Bosca GOLD 400 User manual

GOLD 400 Wood Stove
Installation and Operating Instructions
Save These Instructions
Please read this entire manual before you install and use your BOSCA GOLD 400 Wood Stove.
Failure to follow instructions may result in property damage, bodily injury, or even death.

TABTE OF CONTENTS
SAFETY NOTICES
INTRODIICTION
INSTATLATION
The floor
lnstallation clearanees
CHIMNFY
Chimney Connection 6
6
Factorv Built Chimnev
Masonry Chimney
Masonry Fireplace
Chimnev Heieht
Combustible Wull Chi*ne
MOBILE HOME INSTAILATION 10
OPERATING AND LIGHTING INSTRUCTIONS 11
Iishtins 11
Reloadins l2
MAINTF'NANCF' t2
12
Disposal of Ashes
Glass Reolacement 13
Glass Cleanine 13
Doors Gasket Replacement t4
Refractory Brick Replacement 14
Wood Handle 15
Creosote - Formation and need for removal 15
TROUBLESHOOTING 16
REPT,ACFMENT PARTS 16
13
I,TFETIMF, T,IMITF,D WARR ANTY l8

-
. SAFETY NOTICES I
-
When your BOSCA GOLD 400 is not properly installed, a house fire may result. To reduce the risk of fue, follow the installation
instruciions. Contact local building, llre officials, or authority having jurisdiction about restrictions, permit and installation
inspection requirements in your area.
DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS
GASOIINE, NAPHTHA OR ENGINE OIt.
HOT WHILE IN OPERATION. KEEP CHILDREN, CTOTHING AND
FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS.
NEVER USE GASOLINE, GASOLINE-TYPETANTERN FUEL,
KEROSENE, CHARCOAT LIGHTER FLUID, ON SIMITAR TIQUIDS TO
START OF ''FRESHEN UP" A FIRE IN THIS STOVE, KEEP AtL SUCH
LIQUIDS WEtt AWAY FROM THE STOVE WHITE IT IS IN USE.
DO NOT ELEVATE FIRE, BUILD WOOD FIRE DIRECTLY ON FIREBOX
HEARTH.
BURN NATURAT WOOD ONIY. DO NOT BURN ANY OTHER
FUELS. PREFER HIGH-QUALITY WOOD, ADEQUATETY AIR-DRIED.
AVOID BURNING GREEN WOOD.
KEEP WOOD A SAFE DISTANCE FROM THE STOVE AND KEEP IT
OUT OF THE SPACE AROUND THE STOVE OR AREAS REQUIERED
FOR REFUETING AND ASH REMOVAI.
THE BOSCA GOID 4OO IS APPROVED FOR MOBITE HOME
INSTALTATION. PTEASE FOLTOW THIS MANUAT CAREFULTY
FOR ANY INSTALLATION, INCLUDING IN A MOBILE HOME.

We would like to congratulate you for selecting our BOSCA GOLD 400. By pqrqhqsing a BOSCA product, you receive the
advantage of the strength, guarantee and the more than 20 years experience BOSCA has in producing stoves and heaters
equippe-i with double air combustion systems, which enable efficient consumption of the wood, as well as minimum impact
to the general environment.
BOSCA Chile S.A. is the leading company in the production of wood stoves in Chile, with more than 250,000 stoves sold
and there are Bosca products inslalled in houses in Spain, Portugal, fugentina, Uruguay, Ecuador, and Mexico. In the production
of our stoves, we usb only the finest materials. This, along with the experience of the members of our staff, means for you a
product of high quality and dependability.
The BOSCA GOLD 400 is a clean buming EPA certified, non-catalytic wood buming stove with 4.4 grams per hour particulate.
The BOSCA GOID 400 has been tested and listed by OMNI-Test Laboratories,lnc. The test standards are U[1482 and UIC
s627.
Please read this entire manualbefore you installand use your BOSCA GOLD 400. The pulpose of this manualis to familiarize
you with your GOLD 400's safe installation, operation and maintenance. It contains information that will be useful, so save
it for future reference.
INTRODUCTION
INSTALLATION
For your ultimate safety and the proper function of your stove, it should be installed in accordance with the instructions of
this Manual.
The first step is to decide where is the most appropriate place to install your stove.
It is important to install the stove in an area with adequate air circulation and flow. This allows the warm air to more easily
reach the intended rooms. Additionally, your stove's placement should enable, and not be an obstacle to, free movement
of people, especially children.
Your stove and chimney connector must be far enough from combustible materials to meet all clearance requirements.
The floor
One of the main necessary precautions when installing a wood stove is to leave sufficient space between the stove (top, sides,
back, front, and under stove pipes) and any other material that can catch fire.
If the stove is to be installed on a combustible floor, it must be placed on an approved l/2" (13mm) non-combustible hearth
pad with k = 0.84 BTU/in ft2 hr'F. In the USA, the floor protecior must extend 8" beyond each side of the flue loading door
and 16" to the front. In Canada, the floor protector must extend 8" (200mm) beyond each side and the back of the appliance
and 18" (450mm) to the front. (See fig. 1)
16"-USA
18" (450mm) Canada
Fig. 1

