BuckMaster AIR-TIGHT ZERO CLEARANCE FIREPLACE Administrator Guide

BuckMaster
AIR-TIGHT
ZERO CLEARANCE FIREPLACE
INSTALLATION/OPERATOR’S MANUAL
FOR YOUR SAFETY - Do not store or use gasoline or other flammable vapors and liquids in
the vicinity of this or any other appliance.
Manufactured by New Buck Corp. Effective April, 2003
Spruce Pine, NC 28777
IMPORTANT: INSTALLATION MUST BE MADE IN
ACCORDANCE WITH STATE AND LOCAL ORDINANCES
WHICH MAY DIFFER FROM THIS INSTALLATION
MANUAL.
CAUTION: READ RULES FOR SAFE
OPERATION AND INSTRUCTIONS
BuckMaster

1
TABLE OF CONTENTS
INTRODUCTION............................................................................................................. 3
GENERAL INFORMATION AND SPECIFICATIONS ............................................. 3
PLANNING YOUR FIREPLACE INSTALLATION................................................3-4
LOCATING THE FIREPLACE ......................................................................................... 3
CLEARANCES .................................................................................................................. 3
CHIMNEYS........................................................................................................................ 4
TYPICAL INSTALLATION.............................................................................................. 4
INSTALLATION.........................................................................................................5-20
CHIMNEY.......................................................................................................................5-6
COMBUSTION AIR DUCT .............................................................................................. 7
HOT AIR DUCT INSTALLATION .............................................................................7-13
FIREPLACE DIMENSIONS............................................................................................ 14
FRAMING-IN AND FINISHING...............................................................................13-17
FAN KIT........................................................................................................................... 18
WIRING DIAGRAM...................................................................................................19-20
OPERATION .................................................................................................................. 20
STARTING A FIRE ......................................................................................................... 21
ASH REMOVAL.............................................................................................................. 21
CARE AND MAINTENANCE.................................................................................21-24
CATALYTIC COMBUSTOR REPLACEMENT..................................................22-23
BY-PASS DOOR REPLACEMENT............................................................................. 24
TROUBLE SHOOTING................................................................................................ 24
CHIMNEY FIRES.......................................................................................................... 24
PARTS LISTS............................................................................................................25-27
WARRANTY................................................................................................................... 28

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3
INTRODUCTION
Thank you for your purchase of the BuckMaster Zero-
Clearance Fireplace. By following the instructions in
this manual you can be assured of an installation that
will add both beauty and value to your home as well as
provide safe, efficient supplemental heat.
Your BuckMaster dealer can be a valuable source of
information in helping select the proper components for
your installation as well as recommending professionals
who can assist in installation and maintenance.
IMPORTANT INFORMATION
Read these instructions carefully and keep for future
reference.
√Obtain a building permit and check local codes. This
installation must comply with their rulings.
√NOTE: When burning any unit or appliance that
combust fuel for heat, such as coal, oil, wood or
natural and (L.P.) liquid petroleum gas. We highly
recommend the use of smoke and carbon monoxide
detectors in your home.
√To prevent injury or damage, do not allow anyone
unfamiliar with solid fuel to operate this unit.
√Do not store fuel or other combustible materials
within marked clearances.
√Do not burn garbage, plastics, “green” wood,
composite wood products or coal. These materials can
produce gases and by-products that may harm the fire
chamber anc himney or produce excessive amounts of
creosote.
√Never start a fire with gasoline, kerosene, charcoal
lighter fluid, or other flammable liquids.
√Use only with approved chimney.
√Black metal on front of unit is HOT - keep children
away.
FIREPLACE SPECIFICATIONS
Emissions 2.7 grams/hr.
Maximum BTU Output/Hr. 54,300
Estimated Heating Capacity 1800 sq. ft.
Height ............................................................. 48"
Width........................................................38-1/4"
Depth ........................................................27-3/8"
Flue Size.................................................... 8" I.D.
Hot Air Ducts (Optional).................................. 8"
Maximum Log Length.................................... 24"
Paint..................................................... Flat Black
DISCLAIMER NOTICE
The BTU ranges and heating capacity specifications
are provided as guidelines only and in no way guarantee the
output or capacity of the unit. In warmer climates, on average,
the fireplace can be expected to heat a greater area than
indicated.
Other factors which affect the actual area that the unit
will heat include: the conditions of the building, heat loss, type
of construction, amount of insulation, type of air movements,
and location of the unit. The actual BTU output depends on the
type and condition of the wood being burned, draft setting and
the chimney that the fireplace is hooked up to.
NOTE: Your BuckMaster warranty is at the end of this manual.
Be sure to complete and return the warranty registration to the
manufacturer. If you have any problem your local dealer cannot
help you with, please contact the manufacturer direct.
PLANNING YOUR FIREPLACE
INSTALLATION
Before beginning actual installation, it is important to
thoroughly plan out the location of the fireplace and how it will
be used to provide heat to your home. Read the entire manual to
ensure that your installation meets all requirements and that you
have the necessary materials and equipment to complete
installation.
General Guidelines for Locating the Fireplace
1. Consider how it will be framed and its relation to doors,
windows, adjacent walls, and traffic patterns.
2. If possible, locate the fireplace so the chimney can be
installed without cutting through floor joists or roof rafters.
3. Determine where a duct can be run to provide outside air to
the fireplace for combustion (optional).
CLEARANCES FROM COMBUSTIBLES
Front to Adjacent Wall ...........................................................8"
Non-combustible Hearth .............................................. 20"x46"
Base of Unit to Overhead Combustible ................................49"
Heat Vents to Ceiling ...........................................................18"
Heat Ducts, Approved Chimney Pipe to Combustibles..........2"
Back, Sides, and Top of Unit........................ Flush to Materials
(Built in Spacers)

