BuckMaster 91 CATALYTIC UNIT User manual

FIREPLACE INSERT & FREESTANDING
MODEL 91
CATALYTIC UNIT
FEATURES
PREPARATIONS INSTALLATION
OPERATION MAINTENANCE SAFETY
SAFETY NOTICE
IF THIS HEATER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT.
FOR YOUR SAFETY, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT
THE AUTHORITY HAVING JURISDICTION ( SUCH AS MUNICIPAL
BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE PREVENTION BUREAU,
etc.) CONSULT BEFORE INSTALLATION TO DETERMINE THE NEED TO
OBTAIN A PERMIT. KEEP THESE INSTRUCTIONS FOR FUTURE USE.
LISTED BY: PFS/TECO, COTTAGE GROVE, WI
MANUFACTURED BY NEW BUCK CORPORATION
200 ETHAN ALLEN DRIVE,
SPRUCE PINE, N.C. 28777
Revised February 2020
Buck Stove
www.buckstove.com

TABLE OF CONTENTS
SECTION I
Room Heater Features and safety..................................................................................3
Model 91 Stove Identification ......................................................................................4
Important Statements..................................................................................................... 5-6
Chimney Heights ...........................................................................................................7
SECTION II
Masonry Insert Installation............................................................................................ 8-12
SECTION III
Residential Freestanding Heater Installation............................................................... 13-20
Leg Installation............................................................................................................ 14
Pedestal Installation.....................................................................................................14
Minimum Clearances to Combustibles Single Wall Chimney Connector ................. 15
Minimum Clearances to Combustibles Double Wall Chimney Connector ................ 18
SECTION IV
Wood Heater Safety .................................................................................................... 22
SECTION V
Operation .....................................................................................................................23-24
SECTION VI
Preventive Maintenance ..............................................................................................25
Catalyst Replacement .................................................................................................26
Minimum Clearances to Combustibles Single Wall Chimney Connector ................. 14
Motor Replacement .....................................................................................................27
Wiring Schematic ....................................................................................................... 28
Brick Layout................................................................................................................29
Door Gasket Replacement .......................................................................................... 30
Check Chimney / Cleaning Heater / Care of Glass Door............................................31
Replacement Parts .......................................................................................................32
SECTION VII
Troubleshooting........................................................................................................... 33-34
WARRANTY .............................................................................................................35

SECTION I
When installed and operated as specified in these instructions, and as stipulated on operation and installation labels affixed to unit, The
New Buck Corporation room heater Model 91 Bay is one of the safest and most efficient heating systems available. The unit is designed
to burn wood fuel only.
Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in property
damage, bodily injury or even death.
 NOTE: When burning any unit or appliance that combusts fuel for heat,
we highly recommend use of smoke and carbon monoxide detectors in your home.
Early signs of carbon monoxide poisoning resemble flu, with headaches, dizziness and/or nausea. If you have these
signs, heater may not be working properly. Get fresh air at once!
Throughout manual, you will see this symbol. This indicates areas of importance regarding safety. Please make a special note of
these areas.
Warning: PAINT. This product can expose you to chemicals including ethyl benzene, which is known to the
state of California to cause Cancer. For more information, go to www.P65Warnings.ca.gov
Install and use only in accordance with manufacturer’s installation and operating instructions. Do not connect this unit to a chimney flue
serving another appliance. This unit is not designed for installation in a mobile home.
ROOM HEATER FEATURES
Before attempting to install or operate your heater, it is a good idea to familiarize yourself with features and operating controls of unit.
(See page 4 for reference).
OPERATING CONTROLS
WARNING: Model 91 Bay Heater was not designed for fire grates.
NOTE: Do not use grate, elevate fire or build wood fire directly on hearth.
1. Bypass Damper: The bypass damper control is located in top center of heater front just under top. It is operated by pushing or
pulling rod. The damper is fully open when handle is pulled out and fully closed when it is pushed in. The damper must be OPEN
before door is opened.
2. Blower Control: The blower control (Rheostat) is located on side of the unit. The rheostat is used to vary speed of blower. It can
be set at any position. It must be turned on to activate automatic thermostat on stove.
3. Primary Air Controls: The primary air intake draft controls (4) are located at left and right bottom side of hearth. They are
operated by moving handle out to open (to allow air into the firebox) or in (to control or close off) air into firebox. Shot gun air
control, allows air to center of firebox of stove (4a).
4. Warm Air Outlets: Provides heat extraction from top of firebox.
5. Baffles: Directs air flow around unit for maximum heat transfer.
6. Air Inlet: Allows cool air near floor to be circulated through blower and back into warm air chamber of heater.
7. Door: Provides an “airtight” feature. The door allows a much higher burning efficiency than can be obtained with an open firebox.
8. Hearth Extension: Offers protection from spilled ashes and cinders.
9. Power Cord: Provides electrical power to operate blower.
10. Catalyst: Enables Unit to burn cleanly and efficiently.
11. Catalyst Probe: Probe is located right of the bypass damper rod. It is used to determine (catalyst) temperature.
12. Automatic/Off/Manual Switch: Located behind right cover door under hearth. In the “Manual” position, the blower operates
continuously. In “Automatic” position, blower is controlled by internal thermostat which reacts to temperature of air between the
stove walls. (Not same as the temperature showing on the Catalyst Probe.)
SAFETY STANDARD COMPLIANCE
The Model 91 Bay catalytic solid fuel (wood) burning combination room heater/fireplace stove manufactured by New Buck Corporation
complies with UL 1482-(1996),: UL 1482 (2006): UL 1482 (2010) and UL 737-1995 for residential freestanding and masonry fireplace
insert installations when constructed and installed in accordance with ITS approved documentation.
Page 3