. a rear vent installation the floor protection must also extend under the stovepipe a minimum of 2" (50mm) beyond either
side of the pipe.
How to determine if alternate floor protection materials are acceptable.
All floor protection must be non-combustible (i.e., metals, brick, stone, mineral fiber boards, etc.). Any organic-materials-(i.e.,
plastics, riirood paper products, etc) gre combustible and must not be used. The floor protection specified includes some form
bf thermal desigriatioh such as R-value (thermal resistance) or k-factor (thermal conductivity).
Procedure:
1. Convert specification to R-value:
i. R-value given - no conversion needed.
ii. k-factor is given with a required thickness (T) in inches: n =f x f
iii. K-factor is given with a required thickness (T) in inches:n =1fu x f
iv. r-factor is given with a required thickness (T) in inches: R = r x T
2. Determine the R-value of the proposed alternate floor protector.
i. Use the formula in step (1) to convert values not expressed as "R".
ii. For multiple layers, add R-values of each layer to determine overall R-value.
If the overall R-value of the system is greater than the R-value of the specified floor protector, the alternate is acceptable.
Example: The specified floor protector should be 3/4-inch thick material with a k-factor of 0.84. The proposed alternate is
4" bricit with an i-factor of 0.2 over 1/8" mineral board with a k-factor of 0.29.
Step (a): Use formula above to convert specification to R-value.
R= *" t =*nx 0.75 = 0.8e3
Step (b): Calculate R of proposed system.
- 4" brick of r = 0.2, therefore:
Rbrick=0.2x4=0.431
1/8" mineral board of k = 0.29, therefore
Rmineralboard = "tnx 0.125 = 0.431
Rtotal = Rbrick+ Rmineralboard= 0.8 + 0.431 = l'23I
Step (c): Compare proposed system Rtotal of 1.231 to specified R of 0.893. Since proposed system Rtotal is greater than required,
the system is acceptable.
Definitions
r _ (ftl (hr) ("F)
(Btu) (in) _1 k
- (ftz) (hr) ("F)
K= Btu k= (Ptu) (in) = Kx 12
(ftz) (hr) ('F) .. (Btu) (ft)
t\= (ftz) (hr) ("F)

Installation Clearances
It is extremely important that you respect required installation distances and that you respect local installation regulations.
This is for yorir safbty! The manufacturer is not iesponsible for the product, if it is not iristalled following these recommendations.
These clearances may only be reduced by means approved by the regulatory authority.
A combustible surface is anything that can burn (i.e. sheet rock, wallpaper, wood, fabrics etc.) These surfaces are not limited
to those that are visible anil also include materials that are behind non-combustible materials. If you are not sure of the
combustible nature of a material, consult your local fire o{Iicials.
Parallel Installation Corner Installation
CLEARANCE REQUIREMENTS: STANDARD RESIDENTIAT INSTATLATION
(SINGLEWAII & DOUBTEWALL CONNECTOR): ALCOVE INSTATTATION
WITH (DOUBIE WALL CONNECTOR):
A.. SIDEWALL TO UNIT
B.- BACKWALTTO UNIT
C. CORNERWATLTO UNIT
D.- SIDEWALL TO CONNECTOR
E.. BACKWALLTOCONNECTOR
F. CORNERWALLTOCONNECTOR
G.- UNIT TO CEILING
H.- FLOORTO CEILING
11.5" (292mm)
15" (381mm)
N/A
19" (483 mm)
17.5' (444 mm)
N/A
55" (1.397 mm)
84' (2.134 mm)
l 1.5"
1z'*
6"
18.5',
r4"
t4
55"
a4^
(292 mm)
(304 mm)
(152 mm)
(470 mm)
(356 mm)
(356 mm)
(1.397 mm)
(2.134 mm)
11.5" (292 mm)
12' (305 mm)
N/A
18.5" (470 mm)
14" (356 mm)
N/A
55" (1.397 mm)
84" (2.134 mm)

