New Buck Corporation 81 User manual

NON-CATALYTIC UNIT
MODEL 81
SAFETY NOTICE
FEATURES
PREPARATIONS INSTALLATION
OPERATION MAINTENANCE SAFETY
IF THIS HEATER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT.
FOR YOUR SAFETY, FOLLOW THE INSTALLATION INSTRUCTIONS.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS CONCERNING
RESTRICTIONS AND INSTALLATION INSPECTIONS IN YOUR AREA.
MANUFACTURED BY NEW BUCK CORPORATION - SPRUCE PINE, NC 28777
This product is listed by Warnock-Hersey International, Inc. to the UL Standard No. 1482
Revised May 2001
BUCK STOVE

TABLE OF CONTENTS
Important Instructions......................................................................................................... 3
SECTION I: Introduction ................................................................................................... 4
SECTION II: Masonry Insert Installation........................................................................... 5
Installation Preparation-Fireplace....................................................................................... 7
Mounting the Trim Panels .................................................................................................. 8
SECTION III: Pre-Fab Insert Installation......................................................................... 12
SECTION IV: Residential Freestanding Installation........................................................ 13
Freestanding Installation Clearances ................................................................................ 21
Installation of Close Clearances Shields........................................................................... 23
SECTION V: Freestanding Mobile Home Installation..................................................... 24
SECTION VI: Wood Heater Safety.................................................................................. 29
SECTION VII: Operation ................................................................................................. 30
SECTION VIII: Room air blower operation ................................................................... 32
SECTION IX: Troubleshooting........................................................................................ 33
Parts List ........................................................................................................................... 36
Warranty ........................................................................................................................... 37
1

2

INSTALLATION, OPERATION, AND
MAINTENANCE INSTRUCTIONS
MODEL 81
READ THIS FIRST
IMPORTANT INSTRUCTIONS
WARNING
THESE UNITS GENERATE A LOT OF HEAT, SO TREAT THEM WITH CARE. HOT
WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY.
CONTACT MAY CAUSE SKIN BURNS. READ ALL INSTRUCTIONS BEFORE
INSTALLING AND USING THE APPLIANCE. FAILURE TO FOLLOW INSTRUC-
TIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCES.
• The New Buck Corporation non-catalytic system has been tested by Intertek Testing
Services, Warnock Hersey to ANSI/UL Standards 1482.
• Install and operate your units according to instructions provided in this manual. Local
building codes may apply; therefore, contact your local building inspector or fire marshal
for necessary installation requirements and permits which may go beyond these instruc-
tions.
• If appliance is installed in mobile homes: “DO NOT INSTALL IN SLEEPING
ROOMS.”
• Examine the masonry fireplace and chimney prior to installation of the fireplace
accessory to determine that the construction meets the minimum fireplace construction
requirements illustrated in the instructions, that it is free from cracks, loose mortar,
creosote deposits and other blockage, or other signs of deterioration.
CAUTION
DO NOT USE MORE THAN ONE STOVE TO A CHIMNEY. DO NOT USE A FLUE
INTENDED FOR A GAS APPLIANCE. DO NOT CONNECT THIS UNIT TO A CHIMNEY
FLUE SERVING ANOTHER APPLIANCE. DO NOT CONNECT TO ANY AIR
DISTRIBUTION DUCT OR SYSTEM.
• A factory-built pre-fabricated chimney may be used for your units when installed in
compliance with the manufacturer's specification and uniform building code.
3

CAUTION
YOUR CHIMNEY MUST BE CORRECTLY SIZED. A CHIMNEY THAT IS TOO SMALL
OR LARGE IN DIAMETER, OR TOO SHORT, CAN CAUSE YOUR STOVE TO SPILL
SMOKE WHEN THE DOOR IS OPENED.
SECTION I
INTRODUCTION
Your Buck Stove is a non-catalytic unit designed to meet the most
stringent emissions standards without the use of a catalytic combustor. This effect is
achieved through the use of a secondary air which is mixed with primary air in
the unit's firebox. For peak performance we suggest the use of hard seasoned wood.
DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS.
The primary air, which is controlled by the user, burns the wood. Secondary air is admitted into
the firebox through the secondary air tubes at the top of the firebox. This
secondary air burns the impurities in the smoke released from the initial wood burning. The
temperature necessary for this combustion is maintained through the firebrick refractory. If
any more technical information is necessary, contact your local dealer.
This heater is equipped with a standard room air blower.
For operation and use of these electrical assemblies, see instructions provided in this manual on
page 30.
4

