Travis Industries Flex-95 Owner'S Manual Download Page 1

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OWNER'S MANUAL

PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE

KEEP THIS MANUAL

November, 1992

¥ Residential Freestanding Stove

¥ Masonry Fireplace Insert

Model Flex-95

(E.P.A. Phase II Approved)

Tested to U.L. 127, U.L. 1482, U.L. 907 Standards by:

Warnock Hersey Professional Services, LTD

Manufactured by:

10850 117th Place N.E. Kirkland, WA 98033

Summary of Contents for Flex-95

Page 1: ...EEP THIS MANUAL November 1992 Residential Freestanding Stove Masonry Fireplace Insert Model Flex 95 E P A Phase II Approved Tested to U L 127 U L 1482 U L 907 Standards by Warnock Hersey Professional Services LTD Manufactured by 10850 117th Place N E Kirkland WA 98033 ...

Page 2: ...N THE VICINITY OF THIS APPLIANCE THIS APPLIANCE MUST BE CONNECTED TO A LISTED HIGH TEMPERATURE RESIDENTIAL TYPE CHIMNEY OR AN APPROVED MASONRY CHIMNEY WITH A STANDARD CLAY TILE OR STAINLESS STEEL LINER NEVER BLOCK FREE AIRFLOW THROUGH OPEN VENTS ASHES MUST BE DISPOSED OF IN A METAL CONTAINER WITH A TIGHT FITTING LID AND PLACED ON A NON COMBUSTIBLE SURFACE BEFORE FINAL DISPOSAL NEVER TRY TO REPAIR ...

Page 3: ...stallation Using a Horizontal Connection 22 INSERT INSTALLATION INSERT OPTIONAL EQUIPMENT 24 PREPARATION FOR INSTALLATION 31 FIREPLACE INSERT SPECIFICATIONS 32 MASONRY FIREPLACE INSERT INSTALLATION 34 Installation Using a Direct Connection 34 Installation Using a Positive Connection 36 Installation Using a Face Seal Connection 38 INSTALLATION OF A FIREPLACE BLOCK OFF PLATE 39 OPERATING YOUR APPLIA...

Page 4: ... B T U s hr 74 000 Cord Wood Overall Efficiency 78 1 Oregon Method Emissions grams hr 4 1 EPA Method Maximum Burning Time Hours 12 Flue Opening Diameter 8 in Height from floor to top of stove on Steel Legs 29 3 4 in Brass Legs 31 1 4 in Cast Legs 31 1 4 in Pedestal 35 in Overall Width 29 7 8 in Overall Depth 23 3 4 in Not Including Ashlip Weight 516 lbs On Pedestal Fuel Solid Wood Only Emissions E...

Page 5: ...feet higher than the highest part of the roof opening through which it passes 2 And at least 2 feet higher than any part of the roof within 10 feet measured horizontally A chimney must meet requirement 1 and requirement 2 This rule required by all building codes applies to both factory built and masonry chimneys Minimum Chimney Height on a Sloped Roof 2 Minimum 10 3 Minimum Ridge Minimum Chimney H...

Page 6: ...igned to catch sparks and burning particles emitted with the smoke may be included with factory built chimney caps These spark arresters may become encrusted with creosote blocking the proper flow of flue gases out of the chimney When burning wood it is recommended that the spark arrester be cleaned regularly or removed entirely unless individual conditions or local codes require their use Determi...

Page 7: ...mum clearances other than 2 inches are sometimes required by the manufacturer Maintain a minimum clearance of 2 or what the manufacturer requires whichever is greater Masonry Chimneys If you are going to use an existing masonry chimney for your wood heating appliance make sure the chimney is inspected and found in good and safe condition If the existing chimney is not in good condition repairs sho...

Page 8: ...extender over the flue so it is centered over the opening and the hole for the bypass damper rod is facing forwards The flue extender is held in place with three bolts and tabs that attach to a threaded shaft on the inside the flue extender With the flue extender centered over the flue place a bolt with a tab inserted over it into the threaded shaft from below so the tab extends outwards from the ...

