FireplaceXtrordinair 44A-BI User manual

Page 2
SAFETY PRECAUTIONS
¥ VIEWING DOOR MUST BE CLOSED
AND LATCHED DURING OPERATION.
¥ THIS APPLIANCE HAS BEEN
DESIGNED AND TESTED FOR
BURNING OF WOOD OR NATURAL
GAS ONLY. THE BURNING OF ANY
TYPE FUEL OTHER THAN WOOD OR
NATURAL GAS WILL VOID THE
WARRANTIES AND SAFETY LISTINGS
OF THE APPLIANCE. DO NOT
ATTEMPT TO BURN ANY OTHER FUEL
THAN THOSE SPECIFIED IN THIS
MANUAL. NOTE: WHEN USING
NATURAL GAS YOU SHOULD
FOLLOW THE OPERATING
INSTRUCTIONS THAT ARE SUPPLIED
WITH THE NATURAL GAS LOG SET OR
LOG LIGHTER.
¥ 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 EXHAUST 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 FIREPLACE.
¥ NEVER BLOCK FREE AIRFLOW
THROUGH OPEN VENTS.
¥ 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.
¥ 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.

Page 3
TABLE OF CONTENTS Page
IMPORTANT INFORMATION
Introduction ......................................................................................................................................1
Safety Precautions .........................................................................................................................2
Features And Specifications.........................................................................................................4
Chimney Size And Proper Draft...................................................................................................5
Protecting The Gold On The Fireplace Xtrordinair ...................................................................6
OPERATING YOUR APPLIANCE
Location and Use of Controls.......................................................................................................7
Burning Procedure .........................................................................................................................8
Maintaining Catalytic Light-Off .....................................................................................................9
Burning Your Appliance Efficiently..............................................................................................10
Daily Use of Your Appliance.........................................................................................................10
Wood.................................................................................................................................................11
Seasoning Wood............................................................................................................................12
Storing Wood...................................................................................................................................14
Safety in Operation.........................................................................................................................16
CARE AND MAINTENANCE
Maintenance Schedule .................................................................................................................17
Maintenance Instructions ..............................................................................................................17
BEFORE CALLING FOR SERVICE
Before Calling For Service............................................................................................................23
REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS
Replacement Parts .........................................................................................................................24
Removal Instructions......................................................................................................................24
ADDITIONAL INFORMATION
5-Year Warranty..............................................................................................................................29
Safety Label.....................................................................................................................................30

FEATURES AND SPECIFICATIONS
¥ EPA Phase II approved.
¥ Heavy duty steel construction.
¥ Thermostat for automatic control of
the blower.
¥ Large firebox capacity - 4.3 cu. ft.
¥ Long burn time - 12 Hours.
¥ Large glass doors for maximum
visibility.
¥ Firebrick lining for firebox
protection.
¥ 388 CFM blower for convection
heat and outside combustion air.
¥ Gas line sleeve through the left
side of the firebox for easy
installation of gas log lighter or
gas log set
Heating Capacity ............................................................................up to 3,000 sq. ft. maximum
BTU Output/hr..................................................................................10,700 to 75,700
Overall Efficiency ............................................................................77 % (DEQ Method)
Emissions grams/hr........................................................................2.3 (EPA Method)
Maximum Burning Time.................................................................12 Hours
Fuel....................................................................................................Solid Wood or Natural Gas
Flue Opening Diameter ................................................................8 in.
44A-BI 44A-ZC
Overall Width (Not Including Faceplate)..................................... 39 in. 49 in.
Overall Depth................................................................................... 23 27 in.
Emissions, Efficiency, Heating Capacity and Burn Times may vary depending
on actual home floor plan, type of fuel used, and moisture content. Emissions
and efficiency numbers are those that have been certified by the U.S. E.P.A.
and the Oregon Department of Environmental Quality.
44A-BI 44A-ZC