SECTION II
MASONRY INSERT INSTALLATION
The Model 81 may be installed using an all masonry fireplace built in accordance with the
Uniform Building Code and National Fire Protection Association (NFPA). The first step in
this type of installation is to determine the acceptability of the fireplace and chimney for use
with a woodstove. Both the construction and condition of the fireplace are important consid-
erations when installing a woodstove. It is not necessary to direct connect this unit unless
installed in improper drawing fireplace or oversized flue. The chimney should extend at least
3' above the roof and at least 2' above any point of the roof within 10'.
CAUTION
REMEMBER TO HAVE YOUR CHIMNEY INSPECTED FOR LEAKS AND BLOCKAGE
BEFORE YOU INSTALL YOUR STOVE.
Figure 1
A. Unit to adjust to Side Wall
B. Front Floor Protector
C. Side Floor Protector
D. Side Wood Trim
E. Top Wood Trim
F. Mantel or Brackets
MODEL 81
12"
16"
8"
7"
10"
21"
F
B
A
E
C
D
5

MINIMUM CLEARANCES
1. The hearth must be of masonry construction and must extend a minimum of 16” in front of
the firebox opening and a minimum of 8" to either side of the firebox opening.
2. If there is not minimum hearth protection from the front of the firebox opening and the
front of the masonry hearth, a floor protector must be used in front of the hearth to
protect combustible materials. The floor protector must be 3/8" minimum thickness non-
combustible material or equivalent.
With the floor protector or hearth extension material specified as one layer of 2" thick brick
with a K* factor of 5.0, you may use alternate materials as long as the K* factor (s) is calculated
as follows:
FORMULA: Required thickness = (K of alternate material/K of millboard) X (thickness
of millboard)
EXAMPLE: An alternate inorganic non-combustible millboard with a K* of .9375
would require a thickness as follows:
Required thickness = (.9375/5.0) x 2 in.
= 3/8 inch
K* FACTORS OF ALTERNATE MATERIALS
Material K Required Thickness
Ceroform 126 .21 1/8"
Limestone 8.0 3.2"
Concrete 8.0 3.2"
Sandstone 13.0 5.2"
Marble 18.0 7.2"
Hearth extension or floor protector thickness above four (4) inches are generally not acceptable
due to cost, floor load capacity, and look. The alternate we recommend is using Ceroform No.
126 millboard 1/8" minimum and putting any type decorative brick or stone (any thickness) on
top of it.
* The K* factor represents the thermal conductivity of a material and is the time rate of heat
flow through a homogeneous material under steady-state conditions, through unit area, per unit
temperature gradient in the direction perpendicular to a surface.
6

POSSIBLE TOOLS NEEDED FOR INSTALLATION
If you decide to install your own stove, there are several hand tools you may need to do the
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
Vacuum cleaner or whisk broom
Flashlight
1 tube of RTV silicone, Code 103 or 106, or high temperature rubber cement rated between
450oF. - 600oF.
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 the front of the fireplace to allow free
access to the fireplace.
2. Cover the hearth and adjacent floor areas with the drop cloth to protect from soiling or
marring the surface.
3. Remove the existing fireplace damper plate.
4. Thoroughly clean the fireplace of ashes and soot.
5. If the fireplace has an ash dump or outside air provision, these must be sealed off with
metal or tightly packed non-combustible insulation to prevent this cold air from entering
the fireplace chamber.
CAUTION
CHECK THE CHIMNEY AND SMOKE CHAMBER FOR EX-
CESSIVE BUILDUP OF CREOSOTE OR SOOT. ALSO CHECK FOR OBSTR-
UCTIONS, SUCH AS BIRD'S NESTS. IF THE CHIMNEY IS EXCESSIVELY
DIRTY CLEAN IT, OR HAVE SOMEONE CLEAN IT PROFESSIONALLY BEFORE
INSTALLING OR USING THE ROOM HEATER.
7