1. Bypass Damper
2. Bypass Damper Spring Handle
3. Blower Control (Rheostat)
4. Primary Air Control Air Wash Rod for Both
Sides
4a. Shot Gun Air Control
5. Warm Air Outlets
6. Baffles (Interior of Stove)
7. Air Inlet
8. Door
9. Hearth Extension
10. Hearth Trim
11. Power Cord
12. Catalyst (Interior Firebox)
13. Catalyst Probe
14. Automatic / Off / Manual Switch
15. Brass Cap
16. Hinge Block
17. Quean Ann Legs
18. Leveling Screws
19. Glass Clips/Large; Side, Top, Bottom
20. Door Gasket
21. Door Glass
22. Door Glass Gasket
23. Side Glass
24. Side Glass Gasket
25. Overlays
26. Firebrick
27. Motor
28. Motor Mount Bracket
29. Cover Door
30. Shot Gun Air Box
31. Ash Pan
32. Disc Thermostat
33. Cover Door Hinge
34. Magnet Holder
35. Cover Door Magnet
36. Door Handle
37. Spring Handle
38. -Door Latch
-Door Latch Screw
-Door Handle Bushing
-Door Handle Spacer
-Door Latch Flat Washer
-Door Latch Screws (Phillips Head)
-Door Latch Screws (Allan Head)
39. Lower Heat Shield
40. Hinge Pins
41. 8" Flue Exit
42. Air Wash Screen
EPA COMPLIANCE STATUS
This manual describes installation and operation of the New Buck Corporation Model 91 Bay wood heater. This
heater meets the U.S. Environmental Protection Agency’s Emission limits for wood heaters sold after May 15th
2020. Under specific test conditions, this heater has been shown to deliver heat at rates ranging from
approximately 10,400 to 62,745 BTU/hr for the Model 91 Bay. A weighted average was used to calculate the
overall efficiency across all of the burn rate categories using the higher heating value (HHV 80.4%).
MODEL 91 WOOD STOVE IDENTIFICATION
1 13 41
5
20
42
21
8
23
36
37
24
4
14
11
3
32
18
29
27
26 28
33
30
31
7
35
34
4A
10
9
22
19
40
16
15
12
6
39
17
25
38
2
Page 4

