Travis Industries X-96 Manuel utilisateur

OWNER'S MANUAL

PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE

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

SAFETY PRECAUTIONS

¥ VIEWING DOOR MUST BE CLOSED AND

LATCHED DURING OPERATION.

¥ THE APPLIANCE IS DESIGNED AND

APPROVED FOR BURNING OF WOOD ONLY.

THE BURNING OF ANY TYPE FUEL OTHER

THAN WOOD WILL VOID ALL WARRANTIES

AND SAFETY LISTING OF THE APPLIANCE.

DO NOT ATTEMPT TO BURN ANY OTHER

FUEL THAN SPECIFIED IN THIS MANUAL.

¥ THIS APPLIANCE MUST BE PROPERLY

INSTALLED IN ORDER TO PREVENT THE

POSSIBILITY OF A HOUSE FIRE. FOR YOUR

SAFETY THE INSTALLATION

INSTRUCTIONS MUST BE STRICTLY

ADHERED TO. DO NOT USE MAKESHIFT

METHODS OR COMPROMISE IN

INSTALLATION.

¥ THE FLUE SYSTEM SHOULD BE CHECKED

TWICE A YEAR MINIMUM FOR ANY BUILD-

UP OF SOOT OR CREOSOTE.

¥ CONTACT YOUR LOCAL BUILDING

OFFICIALS TO OBTAIN A PERMIT AND

INFORMATION ON ANY INSTALLATION

RESTRICTIONS OR INSPECTION

REQUIREMENTS IN YOUR AREA. ALSO,

NOTIFY YOUR INSURANCE COMPANY THAT

YOU ARE INSTALLING YOUR WARNOCK

HERSEY LISTED INSERT.

¥ GASOLINE OR OTHER FLAMMABLE LIQUIDS

MUST NEVER BE USED TO START THE FIRE

OR "FRESHEN-UP" THE FIRE. DO NOT

STORE OR USE GASOLINE OR OTHER

FLAMMABLE LIQUIDS IN THE VICINITY OF

THIS APPLIANCE.

¥ 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 OR REPLACE ANY

PART OF THE APPLIANCE UNLESS

INSTRUCTIONS ARE GIVEN IN THIS

MANUAL. ALL OTHER WORK SHOULD BE

DONE BY A TRAINED TECHNICIAN.

¥ DO NOT MAKE ANY CHANGES OR

MODIFICATIONS TO THE APPLIANCE OR AN

EXISTING MASONRY FIREPLACE OR

CHIMNEY TO INSTALL THIS APPLIANCE.

¥ WAIT UNTIL THE APPLIANCE HAS COOLED

BEFORE CARRYING OUT MAINTENANCE

PROCEDURES.

¥ TRAVIS INDUSTRIES, INC. GRANTS NO

WARRANTY, IMPLIED OR STATED, FOR THE

INSTALLATION OR MAINTENANCE OF YOUR

APPLIANCE, AND ASSUMES NO

RESPONSIBILITY FOR ANY

CONSEQUENTIAL DAMAGE(S).

¥ ALWAYS FOLLOW THE INSTRUCTIONS IN

THE OWNER'S MANUAL.

¥ KEEP THIS MANUAL FOR LATER USE.

¥ DO NOT CONNECT THIS APPLIANCE TO

ANY CHIMNEY SERVING ANOTHER

APPLIANCE.

¥ KEEP FURNITURE, DRAPES, CURTAINS,

WOOD, PAPER AND OTHER

COMBUSTIBLES A MINIMUM OF 36" AWAY

FROM THE APPLIANCE.

Page 3

TABLE OF CONTENTS Page

IMPORTANT INFORMATION

INTRODUCTION......................................................................................................................................1

SAFETY PRECAUTIONS...........................................................................................................................2

FEATURES AND SPECIFICATIONS ............................................................................................................4

CHIMNEY INFORMATION & REGULATIONS .................................................................................................5

The 3-Foot, 2-Foot, 10-Foot Rule ..........................................................................................................5

Factory-Built Chimneys ......................................................................................................................6

Determining the Distance Between the Chimney and Combustibles..............................................................6

Masonry Chimneys............................................................................................................................7

INSERT INSTALLATION

OPTIONAL EQUIPMENT...........................................................................................................................8

PREPARATION FOR INSTALLATION ..........................................................................................................14

FIREPLACE INSERT - SPECIFICATIONS .....................................................................................................15