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CLEARANCES TO COMBUSTIBLES HOTAIR DISTRIBUTION
The high BTU output of the BuckMaster fireplace makes
it an excellent heat source. The diagrams on page 8 and
9 show different duct systems that can be used to heat
one or more rooms in your home.
CHIMNEY CONSIDERATIONS
1. Any UL-103 (HT-2100 degree) type HT, or ULC-
S629 (in Canada) factory build chimney system may
be used.
You may connect to a masonry chimney as long as the
conditions in section 8 4.5 of NFPA 211 are met. The
connector from the flue outlet of the BuckMaster and the
masonry chimney must also meet UL 103 type HT
requirements, unless the connector is visible from within
the room and a minimum clearance to combustibles of
18" (460mm) is maintained.
2. Do not vent any other appliance through the
fireplace chimney.
IMPORTANT: CAREFULLY REVIEW
COMPLETE INSTALLATION
SECTION BEFORE BEGINNING ANY
ACTUAL WORK.
TYPICAL INSTALLATION

5
INSTALLATION
PARTS NEEDED CHECKLIST:
1. BuckMaster Fireplace
2. Hot air duct kit
3. 6" wide steel floor safety shield
4. Approved Chimney including:
Anchor Plate
Appropriate number of lengths for proper
height
15o or 30oelbows if necessary
See chimney installation instructions
Firestop radiation shield, Attic radiation shield
Roof flashing
Rain Cap
Supports if necessary
OPTIONAL PARTS
1. Additional hot air ductwork
2. Grill box extension kit
3. Masonry Adapter Kit
4. Temperature probe port extension
5. Non-combustible Face and Hearth
6. Condar temperature probe model 9-85
7. 10" x 10" Grill kit (subject to change)
STRUCTURAL AND FINISHING
MATERIALS OPTIONS
1. Framing and sheathing
2. Facing materials: stone, bricks, tile, etc.
3. Premanufactured fireplace surround and hearth
4. Mantel
PLACING THE FIREPLACE
1. Move fireplace into selected location
2. Hearth preparation:
On combustible flooring, raise the front of the fireplace
enough to slide the 6" wide steel floor safety shield
halfway under the unit. Nail the exposed portion of the
strip to the floor. The safety shied provides added pro-
tection against hot embers which could fall in between
the fireplace and the finished hearth. In all installations
consideration must be given to the thickness of the final
hearth material. NOTE: A clearance of 1/2" minimum
must be maintained between the top of the finished
hearth and the bottom of the lower grill to ensure that
the grill can be fully opened for removal of the ash pan.
Elevate the fireplace as required.
CHIMNEY GENERAL INFORMATION
1. A minimum of 3' is required from the top of the
chimney to the point where it passes through the
roof. In addition, the top of the chimney must be
at least 2' higher than any wall, roof ridge or
building that is within 10'.
2. Where more than one chimney uses the same
chase, or exits the roof in the same location,
maintain the clearances shown to prevent smoke
being drawn from a warm flue to a cold one.
These are suggested clearances only.
3. Whenever possible the entire run of the chimney
should be within the structure. The use of an
exterior chimney may cause poor draft, excessive
condensation and a faster buildup of creosote.
If it is necessary to use an exterior chimney, it should
be framed in with an insulated enclosure.
Do not fill the enclosure with loose fill. A 2" clearance
must be maintained around the chimney pipe.
4. The fireplace will support a maximum chimney
height of 15'. Additional length should be
supported at 10' intervals using components
specified by the chimney manufacturer.