Page 5
CHIMNEY SIZE AND PROPER DRAFT
Your Fireplace Xtrordinair comes with a set of installation instructions. These instructions
should be followed by the installer and kept for future reference. Before installing the
fireplace the chimney's size and draft should be verified. The installation instructions contain
all of the specific information for chimney size and installation. The information below
outlines this information on chimney size and draft.
Draft is the force which moves air from the appliance up through the chimney. The amount of
draft in your chimney depends on the length of chimney, local geography, nearby
obstructions and other factors. Too much draft may cause excessive temperatures in the
appliance and may damage the catalytic combustor. Inadequate draft may cause back-
puffing into the room and plugging of the chimney or the combustor. The performance of your
fireplace depends a great deal on the type and size of your chimney as well as its location.
Your fireplace dealer should have covered the importance of this when you purchased your
fireplace. If you experience any of the above problems, check for the following and correct.
1. IMPROPER CHIMNEY HEIGHT: Your chimney must extend above the roof to the proper
height in order to promote sufficient draft. If the chimney doesn't extend at least 3' above
a flat roof or at least 2' higher than any point within 10' on a pitched roof then your
chimney may have to be extended (see the installation instructions for more details).
This will be especially true if you experience a lazy slow burning fire or smoking into
room when you open the loading doors. Don't mistake these symptoms for trying to burn
wet wood.
2'
Minimum 10' 3'
Minimum
Ridge
2. CHIMNEY SIZE: Your Fireplace Xtrordinair is tested with 8" ID metal chimney and 12" x
12" clay flue liner. The use of any other size is not recommended and is likely to cause
problems in achieving proper draft.
3. ELBOW RESTRICTIONS: If the chimney has too many elbows it will reduce the draft and
you may have to extend the chimney to increase the draft (see installation instructions for
more details and certain restrictions).
4. COLD AIR BLOCK: If the chimney is located outside of the home, it will not heat up as
well to create a draft. This will especially be true of masonry chimneys in cold weather.
Starting a paper fire in the firebox will in most cases put sufficient temperature in the
chimney to start a draft before beginning to add kindling.
5. TREES OR OTHER TOPOGRAPHICAL BARRIERS CLOSE TO CHIMNEY: Anything
close to the chimney that is taller than the chimney will in some way affect the draft.
These types of influences can generally be corrected by caps that isolate the chimney
like wind directional or vacuum caps.

Page 6
PROTECTING THE GOLD ON THE FIREPLACE XTRORDINAIR
Gold is the very best material available for plating fireplace fronts, but it is not indestructible.
The most common complaint with any plated surface on a wood burning appliance is
discoloration. This can only be caused by heat or chemicals. The discoloration is permanent
and cannot be removed. The following warnings will help you protect the shine in the gold
plating.
NOTE: IF YOU ARE INSTALLING YOUR FIREPLACE XTRORDINAIR INTO A
NEW MASONRY OR BLOCK-IN FIREPLACE, YOU SHOULD READ THE
FOLLOWING WARNING ON ACID WASH:
Acid Wash Warning:
In the past gold faceplates and/or doors have become severely tarnished as a direct result of
acid wash that has not been properly neutralized on masonry fireplaces. This condition
occurs when the masonry fireplace is newly constructed and muriatic acid is used to remove
excess mortar. If the mason does not adequately neutralize this muriatic acid with ammonia
and water, the acid will be left on the brick. Whenever the fireplace is heated, either from a
fire or from room heat, acid vapors will be released from the brick. These vapors are
extremely corrosive and will attack any metal surface in the immediate area of the fireplace.
Gold plated surfaces will develop a cloudy film.
Replacement of the faceplate and/or doors WILL NOT CURE THIS PROBLEM! The correct
repair is to have the masonry contractor come out to the house and wash down the entire
fireplace face to neutralize this acid condition. If this is a new home, the repair should be
covered under warranty by the home builder. If this is an older home, the consumer may
have some recourse from the seller. We stress that this condition is not a defect in the
manufacture of the plating, but an acid problem with the brick or stone of the fireplace face.
You can test your brickwork for improper
neutralization by using a spa or pool test strip
which is available at spa and pool stores. Apply
one drop of water to your brick and touch the test
strip to the brick (Refer to instructions on the
packaging when reading the test strip). If the strip
shows a high acid content you will need to take
steps to properly neutralize your brick. Please be
aware that the warranty for your Fireplace
Xtrordinair will not cover damage to the plating as
a result of an improperly neutralized acid wash.
ACID
WASH
New Masonry
Heat Warning:
Gold plating is inherently resistant to heat and will not discolor under normal conditions.
However, there are some conditions that may damage the gold surfaces due to excessive
heat you should be aware of.
The Fireplace Xtrordinair was designed and safety tested to withstand a full load of normal
wood burning at the highest burn rate. However, do not use the fireplace continuously at this
high-temperature level. Be careful with hot-burning wood (dense wood or wood that is in
small pieces). If any part of the interior of the fireplace is glowing red, the fireplace is over-
fired and should be turned to a lower burn rate and allowed to cool down. Also be aware of
excessive temperatures due to a power outage shutting off the blower. With the blower
disconnected from power, the heat from the fireplace will build up quicker and not dissipate
as well. During power outages, do not run the fireplace at high burn rate settings.

