Travis Industries Small Flush Owner'S Manual Download Page 3

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Table of Contents

100-01342

4131101

Introduction ...................................................... 2

Important Information ...................................... 2

Installation Options .......................................... 6

Features ............................................................ 6

Heating Specifications ..................................... 6

Dimensions ....................................................... 6

Emissions and Efficiency ................................ 6

Planning the Installation .................................. 7

Preparation for Installation .................................... 7

Additional Accessories Needed for Installation ..... 7

Packing List ........................................................... 7

Additional Requirements for Canada .................... 7

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

Fireplace Altered Tag ....................................... 8

Insert Placement Requirements ..................... 9

Hearth Requirements ..................................... 10

USA .................................................................... 10

CANADA ............................................................. 10

Masonry Fireplace Requirements ................ 11

Zero-Clearance (Metal) Fireplace
Requirements ................................................. 11

Drafting Performance .................................... 11

Leveling Bolt Installation ............................... 12

Flue Adapter Installation ............................... 13

Vent Overview ................................................ 17

Surround Panel Installation .......................... 18

Face Removal ................................................. 18

Re-Routing the Electrical Cord to the Left
Side .................................................................. 19

Safety Notice .................................................. 20

Before Your First Fire .................................... 20

Verify the Installation ........................................... 20

Curing the Paint .................................................. 20

Over-Firing the Stove .......................................... 20

Opening the Door ........................................... 21

Bypass Operation .......................................... 22

Catalytic Combustor – Use and Cleaning .... 23

Inspecting & Cleaning the Combustor ................. 23

Starting a Fire ................................................. 24

Adjusting the Burn Rate ................................ 25

Approximate Air Control Settings: ....................... 25

Ash Removal .................................................. 25

Blower Operation ........................................... 26

Re-Loading the Stove .................................... 26

Overnight Burn ............................................... 26

Normal Operating Sounds ............................ 26

Hints for Burning ........................................... 27

Selecting Wood .............................................. 27

Why Dry Wood is Key ......................................... 27

Wood Cutting and Storage .................................. 27

Troubleshooting ............................................. 28

Daily Maintenance (while stove is in use) ... 29

Remove Ash (if necessary) ................................. 29

Clean the Glass (if necessary) ............................ 29

Monthly Maintenance (while appliance is in
use) .................................................................. 30

Door and Glass Inspection .................................. 30

Door Latch Adjustment ....................................... 30

Creosote - Formation and Need for Removal ..... 30

Cleaning the Catalytic Combustor ....................... 31

Yearly Maintenance ....................................... 32

Touch-Up Paint ................................................... 32

Cleaning the Air Duct and Blower (if applicable) . 32

Firebrick and Baffle Inspection ............................ 32

Door Parts ....................................................... 33

Replacing the Glass ............................................ 33

Replacing the Door Gasket ................................. 33

Blower and Electrical Parts .......................... 33

Firebox Parts .................................................. 34

Baffle Parts ......................................................... 34

Baffle Removal .................................................... 34

Combustor .......................................................... 34

Air Tube Removal & Replacement ............... 35

Brick Removal & Replacement ........................... 36

Catalytic Combustor Temperature Probe
Installation Instructions ................................ 37

GreenStart

Igniter – Firebrick and Housing

Installation ...................................................... 38

Minimum Fireplace Size ...................................... 38

Igniter Firebrick and Housing .............................. 38

Listing Label ........................................................ 42

Summary of Contents for Small Flush

Page 1: ...TICE 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 Travis Industries Inc 4800 Harbour Pointe Blvd SW Mukilteo WA 98275 www travisproducts com Copyright 2013 T I 10 00 100 01342 4131101 Listed Tested to U L 1482 UL...

Page 2: ...ence We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your appliance Important Information No other Small Flush Wood Insert appliance has the same serial number as yours The serial number is stamped onto the label on the back of the appliance This serial number will be needed in case you require service of any type Model Small Flush Wood Insert...

Page 3: ...ing Cleaning the Combustor 23 Starting a Fire 24 Adjusting the Burn Rate 25 Approximate Air Control Settings 25 Ash Removal 25 Blower Operation 26 Re Loading the Stove 26 Overnight Burn 26 Normal Operating Sounds 26 Hints for Burning 27 Selecting Wood 27 Why Dry Wood is Key 27 Wood Cutting and Storage 27 Troubleshooting 28 Daily Maintenance while stove is in use 29 Remove Ash if necessary 29 Clean...

Page 4: ... of the danger of a high temperature appliance Young children should be supervised when they are in the same room as the appliance Keep furniture drapes curtains wood paper and other combustibles a minimum of 36 away from the front of the appliance This appliance must be properly installed to prevent the possibility of a house fire The instructions must be strictly adhered to Do not use makeshift ...