MASONRY FIREPLACE INSERT INSTALLATION ...........................................................................................17

Installation Using a Direct Connection ...................................................................................................17

Installation Using a Positive Connection ................................................................................................19

Installation Using 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 Use of Your Appliance.................................................................................................................31

Wood ..............................................................................................................................................32

Seasoning Wood...............................................................................................................................33

Storing Wood....................................................................................................................................35

CARE AND MAINTENANCE

CARE AND MAINTENANCE .......................................................................................................................38

Maintenance Schedule.......................................................................................................................38

Maintenance Instructions ...................................................................................................................38

BEFORE CALLING FOR SERVICE

BEFORE CALLING FOR SERVICE ..............................................................................................................41

REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS

Replacement Parts............................................................................................................................42

Removal Instructions.........................................................................................................................42

5-YEAR WARRANTY ................................................................................................................................48

SAFETY LABEL ......................................................................................................................................49

Page 4

FEATURES AND SPECIFICATIONS

* EPA Phase II Approved

* Large Firebox Capacity - 2.3 cu. ft.

* 3/16 and 5/16" Steel Plate Construction

* Long Burn time - Up to 10 Hours

* Heavy Duty Firebrick Lining

* Conveniently Located Single Push-Pull

Combustion Air Control

* 19 1/2" Log Length Capacity

CONVENIENT

HIGH HEAT OUTPUT

VERSATILE

CLOSE CLEARANCES

DURABLE

Heating Capacity ............................................................................1,200 to 1,800 sq. ft.

Maximum B.T.U.'s/hr ......................................................................71,300 (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

home floor plan, type of fuel used, and moisture content of wood. Emissions and

efficiency numbers are those that have been certified by the U.S. E.P.A. and the Oregon

Department of Environmental Quality.

Page 5

CHIMNEY INFORMATION & REGULATIONS

Whether you install your wood heating appliance with a factory-built chimney or masonry chimney, there

are certain rules that must be followed. The following guidelines for chimney installation are included in

this manual to augment the information supplied with either the manufacturer's information for factory-built

chimneys or to insure that your present masonry chimney is suitable for this wood heating appliance. Do

not use makeshift methods or compromise in installation of any chimney equipment.

The 3-Foot, 2-Foot, 10-Foot Rule

The 3-foot, 2-foot, 10-foot rule states that all chimneys (factory-built or masonry) must be:

1. At least 3 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 Height on a Flat Roof

42"

24"

18"

Less

Than 10'

36"

10' or Greater

Wall or

Parapet

"A" "B"

These minimum chimney heights are required by building codes for safety purposes, to allow time for

sparks exiting a chimney to cool before they land on the roof. In some problematic situations, additional

chimney height above the specified minimums may be necessary to reduce wind-induced down drafting

and back puffing, or to increase draft, thereby improving appliance operating characteristics.

Page 6

CHIMNEY INFORMATION & REGULATIONS (Cont.)

Factory-Built Chimneys

Depending on the manufacturer and where the chimney is to be installed, special supports, roof

assemblies, radiation shields, or locking bands may be supplied as a part of the chimney system. The

manufacturer's installation instructions, which are reviewed by the listing agency, specifies when and

where each of these components must be used.

There are three standard installations with factory-built chimneys. Each type of installation should use

flashing and an adjustable storm collar at the roof line to prevent water from entering the house.

Manufacturers require that chimneys extending beyond a certain height above the roof (frequently above

5 feet) must also be braced.

A chimney cap keeps out rain, birds and other animals, and may reduce down drafts. Spark arresters,

wire mesh devices designed 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.

Determining the Distance Between the Chimney and Combustibles

The chimney must be kept a minimum distance of 2" away from combustibles (e.g., drywall, wood framing,

etc.). The distance between the outside surface of a chimney and combustibles is measured horizontally,

at right angles to the chimney. The pitch of the platform (e.g., the roof) must be considered in calculating

the size of the hole that is cut.

Calculating the Cut-Out on a Slanted Roof

Combustible Roof

Factory-Built Chimney with

Required 2" Clearance

Length of Cut-Out in Roof

2" Min.

90û

Width of Cut-Out in roof

= 4" + chimney width

Length of Cut-Out in Roof

= "c" times 2 + chimney width

Width of

Cut-Out in Roof

Page 7

CHIMNEY INFORMATION & REGULATIONS (Cont.)