OPERATING YOUR APPLIANCE
Location and Use of Controls
NOTE: The Combustion Air Control and Combustor By-Pass Control become hot
during operation. Use a glove to adjust these controls while the appliance is
hot.
Combustion Air Control
The Combustion Air Control is located in the center over the door and is operated by sliding it
from left to right. When the control is completely to the left, it is in the fully open position.
When it is completely to the right, it is in the fully closed position.
Combustor By-Pass Control
The Combustor By-Pass Control is located on the upper right of the appliance and is
operated by pushing or pulling the control. When pulled out all the way, the catalytic
combustor is bypassed.
Blower Speed Control
The blower system is controlled by a thermostat located under the firebox which turns the
blower on automatically as the firebox heats up (approximately 45 minutes from start). The
blower will continue to run as long as the firebox has sufficient heat. Adjust the blower speed
by turning the control knob in the lower right corner of the fireplace face (see the illustration
below). For low heat range settings operate at the lowest setting and increase the air flow as
the heat range setting is increased by turning the control knob clockwise. The fireplace is
equipped with an automatic blower shut off switch to shut off the blower when the doors are
opened. The blower will always run as long as the firebox has sufficient heat and the doors
remain closed.
Arched Face Square Face
Combustor
By-Pass Control
Blower Speed Control
Combustion
Air Control
Combustion
Air Control
Combustor
By-Pass Control
Blower Speed Control

OPERATING YOUR APPLIANCE (Continued)
To build a fire in disregard of the information provided in this section can
cause permanent damage to your appliance and void your warranty.
This appliance is not designed for use with the door open. Burning with the loading door
open could create a safety hazard.
Burning Procedure
1. Open the door and place some paper and kindling or a solid wax impregnated firestarter
inside the appliance.
2. Make sure that the combustion air intake control is fully open by pushing the control knob
all the way to the left. Pull the combustor by-pass control, located on the upper right of
the appliance, all the way out.
3. Now light the fire. Close the doors against the latch but do not lock them, this will help
create a draft to start the fire. Once the kindling is burning, add some small dry pieces of
wood and close the loading door. NOTE: The first two or three fires in your new
appliance will cause the high temperature paint to give off a slight odor and a small
amount of smoke. This is the paint curing. For best results during the curing of the paint,
burn small intense fires so the appliance does not overheat. The high temperature paint
cures best at medium temperatures. To prevent the door gasketing from sticking to the
seasoning paint during the first few operations, open the doors slowly and often. Also,
the viewing glass may become somewhat obscure the first few times, as your appliance
is drying all moisture from bricks and even the steel itself. During the first few fires it may
be a little harder to start the fire because the firebricks will contain some moisture.
4. Next add two or three medium size dry logs (use of green or wet wood in your appliance
will develop creosote, cloud glass, and greatly decrease its efficiency). At this time
establish a hot fire with a bed of red hot coals. Once the fire is well established, close
and latch the doors.
5. To slow the rate of burn, close (push to right) the combustion air control as needed.
Slide the control
to the left to
open the air
control (speed
up combustion)
Slide the control
to the right to
close the air
control (slow down
combustion)
6. The combustor by-pass control should be pushed in only when the appliance has
reached operating temperature (usually 20 to 30 minutes).
7. When adding wood to the fire, first open the combustion air control (all the way left) and
combustor by-pass control (all the way out) before opening the loading doors. this will
prevent the possibility of smoke spillage into your house and insure that the catalytic
combustor does not lose its operating temperature.
NOTE:Do not open the door of your appliance when the air control inlet is fully
closed. There is a possibility with a solid fuel burning appliance that
doing so could result in a sudden flash of flames as the fire ignites with
oxygen. However, your Fireplace Xtrordinair has been thoroughly
safety tested to reduce this possibility. Keep all wood behind the log
retainer. Over-restricting the amount of combustion air into the
appliance will cause creosote build-up on glass and in the appliance
and flue. This will also greatly decrease the efficiency of the appliance.