CATALYST EQUIPPED
"This wood heater contains a catalytic combustor, which needs periodic inspection and replacement for proper operation. It is against
federal regulations to operate this wood heater in a manner inconsistent with operating instructions in this manual, or if the catalytic
element is deactivated or removed."
"Combustors should be visually inspected at least three times during the heating season to determine if physical degradation has
occurred. Actual removal of the combustor is not recommended unless more detailed inspection is warranted because of decreased
performance. If any of these conditions exists, refer to Catalyst Troubleshooting section of this owner's manual."
CATALYST WARRANTY
The combustor supplied with this heater is a set of (3) (2" x 3-1/2" x 6" x 25" cells). Consult catalytic combustor warranty also supplied
with this heater. All warranty claims should be addressed to:
Applied Ceramics
Customer Service Department
P.O. Box 29664
Atlanta, GA 30359
770-448-6888
See enclosed catalyst warranty for instructions. New Buck Corporation does not handle catalyst replacements. Customer can order
directly from Applied Ceramics.
DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE.
DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS.”
PROPER FUEL SELECTION
For best results, this heater is designed to burn (dry), natural seasoned hardwood. Higher efficiencies and lower emissions
generally result when burning air dried natural seasoned hardwoods, as compared to softwoods or freshly cut hardwoods. Green
or freshly cut hardwoods (wood with high moisture content) will not produce the BTU’s needed to heat your home. The result
will be low temperature reading on the catalyst probe, thus low BTU output.
DO NOT BURN:
1) Treated Wood 3) Garbage 5) Solvents 7) Trash
2) Coal 4) Cardboard 6) Colored Paper
Burning treated wood, garbage, solvents, colored paper or trash may result in release of toxic fumes and may poison or render the
catalytic combustor ineffective.
Burning coal, cardboard or loose paper can produce soot or large flakes of char or fly ash that can coat combustor, causing smoke
spillage into room and rendering combustor ineffective. (Not covered under warranty.)
ACHIEVING CATALYTIC LIGHT-OFF
The temperature in stove and gases entering combustor must be raised to between 700o F to 900oF for catalytic activity to be initiated.
The temperature can be determined by the Catalyst Monitor Probe. During start up of a cold stove a medium to high firing rate must be
maintained for about 20 minutes. This can be achieved by starting fire with dry kindling, paper and small split wood. Have the Bypass
Damper fully open (pulled out). This ensures that the stove, catalyst and fuel are all stabilized at proper operating temperatures. Even
though it is possible (and likely) to have gas temperatures reach 600o F within two to three minutes after a fire is started, if the fire is
allowed to die down immediately it may go out or the combustor may stop working. Once the combustor starts working, heat generated
in it by burning smoke will keep it working.
ACHIEVING CATALYTIC LIGHT-OFF WHEN REFUELING
During refueling and rekindling of a cool fire, or a fire that has burned down to charcoal phase, operate stove at a medium to high firing
rate for about 10 minutes to ensure that catalyst reaches approximately 800
o
F.
Page 5
Warning: INTERAM GASKET. This product can expose you to chemicals including aluminosilicate, which is known to the
state of California to cause Cancer. For more information, go to www.P65Warnings.ca.gov

CATALYST MONITORING
It is important to periodically monitor operation of catalytic combustor to ensure that it is functioning properly,
and to determine when it needs to be replaced. A non-functioning combustor will result in a loss of heating
efficiency and an increase in creosote and emissions. See Troubleshooting section for detailed instructions
BEFORE attempting to remove catalyst.
This catalytic heater is equipped with means to monitor catalyst operation. Properly functioning combustors
typically maintain temperatures in excess of 1000oF. If catalyst temperatures are not in excess of 500o F, refer to
Catalyst Troubleshooting section of this owner’s manual.
CAUTION AGAINST OVER-FIRING
Do not over-fire this heater.
Attempts to achieve heat output rates that exceed heater design specifications can result in permanent damage to t
heater and to catalytic combustor.
ASH REMOVAL
CAUTION: Never remove ashes from heater with blower running. Be sure to turn room air blower off
before removing ashes
Whenever ashes build up in firebox and when fire has burned down and cooled, remove excess ashes. Leave an
ash bed approximately 1 inch deep on firebox bottom to help maintain a hot charcoal bed. To remove ashes the
dump is located at left inner bottom. By lifting dump door, place ashes through the dump opening. The ashes fall
directly into ash pan. The ash pan is located at left side under the hearth behind cover door.
NOTE: Be sure to turn room air blower off before removing ashes. Open cover door and slide ash pan out.
NOTE: Fueling and ash removal door (s) must remain closed when in operation.
Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should be placed
on a non-combustible floor or on ground, away from all combustible materials, pending final disposal. The ashes
should be retained in the closed container until all cinders have thoroughly cooled.
NOTE: Be sure to turn room air blower back on when job is completed.
NOTE: The room heater is not to be connected to any air distribution duct.
CREOSOTE - FORMATION AND NEED FOR REMOVAL
When wood is burned slowly, it produces tar and other organic vapor, which combined with expelled moisture
forms creosote. The creosote vapors condense in a relatively cool chimney flue of a slow-burning fire. As a result,
creosote residue accumulates on flue lining. When ignited, this creosote makes an extremely hot fire.
Select an installation location that will give best airflow from front of heater to remainder of home.
Page 6

Page 7
Stack wood in criss-cross
pattern under a shelter to allow
air flow to dry wood and to keep
wood from rain. Green wood
may have 50-60% moisture
content. Wood seasoned outside
uncovered may have 40%
moisture content. Wood
properly seasoned in a covered
environment will have less than
20% moisture content.
3 FT.
2 FT.
LESS THAN
10 FT.
2 FT.
10 FT.
GREATER
THAN
10 FT.
3 FT.
METAL
CHIMNEY
MASONRY
CHIMNEY
2 FT. MINIMUM HEIGHT ABOVE THE
ROOF WITHIN 10 FT. HORIZONTALLY
CHIMNEY “10 FT.” RULE (MINIMUM HEIGHTS)
NOTE: MINIMUM CHIMNEY HEIGHT 15 FT.
CHIMNEY HEIGHTS
HOW TO STACK WOOD

