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Travis Industries X-96, Owner'S Manual

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Travis Industries X-96 Owner'S Manual Download Page 27

Page 27

ZERO CLEARANCE (METAL) FIREPLACE INSTALLATION

Your new wood burning insert is approved for use in suitable zero clearance (metal) fireplaces.  Make
sure to follow all of the steps listed below to insure proper installation.  The installation technique below
illustrates one way of installing your insert.  Check with your dealer or installer for information on other
installation options available to you.

1.  Inspect the chimney and make sure it follows all the rules outlined in the section titled "CHIMNEY

INFORMATION & REGULATIONS".

2.

Follow all of the regulations and guidelines specified in the sections titled "ZERO CLEARANCE
(METAL) FIREPLACE INSERT - SPECIFICATIONS" and "PREPARATION FOR INSTALLATION -
ZERO CLEARANCE (METAL) FIREPLACE INSERT ".  Make sure that your brand of zero clearance
(metal) firepalce matches one that is listed.  Check with your dealer or installer if there are any
discrepencies.

3.

The next step in installing a zero clearance insert is to remove all of the unnecessary components on
your brand of fireplace.  Because of the wide differences between fireplace brands and models, it
would be difficult to list all the variations.  Below, we have provided a generic view of a typical zero
clearance fireplace to illustrate which parts may or may not be removed.

Parts that may be removed:

1. Damper plate (Must be removed)
2. Smoke shelf
3. All internal baffles
4. Grates (Must be removed)
5. Metal Screen
6. Glass Screen or Doors

Parts that may not be
removed:

¥ Masonry lining or firebricks
¥ Any insulating materials.
¥ Any structured rigid frame
members (metal sides, floor, door
frame, face of fireplace, etc.)

1

2

5

3

6

4

NOTE: The installation of the decorative panels and trim is optional and not required.  An alternative to
using the decorative panels is to simply draw the fireplace screens closed around the insert.

4.

THE ZERO CLEARANCE FIREPLACE MUST BE INSTALLED
WITH A STAINLESS STEEL STARTER PIPE THAT
PENETRATES BEYOND THE SMOKE SHELF AND IS
DIRECTLY CONNECTED TO THE FIREPLACE CHIMNEY.
The chimney connector that connects to the insert must either
be a 6" flue adapter (See the section titled "OPTIONAL
EQUIPMENT") or a connector that has been notched 1 1/4"
above the bottom edge of the connector (1/2" wide).  See the
illustration to the right.  You may want to construct a steel block
off plate and install it or use a pipe adaptor to fill the gap
between the fireplace chimney and the 6" stainless steel
starter pipe that you will be installing.  See the illustration of a
block-off plate example on the next page for what a block-off
plate should look like in a zero clearance (metal) fireplace.

T o p

6" 

Notch for 
bypass 
damper rod 
(1/2" wide)

1 1/4"

Summary of Contents for X-96

Page 1: ...NCE KEEP THIS MANUAL November 1992 Masonry Fireplace Zero Clearance Metal Fireplace Model X 96 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: ... OR OTHER FLAMMABLE LIQUIDS IN 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 ...

Page 3: ...sing a Face Seal Connection 21 INSTALLATION OF A FIREPLACE BLOCK OFF PLATE 22 ZERO CLEARANCE METAL FIREPLACE INSTALLATION PREPARATION FOR INSTALLATION 24 ZERO CLEARANCE METAL FIREPLACE SPECIFICATIONS 25 ZERO CLEARANCE METAL FIREPLACE INSTALLATION 27 OPERATING YOUR APPLIANCE OPERATING YOUR APPLIANCE 29 Location and Use of Controls 29 Burning Procedure 30 Burning Your Appliance Efficiently 31 Daily ...

Page 4: ... 300 Cord Wood Overall Efficiency 72 5 Oregon Method Emissions Grams hr 7 2 EPA Method Maximum Burning Time Hours 10 Flue Opening Diameter 6 in Height from Floor to Top of Appliance 21 in Includes damper rod Overall Width in Fireplace 24 1 4 in Overall Depth in Fireplace 14 7 8 in Fuel Solid Wood Only Weight 400 lbs Emissions Efficiency Heating Capacity and Burn Times may vary depending on actual ...