Page 9
OPERATING YOUR APPLIANCE (Continued)
Maintaining Catalytic Light-Off
Your Fireplace Xtrordinair is equipped with a catalytic combustor which increases the
efficiency of your appliance. It is located along the roof of the firebox and is accessed from
within. Its purpose is to re-ignite the flue gases before they exit up the chimney. This
process, called catalytic light-off, increases the heat output of your fireplace and reduces the
amount of emissions.
While starting a fire the catalytic combustor is by-passed to allow the fire to get up to
temperature. Once the fire is up to temperature the combustor by-pass control can be
pushed in to allow the flue gases to be routed through the catalytic combustor. The amount
of time it takes for the fire to get up to temperature varies depending upon the amount of draft
and quality of wood. In most cases the appliance is up to temperature in 30 minutes or less.
When to Push in the Combustor By-Pass
The temperature in the appliance and the flue gases entering the combustor must be raised
to between 500 and 700 degrees F. for the catalytic combustor to work correctly. During the
start up of a cold appliance a medium to high heat range setting must be maintained for a
minimum of 20 minutes. This insures that the appliance, catalyst and fuel are all stabilized at
their proper operating temperature. Even though it is possible to have gas temperatures
reach 600 degrees F. within 2 to 3 minutes after a fire is started, if the fire is allowed to die
down immediately it may go out and the combustor may stop working. Once the combustor
starts working, the heat generated in it by burning the smoke will keep it working.
What to do After Refueling Your Fireplace
During the refueling and rekindling of a cool fire or a fire that is in the charcoal phase,
operate the appliance at a medium to high firing rate for about 10 minutes to insure that the
catalyst reaches approximately 600 degrees F. This will insure catalytic light-off.
CATALYTIC LIGHT-OFF
Flue Gases
from Fireplace
Catalytic Combustor
(Heated to between 500
and 700 degrees F.)
Flue Gases Re-Ignite
Inside the Catalytic
Combustor, Cutting
Emissions

OPERATING YOUR APPLIANCE (Continued)
Burning Your Appliance Efficiently
Your Fireplace Xtrordinair is designed to heat your home efficiently with the lowest amount of
creosote build-up and pollutants emitted. The following steps provide a guideline to efficient
burning:
On cold days, when you wish for high heat output from your appliance, load the appliance
fully after the fire has been established and burn at a medium-high to high burn mode. When
a comfortable heat level in your home has been reached, subsequent loadings would be of
lesser amounts of wood. On warmer days, burn smaller fires, using less wood. This method
will give you the most efficient burn possible.
Although the fire will burn longer at a lower setting, your appliance will not produce as much
heat and it will increase soot accumulation on the appliance, chimney and glass.
For an overnight burn, establish a hot fire. Before you are ready to retire, completely fill the
appliance with wood. With the controls in the fully open position, let the fire burn intensely for
10 to 15 minutes. Next adjust the draft control so that a low, lazy flame is visible. In the
overnight burn, you should be able to maintain a fire for about 10-12 hours, depending on the
type of wood used, and still have a coal bed, with no visible flame, left to start the morning
fire. To re-establish a fire after an overnight burn, open the controls fully and stir the ashes to
bring hot coals to the surface. Then load more wood to re-establish the fire. If you dampen
the fire down too low, you will not only lower the heat output, but you will be promoting
creosote build-up. It will take a few days of practice to achieve the desired settings.
APPROXIMATE COMBUSTION AIR CONTROL SETTINGS
TYPE OF BURN RATE AIR CONTROL SETTING
Overnight Burn ................................................................................Fully Closed
Medium Burn ...................................................................................Open 1/16"
Medium High Burn..........................................................................Open 1/8" to 3/8"
High Burn .........................................................................................Fully Open
Slide the
control to
the left
for a high
burn
Slide the control
to the right until
you get a low, lazy
flame for an
overnight burn
Daily Use of Your Appliance
Some helpful hints: After loading your appliance, open the air control and allow your
appliance to burn vigorously for 20 or 30 minutes. This will assist in the burn-off of any
creosote which accumulates over periods of extended use at low settings.