Page 5: ... seal and keep them in good condition Do not operate this heater with broken or missing glass Avoid placing wood against the glass when loading Do not slam the door or strike the glass Over firing the appliance may cause a house fire If a unit or chimney connector glows you are over firing Do not throw this manual away This manual has important operating and maintenance instructions that you will ...

Page 6: ...e feet 650 to 1 000 Maximum Burn Time Up to 7 Hours Heating capacity will vary depending on the home s floor plan degree of insulation and the outside temperature It is also affected by the quality and moisture level of the fuel Dimensions a Measure clearances from base of insert b Fireplace Opening c Extension Onto Hearth for hearth depth Emissions and Efficiency 0 89 Grams per Hour EPA Phase II ...

Page 7: ...e firebox replace cracked firebrick and make sure baffle and combustor is in place The fireplace insert can be lightened by removing the firebricks pg 36 replace before operation Additional Accessories Needed for Installation Face Surround Panels see page18 for sizing Packing List Flue Attachment Gasket with screws Bypass Tool GreenStart Igniter FireBrick and Igniter Housing used with GreenStart i...

Page 8: ...place opening 17 5 445mm USA 19 5 496mm Canada g Hearth Width 40 75 1036mm h Facing Width 37 25 947mm i Facing Height Above Base of Insert 37 5 953mm j Mantel Height Above Base of Insert 37 5 953mm Includes 2 51mm for power cord installation and face brackets Fireplace Altered Tag Attach the This fireplace has been altered plate to the fireplace use two screws or other suitable method You may wish...

Page 9: ...loor The minimum clearances facing and hearth requirements listed below must be met Minimum Clearances k Sidewall 11 625 296mm l Side Facing non combustible 6 25 159mm m Top Facing non combustible 37 5 953mm n Mantel combustible maximum 12 305mm deep 37 5 953mm o Front Hearth 16 407mm USA 18 458mm Canada p Side Hearth 8 204mm q Front of Insert 36 915mm s Mantel Column max 8 204mm deep 6 25 159mm x...

Page 10: ...earth must be non combustible cement board tile etc No R value thermal resistance is required CANADA When installing into a zero clearance fireplace the hearth must extend 18 458mm to the front and 8 204mm to the sides of the insert The hearth must provide an R value thermal resistance of 1 19 or greater If the insert is a minimum 2 51mm above the combustible floor carpet wood etc the hearth must ...

Page 11: ...be clean and undamaged Any damage must be repaired prior to installation of the insert Entire fireplace including chimney must meet local building requirements Chimney height 15 4 5M minimum 33 10M maximum measured from base of insert Minimum cross section 28 65 square inches 18626 sq mm The damper A and grate B must be removed see Figure 1 The smoke shelf C internal baffles D screen E and metal o...

Page 12: ...olts remove the back corner firebricks and cover plates a and b The bolts are pre threaded to a weld nut on the base of the insert Use a 3 4 socket wrench to screw the bolts down clockwise until the insert is level see c SEALING THE COVER PLATE We recommend sealing the cover plate with furnace cement place on underside of cover plate BOLT LENGTH The included bolts allow approximately 1 of rise If ...

Page 13: ...ver NOTE Flue adapter is tight and will need to be knocked loose with a hammer 2 Prepare the liner connector for attachment to the flue adapter Notch the liner around the bypass rod and check fit 3 The liner adapter will fit loose in the flush wood insert flue collar and must be sealed with the gasket tape provided in the hardware pack with the insert Start above the bypass rod notch and wrap the ...

Page 14: ...ure the adapter is centered 8 1 2 behind the fireplace opening and approximately 18 from the floor of the fireplace HINT Placing the flue connector near its final position is key to an easy installation 5 Slide the insert into place Make sure the adapter fits over the opening for the flue 6 A flue adapter pull stick is included to help position the flue adapter in place Insert the pull stick throu...

Page 15: ...Travis Industries 100 01342 4131101 7 Thread the pull stick into the flue adapter and turn 4 to 6 times 8 Use the pull stick to guide the flue adapter into position Push the insert slightly then pull on the pull stick 9 Repeat step 8 until the insert is in position ...

Page 16: ...lers only Travis Industries 100 01342 4131101 10 Remove the pull stick and place it aside behind surround panels inside the fireplace for future use 11 Replace the two bolts removed in step 1 Tighten the bolts fully making sure the flue adapter is seated ...

Page 17: ...the fireplace enclosure By sealing the top and bottom of the chimney and the surround panels you will be ensuring outside air is not pulled into the chimney The liner must be stainless steel connector or flexible vent Follow the liner manufacturer s insturctions for installation and support Remove damper or wire it open Airtight Insulated Clean Out Combustible Mantle Flue Liner See the section Ins...