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: ...ight 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 questions on selection of the surround panels should be directed towards your dealer To install the surround panels 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 i...

Page 9: ... goes inside the panel on the side of the insert INSULATION INSTALLATION INSTRUCTIONS The installation of the insulation is required only for face seal connections Direct and positive connections do not require the insulation to be installed Refer to the installation instructions for more details on the type of installations available and the items that are required for each type of installation 1...

Page 10: ...edge of the side panels until the bottom edge of the brass trim is flush with the bottom of the side panels and the top panel is in the groove of the top brass trim piece 3 Bay Kit The bay kit for your insert is sold separately and offers an attractive facade for your installation It is very important that your installation is adequately suited for the bay kit before deciding on that type of insta...

Page 11: ...e bay and place it so the inward flange goes inside the panel on the side of the insert 2 Un screw the handle on the damper rod before installing the bay kit top panel Slide the top panel onto the flange on top of the side bays The top panel has four joggle clips that hold the top panel in place against the insert and the side bays The best way to insert the top panel is to hold it at an angle and...

Page 12: ... of this manual if insulation is needed 4 Blower Front The front blower is designed to improve the natural convection of the stove by pushing air through the convection chamber of the stove and causing the heated air to exit through the vents along the top of the stove It also has a thermodisk which turns the blower on and off automatically Refer to the illustration below while following the direc...

Page 13: ...tic 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 This is to allow the s...

Page 14: ...tion 2 Surround Panel Brass Trim Included with Surround Panels 3 Bay Kit 4 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 until after repairs have been...

Page 15: ...4 3 4 12 1 8 14 7 8 Surround Panels or Bay Sides 20 1 4 10 Extension onto hearth FIREPLACE SIZING Measure and center the insert into the fireplace based on the provided measurements A Minimum Height Front 21 B Minimum Height Back 21 C Minimum Width Front 24 1 4 D Minimum Width Back 24 1 4 E Depth into Fireplace 14 7 8 F Extension onto Hearth 10 From Face of Fireplace A D C B E F ...

Page 16: ...Panel B C Edge of Firebox NOTE For clearances use this clearance diagram or the clearance diagram on the safety label attached to the back of the appliance 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 p...

Page 17: ... up through the damper It must extend up to the flue liner or at least one foot past the block off plate Top 6 Notch for bypass damper rod 1 2 wide 1 1 4 Block off Plate 6 Install the surround panels by following the directions in the section titled OPTIONAL EQUIPMENT You may now place your new appliance into the fireplace opening and position the connector pipe so that it can be easily pushed int...

Page 18: ...E 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 Follow the directions on the previous page for...

Page 19: ...ACE INSERT SPECIFICATIONS and PREPARATION FOR INSTALLATION MASONRY FIREPLACE INSERT 4 The chimney connector that connects to the insert must either be a 6 flue adapter See the section titled OPTIONAL EQUIPMENT or a connector that has been notched 1 1 4 above the bottom edge of the connector 1 2 wide See the illustration to the left below 5 If you are using a block off plate slide the pipe into the...

Page 20: ...ake sure that the insert is properly aligned and that the connector fits tight into the flue collar on the top of the insert 9 Take a look at the figure 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 In...

Page 21: ...ney to make sure the fireplace meets all of the rules outlined in the 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 firepl...

Page 22: ... 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 23: ... 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 24: ...m Minimum Vertical 33 Feet 15 Feet OPTIONS Your fireplace insert comes completely assembled Options available for your fireplace insert are listed below Installation instructions for these options are in the section INSERT OPTIONAL EQUIPMENT 1 Surround Panels 8 10 and 12 Sizes Includes Insulation 2 Surround Panel Brass Trim Included with Surround Panels 3 Bay Kit 4 Blower Front 5 Flue Adapter 6 SA...