Page 11
OPERATING YOUR APPLIANCE (Continued)
Wood
This appliance is designed to burn natural wood only. Higher efficiencies and lower
emissions generally result when you burn air dried, seasoned hardwoods as compared to
softwoods or to green or freshly cut hardwoods. DO NOT BURN treated wood, garbage,
solvents, trash, coal, cardboard, colored paper, or wax impregnated logs (i.e. Duraflame,
etc.). Burning treated wood, garbage, solvents, colored paper or driftwood from salt water
may result in release of toxic fumes and may render the appliance ineffective and void the
limited warranty. Burning coal, cardboard or loose paper can produce soot, large flakes, char
or fly ash that can coat the inside of your appliance, causing smoke spillage into the room.
Choosing the kind of firewood to burn in your appliance depends on what is available to you.
If all you can obtain is softwoods, obviously, that will be your choice.
Softwoods such as pine and fir are easily ignited and burn rapidly with hot flames. Since
they burn so easily and quickly you will have to spend more time loading your firebox,
especially in the high burn mode. With softwoods it will be much more difficult to achieve an
overnight burn. Furthermore, softwoods make it necessary to reload the appliance more
often. The chart below outlines the advantages of using hardwood.
SPECIES* LBS./CORD** BTU's/CORD** Hours per Cord at 40,000 BTU's
per Hour**
ALDER 2540 19,050,000 476
APPLE 4400 33,000,000 825
ASH 3440 25,800,000 645
BIRCH 3040 22,800,000 705
CEDAR 2060 15,450,000 386
COTTONWOOD 2160 16,200,000 405
DOGWOOD 4320 31,725,000 793
ELM 2260 16,950,000 423
FIR, DOUGLAS 2970 22,275,000 556
HEMLOCK 2700 20,250,000 506
MAPLE 3200 24,000,000 600
OAK, RED 3680 27,600,000 690
OAK, WHITE 4200 31,500,000 787
PINE 2250 16,875,000 421
REDWOOD 2400 18,000,000 450
SPRUCE 2240 16,800,000 420
* At 20% moisture content
** All values are approximate
If you have a choice it is best to use the more dense hardwoods for a longer lasting fire. The
best arrangement is to have a mix of softwoods and hardwoods for ease of start-up and a
longer lasting fire. Also, it is a good idea once the fire is established to use larger diameter
logs stacked tightly together. This will promote a longer burn time.
Wood is typically sold by the "cord". A cord is a nicely stacked pile of logs measuring 4 feet
wide by 4 feet high by 8 feet long. Always look for the driest wood especially if you purchase
your wood by weight. Unseasoned, wet wood is much heavier.
Moisture content of the wood greatly affects the way any appliance operates. Well seasoned
wood (split, stacked and kept dry for at least 12 months) is your best fuel choice.

Page 12
OPERATING YOUR APPLIANCE (Continued)
Wood (Continued)
Wet wood not only causes more work for you due to the increase in weight making it more
burdensome to carry, but most importantly it will not burn as efficiently. You will receive less
heat output from a wet piece of wood because it wastes energy evaporating the water,
energy that should be used for heating your home. When a wet piece of wood is placed in
your appliance it will also cause more creosote accumulation on the glass, in the appliance,
flue and chimney. The primary reason for this is, as the water evaporates from the wood it
will "spit" creosote-like material. If you can hear your wood sizzle or you can see moisture
bubbling from the ends of the logs placed in a HOT appliance, your wood is too wet! Another
big advantage to burning seasoned wood, aside from higher efficiency and less creosote, is
LESS POLLUTION!
Seasoning Wood
Green wood will burn, but seasoned or dry wood is lighter, has more heat value, and is less
apt to form creosote deposits. Any moisture in the wood reduces the recoverable heat
because water absorbs heat in the process of being changed to steam. The net heat from a
pound of completely dry (no moisture) hardwood is about 7,950 BTU's. All wood has some
moisture in it which reduces the net usable heat at a rate of 1,200 BTU's per pound of water.
The moisture in the wood of living trees varies among species, within a species, and even
within individual trees. Frequently, there is a significant difference between the quantity of
moisture contained in the central column of heartwood of a tree and the outer layers of
sapwood which is surrounded with bark. For example, freshly cut American beech has been
found to have a heartwood moisture content of 72%. In contrast, heartwood moisture
contents in American elm, northern red oak, and white ash are 95, 80 and 46%, respectively.
When drying wood, the greater the surface area exposed to the air, the more rapid the drying.
Therefore, stack the wood in loose piles that are raised off the ground. Wood greater than 8
inches in diameter or longer than 4 feet dries very slowly. Reduce the size of such sticks by
splitting and/or sawing.

Page 13
OPERATING YOUR APPLIANCE (Continued)
Seasoning Wood (Continued)
Place firewood in an open area to obtain rapid drying and to prevent deterioration.
Preferably, put a cover on the top tier of wood. If you cut trees in summer, let them lie for a
week. The leaves will draw moisture from the wood and dry it more quickly than if you limb
the tree immediately.
Seasoning can be accelerated greatly by simply stacking fuelwood in a sunny location and
then covering it with clear plastic sheeting. In sunny weather, temperatures within the plastic
covering will rise much higher than outside, warming the wood and evaporating the
contained moisture. The water vapor produced either escapes or condenses on the plastic
covering; therefore some arrangement for ventilation is necessary. It is also desirable to hold
the plastic away from the rough ends of the wood to prevent abrasion, allow air to flow, and
keep any condensation from re-wetting the wood.
SOLAR WOOD DRYER
In sunny weather, the temperature within the dryer rises much higher than outside
temperatures, warming the wood and evaporating the contained moisture.
Raise stack off
the ground to
increase air flow
Cover with 4 mil Polyethylene
Prevailing Winds
Air flow
Air flow
Air flow
Many arrangements for plastic covering are possible. Thin 2 millimeter, clear polyethylene
sheeting sold for drop cloths or garden mulching is not recommended because it is easily
torn. The 4 millimeter thickness is more satisfactory and less costly than 6 millimeter. Any
clear polyethylene deteriorates badly after a few months of exposure to full sunlight, so the
stack may have to be re-roofed to remain dry over winter.