SECTION II
MASONRY INSERT INSTALLATION
INSTALLATION OPTIONS
This unit (appliance) may be installed into an all masonry fireplace, built in accordance with Uniform Building Code and
National Fire Protection Association (NFPA 211).
NOTE: Check with local building officials for any permits required for installation of this stove and notify your insurance
company before proceeding with installation.
OPTION A. (See Below See Figure 4).
At a minimum, a starter pipe reaching from stove flue exit to base of existing code approved
masonry chimney (flue-liner) and an airtight face seal.
OPTION B. (See Page 9 Figure 5).
Direct connection: In accordance with NFPA-211-9-4.5, Connection to Masonry Fireplaces. A solid fuel-burning
appliance such as a stove or insert shall be permitted to use a masonry fireplace flue where the following conditions
are met:
Exception: Listed fireplace accessories shall be permitted to use a masonry fireplace flue.
1. There is a connector that extends from the appliance to flue liner.
2. The cross-sectional area of flue is no more than three times the cross-sectional area of flue collar of
appliance.
3. If appliance vents directly through chimney wall above smoke chamber, there shall be a noncombustible
seal below the entry point of the connector.
4. The installation shall be such that the chimney system can be inspected and cleaned.
5. Means shall be provided to prevent dilution of combustible products in the chimney flue with air from the habitable
space.
OPTION C. (See Page 9 Figure 6).
It may be necessary to positive connect this unit to enhance the performance, if any of the following conditions exists:
1. Poor Drawing Flue 3. Double Flues 5. Stone Front Fireplace/ or damaged flue liner
2. Oversized Flue (17” x 7) 4. Ash Dump 6. Chimney that does not exceed 12’
Check with your dealer if any of above conditions exist before installing your stove. Proper installation is critical to the
performance of the Model 91.
Use Fireplace Kit PA FP91 for installation. An optional oversized fireplace kit is available for larger fireplaces. Check
with dealer.
SEAL TRIM PANELS WITH INSULA-
TION / AND OR HIGH TEMPERA-
TURE CAULK
OPTION (A)
STARTER PIPE
REMOVE
DAMPER
OR WIRE
IT OPEN
AIRTIGHT INSU-
LATED CLEAN-
OUT
NOTE: New Buck Corporation grants no
warranty, implied or stated, for the installation
or maintenance of your appliance, and assumes
no responsibility of any consequential damage
SAFETY NOTICE
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.
Page 8
FIGURE 4

FIGURE 7
FIREPLACE INSERT
30"
20" 15"
20"
8"
24"
HEARTH EXTENSION
MANTEL
INSTALLATION (Fireplace Insert)
Minimum Clearances to Combustible Materials (in inches)
TRIM PANELS
OPTION (B) OPTION (C)
SEAL TRIM PANELS
WITH INSULATION /
AND OR HIGH TEM-
PERATURE CAULK
REMOVE
DAMPER
OR WIRE IT
OPEN
AIRTIGHT
INSULATED
CLEAN-OUT
BLOCK-OFF PLATE
OR DAMPER
ADAPTER
STAINLESS
STEEL
CHIMNEY
CONNEC-
TOR MUST
EXTEND 1’
PAST THE
BLOCK-OFF
PLATE OR
TO THE
FLUE LINER
NOTE: Follow installation
instruction with Positive
Connection Kit.
(Kit sold separately)
NOTE: Follow installation instruction
with Direct Connection Kit.
(Kit sold separately)
CAP(PREVENTS
WATER FROM
ENTERING)
INSTALL A NON-COMBUSTIBLE
COVER PLATE TO PREVENT
WATER FROM ENTERING THE
CHIMNEY
FLUE
LINER
THE LINER MUST
BE STAINLESS
STEEL CONNEC-
TOR OR FLEXIBLE
VENT. FOLLOW
THE LINER
MANUFACTURE’S
INSTRUCTIONS
FOR INSTALLA-
TION AND SUP-
PORT.
AIRTIGHT
INSULATED
CLEAN-OUT
REMOVE
DAMPER
OR WIRE
IT OPEN
Page 9
FIGURE 6FIGURE 5