Page 9: ...asten the leg to the stove with the supplied attachment bolts and washers making sure the legs are flush with the corners of the stove Attach Bolt with washer to Stove From Below To level the stove first make sure the leveling bolts with the rubber ends some models come with steel bolts the same directions apply are screwed into position and backed off just enough to penetrate below the steel port...

Page 10: ...rews in each hole Pull the blower assembly up as far as it will go to eliminate any space between the blower and ashlip 4 Tighten both screws securely Insert the plug into a grounded outlet FRONT BLOWER OPERATION The blower controls are located on the switch box that is connected by a cord to the blower There are two rocker switches that determine the speed and mode automatic or manual of the blow...

Page 11: ...es the stove line up with the flue in the right location avoiding structural members of the roof 2 Does the hole that is cut in the floor and hearth for the outside air avoid all structural members of the floor These two questions must be considered in determining the final location for the stove To determine the size shape and location of the hole in the hearth and floor refer to the directions i...

Page 12: ... L of non combustible material with a minimum thickness of 26 gauge floor protection must extend under the appliance Front 16 Sides 6 Back 6 CHIMNEY LENGTHS Maximum Minimum Vertical 33 Feet 15 Feet FACTORY BUILT CHIMNEYS CONNECTORS If you are going to use a factory built chimney it should be 8 in diameter and a type suitable for use with solid fuels Follow the manufacturer s installation instructi...

Page 13: ...all to unit B Backwall to unit C Cornerwall to unit D Connector to sidewall E Connector to backwall F Connector to cornerwall Components required for alcove mobile home and reduced clearance installations are one of the following listed double wall connectors and chimney systems DURAVENT model DVL with DURA PLUS chimney AMERI TEC model DCC with model HS chimney SECURITY model DP with SECURITY mode...

Page 14: ...ANDING INSTALLATION SPECIFICATIONS Cont TOP VIEW Edge of Faceplate 29 7 8 6 3 4 23 3 4 4 3 4 14 15 16 26 SIDE VIEW See Chart Below Overall Height With Steel Legs 29 3 4 Brass Legs 31 1 4 Cast Legs 31 1 4 Pedestal 35 ...

Page 15: ...nto consideration the necessary clearances to combustibles and the placement of the chimney NOTE When the chimney connector extends to a standard ceiling as shown to the right a support package and sometimes a chimney connector adapter are installed at the ceiling Working from the attic or roof sufficient sections of factory built chimney available in different lengths are installed to go through ...

Page 16: ... sure to take into consideration the necessary clearances to combustibles and the placement of the chimney NOTE In rooms with cathedral ceilings the roof and ceiling are combined For this type of installation manufacturers of factory built chimneys provide a special cathedral ceiling roof support kit with instructions that should be followed Chimney Connector Minimum Air Space in Accordance with C...

Page 17: ...e make sure to take into consideration the necessary clearances to combustibles and the placement of the chimney NOTE An exterior chimney is subject to cold outdoor temperatures leading to greater heat loss creosote accumulation and moisture condensation in the chimney To reduce this possibility the chimney may be enclosed in a chase Specified minimum clearances from combustibles must be maintaine...

Page 18: ...IONS 2 If a block off plate is desired optional follow the directions for making a block off plate in the section titled INSTALLATION OF A FIREPLACE BLOCK OFF PLATE 3 Follow all of the clearance regulations for placement of your stove specified in the sections titled FREESTANDING INSTALLATION SPECIFICATIONS and PREPARATION FOR INSTALLATION FREESTANDING 4 If you are using a block off plate slide th...

Page 19: ...e or Damper Adapter Optional Remove Damper or Wire it Open Airtight Insulated Clean Out Stainless Steel Chimney Liner System Follow Liner Manufacturer s Instructions on Installation and Support Min 16 Floor Protection 18 Min Combustible Mantle Follow the directions on the previous page for installation ...

Page 20: ...all of the clearance regulations for placement of your stove specified in the sections titled FREESTANDING INSTALLATION SPECIFICATIONS and PREPARATION FOR INSTALLATION FREESTANDING 4 Once the plate is in position slide the pipe into the plate up through the damper It must extend up to the flue liner or at least one foot past the block off plate 5 You may now position the hearth stove and connector...