Page 14
OPERATING YOUR APPLIANCE (Continued)
Seasoning Wood (Continued)
The bathroom scales can be used to check if firewood is still seasoning. Weigh a basket or
bag of a few pieces of firewood. Place them back in the wood pile as an identified unit. Then
weigh them again in about a month. If they have lost weight, the wood is still drying. Cracks
that appear in the end of logs are good signs that the wood is well seasoned.
Generally, wood that is 1) cut to length, 2) split, and 3) stacked in the open, preferably with a
cover, during the winter, should be thoroughly seasoned by the next heating season.
Storing Wood
Firewood is best stored outdoors, under cover and near the house so that valuable space in
the house is not used, insects are kept outside, and the dirt problem is reduced. Store the
wood under cover to keep it dry and its fuel value high. It can be stored in a wood shed, utility
building, garage or under a sheet of plastic or sheet metal roofing.
When drying wood, the greater the surface area exposed to the air, the more rapid the drying.
Wood greater than 8" in diameter or longer than 4' dries very slowly. Reduce the size of such
sticks by splitting and/or sawing. Be sure to keep an air space between the wood and any
covering. Stack the wood in loose piles that are raised off the ground. This will promote air
circulation that helps dry the wood.
TYPICAL WOOD SHED
3' Depth
8' Width
Sheet Metal Roofing
2x4 Purlins
4x4x2 Posts Spaced 8' Apart
2x6x12 Rafter
Siding and Girts
(Optional)
2x8x8' Girder

Page 15
OPERATING YOUR APPLIANCE (Continued)
Storing Wood (Continued)
If sufficient space is available under a roof, seasoning and storage can be accomplished in
one handling. This practice eliminates the extra handling of moving wood that has been
dried outside into a covered storage area. Outside, wood will dry to between 14 and 25%
moisture content depending on humidity, temperature, and wind. In a garage or woodshed it
may dry to between 10 and 15% moisture content; and wood may dry to between 5 and 12%
in the house.
End braces can be used if you have difficulty stacking wood and if the pile collapses at either
end. Constructed with two-by-fours, end braces are like book ends and can be built to
accurately measure a standard cord. The boards beneath the woodpile keep the bottom row
off wet ground.
In some homes a wood box can be constructed inside the house, convenient to the wood
appliance and which has loading access outside. The access door to the wood box from the
outside of the house should be tight fitting.
Dry Wood
More Smoke
& Creosote
Less Smoke
& Creosote
More Heat
Less Heat
Wet Wood
Leads
To
Leads
To
Leads
To
Leads
To

Page 16
OPERATING YOUR APPLIANCE (Continued)
SAFETY IN OPERATION
The Following Safety Rules Should Be Followed Whenever Using Your Appliance:
1. Do not use this appliance for any purpose other than heating.
2. Never use gasoline, gasoline-type lantern fuel, kerosene, engine
oil, charcoal lighter fluid, or similar liquids to start or "freshen up"
a fire. Keep all such liquids well away from the fireplace while it
is in use.
3. Do not burn garbage in your appliance, or use chemicals or fluids
to start the fire.
4. Use caution when loading fuel into the appliance after it is
already burning vigorously.
5. Do not over-fire the appliance at any time. If the appliance glows
red, it is over-fired.
6. Keep all household combustibles and appliance fuel at least 3
feet from the appliance at all times. Store fuel in a dry place well
away from the appliance.
7. Use only the grate provided with the appliance.
8. Educate your children of the dangers associated with fire and the
presence of a hot appliance. Touching a radiating surface can
cause serious burns. Child guards are available through your
dealer.
9. Keep loading door closed at all times except to load fuel.
10. Keep all wood and logs behind the log retainer. Avoid placing
logs and fire against viewing glass.
11. Maintain the door and glass seal and keep them in good
condition.
12. Do not modify your combustion air control to allow more air into
your appliance.
13. Do not burn any kind of coal in this appliance.
14. Do not slam door or strike glass.