REQUIRED FIREPLACE DIMENSIONS
Minimum fireplace dimensions:
Height Width Depth
Min. Min. Min.
Model 91 Bay 23 1/2" 31 3/4" 15 1/2"
POSSIBLE TOOLS NEEDED FOR INSTALLATION
If you decide to install your own stove, there are several hand tools you may need to do job. If you do not already have
them, they are readily available at most hardware stores.
Caulking gun
Large adjustable wrench (may not be needed)
Drop cloths or newspapers
Vacuum cleaner or whisk broom
Flashlight
1 tube of RTV silicone, Code 103 or 106, or high temperature rubber cement rated between 450oF- 600o F.
7/32" drill bit and drill
Socket/Ratchet Set
Insulation (Provided in Trim Kit package)
INSTALLATION PREPARATION
Fireplace:
1. Locate furniture and other materials away from front of fireplace to allow free access to fireplace.
2. Cover hearth and adjacent floor areas with drop cloths to protect from soiling or marring surface.
3. Remove existing fireplace damper plate.
4. Thoroughly clean the fireplace of ashes and soot.
5. Have your existing chimney inspected before inserting this unit. Some chimneys must be relined or replaced before
they are safe to use.
6. Check the chimney and smoke chamber for excessive buildups of creosote or soot. Also, check for obstructions, such
as bird’s nests. If chimney is excessively dirty, clean it or have someone clean it professionally BEFORE installing
or using room heater.
7. If fireplace has an ash dump or outside air provision, these must be sealed off with metal or tightly packed non-
combustible insulation to prevent cold air from entering fireplace chamber.
Heater:
1. Inspect unit for any obvious physical damage.
2. Check primary air draft controls to ensure that they slide freely.
3. Check operation of damper control to ensure it will open and close properly.
4. Check Manual/Automatic Switch to ensure that motor is working. *Place switch in the “MANUAL” position.
(Plug in stove.) You cannot check motor in the “AUTOMATIC” position, unless a heat gun is used to heat
internal thermostat.
MINIMUM CLEARANCES:
The Model 91 Bay Fireplace Insert is intended for installation in accordance with standard for chimneys, fireplaces, vents
and solid-fuel burning appliances. NFPA-211 Code: NOTE-This model is not intended for installation into Zero Clear-
ance or pre-fabricated fireplace.
1. The hearth must be of masonry construction and must extend a minimum of 24" in front of firebox opening and a
minimum of 8" to either side of firebox opening.
2. Floor protector must be 3/8" minimum thickness non-combustible material or equivalent.
3. If your fireplace has wood trim above it, the wood trim must be at least 20" above top of unit and may be a maxi-
mum of 1/2" thick.
4. If your fireplace has a wood mantel, mantel or mantel supports must be located at a height of 30" above top of the
stove.
Page 10

POSITIONING THE HEATER
When positioning heater, the following conditions MUST be met! (See Figure 8.)
1. The front of damper opening must be positioned BEHIND back edge of lintel to ensure proper draft. (See
Figure 8.)
2. The vertical plane of fireplace front must fall BEHIND side panels of the unit. (In other words, it is possible
to have heater too far in as well as not far enough.)
3. Center the heater in fireplace opening.
MOUNTING TRIM PANELS
After unit is positioned, mark mounting position of trim panels as follows:
1. Place side trim panels flat against face of fireplace. Mark inside edge of trim panel to make a vertical
reference line. (See Figure 9.)
2. Place top (long) trim panel on top of unit. The panel should be flat against outside face of fireplace, and
standing vertically. Mark lower edge of trim panel with a pencil to make a reference line for mounting.
3. Slide unit out of fireplace far enough to work behind trim panel reference lines.
4. Mount side trim panels. (See Figure 9.)
a. Position trim panel on reference line.
b. Drill mounting holes in center of trim panel mounting brackets to allow for adjustment in
and out if necessary.
c. Mount trim panel using self-tapping screws provided.
5. Place top panel back on reference mark. Top trim panel mounting bracket is supplied with unit. Position
bracket so it overlaps rear lip of top trim panel. Drill mounting holes in top of stove using holes in bracket as
guide. Tighten screws.
6. Follow installation procedures in listed direct connect or positive connect kit you are using and install heater
and connect kit in fireplace.
FIGURE 8 POSITIONING FIGURE 9 MOUNTING TRIM PANELS
VERTICAL PLANE
LINTEL EDGE
DAMPER
OPENING
CENTER
LINE
Page 11