'himney Connection
The chimney connector is a single walled pipe used to connect the stove to the chimney. For use with the appliance the
chimney connector MUST be 6" in diameter, with a minimum thickness of 24 gauge black steel or 26 gauge blued steel.
Aluminium and galvanized steel pipe is not acceptable for use with the appliance. These materials cannot withstand the
extreme temperatures of a wood fire and can give off toxic fumes when heated.
Do not use the connector pipe as a chimney.
Each chimney connector or stovepipe section must be installed to the stove flue collar and to each other with the male
(crimped) end toward the stove. See fig 2.
This prevents any amount of condensed or liquid creosote from running down the outside of the pipe or the stovetop. All
joints, including the flue collar connection must be secured with three sheet metal screws to ensure that the sections do not
separate.
For the best performance the chimney connector should be as short and direct as possible, with no more than two 90 elbows.
The maximum horizontal run is 36" and a recommended total length of stovepipe should not exceed 10 feet. Always slope
horizontal runs upward l+" per foot toward the chimney.
No part of the chimney connector may pass through an attic or roof space, closet or other concealed space, or through a
floor ceiling. All sections of the chimney connectors must be accessible for cleaning. Where passage through a wall or parti'tion
of combustible construction is desired, the installation must conform with NFPA 2Il or CAN/CSA-8365, and is also addressed
in this manual.
Fig.2
CHIMNEY
DO NOT CONNECT THIS UNIT TO A CHIMNEY
FLUE SERVING ANOTHER APPLIANCE. DO NOT
CONNECT TO ANY AIR DISTRIBUTION DUCT OR
SYSTEM.
{his room heater must be connected to a 6" factory built UL 103 HT chimney (ULC 5629, in Canada) or a code-approved
asonry chimney with a flue liner.
,,J-,ffi,,"1"^,
"i'no*Too'

Factory Built Chimney
When a metal prefabricated chimney is used, BOSCA's
installation inshuctions must be followed. You must also purchase
(from an authorized retailer) and install the ceiling support
package or wall pass{hrough and'T" section package, firestops
(where needed), insulation shield, roof flashing, chimney cap,
etc. Maintain proper clearance to the strucflrre as recommended
bv BOSCA. The-chimne.y must be the required height above
tlie roof or other obstrlctions for safety and proper draft
operation. (See fig.3)
Masonry Chimney
Ensure that a masonry chimne.y meets the minimum standards
of the National Fire Piotection Association (NFPA) by having it
inspected by a professional. Make sure there are no cracks,
loose mortaror other signs of deterioration and blockage. Have
the chimney cleaned before the stove is installed and operated.
When conirecting the stove through a combustible wallto a
masonry chimnei, special methods are needed (See fig. 4).
Refer to-Combustible Wa-ll Chimney Connector Pass-Throughs
on page 9.
Sunoort Box
widh'built - in
starter section
One storv house installation with atlic
Chimriey is supported by celling
Adjustable roof
Flashing
Chimney Sections
Chase Enclosure
Wall Strap
WallThimble
Tee Support
Bracket
Tee Clean - Oul
Access Door
Chimney through outer wall with enclosed chase
Chimney is supported by tee support bracket
Fig.3

Iasonry Fireplace
There are listed kits available to connect a stove to a masonry
fireplace. The kit is an adapter that is installed at the location of
the'fireplace damper. Th'e existing damper may have to be
removed to allow installation. (See fig. 5)
Chimnev throueh ouler wall wilh enclosed chase
Chimirey is sripported by tee suppon bracket Fig.5
Chimney Height
A masonrv chimnev or a listed factory-build chimney must be the required height above the roof and any other nearby
;;;iil t;;t.'ift" .'trt"ir*v -rti U" ,i teast 3; (90 cni) higher than the'highest p-oint wherg it pass^es through the roof and
;il";;ii;i6-0 ;i h[h;;l'hi" tn" nign"sipart'of the iootor structure thalis within 10' (305 crir; of the chimney, measured
horizontally (See fig. 6).