Page 17
CARE AND MAINTENANCE
Maintenance Schedule
The following schedule should be followed to insure your appliance stays in peak condition.
Weekly Maintenance: The following should be done once a week:
ASH DISPOSAL
CLEANING OF GOLD PLATED SURFACES
GLASS CLEANING
Bi-Monthly Maintenance: The following should be done every two months
during the heating season:
DOOR AND WINDOW GASKET INSPECTION
LUBRICATE
DOOR LATCH INSPECTION AND ADJUSTMENT
CHECK FOR CREOSOTE
Yearly Maintenance: The following should be done after each heating season:
CATALYTIC COMBUSTOR INSPECTION & CLEANING
FIREBOX INSPECTION AND CLEANING
APPLIANCE TOUCH-UP
BLOWER CLEANING
CHIMNEY SYSTEM CLEANING
Maintenance Instructions
ASH DISPOSAL
During constant periods of use ashes must be periodically removed from the appliance to
prevent a build-up which will affect the performance and limit the fuel load capacity. Ashes
should be placed in a metal container with a tight fitting lid. The closed container of ashes
should be stored on a non-combustible floor or on the ground, well away from any
combustible material, pending final disposal. If the ashes are to be disposed of by burial in
soil or otherwise locally dispersed, they should be retained in the closed container until all
cinders have thoroughly cooled. Other waste must not be placed in this container.
CLEANING OF GOLD PLATED SURFACES
Gold is the very best material available for plating fireplace fronts, but it is
not indestructible. The most common complaint with any plated surface on
a wood burning appliance is discoloration. This can only be caused by
heat and chemicals. The discoloration is permanent and cannot be
removed without removing the gold plating. The following suggestions will
help you keep the shine in your gold plating.
Keep plating free of dust and finger prints with DENATURED ALCOHOL
applied with a very soft cloth. Do not use any other cleaners or polishes.
Do not start a fire if there are finger prints or smudges on the gold plating, as
they could become permanently etched in the gold plating. Make sure that
the brick or stone is free of acid before installing the gold plating, consult
your mason.
D e n a t u r e d
Alcohol

CARE AND MAINTENANCE (Continued)
GLASS CLEANING
Clean the glass only when the appliance is cool, using a non-abrasive cleaner. If the glass
cracks or breaks, let the appliance cool before replacing it. DO NOT OPERATE THE
APPLIANCE WITH BROKEN OR MISSING GLASS. IF THE GLASS DOES BREAK, FOLLOW
THE DIRECTIONS IN THE SECTION TITLED "REPLACEMENT PARTS AND REMOVAL
INSTRUCTIONS" FOR REPLACING THE GLASS.
DOOR AND WINDOW GASKET INSPECTION
A damaged or deteriorated window or door gasket will allow air to enter the appliance
through the space between the door and firebox. This may allow smoke to enter the room
and hamper efficient burning. Inspect the door gasket to make sure it is flexible and
completely intact. Any torn or broken gaskets should be replaced by following the directions
in the section titled "REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS".
Door Gasket
Window Gasket
LUBRICATE
It is highly recommended that you periodically lubricate any moving parts such as the door
hinges and combustion air control. This will eliminate any scraping or squeaking noises as
well as allow the parts to move freely. A high temperature lubricant, such as Permatex
Industrial (R) Anti-seize lubricant, is required. Graphite or low-temperature lubricants will
only last a few days.
DOOR LATCH INSPECTION AND ADJUSTMENT
The door latch must be tested periodically to insure that a tight seal is being maintained
between the door gasket and the fireplace. To test the door latch, close the fireplace door
and secure the latch. Grasp the right side door handle and pull it back and forth. There
should be approximately 1/16" of play. The handle should also be able to be turned all the
way down. This movement is due to the door gasket compressing and expanding. If there is
more than 1/16" of play, or if the door handle can not be turned down all the way, follow the
directions in the following paragraphs to adjust the door.
The door latch is held onto the handle with two nuts (refer to the illustration on the following
page). These nuts work in conjunction with three washers to space the latch the appropriate
distance away from the door. The closer the latch is to the door, the tighter the latch will hold.
The farther away from the door the latch is to the door, the more loose the latch will hold.

