC., including the name of the dealership where youpurchased the appliance, a copy of your receipt showing the date of the applianceÕs purchase, and the serial number on your appliance. At that time, you may be asked to ship yourappliance, 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 to5) prepaid by TRAVIS INDUSTRIES, INC., to your regional distributor, or dealership.
Check with your dealer in advance for any costs to you when arranging a warranty call. Dealers may require you to pay a service or trip charges for any warranty work. This charge
can vary from store to store.

PAGE 28

PRODUCT LISTING INFORMATION

The data on the label below matches the data on the label attached to the side of your insert.

OPTIONAL EQUIPMENT

PAGE 29

SURROUND PANEL INSTALLATION (SEE TABLE BELOW FOR PART NUMBER)
Surround panel size is determined by the type of installation and the size of the fireplace opening.
Direct and positive connections do not require insulation or panels that overlap the fireplace opening(panels that overlap the fireplace opening are usually more attractive). Face seal connections requiresurround panels that overlap the fireplace opening on the top and sides at least 2" (2 1/2" for roughsurfaces). This overlap is needed for the insulation that forms the airtight seal between the surround
panels and the fireplace. Any questions on selection of the surround panels should be directed towards
your dealer. The table below details the size of the surround panels when installed.
SURROUND PANEL SIZE
8"
10"
12"

SIZE ON APPLIANCE (Including Trim)
45 3/8" width by 29 1/2" height
49 3/8" width by 31 1/2" height53 3/8" width by 33 1/2" height

PART #
99300104
99300105
99300111

The surround panels should be installed prior to installing the insert. Place the insert 12" from thefireplace opening before installing the surround panels.
1. Follow the directions in the illustration below to install the side panels.
1. Place two clips(included in theowner's pack) over
one of the surround
panels (flat side in).

Cook TopTop of Insert

Side
Convection
JacketBackofInsert2.

Rotate the panel
back and place it so
the inside flange fits
inside the side
convection jacket.
Note how the cook
top fits into thenotch.

InsideFlange3. Insert the two screws(included with the panels)
through the convection
jacket and into the twoclips installed in step one.
Turn a couple of times but
do not tighten.
4. Repeat for the opposite side.

PAGE 30OPTIONAL EQUIPMENT (CONTINUED)SURROUND PANEL INSTALLATION (CONTINUED)
3. Install the top panel (see the illustration below). Adjust the top panel so its edges are flush withthe side edges of the side panels.
Top Panel
The joggle clips on the
top panel slide over theoffset portion on top of
the side panels and overthe mounting flange.

Mounting Flange

4. Adjust the position of the side panels so they are: 1) flush with the bottom of the insert; 2) boththe same distance back from the front of the insert; 3) perpendicular to the floor. Tighten thenuts that hold the side panels in place.
Insulation Installation
The installation of the insulation is required only for face seal connections. Direct and positive
connections do not require the insulation to be installed.
1. With the insert drawn 12" away from the fireplace, glue the insulation strip included with thesurround 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 thepanels and the fireplace face. Let the silicon or cement dry.
2. Push the insert into the fireplace, insuring a seal is made with the insulation between the panels
and the fireplace face. Use a screwdriver to tuck any exposed insulation behind the panels.
Brass Trim Installation (Optional)
The optional surround panel brass trim greatly enhances the appearance of your insert and is easy toinstall. Follow the directions below to install.
1. Lay the three pieces of brass trim on the floor in front of the insert. Arrange the brass trim sothat it resembles the illustration below. The rounded edge of the trim that will be facing
outwards when installed should be facing down.
2. Insert each "L" bracket leg into the groove in the 45° cut end of each side piece. Slide the otherleg of each "L" bracket into the groove in each end of the top piece. Tighten the four set screws
with a screwdriver into the "L" brackets, insuring that the 45° cuts are butted together to form aneat joint. Pick up the brass trim and slide it over the top panel until the trim is flush with thebottom edge of the top panel.
CROSS SECTION OF BRASS TRIM

InsertLay the trim on thefloor in front of theinsert with the rounded
portion facing down.

Set screw that holds the"L" bracket in place
Groove where the "L"bracket fits into
Left Trim
Groove Where Top
Panel Fits IntoRight Trim
"L" Brackets

Front SideTop Trim

OPTIONAL EQUIPMENT (CONTINUED)

PAGE 31

SURROUND PANEL INSTALLATION (CONTINUED)
3. Some kits include double-back tape. For those kits, follow the instructions below.
Attach a square of double-back tape to each of the bottom corners of the surround
panels before installing the trim. This will keep the panels from flaring at the bottom.