Combustible Wall Chimney Connector Pass - Throughs
Minimum chimenev cleaance lo brick
and combustibles Z in. (50.8 mm)
rllll
tffi]
ffiEt
Tlffill
I lF:*r# ll
U-rT --11
Minimum 12 in. (304.8 mm)
to comhrrsiibles
E
O
Minimum clearance
9 in. (228.6 mm)
Chimnev
Conneclor
Use chimnev
mfrs. Darts td
attach connector
securely
U F7l' \ Solid-insulated
{-* fn Ulsted factorv buill
llqsoroy \ \ chimneylehght
Uhimney Sheet steel
supports
Minimum chrmeney clearance to
sheet steel suDborts and
combustibles 2 in (50.8 mm)
Two air channels
each lin. (25.4mm)
Chimney
conneal6r
Minimum 6 in.
(152.4 mm)
glass fiber insuhtion
Masonrv
Chimney iheet steel
supports
Minimum chimenev clearance to
sheet steel suDborts and
combustibles 2 iri. (50.8 mm)
Minimum clearance
1 in. (25.4 mm)
Masonrv
Chimne'y
NOTES:
Method 4.I2" (304.8 mm) Clearance to Combustible Wall
Member: Using a minimum thickness 3.5" (89 mm) brick and
a 5/8" (15.9 mm) minimum wall thickness clay liner, construct
a wall pass{hrough. The clay liner must conform to ASTM C31 5
(Standard Specification for Clay Fire linings) or its equivalent.
I(eep a minimum of 12" (304.8 mm) of brick masonry between
the clay liner and wall combustibles. The clay liner shall run
from the brick masonry outer surface to the inner surface of the
chimney flue liner buinot past the inner surface. Firmly grout
or cement the clay liner in place to the chimney flue liner.
Method 8.9" (228.6 mm) Clearance to Combustible Wall
Member: Using a 6" (L52.4 mm) inside diameter,listed, factory-
built Solid-Pak chimney section with insulation of 1" (25.4 mm)
or more, build a wallpass-through with a minimum 9" (228.6
mm) air space between the outer wall of the chimney length
and wall combustibles. Use sheet metal supports fastened
securely to wallsurfaces on all sides, to maintain the 9" (228.6
mm) air space. When fastening supports to chimney length,
do not penehate the chimney liner (the inside wall of the Solid-
Pak chimney). The inner end of the Solid-Pak chimney section
shallbe flush with the inside of the masonry chimney flue, and
sealed with a non-water soluble refractory cement. Use this
cement to also seal to the brick masonry penetration.
Method C. 6" (152.4 mm) Clearance to Combustible Wall
Member: Starting with a minimum 24 gage (.02a" [.61 mml)
6" (152.4 mm) metal chimney connector, and a minimum24
gage ventilated wall thimble which has two air channels of 1"
(25.4 mm) each, construct a wall pass-through. There shall be
a minimum 6" (152.4) mm separation area containing fiberglass
insulation, from the outer surface of the wall thimble to wall
combustibles. Support the wall thimble, and cover its opening
with a Z$-gage minimum sheet metal support. Maintain the 6'
(152.4 mm) space. There should also be a support sized to fit
and hold the metal chimney connector. See that the supports
are fastened securely to wall surfaces on all sides. Make sure
fasteners used to secure the metal chimney connector do not
penetrate chimney flue liner.
Method D. 2" (50.8 mm) Clearance to Combustible Wall
Member: Start with a solid-paklisted factory built chimney section
at least 12" (3O4 mm) long, with insulation of 1" (25.4 mm) or
more, and an inside diameter of 8" (2 inches [51 mm] larger
than the 6" 1152.4 mml chimney connector). Use this as a pass-
through for a minimum Z\-gage single wall steel chimney
connector. Keep solid-pak section concentric with and spaced
1" (25.4 mm) offthe chimney connector by way of sheet metal
support plates at both ends of chimney section. Cover opening
with and support chimney section on both sides with 24 gage
minimum sheet metal supports. See that the supports are fastened
securely to wall surfaces on all sides. Make sure fasteners used
to secure chimney flue liner.
1. Connectors to a masonry chimney, excepting method B, shall extend in one continuous section through the wall pas{hrough system and the chimney wall, to but not past
the inner flue liner face.
2. A chimnev connector shall not an attic or roof space, closet or similar concealed space. or a floor. or