Page 19
CARE AND MAINTENANCE (Continued)
If the door is too loose (it has more than 1/16" of play), the latch needs to be adjusted closer
to the door (tightened). To do this, first remove the outer nut, the washer next to it, the latch,
the inner nut, and the two washers next to the inner nut. Re-assemble the handle, putting
only one of the washers between the door and the inner nut. The inner nut should only be
tightened slightly, over-tightening will prevent the handle from turning. Put the other two
washers between the latch and the nut farther away from the door. This will tighten the latch
by approximately 1/16". To make minor adjustments, loosen the outer nut, then turn the inner
nut until the desired distance is obtained. Then tighten the outer nut against the inner nut,
making sure the inner nut does not turn by holding it in place with an open-end wrench.
If the door is too tight (the handle can not be turned down all the way), the latch needs to be
adjusted away from the door. To do this, first remove the outer nut, the washer next to it, and
the latch. Then loosen the inner nut approximately 1/2 turn. Re-assemble the items that were
removed, making sure to line the latch up correctly with the flat side of the threaded shaft.
Test the door to see if door handle can be turned down all the way. If it still needs
adjustment, remove both of the nuts, the latch, and the washers. Re-assemble the handle,
this time putting all three of the washers between the door and the inner nut. This will loosen
the latch a significant amount. To make minor adjustments, loosen the outer nut, then turn
the inner nut until the desired distance is obtained. Then tighten the outer nut against the
inner nut, making sure the inner nut does not turn by holding it in place with an open-end
wrench.
Washers
(Used as
spacers)
Door
Handle
Threaded
portion
of handle
Latch
Door Gasket
Inner Nut
Outer Nut
CHECK FOR CREOSOTE
Creosote is a tarry liquid or solid resulting from the distilling of wood during the combustion
process. Using wet wood or burning at lower temperatures will result in a heavier creosote
deposit. Creosote vapors will condense in a relatively cool chimney flue of a slow burning
fire. As a result, creosote residue accumulates on the interior surface of the chimney and flue
pipes, considerably reducing their diameter. When ignited, this creosote makes an extremely
hot and dangerous fire. The chimney should be inspected at least once every 2 months
during the heating season to determine if a creosote build-up of approximately 1/4" has
accumulated. If this is the case, the creosote should be removed to reduce the risk of a
chimney fire.

Page 20
CARE AND MAINTENANCE (Continued)
CHECK FOR CREOSOTE (Continued)
Most problems with creosote are due to poor chimneys with low draft and/or cold chimney
walls, and to a low rate of burn when little heat is needed during the spring and fall months.
Burning green and wet wood also creates creosote.
To prevent creosote accumulation:
1. Burn your appliance with the combustion air control wide open for about 20-30 minutes
daily during the burning season. This will burn out creosote deposits in your appliance.
2. Burn the appliance with the combustion air control wide open for about 20 minutes every
time you apply fresh wood. This allows the wood to achieve the charcoal stage faster
and burns the wood vapors which might otherwise be deposited within the system.
3. Burn only seasoned, dry wood. Seasoned wood is wood that has been dried for at least
one year.
4. A small, more intense fire is preferable to a large smoldering one that will deposit
creosote within the system.
5. Establish a routine for using your new appliance. Be aware that the hotter the fire, the
less creosote is deposited on the glass and chimney system. Weekly inspection and
cleaning may be necessary during times of heavy appliance usage. Contact your local
fire authority for information on how to handle a chimney fire. Have a clearly understood
plan to handle such a fire.
6. We recommend you have your chimney system and appliance checked and cleaned by
a competent chimney sweep at least once a year.
CATALYTIC COMBUSTOR INSPECTION & CLEANING
It is important to periodically monitor the operation of the catalytic combustor to insure that it is
functioning properly and to determine when it needs to be cleaned or replaced. A non-
functioning combustor will result in a loss of heating efficiency and an increase in creosote
and emissions. The following is a list of ways to monitor the catalytic combustor.
Visual Inspection & Cleaning Of The Catalytic Combustor
Combustors should be visually inspected before and after each heating season to determine
if physical degradation has occurred. Removal of the mixing screen in front of the combustor
is required for this inspection. Refer to the "REPLACEMENT PARTS AND REMOVAL
INSTRUCTIONS" section of this owner's manual for removal instructions. Do not remove the
catalyst from the combustor assembly unless it needs replacement because it is fragile.
Check the combustor for plugging. If the front of the combustor and/or mixing screen is
covered with a fine dust plugging some of the openings, either vacuum it or use a soft paint
brush to brush off the dust. Check to see if the combustor is cracked, broken , or deteriorated.
Replace the combustor if damaged (available at your dealer).
Periodic Inspection Of Catalytic Combustor Performance
To get an indication of whether the catalyst is working, compare the amount of smoke leaving
the chimney when the smoke is being routed through the combustor to the amount of smoke
leaving the chimney when the smoke is not routed through the combustor (by-pass open