7. Slide unit back into fireplace. Check to be sure that trim panels are properly positioned and lie flat against
front of fireplace. If one or more of panels is out of position, slide unit out and reset by loosening mounting
screws and repositioning in slot.
8. Reinstall top trim panel by sliding rear lip of top trim panel underneath front lip of mounting bracket.
NOTE: Mount top trim panel so that it sits in front of top of side trim panels..
9. Obtain brass trim kit provided with unit and slip over top and sides of trim panels. (Top ends of brass may
need to be trimmed to fit.)
10. Ensure that starter pipe or connector is properly secure in stove flue exit, and aligned with chimney flue.
11. Mount top trim panel by drilling mounting holes in center of trim panel mounting brackets, with top end side
of top panel overlapping side panel.
12. Using insulation provided, peel and stick to back of panels overlapping fireplace dimensions by 1" on each
side and top. (See Figure 10.)
13. Using high heat silicone or furnace cement run heavy bead of caulking where panels meet stove. (See Figure
10.)
14. Slide unit back into fireplace. Check to be sure that trim panels (and brass) are properly positioned and lie flat
against front of fireplace. If panels are out of position, slide unit out and reset by loosening mounting screws
and repositioning in slot. With bar, lift stove up in front. Place insulation across front and surface of hearth or
bottom of fireplace to make complete seal.
15. To check seal of panels, use candle flame and go around entire area sealed by silicone and insulation. If flame
leans toward inside of fireplace, add additional insulation. This ensures an airtight seal.
FINAL CHECK
1. Recheck specified clearances.
2. Remove all foreign material from firebox area.
3. Open primary air draft, shot-gun air draft and damper bypass,
make sure ash drawer is sealed properly.
4. Plug power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure
motor operates properly.
5. Place 4 or 5 pieces of newspaper in stove. Light paper and close door. Ensure that stove draws properly
through primary drafts.
6. Check for smoke leaks around door.
7. Open door (slowly) and check for smoke escaping from front of stove. Smoking usually indicates a defective
or poorly positioned chimney. Some chimneys with a marginal draft can be preheated by lighting newspaper
and holding it near the open damper with a poker or fire tong. Once chimney heats up, a proper draft can
usually by obtained.
NOTE: A poor drafting chimney can lead to poor heater performance. This is not a defect of the heater, but
with the chimney. Poor performance due to a poor drafting chimney is NOT a warranty problem.
If a thorough review of Troubleshooting Guide does not solve your problem,
contact your dealer for assistance. If homeowner installed unit himself, there generally is a charge for
dealer to service the stove and inspect installation.
8. The unit is painted with a specially formulated high temperature paint that cures during the first two or three
firings. DO NOT BUILD A LARGE ROARING FIRE UNTIL THIS CURING IS COMPLETE OR
HEATER FINISH MAY BE DAMAGED. (Paint may blister or peel off. This is not covered by warranty.)
You may notice a slight smoking effect and an odor of burning paint when you build the first fires. This is
normal and is not a cause for alarm. In some cases these fumes will activate a smoke alarm. Opening a
window near unit will allow these fumes to escape.
Page 12
FIGURE 10

SECTION III
RESIDENTIAL FREESTANDING ROOM HEATER
INSTALLATION
INSTALLATION PRECAUTION
Select an installation location that will give best airflow from front of heater to remainder of home.
Extensive field and laboratory testing has shown that catalytic stoves perform best as freestanding stoves when
vented into a masonry chimney that include the following:
1. A rain cap is installed on the chimney.
2. Height of chimney is at least 15 feet high.
3. Location of chimney is on interior. (Not on an outside wall)
Satisfactory results have been reported with installations other than listed above. However, draft problems are
possible if a hot chimney is not maintained.
CAUTION: Do not connect this unit to a chimney flue serving another appliance.
Page 13

Inspect unit for any obvious physical damage.
Remove any items from within firebox.
Plug power cord into a 115V AC outlet to test motor. Do not run power cord under unit or in high
traffic areas.
Check primary air and control to ensure that it slides freely.
LEG INSTALLATION
Use Leg Kit # FA FS9151 for Model 91
1. Spread a dropcloth on floor behind heater. Next, tilt heater so that back is on drop cloth.
2. Obtain four the legs and attach legs to holes in bottom of unit with bolts and washers provided.
(See Figure 12).
3. Reposition heater to upright position.
PEDESTAL INSTALLATION
Use Pedestal Kit # FA P4150B for Model 91
1. Spread a dropcloth on floor behind heater. Next, tilt heater so that back is on drop cloth.
2. Obtain Pedestal and place pedestal against bottom of heater. Center pedestal from left to right and from front
to rear. Mark holes thru pedestal brackets onto bottom of unit. Lay the pedestal aside. Drill four 1/8” holes
through marks. Replace pedestal and secure with provided screws. (See Figure 13).
4. Stand heater to upright position. Place heater in the desired location.
Page 14
FIGURE 12
FIGURE 13