Page 21: ... off Plate or Damper Adapter Remove Damper or Wire it Open Airtight Insulated Clean Out Floor Protection Stainless Steel Chimney Connector Must Extend 1 past the Block off Plate or to the Flue Liner Min 18 Min 16 Combustible Mantle Follow the directions on the previous page for installation ...

Page 22: ...o all of the rules outlined in the section titled CHIMNEY INFORMATION REGULATIONS 2 Close the damper and seal the edges with non combustible material It is a good idea to also remove the damper control rod to avoid anyone trying to re open the damper 3 Follow all of the clearance regulations for placement of your stove specified in the sections titled FREESTANDING INSTALLATION SPECIFICATIONS and P...

Page 23: ...k off Plate if damper can not be sealed Minimum Clearance from Chimney Connector to Unprotected Ceiling 18 Listed or Approved Thimble Assembly Combustible Wall 1 Clearance for Completely Exterior Chimney or 2 Clearance for Interior Chimney and 2 Clearance for N F P A 211 Type Approved Thimbles Chimney Connector Combustible Mantle Min 20 1 2 for Single Wall 14 1 2 for Reduced Clearance Connector Fo...

Page 24: ... your surround panels overlap the fireplace opening by 1 4 or more This will insure a good seal and provide a more attractive facade When determining your surround panel size remember that the panels must overlap the fireplace opening in both width and height The surround panels may overlap the fireplace opening by more than the 1 4 recommendation if it is to allow for a complete seal Any question...

Page 25: ... top panel has four joggle clips that hold the top panel in place against the insert and the side panels The best way to insert the top panel is to hold it at an angle and insert one side first and gradually lower it until the opposite side is inserted Adjust the top panel so its edges are flush with the side edges of the side panels 4 Adjust the position of the side panels so they are 1 flush wit...

Page 26: ...eatly enhances the appearance of your insert and is easy to install 1 Lay the three pieces of brass trim on the floor in front of the insert Arrange the brass trim so that it resembles the illustration below The rounded edge of the trim that will be facing outwards when installed should be facing down Lay the trim on the floor in front of the insert with the rounded portion facing down Insert CROS...

Page 27: ...wo holes on the top extender with the two holes on the top flange of the insert Attach the top extender with two screws 5 Included with the flush kit is a bypass damper rod extension Unscrew the bypass damper rod pull ring and install the rod extension Replace the pull ring on the end of the extension 6 The flush kit is now installed When installing the surround panels refer to the section on inst...

Page 28: ...more than the 1 4 recommendation if it is to allow for a complete seal Any questions on the use of the bay kit should be directed towards your dealer To install the bay kit first refer to the type of installation you are using e g Face Seal Connection Direct Connection etc Follow the directions listed for the type of installation you are doing and follow the directions below when the surround pane...

Page 29: ...st the position of the side bays so they are 1 flush with the bottom of the insert 2 both the same distance back from the front of the insert 3 perpendicular to the floor Tighten once the side bay is properly aligned NOTE If using a positive or direct connection the top panel should be installed after the flue is connected to the appliance 5 The brass trim is pre assembled and can be slid over the...

Page 30: ...peed and mode automatic or manual of the blower The two speeds are RUN slower and STARTUP faster The two modes are AUTO the thermodisk controls the switch and the temperature of the firebox will determine when the blower starts or stops and MAN manual Ð the blower will run on the speed setting selected The blower should be switched OFF for approximately 30 minutes after each reload of the stove Th...

Page 31: ...with Surround Panels 3 Flush Kit For use with any of the Surround Panel sizes listed above 4 Bay Kit 5 Blower Front SAFETY For your safety examine the fireplace and chimney prior to installation of the insert to determine that they are free from cracks loose mortar creosote deposits blockages or other signs of deterioration If evidence of deterioration is noted the insert should not be installed u...