6
INSTALLING THE CHIMNEY
Follow chimney manufacturer’s instructions for
proper installation. Be sure the chimney is equipped
with the corresponding anchor plate for attachment to
the fireplace.
Whenever possible, the chimney should take a
straight vertical path to the roof. If a bend is required,
use only one angled section with a maximum of two
elbows. Only 15oor 30oelbows are approved for this
unit. Consult your dealer for selection of components
and observe required clearances.
1. Cut and frame in holes in ceiling and roof where
chimney will pass with 2" x 4"s. Finished
opening should be 13" x 13" . Use a plumb bob
to line up centers of holes with flue opening on
fireplace.
2. Attach a firestop radiation shield on the underside
of the framing for each floor that the chimney
goes through. At the attic level install an attic
radiation shield.
3. Place bead of hi-temp silicone caulk under
appropriate chimney anchor plate and push plate
collar into fireplace flue. Secure with metal
screws. Connect first chimney section per
manufacturer’s instructions. Continue adding
sections until required height is achieved.
4. If the chimney is not enclosed and passes through
a vented attic space or roof, proceed as follows:
A. Slide roof flashing over chimney and seal
flashing to roof with roofing compound. If
roof is sloped, place top edge of flashing
under shingles and bottom edge on top of
shingles. Secure with roofing nails.
B. Place storm collar over chimney and
flashing. Tighten collar and seal joint with
good quality caulking compound.
C. Install raincap or chimney and secure.
D. Clean flashing with vinegar or solvent and
apply a coat of rustproof paint.
5. If the chimney is enclosed in the attic it must be
fitted with a good radiation shield and vented
flashing.
A. Install radiation shield in roof and attach with
four 3/4" screws or 1" nails.
B. Seal roof flashing to roof with roofing
compound. On sloped roofs, place top edge
of flashing under shingles and bottom edge
on top of shingles. Secure with roofing nails.
C. Place storm collar over chimney and push
down so collar makes contact with flashing.
Seal the collar joint with silicone or high
quality caulking.
D. Install and secure raincap.

7
COMBUSTION AIR DUCT
It is required that a separate source of outside
combustion air be provided for all installations. This
is particularly important in well insulated houses. The
BuckMaster outside air kit assures proper combustion
of the wood. The kit consists of an exterior vent,
flexible vent pipe, and mounting hardware.
The BuckMaster Fireplace is equipped with an
opening on both sides of the unit for connection of the
outside air duct. The actual duct may be run above or
below the floor level.
1. Cut a 4 1/4" hole in the outside wall of the house.
From the outside, install the vent with the vent
openings pointing down.
2. Push one end of the aluminum air duct over the
neck of the outside vent and the other end over
the fireplace connector.
3. Secure duct at each end with clamps supplied (2).
8" WARM AIR OUTLETS
The two 8" heat duct outlets at the unit top are
blocked off during manufacturing so the heat exits the
fixed-open permanent grill at the unit front. If the 8"
heat ducts are installed, however, they cannot be
blocked or have closeable dampers at the heat register
outlet.
An exception to this would be the self-closing
dampers which are installed when using the booster
fans for extended duct runs over head. Their closure
would only occur in isolated instances, if at all.
NOTE: Combustion air must be
connected to both sides of the unit and
cannot terminate in attic spaces.
CAUTION!
IMPROPER INSTALLATION OF THE AIR INLET DUCT CAN STARVE OTHER
FUEL BURNING APPLIANCES OF COMBUSTION, VENTILATION, AND DILUTION
AIR AS A RESULT OF FIREPLACE OPERATION.