Page 18: ...sh to use the face only see dimensions below Face Removal WARNING Unplug or disable power to the appliance prior to removing the face 1 Open the door and lift it off its hinges 2 Pull the bypass all the way forward Unscrew the bypass rod from the bypass yoke make sure to detach the handle and rod as one piece 3 Unscrew the air control rod from the air control 4 The face uses hooks to hang in place...

Page 19: ...ockout is provided if using the insert wiring kit Route the power through one hole the rheostat through the other Power Cord Rheostat Wires Disconnect the molex connector leading from the power cord Use pliers to compress the strain relief from the top and bottom while pulling it out of the hole in the side of the insert Remove the power cord Leave the rheostat wires in place Make sure the power c...

Page 20: ... while starting the first fire Open doors and windows to the room to vent these fumes This typically lasts two to four hours You may also notice oil burning off of the interior of the heater This rust stopping agent will soon dissipate Door Gasket The door gasket might adhere to the paint on the front of the heater Leave the door slightly ajar for the first fire and be careful when opening the doo...

Page 21: ...andle is hot To prevent smoke from entering the room open the bypass before opening the door see following page for directions You can also open the door a small amount and let air enter the firebox Rotate the handle up Swing the door open Opening the Doors Closing the Doors Rotate the handle down to secure the door Lift the handle and close the door ...

Page 22: ...re draft When pushed in the smoke goes around the baffle through the combustor utilizing secondary combustion and making the heater more efficient When starting or re loading pull the bypass out if necessary During normal operation push the bypass in Use the included pull tool to operate the bypass rod Bypass Pushed In Used for normal operation Bypass Pulled Out Used for starting and re loading ...

Page 23: ...up on the combustor See the directions below to inspect and clean the combustor with the included brush Inspecting Cleaning the Combustor The combustor becomes very hot during operation Let the heater cool before cleaning the combustor The combustor is located directly above the firebox opening Make sure the square openings are open for air to pass through If ash is accumulating use the brush to c...

Page 24: ...es or within the space required for charging and ash removal If using a fire starter use only products specifically designed for stoves follow the manufacturer s instructions carefully HOT WHILE IN OPERATION KEEP CHILDREN CLOTHING AND FURNITURE AWAY CONTACT MAY CAUSE SKIN BURNS If the smoke does not pass up the chimney ball up one sheet of newspaper place it in the center of the firebox and light ...

Page 25: ...r control may take several minutes to influence the burn rate When making adjustments you may wish to let the stove burn for 10 minutes to gauge performance Ash Removal Ashes should be placed in a metal container with a tight fitting lid The closed container of ashes should be placed on a noncombustible floor or on the ground away from all combustible materials pending final disposal If the ashes ...

Page 26: ... the doors fully 3 Load wood onto the fire Overnight Burn Follow the steps below to achieve an overnight burn 1 Move the air control to high burn and let the stove become hot burn for approximately 15 minutes 2 Load as much wood as possible Use large pieces if possible 3 Let the stove burn on high for 15 minutes to keep the stove hot and then turn the air control to low 4 In the morning the stove ...

Page 27: ...ss smoke and creates less creosote Testing Wood Moisture Split wood stored in a dry area will be fully dry within a year This insures dry wood If purchasing wood for immediate use test the wood with a moisture meter Some experienced wood burners can measure wood moisture by knocking pieces together and listening for a clear knock and not a thud Why Dry Wood is Key Wet wood when burned must release...

Page 28: ...n these cases a small amount of smoke may enter the home Adding more piping or a draft inducing cap may help Chimney liner joints are not properly sealed at the insert connection Stove Does Not Burn Hot Enough Wood is Wet see the section Selecting Wood on page 27 for details on wood Make sure the air control is all the way open Slide the control back and forth to insure the control is not stuck In...

Page 29: ...inguished 2 Place a cloth or cardboard protector over the hearth to catch ash and protect against scratching 3 Open the doors and scoop the ash into a metal container with a tight fitting lid The closed container of ashes should be placed on a noncombustible floor or on the ground away from all combustible materials pending final disposal Improperly disposed ashes lead to fires Hot ashes placed in...

Page 30: ... for Removal When wood is burned slowly it produces tar and other organic vapors which combine with expelled moisture to form creosote The creosote vapors condense in the relatively cool chimney flue of a slow burning fire As a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire The chimney and chimney connector should be inspected at least...

Page 31: ... catalytic combustor If you do not have one you may use a brush to dislodge flyash 1 With the stove fully cooled insert the ash vacuum nozzle into the area directly above the door opening 2 Carefully place the brush surface of the nozzle over the catalytic combustor openings and remove any ash or debris Take care to prevent damage to the catalytic combustor the surface is fragile ...