Installation Procedure
Positioning the Heater
NOTE: It is not necessary to direct connect this unit unless installed in improper drawing
fireplace or oversized flue. It is recommended a chimney connector be installed from the
appliance flue collar to the first fireplace chimney section.
WARNING
WHEN POSITIONING THE HEATER, THE FOLLOWING CONDITIONS MUST BE MET!
1. The front of the damper opening must be positioned BEHIND the rear edge of the lintel to
ensure proper draft.
2. Center the heater in the fireplace opening.
Mounting the Trim Panels
After the unit is positioned, mark the mounting position of the trim panels as follows:
1. Set the side trim panels in place, flat against the face of the fireplace. Mark down the
inside edge of the trim panel to make a vertical reference line.
2. Set the top (long) trim panel in place on top of the unit. The panel should be flat against
the outside face of the fireplace, and standing vertically. Mark along the lower edge of the
trim panel with a pencil to make a reference line for mounting.
3. Slide the unit out of the fireplace far enough to work behind the trim panel reference lines.
4. Mount the side trim panels. (See Figure 2.)
a. Position the trim panel on the reference line.
b. Drill mounting holes in center of trim panel mounting brackets to allow for adjustment in
and out if necessary.
c. Mount the trim panel using the self-tapping screws provided.
5. Place top panel back on reference mark. Take top trim panel mounting bracket 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 down screws.
6. Now, follow the installation procedures in the listed direct connect or positive connect kit
you are using and install the heater and connect kit in the fireplace.
8

Figure 2
7. Slide the unit back into the fireplace. Check to be sure that the trim panels are properly po-
sitioned and lie flat against the front of the fireplace. If one of more of the panels is out of
position, slide the unit out and reset by loosening the mounting screws and repositioning in
the slot.
8. Reinstall the top trim panel by sliding the rear lip of the top trim panel underneath the front
lip of the mounting bracket already secured to top of unit.
NOTE: Mount the top trim panel so that it sits in front of the top of the side trim panels.
9. Obtain the brass trim kit provided with unit and slip over the top and sides of trim panels.
(Top ends of brass may need to be trimmed to fit.
10. If direct connect or positive connect kit is not used, follow instructions in steps 1-4c on pre-
vious page.
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 3.)
13. Next using high heat silicone or furnace cement run heavy bead of caulking around where
panels meet the stove. (See Figure 3.)
9

14. Slide the unit back into the fireplace. Check to be sure that the trim panels (and brass) are
properly positioned and lie flat against the front of the fireplace. If panels are out of posi-
tion, slide the unit out and reset by loosening the mounting screws and repositioning in the
slot. With bar, lift stove in front. Place insulation across front and the surface of hearth or
bottom of fireplace, to make complete seal.
15. To check seal of panels, use candle flame and go around the entire area sealed by silicone
and insulation. If flame leans toward inside of fireplace, add additional insulation. This en-
sures an airtight seal.
Figure 3
Final Check
1. Recheck the specified clearances.
2. Remove all foreign material from the firebox area.
3. Open the primary air draft.
NOTE: Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to
“High” position to ensure motor operates properly. Route the cord to prevent damage to the
cord insulation from heat and sharp objects. Keep the cord out of the way of traffic to prevent
damage caused by tripping, etc.
10