FLOOR PROTECTION
If a freestanding model is to be installed on a combustible floor, a non-combustible pad must be placed under unit
to protect floor from burning material from the stove. The pad must be 50 inches wide. NOTE: The floor must
extend 16" from door opening in front of stove, 8" from door opening on each side of unit and should be under the
chimney connector. Floor protector must be 3/8" in minimum thickness, non-combustible material or equivalent.
NOTE: For clearance reductions using wall protectors, refer to the NFPA-211 Code.
TOOLS FOR INSTALLATION
Drop Cloth
Electric Drill with 7/32" drill bit
1/2" - 9/16" combination wrench
3/8" magnetic socket chuck adapter, 3/8" wrench (box or socket) or adjustable wrench
Socket Set
Tape Measure
Pencil
Level
Screw Driver
MINIMUM CLEARANCES
The New Buck Corporation Model 91 Bay must be installed in compliance with instructions contained in this
manual.
Clearance from combustible walls and ceilings. (Using single wall chimney connector)
The minimum lateral distance between any part of room heater and combustible walls is shown in (Figures 14 and 15).
BACK WALL
SIDE WALL
A
E
B
F
CC
D
G
F
G
D
B
A
E
BACK WALL
SIDE WALL
A
E
B
F
CC
D
G
C C
BACK WALL
SIDE WALL
A B C D E F G
MODEL 91 24” 23” 16” 26” 8” 3” 16”
FIGURE 14 MINIMUM CLEARANCES 50”
FIGURE 15
Page 15

Page 16
FLOOR PROTECTION
Floor protector must be 3/8" minimum thickness non-combustible material or equivalent.
How to use alternate materials and how to calculate equivalent thickness
An easy means of determining if a proposed alternate floor protector meets requirements listed
in the appliance manual is to follow this procedure:
1. Convert specification to R-value:
R-value is given—no conversion is needed.
K–factor is given with a required thickness (T) in inches:
C-factor is given: R=1/C
2. Determine the R-value of the proposed alternate floor protector.
Use the formula in step (1) to convert values not expressed as “R”
For multiple layers, add R-values of each layer to determine the overall R-value.
3. 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” thick material with a K-factor of 0.84.
The proposed alternate is 4” brick with a C-factor of 1.25 over 1/8” mineral board with a
K-factor of 0.29.
Step (a): Use formula above to convert specification to R-value. R= 1/K x T = 1/0.84 x .75 =
0.893
Step (b): Calculate R of proposed system. 4” brick of C=1.25, therefore Rbrick = 1/C = 1/1.25
= 0.80 1/8” mineral board of K = 0.29, therefore Rmin.bd. =1/029 x0.125 = 0.431
Step (c): Compare proposed system R of 1.231 to specified R of 0.893. Since proposed
system R is greater than required , the system is acceptable.
Definitions:
Thermal conductance = C = Btu = W
(hr)(ft²)(°F) (m²)(°K)
Thermal conductance = K = (Btu)(inch) = W = (Btu)
(hr)(ft²)(°f) (m)(°K) (hr)(tf)(°F)
Thermal conductance = R = (ft²)(hr)(°F) = (m²)(°K)
Btu W
Install in accordance with 24 CFR, Part 3280 (HUD).
MINIMUM CLEARANCES

CHIMNEY
Ceiling Exits:
The Model 91 Bay is designed for connection to: 1)
Simpson Dura-Vent, 2) Security, 3) Selkirk Metal 4)
Metal Fab, 5) Air Jet, listed as 2100opipe and parts.
Follow chimney and chimney connector manufacturers
instructions and local building codes for installation
through combustible walls or ceilings. This heater can
only be installed freestanding by using one of the
following requirements: 1) Must use a brand of chimney
pipe, as listed above, complying to the requirements for
Type HT chimneys in the standard code for chimneys,
Factory-Built, Residential Type and Building Heating
Appliance, UL 103 or 2) A code approved masonry
chimney with a flue liner.
CAUTION: Certain installation types require use of
certain chimney types. Please follow these instructions
exactly.
DETERMINING CHIMNEY LOCATION
A. Ceiling Exit (Using Single Wall Pipe and UL 103
HT type chimney system listed with
manufacturers in this section of manual)
1. Suspend a plumb bob from ceiling above unit
so that weight is hanging in the center of flue
exit. (A small weight on a string will
serve as a plumb bob.) Mark ceiling where string is suspended to locate center of chimney.
2. After locating the center of the hole, install the ceiling support box, chimney, flashing, and rain cap per
the chimney manufacturer’s instructions.
3. Connect stove to ceiling support box by using #24 ga. minimum blued or black steel chimney pipe.
(DO NOT use galvanized pipe.) Each section should fit into section below or into opening on stove, for
drip-free operation. Secure each section together by using at least three (3) sheet metal screws or rivets.
(See Figure 16).You may secure chimney pipe to stove with Optional NBC Cast Chimney Connector.
CEILING
SUPPORT BOX
SINGLE WALL
PIPE
FIGURE 16
OPTIONAL NBC
CAST CHIMNEY
CONNECTOR
Page 17
PREPARING THE STOVE FOR INSTALLATION
1. Inspect unit for any obvious physical damage.
2. Check primary air draft controls to ensure that they operate freely.
3. Check operation of bypass damper control to ensure that it will open and close properly.
4. To attach legs, remove any items within firebox. Spread drop cloth on floor behind heater. Tilt heater so that
back is on drop cloth. Attach legs to pre-drilled holes in bottom of heater. If using optional pedestal,
mounting holes will need to be drilled.
5. Reposition heater to upright position.
6. Plug power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure
motor operates properly. You cannot check motor when switch is in the “Off” or “Automatic” position, unless
a heat gun is used to heat internal thermostat.