Page 32: ...a vacuum to clean the air ducts channels This prevents dust from burning and creating odors The blower should be vacuumed every year to remove any buildup of dust lint etc Firebrick and Baffle Inspection Use the illustration on page 33 as a reference for checking the following items Make sure the appliance is cool before proceeding Baffle check the baffle plate along the ceiling of the firebox to ...

Page 33: ...in the door frame cut off excess gasket Place the glass on the gasket Secure the glass clips to hold the glass in place make sure the glass clip gaskets are in place Replacing the Door Gasket The door gasket inserts into the outer groove of the door retainer Stove gasket cement holds it in place Before installing remove any residual cement Lay the gasket in place start at the lower left corner and...

Page 34: ... visually check the condition of your combustor by opening the door and looking above the baffle with a flashlight If there is visible ash accumulation on the surface of your combustor it should be cleaned off with a soft bristled brush If there is visible creosote buildup tar substance on the combustor burn your stove on high and the creosote should burn off If the creosote does not burn off your...

Page 35: ...en this bolt 2 or 3 turns do not remove Note how the center of the air tube pin inserts into a hole on the air tube 3 8 Wrench With the bolt loosened the air tube can be slid out of the air channel The pin will then disengage from the air tube you may wish to rotate the tube slightly Pivot the air tube downwards and slide it out of the air channel on the opposite side Air Tube Bolt Air Tube Air Tu...

Page 36: ... Brick 6 9 x 4 5 3 251 00074 2 Cut Brick 6 9 x 1 7 x 3 5 2 251 00075 3 Brick Full 4 5 x 9 6 251 00000 4 Cut Brick 9x 3 6 1 251 00049 5 Cut Brick 9 x 2 4 1 251 00076 Igniter Brick not pictured 1 251 00077 Do not pry the brick they chip and crack easily Remove the floor bricks first The side bricks are pinned in place by the floor firebrick Clean the firebox prior to replacing the brick ...

Page 37: ...move the button plug from the top of the heater as shown below 2 Use a center punch to mark the convection top location as shown below 3 Drill a hole through the convection top Make sure to use the correct drill bit size to allow for an air tight seal 4 Insert the temperature probe to location near the combustor as shown below ...

Page 38: ...are using the igniter install these components as shown below The igniter is installed as shown in the instructions included with the igniter kit Igniter Firebrick Igniter Housing HINT If you are not using the igniter store these components inside the fireplace cavity in case the homeowner later decides to install them 1 Remove the two firebricks from the front left corner of the firebox 2 Place t...

Page 39: ...o complete the installation 4 Remove the cover and gasket using a 5 16 nutdriver See the photos below 5 Install the housing as shown below NOTE The gasket s hole patterns are unique The housing must be re installed in the same configuration If the holes are not aligned rotate the gasket 90 ...

Page 40: ...egs Pedestal Blower Re Installation Allowance In cases where heater must be removed from home for repairs a partial cost of re installation is covered pre authorization required One Way Freight Allowance One way freight allowance on pre authorized repair done at factory is covered Exclusions Paint Gasketing Years 3 THROUGH 5 COVERAGE PARTS LABOR Firebox Assembly Firebox Baffle Supports Air Tubes A...

Page 41: ... fuel other than that for which the appliance is configured use cord wood only 14 Damage to brass or plated surfaces caused by fingerprints scratches melted items or other external sources left on the surfaces from the use of abrasive cleaners is not covered in this warranty Damage to the surfaces from over firing operation where the steel may glow red is not covered in this warranty 15 TRAVIS IND...

Page 42: ...mney liner extending from the fireplace insert to the top of the chimney A chimney liner shall be tested for conformance with Class 3 requirements of CAN ULC S635 Standard for Lining Systems for Existing Masonry or Factory Built Chimneys and Vents or CAN ULC S640 Standard for Lining Systems for New Masonry Chimneys PREVENT HOUSE FIRES Install and use only in accordance with the manufacturer s inst...

Page 43: ...Listing Information 43 Travis Industries 100 01342 4131101 ...

Page 44: ... 6 Face Removal 18 Features 6 Firebox Parts 34 Firebrick and Baffle Inspection 32 Fireplace Altered Tag 8 Fireplace Requirements 8 Flue Adapter Installation 13 GreenStartTM Igniter Firebrick Installation 38 Hearth Requirements 10 Heating Specifications 6 Hints for Burning 27 Important Information 2 Insert Placement Requirements 9 Installation Options 6 Introduction 2 Listing Label 42 Masonry Firep...

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