Determining the Distance Between the Chimney and Combustibles (Continued)

Installers may find it convenient to create hole cut-out templates for pitches common to their area rather

than performing the calculations or using a trial "cut and measure" system for each installation.

Carefully read the specifications, as minimum 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 should be made before installation.

WARNING:

Do not connect this unit to a chimney flue serving another appliance.

Do not use makeshift compromises in the installation.

Page 8

OPTIONAL EQUIPMENT

Your X-96 comes assembled and only needs the panels or bay kit attached. The options available for the

appliance are listed below and require some assembly.

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

1. Surround Panels

The surround panels for your insert are sold separately and come in the three sizes listed below. It is very

important that you choose the surround panels that will adequately suit your installation. For direct or

positive connections the surround panels do not require insulation for an airtight seal. For face seal

connections the surround panels must overlap the fireplace at least 2" on the top and sides and require

insulation to insure an airtight seal.

SURROUND PANEL SIZES SIZE ON APPLIANCE (INCLUDING TRIM)

8" 40 1/2" width by 27 3/4" height

10" 44 1/2" width by 29 3/4" height

12" 48 1/2" width by 31 3/4" height

NOTE: For a Face Seal Connection it is recommended that you have at least 2" of

overlap. On brick or stone facing an overlap of 2 1/2" may be necessary for an airtight

seal due to the rough surface.

It is very important that 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 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 installation you are doing, and follow the directions below when

they are referred in that section. The insert should be placed on the hearth one foot away from the

fireplace opening to install the surround panels. After the side surround panels are installed, the insert

can be placed into position.

1. Place the side panels against the side of the insert so the inward flange of the side panel goes inside

the panel on the side of the insert. Line up the slots in the panel with the holes in the side of the

insert. Attach each panel with two screws and nuts included with the panel kit. The screws should

pass through the insert and side panel from the inside out. Do not tighten all the way at this point.

See the illustration on the following page.

2. Slide the top panel onto the offset on top of the side panels. The top panel must also slide over the

mounting flange that is on the insert. The 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.

Page 9

OPTIONAL EQUIPMENT (Continued)

1. Surround Panels (Continued)

3. Adjust the position of the side panels 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 the screws and

nuts that hold the panels in place to complete the surround panel installation.

NOTE: If using a positive or direct connection, the top panel should be installed after the

flue is connected to the appliance.

Side Panel Side Panel

Top Panel

Joggle clips

Mounting

Flange

The damper rod

must line up

with the channel

in the center of

the top panel.

Attach the side

panels with two

screws and nuts

as shown here.

The inward flange

on the side panel

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. With the insert drawn at least 6" away from the fireplace, glue the insulation strip included with the

surround panel kit to the back of the panels using RTV silicon or stove gasket cement. The insulation

should be installed so it overlaps the fireplace opening to form a seal between the panels and the

fireplace face.

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.

Page 10

INSERT OPTIONAL EQUIPMENT (Continued)

2. Surround Panel Brass Trim (Included with Surround Panels)

The surround panel brass trim is an item included with your panels that greatly 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

CROSS SECTION OF BRASS TRIM

Set-screw that

holds the larger "L"

bracket in place

Groove where the

larger "L" bracket

fits into

Groove Where

Surround Panels

Slide

Groove where the

smaller "L" bracket

fits into

Front Side

Larger "L"

Brackets

Top Trim

Left Trim Right Trim

Smaller "L"

Brackets

2. Insert a large and small "L" bracket leg into the groove in the 45ocut end of each side piece. Slide the

other leg of each "L" bracket into the groove in each end of the top piece.

3. With the allen wrench included with the trim, tighten the set-screws into the "L" brackets, insuring that

the 45ocuts are butted together to form a neat joint.

4. Lift the complete brass trim assembly and slide the side pieces down over the 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

installation. For direct or positive connections the bay kit does not require insulation for an airtight seal.

For face seal connections the bay kit must overlap the fireplace at least 2" on the top and sides and

requires insulation to insure an airtight seal (See "Surround Panel Insulation Installation").

BAY KIT DIMENSIONS: 37" Wide 28" Height

NOTE: For a Face Seal Connection it is recommended that you have at least 2" of

overlap. On brick or stone facing an overlap of 2 1/2" may be necessary for an airtight

seal due to the rough surface.

It is very important that the bay kit overlaps the fireplace opening by 1/4" or more. This will insure a good

seal and provide a more attractive facade. The bay kit must overlap the fireplace opening in both width

and height. The bay kit may overlap the fireplace opening by 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...).

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