8
HOTAIR DUCT INSTALLATION
The BuckMaster Fireplace can be used to heat a single room or an entire house. The diagrams on this and the
following three pages show approved duct configuration.
1) SAME ROOM WITH
DUCT OPTION
United States and
Canada (WIRING
OPTION A) 2) SAME ROOM AND
SECOND ROOM United
States and Canada (WIRING
OPTION A)
3) CENTRAL HEATING
United States and Canada (See
complete layout on following
page.)
(WIRING OPTION B,C or D)
4) TWO ADJACENT ROOMS
United States Only (WIRING
OPTION B or D)
5) BASEMENT, SAME
ROOM AND SECOND
ROOM
United States Only
(WIRING OPTION B)
NOTES:
A. In installations where ductwork is run downward, one
standard hot air vent must also open into the fireplace
room.
B. Booster fans must not be enclosed with a chase.
C. Booster fans on upward ductwork must be equipped
with snap disk, heat sensitive switches. Booster fans
on downward ductwork may be equipped with snap
disk, heat sensitive switches or an on/off switch.
D. All hot air ductwork must be 8" diameter B-Vent
through the initial wall or ceiling penetration. Single
wall pipe may then be used providing booster fans and
self closing dampers are installed on upward ducting.
E. See wiring section for detailed electrical requirements.
F. B-Vent will retain heat much better than single wall
pipe for longer runs.
G. Cut hole in outer skin of B-Vent to install snap disk.

9
TYPICAL DUCTWORK LAYOUT FOR CENTRAL HEATING
Approved for United States and Canada
NOTE:
DUCT WORK MAY
BE RUN OVERHEAD
OR BELOW FLOOR
FOR UNITED
STATES - BELOW
FLOOR ONLY FOR
CANADA.
When running ductwork
down, standard hot air
registers must also open
into room with
fireplace.
NOTE: All hot air ductwork must be 8"
diameter B-Vent through the initial wall or
ceiling penetration. Single wall pipe may then
be used providing booster fans and self-closing
dampers are installed on upward ducting.
CLEARANCE CONSIDERATIONS WHEN INSTALLING HOTAIR DUCTWORK
BuckMaster Fireplace

10
CENTRAL HEATING DUCT SYSTEM
CLEARANCES
All hot air ductwork must be 8" diameter B-Vent
through the initial wall or ceiling penetration.
Single wall pipe may then be used providing
booster fans and backdraft dampers are installed
on upward ducting.
2" clearance to combustibles must be maintained
around the hot air ductwork.
NOTE: When ducting down, attach a 90oelbow to the top
of “T” connector for installation of room hot air register.
This is essential to dissipate heat in the event of fan failure.
Attach 90oelbow to side of “T” to run ducting to
basement or crawl space.