CLOSE CLEARANCE INSTALLATIONS (in inches)
Close clearance installation is possible by using the following brands of black, double-wall chimney pipe. (See Figure 17 and Figure 18
for clearances.)
1. Simpson Dura-Vent double wall chimney connector “Type DVL” and 8" Simpson Dura-Vent 2100oHT “Type DP” chimney
2. 8" Security Type DL double wall connector and 8" Security Type “ASHT” High Temp Chimney.
3. 8" Selkirk Metal Bestos Model “DS” double wall connector-8" Selkirk Metal Bestos Model SSII type HT Chimney System.
4. 8" Metal Fab type “DW” double wall connector - 8" Metal Fab 2100oHT chimney.
5. 8" Air Jet
FIGURE 19
1/4” Rise Per. FT.
BACK WALL
SIDE WALL
A
E
B
F
CC
D
G
F
G
D
B
A
E
BACK WALL
SIDE WALL
A
E
B
F
CC
D
G
C C
BACK WALL
SIDE WALL
FIGURE 17 MINIMUM CLEARANCES
Page 18
FIGURE 18
A B C D E F G
MODEL 91 14” 14” 12” 16” 8” 8” 16”
TOOLS FOR INSTALLATION
Drop Cloth
Electric Drill with 3/32" drill bit
5/16" combination wrench
5/16" magnetic socket chuck adapter,
5/16" wrench (box or socket) or adjustable wrench
Pencil Socket Set
Level Tape Measure
Screw Driver
1. Mark plumb line on the wall directly behind the center of heater. (See Figure
19.)
NOTE: When using #24 ga. min. blue or black
steel pipe, maintain 18" between pipe and
ceiling.
2. Place vertical portion of heater pipe and elbow in position and project a point
onto plumb line level with center of elbow.
3. Measure so there will be at least 1/4" rise per foot of horizontal connector
pipe, maintaining clearances to ceiling as noted in Figure 20. This will give
you the center of the hole for chimney penetration.
4. After locating center of penetration, install tee-box and chimney as per
chimney manufacturer’s specifications.
5. Connect chimney pipe to tee-box using #24 ga. minimum blued or black steel
pipe. (DO NOT use galvanized pipe.) Each section should fit into section
below or into opening on stove, for drip-free operation. Secure each section
together by using at least three (3) sheet metal screws or rivets.
Wall Exit into Metal Tee-Box (Using Single Wall Pipe)

Wall Exit Into Masonry (Using Single Wall Pipe)
1. Before connecting Model 91Bay to a masonry chimney, determine if masonry fire-place wall pass-through connector
thimble meets NFPA-211 Code and local building codes and is a minimum of 18" from ceiling. See Figure 20. If
connector thimble does not meet these codes, the pass-through connector must be modified.
Connectors may pass through walls or partitions constructed of combustible material if connector is:
(a) Either listed for wall pass-through or is routed through a device listed for wall pass-through and is installed in
accordance with conditions of listing.
(b) Selected or fabricated in accordance with conditions and clearances as stated in NFPA 211-Code. Any unexposed
metal that is used as part of a wall pass-through system and is exposed to flue gases shall be constructed of stainless
steel or other equivalent material that will resist corrosion, softening, or cracking from flue gases at temperatures up to
1800oF.
In addition, a connector to a masonry chimney shall extend through wall to the inner face or liner but not beyond, and shall be
firmly cemented to masonry.
EXCEPTION: A thimble may be used to facilitate removal of chimney connector for cleaning, in which case thimble shall be
permanently cemented in place with high temperature cement.
2. Once through-the-wall thimble codes are met, simply connect chimney pipe to the wall pass-through connector using #24
ga. minimum blued or black steel pipe as follows:
(a) Maintain 1/4" rise per foot (horizontal length) from the appliance to chimney.
(b) Each section of pipe should fit into section below or into opening on the stove for drip-free operation.
(c) Secure each section to each other using at least three (3) sheet metal screws or rivets.
Page 19
FIGURE 20
1/4” Rise Per. FT.
18” MINIM