Page 32: ...nded Bay 4 3 4 14 15 16 26 19 Flush 23 3 4 FIREPLACE SIZING Measure and center the appliance into the fireplace based on the provided measurements A Minimum Height Front B Minimum Height Back C Minimum Width Front D Minimum Width Back E Depth into Fireplace F Extension onto Hearth Extended or Bay 22 3 4 22 3 4 29 1 2 23 13 5 8 9 7 8 Flush 22 3 4 22 3 4 29 1 2 23 19 4 1 2 A D C B E F ...

Page 33: ...8 COMBUSTIBLE SIDEWALL COMBUSTIBLE MANTLE A D E F Fireplace Facing Combustible Surface Combustible Surface Surround Panel B C Edge of Firebox LEVELING BOLTS If your fireplace is stepped down from the hearth you will be required to use the leveling bolts located within the hardware package Prior to placing the insert in the fireplace opening measure the step down Screw the 1 2 bolts provided into t...

Page 34: ...nnector 1 2 wide to accomodate the bypass damper rod See the illustration to the left below 5 Once the plate is in position slide the pipe into the plate up through the damper It must extend up to the flue liner or at least one foot past the block off plate Top 8 Notch for bypass damper rod 1 2 wide 1 1 4 Block off Plate 6 Once this has been accomplished reach in and pull the connector pipe down i...

Page 35: ...cleaning SIDE VIEW OF FIREPLACE INSERT DIRECT CONNECTION Non Combustible Material Optional Surround Panel Block off Plate Remove Damper or Wire it Open Stainless Steel Chimney Connector Must Extend to Clay Flue Liner or at least one foot beyond Block off Plate Insulation Optional Airtight Insulated Clean Out Clay Flue Liner with Required Air Space Block off Plate Insulation 18 Min The Extended Ins...

Page 36: ... all of the regulations and guidelines specified in the sections titled FIREPLACE INSERT SPECIFICATIONS and PREPARATION FOR INSTALLATION MASONRY FIREPLACE INSERT 4 The chimney connector that connects to the insert must be notched 1 1 4 above the bottom edge of the connector 1 2 wide to accomodate the bypass damper rod See the illustration to the left below 5 If you are using a block off plate slid...

Page 37: ... Take a look at the illustration below Make sure all of the items listed below are completed Non Combustible Material Remove Damper or Wire it Open Insulation Optional Airtight Insulated Clean Out Stainless Steel Chimney Liner System Follow Liner Manufacturer s Instructions on Installation and Support Optional Face Seal Must be sealed at the top preferable or with a block off plate 18 Min The Exte...

Page 38: ...e section titled CHIMNEY INFORMATION REGULATIONS Make sure the fireplace and chimney are thoroughly cleaned and in good condition 2 Follow all of the regulations and guidelines specified in the sections titled FIREPLACE INSERT SPECIFICATIONS and PREPARATION FOR INSTALLATION MASONRY FIREPLACE INSERT 3 Wire open or remove the fireplace damper 4 Follow the directions specified in the section titled S...

Page 39: ... Measure the width below damper area from side to side at front of smoke chamber Label this Measurement B 3 Measure the depth below damper front to back of smoke chamber Label this Measurement C 4 Make a template of your measurements but add 2 to each of the sides CROSS SECTION OF FIREPLACE B C A Your template should resemble the drawing on the next page with the dotted lines indicating your initi...

Page 40: ... of where to cut the 6 1 4 hole in the sheet metal plate so that it lines up with the chimney flue opening and the final position of the wood burning appliance then cut the hole If you are installing surround panels with your insert refer to the section SURROUND PANEL INSTALLATION for how to position your insert correctly 7 Put the plate in position and drill the mounting holes Then bolt into posi...

Page 41: ...he center and is operated by pushing or pulling the control When pulled out all the way the bypass damper is open causing the catalytic combustor to be bypassed When it is pushed in the flue gases are channeled through the catalytic combustor Catalytic Combustor Gage The Catalytic Combustor Temperature Gage is used to measure the temperature inside the catalytic combustor This temperature is used ...