SurroundPanel

Surround Panel
Brass Trim

FLUE ADAPTER INSTALLATION (PART NUMBER 98900120)
The flue adapter has a built in flue collar with pre-drilled holes designed to make flue attachment easier.
It may also be used to adjust the position of the flue exit, up to 2 1/2" forward or 1 5/8" back.
1. Determine the position of the flue adapter that best suits the installation. Mark the location of thefour mounting holes on the top of the insert (NOTE: the position is variable Ð see the illustration
below for details). Remove the flue adapter and drill four 5/32" holes into the top.
2. Adhere the self-adhesive gasket included with the flue adapter along the bottom perimeter of theadapter. Cut off any excess gasket.
3. Place the flue adapter in place. Use a 5/16" nutdriver to attach the four screws that secure it to
the insert.
Attach the adapter to the insert
with the four screws included withthe kit (use a 5/16" nutdriver).

Flue
Adapter
Place theself-adhesive
gasket along
the bottom
perimeter of
the adapter.

Make sure the cover plate is inplace. If it is not, place somethingover this hole (Kaowool or otherhigh-termperature insulation willwork).

Drill 5/32"
diameterholes forthe screws.
Flue Exit

The flue adapter may offset
the flue location up to 1 5/8"
back. On models withsurround panels, the adapter
may offset the flue location up
to 2 1/2" forward.

Centerof Flue
Exit

Place the adapter like thisto offset the flue backward.

Centerof Flue
Exit

Place the adapter like thisto offset the flue forward.

PAGE 32

INDEX

Adjusting the Heat Output ............................................ 14

Heating Capacity.......................................................... 5

Air Control Settings ...................................................... 12

Insert Placement Requirements ................................... 7

Ash Removal................................................................ 19

Insert Size Requirements ............................................. 7

Baffle (removal and replacement) ................................ 23

Insulation Installation (for panels) ................................ 30

Block-Off Plate Installation ........................................... 9Leveling Bolt Installation .............................................. 8

Blower (cleaning) ......................................................... 22

Listing Information........................................................ 28

Blower (installation)...................................................... 8

Location of Controls ..................................................... 12

Blower (operation)........................................................ 16

Log Length (Up to 24") ................................................. 5

Brass Cleaning ............................................................. 19

Maintenance Schedule................................................. 19

Brass Trim Installation (for panels)............................... 30

Masonry Fireplace Requirements ................................ 8

BTU Output .................................................................. 5

Offset (Flue Adapter) ................................................... 31

Bypass Control ............................................................. 13

Optional Equipment Requirements .............................. 6

Chimney Inspection (Creosote Inspection) .................. 19

Overnight Burn ............................................................. 15

Chimney Requirements (Masonry Fireplace Req.) ...... 8

Paint (touch-up) ........................................................... 22

Clearances ................................................................... 7

Paint Curing ................................................................. 12

Creosote Inspection ..................................................... 19

Panels .......................................................................... 29

Dimensions................................................................... 5

Parts List ...................................................................... 25

Direct Connection......................................................... 10

Positive Connection ..................................................... 10

Door (Inspection) ......................................................... 20

Reloading Your Appliance ........................................... 14

Door Cam ..................................................................... 20

Replacement Parts List ................................................ 25

Door Gasket ................................................................. 21

Safety Label ................................................................. 28

Door Hinge (lubricating) ............................................... 21

Safety Precautions ....................................................... 2

Efficiency...................................................................... 5

Secondary Air Tube (replacement) .............................. 25

Emissions ..................................................................... 5

Secondary Air Tube (warranty - 5 yrs) ......................... 27

EPA Emission .............................................................. 5

Specifications ............................................................... 5

Face Seal Connection.................................................. 11

Starting the Fire ........................................................... 13

Fan Cleaning (Blower) ................................................. 22

Surround Panel Installation .......................................... 29

Fan Installation (Blower) .............................................. 8

Table of Contents ......................................................... 4

Fan Operation (Blower)................................................ 16

Troubleshooting Table ................................................. 26

Firebox Size ................................................................. 5

Warranty....................................................................... 27

Firebrick (inspection and cleaning) ............................. 22

Weight (Dimensions).................................................... 5

Firebrick (removal and replacement) ........................... 23

Wood Types ................................................................. 17

Fireplace Requirements ............................................... 8
Fireplace Sizing ........................................................... 7
Floor Protection (see Hearth Requirements) ............... 7
Flue Adapter Installation .............................................. 31
Flue Size (6") ............................................................... 5
Fuel to Use (cord wood only) ....................................... 17
Glass (Inspection) ........................................................ 20
Glass Cleaning ............................................................. 19
Glass or Glass Gasket ................................................. 21
Hearth Requirements ................................................... 7