11
OPTIONAL HOT AIR DUCT KIT
2 - 8" diameter, 12" lengths, B-Vent
2 - 8" diameter 90oelbows, B-Vent
OPTIONAL 10" x 10" GRILL KIT (Subject to change)
2 - Hot air grills
2 - Grill Boxes
OPTIONAL PARTS: (from dealer)
8" x 36" length
8" x 18" length
8" x 6" length
8" - 3" - 9" adjustable length
GRILL BOX EXTENSION KIT
2 - Grill Box Extensions
Cut out in drywall for grill box is 11 1/8" square.
HOTAIR DUCT INSTALLATION
The hot air outlets may be vented into the same room as the
fireplace or to an adjacent room or second floor. When going
through a combustible wall or floor, a radiation shield must
be installed in the wall. The required hole size is 13" x 13"
for studs and flooring.
CAUTIONS:
1. Do not install heat registers below the level of the two
hot air outlets on the top of the fireplace.
2. Do not tie the ducts into a central heating system.
3. All hot air ductwork must be 8" diameter B-Vent
through the initial wall or ceiling penetration. Single
wall pipe may then be used providing booster fans and
backdraft dampers are installed on upward ducting.
4. Use only outlet registers approved for this unit.
Other registers may restrict air flow causing
overheating.
5. Do not run hot air ducts for a distance greater
than 10' unless system is equipped with booster
fans. (See page 6.)
6. Maintain a 2" minimum clearance from ducts to
combustibles.
NOTE: The grills must exit at least 18" away from
the ceiling and 16" from the side walls.
2" from sidewall if duct booster fans are installed
with snap disks.
OPTIONAL HOTAIR DUCT KITAND 10" x 10" GRILLKIT

12
FLUSH FIREPLACE INSTRUCTIONS WHEN
INSTALLED WITH 8" DUCT KIT
1. Fit a 90oelbow to the to of each duct sections.
Push down firmly to snap lock them together.
2. Attach the duct sections to the hot air outlets on
top of the fireplace. Fasten them in place by
screwing three metal screws through the pipe and
into the fireplace hot air outlets. Be sure face of
each elbow is parallel to the front of the fireplace.
3. The hot air outlet registers are in two parts (grill
and grill box). Put the grills aside for now. Slide
grill boxes over end of 90oelbows. Using a
straightedge, check that front of grill boxes are
even with front of fireplace. Secure each grill box
to elbows with two sheet metal screws.
RECESSED FIREPLACE INSTALLATIONS WHEN
INSTALLED WITH 8" DUCT KIT
When the hot air ducts will pass through a masonry
surround built around the fireplace, a grill box
extension kit must be used to make the face of the hot
air registers flush with the brick or stosne. Proceed as
follows:
1. Fit a 90oelbow to the top of each duct section.
Push down firmly to snap-lock them together.
2. Attach the duct sections to the hot air outlets on
top of the fireplace. Fasten them in place by
screwing three metal screws through the pipe and
into the fireplace hot air outlets. Be sure the face
of each elbow is parallel to the front of the
fireplace.
3. Screw grill box extensions onto standard grill
boxes using four metal screws. Slide grill box
assemblies over end of 90oelbows and adjust so
face of grill boxes will be flush with finished brick
or stone wall. Use two sheet metal screws to
secure each grill box assembly to the 90oelbows.
4. Slide 5 1/4" round duct extensions over inner grill
box duct collar.
If you have designed your masonry surround to extend
down over the face of the fireplace, you must also add
a masonry adapter for the front grill. An optional way
to deal with the front grill is to entirely remove it and
construct a soldier course of bricks over the opening.
(See finishing details on page 13.) Depending on the
amount of overlap it may also be necessary to add an
extension tube for the temperature probe access port
and replace the standard by-pass handle with an
extended version. (Consult your dealer.)
INSTALLING EXTENDED BY-PASS ROD AND
ACCESS PORT EXTENSION
1. Pull off top grill and remove set screw from by-
pass rod retaining collar.
2. Pull out existing rod, insert extended rod and
replace set screw. If necessary, access door on by
-pass chamber may be removed to facilitate
alignment of rod.
NOTE: When bricking in the access port extension
sleeve (smaller one) and the extended by-pass rod
sleeve, make sure they are aligned properly.