Page 42: ...ng glass may become somewhat obscure the first few times as your appliance is drying all the moisture from bricks and even the steel itself During the first few fires it may be a little harder to start the fire because the firebricks will contain some moisture 4 Next add two or three medium size dry logs use of green or wet wood in your appliance will develop creosote cloud glass and greatly decre...

Page 43: ...or a minimum of 20 minutes This ensures that the appliance catalyst and fuel are all stabilized at their proper operating temperature Even though it is possible to have gas temperatures reach 600 degrees F within 2 to 3 minutes after a fire is started if the fire is allowed to die down immediately it may go out and the combustor may stop working Once the combustor starts working the heat generated...

Page 44: ...he fire burn intensely for 20 30 minutes Next adjust the air control so that a low lazy flame is visible In the overnight burn you should be able to maintain a fire for about 10 12 hours depending on the type of wood used and still have a coal bed with no visible flame left to start the morning fire To re establish a fire after an overnight burn open the controls fully and stir the ashes to bring ...

Page 45: ...necessary to reload the appliance more often The chart below outlines the advantages of using hardwood SPECIES LBS CORD BTU s CORD Hours per Cord at 40 000 BTU s per Hour ALDER 2540 19 050 000 476 APPLE 4400 33 000 000 825 ASH 3440 25 800 000 645 BIRCH 3040 22 800 000 705 CEDAR 2060 15 450 000 386 COTTONWOOD 2160 16 200 000 405 DOGWOOD 4320 31 725 000 793 ELM 2260 16 950 000 423 FIR DOUGLAS 2970 2...

Page 46: ...s less apt to form creosote deposits Any moisture in the wood reduces the recoverable heat because water absorbs heat in the process of being changed to steam The net heat from a pound of completely dry no moisture hardwood is about 7 950 BTU s All wood has some moisture in it which reduces the net usable heat at a rate of 1 200 BTU s per pound of water The moisture in the wood of living trees var...

Page 47: ...re some arrangement for ventilation is necessary It is also desirable to hold the plastic away from the rough ends of the wood to prevent abrasion allow air to flow and keep any condensation from re wetting the wood SOLAR WOOD DRYER In sunny weather the temperature within the dryer rises much higher than outside temperatures warming the wood and evaporating the contained moisture Raise stack off t...

Page 48: ...over and near the house so that valuable space in the house is not used insects are kept outside and the dirt problem is reduced Store the wood under cover to keep it dry and its fuel value high It can be stored in a wood shed utility building garage or under a sheet of plastic or sheet metal roofing When drying wood the greater the surface area exposed to the air the more rapid the drying Wood gr...

Page 49: ...oodshed it may dry to between 10 and 15 moisture content and wood may dry to between 5 and 12 in the house End braces can be used if you have difficulty stacking wood and if the pile collapses at either end Constructed with two by fours end braces are like book ends and can be built to accurately measure a standard cord The boards beneath the woodpile keep the bottom row off wet ground In some hom...

Page 50: ... If the appliance glows red it is over fired 6 Keep all household combustibles and appliance fuel at least 3 feet from the appliance at all times Store fuel in a dry place well away from the appliance 7 Do not support or elevate the fire off of the firebrick Burn the fire directly on the bricks Do not use a grate 8 Educate your children of the dangers associated with fire and the presence of a hot...

Page 51: ...stored on a non combustible floor or on the ground well away from any combustible material pending final disposal If the ashes are to be disposed of by burial in soil or otherwise locally dispersed they should be retained in the closed container until all cinders have thoroughly cooled Other waste must not be placed in this container BRASS CLEANING Your Lopi Flex 95 may come with a solid brass doo...

Page 52: ...cants will only last a few days CHECK FOR CREOSOTE Creosote is a tarry liquid or solid resulting from the distilling of wood during the combustion process Using wet wood or burning at lower temperatures will result in a heavier creosote deposit Creosote vapors will condense in a relatively cool chimney flue of a slow burning fire As a result creosote residue accumulates on the interior surface of ...