Page 25: ... Extension onto hearth 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 21 21 26 1 4 26 1 4 15 7 8 10 A D C B E F These dimensions include the 1 air space required between the sides and back of the insert and t...

Page 26: ...f Firebox NOTE For clearances use this clearance diagram or the clearance diagram on the safety label attached to the back of the appliance 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 the...

Page 27: ...to illustrate which parts may or may not be removed Parts that may be removed 1 Damper plate Must be removed 2 Smoke shelf 3 All internal baffles 4 Grates Must be removed 5 Metal Screen 6 Glass Screen or Doors Parts that may not be removed Masonry lining or firebricks Any insulating materials Any structured rigid frame members metal sides floor door frame face of fireplace etc 1 2 5 3 6 4 NOTE The...

Page 28: ...it 8 Put the starter pipe through the block off plate leaving enough sticking through to allow it to be connected to the appliance BLOCK OFF PLATE 14 14 6 1 4 1 8 Holes 9 You can now place your appliance into the fireplace opening and position the starter pipe so it can be easily pushed into the flue opening on top of the insert 10 If the stove needs to be leveled follow the directions for using t...

Page 29: ...pletely pulled out it is in the fully open position Bypass Damper Control The bypass Damper Control is located on the center top of the appliance and is operated also by pushing or pulling the control When pulled out all the way it is in the fully open position When pushed in all the way it is in the fully closed position NOTE The Bypass Damper Control becomes very hot during operation and should ...

Page 30: ...paint cures best at medium temperatures Also the viewing glass may become somewhat obscured the first few times as your appliance is drying all moisture from bricks and even the steel itself 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 decrease its efficiency At this time establish a hot fire with a bed of red...

Page 31: ...n you should be able to maintain a fire for about 8 10 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 hot coals to the surface Then follow the instructions under first fire If you dampen the fire down too low you will not only l...

Page 32: ...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 33: ...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 34: ...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 35: ... cover 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 ...

Page 36: ...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 37: ... 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 38: ...mbustible 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 appliance may come with a solid brass door ashlip trim and pan...

Page 39: ...ature lubricants 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 ...

Page 40: ...t the end of each heating season remove all of the ash inside the firebox and check for any scale that may have built up during the heating season Remove 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 secti...

Page 41: ...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 42: ...4000 Secondary Air Tube 92 5006 Includes Pins Center Baffle Air Tube 90 5036 By Pass Damper Adjustment Tool 90 2010 Door Handle 90 2052 Spring Door Cam 90 2040 Cast Brass Air Control Handle 90 2057 Spring By Pass Damper Handle 90 2015 Owner s Manual 92 3007 Cast Glass Retainer 90 2021 Removal Instructions The remaining text in this section details the items below Make sure to follow the directions...

Page 43: ...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 44: ...8 by 4 1 2 with a 1 1 4 thickness Cut Size 7 7 8 by 1 1 2 with a 1 1 4 thickness Floor bottom 4 2 1 1 Side and Back 10 Baffle top 4 2 REMOVING THE FLOOR BOTTOM FIREBRICKS 1 Make sure the appliance is cool and cleaned out 2 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 easily 3 Remove the forward firebricks by...

Page 45: ...her and against the walls of the firebox 1 2 3 4 5 6 7 8 9 10 Metal clips that hold 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 Push the damper bypass control all the way in 4 Remove the baffle top f...

Page 46: ... of the damper holder guide on both sides of the firebox The damper will slide off of the holder and come off of its attachments to the damper rod Holes on the Bypass Damper Bypass Damper Holder These pegs on the Bypass Damper Rod slide into the holes on the Bypass Damper Bypass Damper Holder Guide Slide the Bypass Damper Holder forward off of the guide Remove the damper once it is free Then rotat...

Page 47: ...y 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 collar to a short tube welde...

Page 48: ...vered 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 BY TRAVIS INDUST...

Page 49: ...Page 49 SAFETY LABEL The following is a safety label that is attached to your appliance for installation purposes It is included here in case it is removed or becomes unreadable ...

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