13
FRAMING-IN AND FINISHING
INSTALLATION
The BuckMaster fireplace has been designed so it can
be framed-in using standard combustible building
materials without providing additional fireproofing or
air spaces.
PRECAUTIONS
Do not place unit directly against an exposed vapor
barrier. A vapor barrier should be covered with sheet
rock or similar material.
When installing unit, be sure it is completely wired
during the rough framing stage. (See pages 17-18.)
FRAMING
1. Frame the fireplace using 2" x 4" or heavier
lumber. Use double studs on either side of the
fireplace. The header above the front black fcing
must by 2" x 4" set on edge.
2. Frame-in vertical sides of grill boxes with 2" x 4"s
(when applicable) and secure boxes with corner
nailing strips. See illustrations for general frming
layout.
3. Combustible wall material must be installed flush
with the fireplace facing. It may not project out in
front of the fireplace.
4. When facing the fireplace with brick, etc., the
material must not overlap the front of the unit
more than 2" on the sides to allow proper
operation of the doors.
5. When the front finish is complete, install the hot
air outlet grills with screws provided. The grills
should point downward to direct the hot air toward
the floor.
WARNINGS
1. Do not build in the area directly above the fireplace.
This area must remain empty.
2. The header should rest on top of the metal spacer.
Do not alter the spacers or notch the header to fit
around them.
3. Do not put wood or combustibles directly on
fireplace.
4. Do not block the rectangular air inlet or outlet, as
this will cause the fireplace to overheat. If installing a
brick soldier course as shown, the top metal grill must
first by removed.
5. A wood mantel, if installed,must be at least 49"
above the base of the fireplace.
6. Do not use a fireplace insert or other products not
specified for use with this furnace.
INSTALLING MASONRY ADAPTER
1. With the top grill removed, position the masonry
adapter over the opening and mark the position of
the six holes in the adapter’s rear flange.
2. Drill holes into the face of the fireplace and attach
the adapter.
3. When finishing details are complete push grill
into adapter.

14
FIREPLACE DIMENSIONS (in inches)
NOTE: Rough opening size:
38 1/2" WIDE x 52" HIGH

15
NON-COMBUSTIBLE FACING CUT-OUT DIMENSIONS
Required for tile or marble facing
SET-BACK FOR FACING OPTIONS

16
ROUGH OPENING DIMENSIONS ROUGH FRAMED FLOOR LEVEL INSTALLATION
SHOWN WITH OPTIONAL 10" x 10" GRILL KIT
HEADER DETAIL ROUGH FRAMED RAISED INSTALLATION
SHOWN WITH OPTIONAL 10" x 10" GRILL KIT

17
FINISHING DETAILS AND OPTIONS
PARTIALLY OVERLAPPED NON-COMBUSTIBLE FACING
FINISHING HEARTH:
A non-combustible hearth (e.g. ceramic tiles, stone, bricks, etc.) must extend 24" in front of and 8" beyond the
sides of the fuel loading door. This hearth extension musts be placed on non-combustible flooring. If this unit is to
be installed with a raised hearth, a non-combustible hearth must extend 16" in front of and 8" beyond the sides of
the fuel loading door.

18
STANDARD FORCEDAIR FAN
WIRING OF FAN SHOULD BE PERFORMED
BY A QUALIFIED ELECTRICIAN.
The forced air fan comes factory installed and includes the
prewired motor with fan blade and mounting hardware.
The directions below describes how to wire the fan for a
standard duct system equipped with booster fans and/or
snap disks. Refer to the Wiring Diagrams on pages 19 and
20 for further instructions.
1. Mount a 2" x 4" electrical box on the framing near the
fireplace for installing a switch to control the fan kit.
2. On the left side of the fireplace closest to the switch
location, feed a length of flexible conduit through the
7/8" hole in the sidewall of the fireplace.
3. The conduit must have three conductors: hot, neutral,
and ground.
4. Open the electrical box on the fan motor which is
located on the left side of the power conduit.
5. Run power conduit to switch box. Secure with BMX
connector (not supplied).
6. Run grounded electrical cable from a new or existing 15
AMP circuit to the switch box and connect wires and
switch as shown in wiring schematic.
NOTE: If any of the original wire as supplied with the
appliance must be replaced, it must be replaced with
type 16 ga., 105oC. rating wire or its equivalent.
NOTE: Installation and repair should be done by a
qualified service person. This heater should be
inspected before use and at least annually by a
qualified service person. More frequent cleaning
may be required due to excessive lint from
carpeting, bedding material, pet hair, etc. It is
imperative that control compartments and
circulating air passageways of the heater be kept
clean.