Page 53: ...emove any scale from the inside of the firebox with a wire brush or scraper With a flashlight check to see that all of the firebrick lining the firebox is in good condition If any of the firebrick is cracked or broken follow the directions in the section titled REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS for removal and replacement of any damaged firebrick APPLIANCE TOUCH UP The outside of the appl...

Page 54: ...teps to determine your catalytic combustor s performance Step 1 Light fireplace Let the fireplace reach operating temperature 20 30 minutes Step 2 With smoke routed through the catalyst bypass closed pushed in go outside and observe the emissions leaving the chimney Step 3 Open the bypass and again observe the emissions leaving the chimney You should see significantly more smoke when the exhaust i...

Page 55: ...ion air control closed Combustion air inlet is not blocked Combustion air control is open Lazy orange smoky flame Bad Fuel Restricted Flue Poor Draft Wood is dry seasoned Chimney is clean unrestricted Sufficient chimney length correct size Smoke smell inside house Restricted chimney or reverse flow down draft Air leak from faulty door or glass gasket Door is out of adjustment Chimney is clean unre...

Page 56: ...atalytic Combustor With Gasket 90 5060 Catalytic Combustor Replacement Information The catalytic combustor supplied with this appliance is a Corning Inc Model 2 5 X 2 6 X13 1 cell density 16 per square inch Consult the combustor warranty supplied with this appliance Warranty claims for the combustor should be addressed to Corning Incorporated Technical Products Division Corning New York 14831 607 ...

Page 57: ...e Pins Remove the ten screws holding in the glass retainer with a 5 16 nut driver Glass Door Gasket DOOR Removing and Replacing the Glass Gasket A damaged or deteriorated glass gasket will allow air to enter the appliance through the space between the door and glass This may cause smoke to enter the room and hamper efficient burning To replace the glass gasket follow the directions for removal of ...

Page 58: ...p the door by both ends It is heavy and can be damaged The illustration below shows how the probe slides into the catalytic combustor With one hand reach into the unit and hold the probe With the other hand grasp the temperature gage Making sure the probe comes straight out of the catalytic combustor pull with both hands to remove the probe The left side of the catalytic combustor may need to be m...

Page 59: ...Remove the door by opening it 90 degrees and pulling it upwards Make sure to grasp the door by both ends It is heavy and can be damaged 3 Remove the left back firebrick by rotating it out from its lower edge see illustration to the right Do not use any object to pry the firebrick for this may cause the firebrick to chip or crack 4 Remove the rest of the back bricks one by one following the order l...

Page 60: ...the bricks snug against each other and against the walls of the firebox 5 6 7 8 2 1 3 4 Metal clips that hold the side firebricks in place REMOVING THE BAFFLE TOP FIREBRICKS COMPONENTS 1 Make sure the appliance is cool and cleaned out 2 Remove the door by opening it and pulling it upwards Make sure to grasp the door by both ends It is heavy and can be damaged 3 The illustration to the right shows ...

Page 61: ...ck end down Twist the brick so that it is on end and then feed it out TOP VIEW OF REAR BAFFLE FIREBRICKS 4 With the rear baffle firebricks removed the rear baffle support can be slid backwards approximately one inch This will allow the forward baffle firebricks to be slid out through the space between the front and rear baffle support 5 The front and rear baffle support angles can be removed at th...

Page 62: ...fore you may have to pry with some amount of force when trying to remove them Secondary Air Tube Pins that hold Secondary Air Tube and Collar in Place Collar Air Induction System Welded to side of Firebox Slide collar to the left after removing both of the pins Short Tube that is welded to the Air Induction System One pin holds the secondary air tube to a collar while the other pin holds the colla...

Page 63: ...I appliance is covered by this warranty If the appliance is used for commercial purposes it is excluded from this warranty No dealer distributor or similar person has the authority to represent or warrant LOPI products beyond the terms contained within this warranty TRAVIS INDUSTRIES INC assumes no liability for such warranties or representations THIS LIMITED WARRANTY IS THE ONLY WARRANTY SUPPLIED...

Page 64: ... a safety label that is attached to your appliance for installation purposes It is included here in case it is removed or becomes unreadable For discrepancies in listings between the label and this manual follow the listings in this manual ...

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