4. Place crumpled pieces of newspaper in the stove. Light it and close the doors. Ensure
that the stove draws properly through the primary draft. NOTE: “Do not use grate or
elevate fire. Build wood fire directly on floor of stove.”
5. Check for smoke leaks around the doors.
6. Open the doors and check for smoke escaping from the front of
the 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 the chimney heats up, a proper
draft can usually be obtained.
If a thorough review of the Troubleshooting Guide in the rear of the manual does not reveal
the problem, contact your dealer for assistance.
CAUTION
THE UNIT IS PAINTED WITH A SPECIALLY FORMULATED
HIGH TEMPERATURE PAINT THAT CURES DURING THE FIRST TWO OR
THREE FIRINGS. 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 THE UNIT
WILL ALLOW THESE FUMES TO ESCAPE. DO NOT BUILD A LARGE, ROARING
FIRE UNTIL THIS CURING IS COMPLETE OR THE HEATER FINISH MAY BE
DAMAGED.
The connector and/or chimney should be inspected at least once a month during the heating
season to determine if a creosote buildup has occurred.
CAUTION
NEVER USE GASOLINE, GASOLINE-TYPE LANTERN FUEL, KEROSENE,
CHARCOAL LIGHTER FLUID OR SIMILAR LIQUIDS TO START OR "FRESHEN
UP" A FIRE IN THE HEATER. KEEP ALL SUCH LIQUIDS WELL AWAY FROM
THE STOVE WHEN IT IS IN USE. ALL FLUIDS OF THIS TYPE GIVE OFF
VOLATILE FUMES AND CAN AND WILL EXPLODE!! DON'T TAKE A CHANCE
WITH THE SAFETY OF YOUR HOME AND FAMILY.
11

SECTION III
PRE-FAB INSERT INSTALLATION
The Model 81 may be installed into any UL listed pre-fabricated fireplace that is large enough
to accept it.
NOTE: When installing the Model 81 into a Pre-Fab Zero-Clearance fireplace, a
UL-1777 LINER must be installed the Full Length of the chimney and attached to the flue
exit of the Insert.
NOTE: The ash lip, smoke baffle, and smoke shelf of the pre-fab fireplace may be removed if
necessary to provide room for these models. Any other alteration to the unit will void ALL
NBC manufacturer's responsibility, liability. The warning label below must be attached to the
back of the fireplace.
NOTE: Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to
“High” position to ensure motor operates properly. Route the cord to prevent damage to the
cord insulation from heat and sharp objects. Keep the cord out of the way of traffic to prevent
damage caused by tripping, etc.
NOTE: DO NOT BLOCK ANY EXISTING LOUVERS OR VENTS ON THE EXISTING
PRE-FAB WITH ANY TRIM PANELS FOR THE MODEL 81.
Except for the “NOTES” above, please follow the instruction of masonry installation,
Section II.
Instruction
Minimum clearances for stove
Minimum clearances for floor protector
WARNING: This fireplace must be
restored to it’s original condition for safe use
if the fireplace insert is removed.
12

SECTION IV
RESIDENTIAL FREESTANDING INSTALLATION
MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL
PREPARING THE STOVE FOR INSTALLATION
1. Inspect the unit for any obvious physical damage.
NOTE: Plug the power cord into a 115V AC outlet to test the fan and motor. Set switch to
“Manual” and rheostat to “High” position to ensure motor operates properly. Route the cord to
prevent damage to the cord insulation from heat and sharp objects. Keep the cord out of the
way of traffic to prevent damage caused by tripping, etc.
2. Check the primary air draft control to ensure that it slides freely.
3. Remove any items from within the firebox. Spread the drop cloth on the floor behind the
heater. Next, tilt the heater so that the back is on the drop cloth.
4. If leg kit is to be used follow steps 1-3. Then obtain legs, bolts, washer & nuts. Attach the
legs to holes in bottom of unit.
5. If pedestal kit is being used, open the corresponding freestanding kit and obtain the stand.
Place the stand against the bottom of the heater (angle side to heater) at the marked line.
Center the stand left and right and mark screw locations on bottom through outer holes
of stand mounting angles. Set stand aside and drill four 7/32" holes in heater bottom.
(See Figure 4.)
Figure 4
6. Obtain four 1/4" self-tapping screws and secure the stand to the heater.
7. Reposition the heater to the upright position.
13

ALTERNATE FLOOR PROTECTORS MATERIAL
Floor protector must be 3/8" minimum thickness non-combustible material or equivalent.
With the floor protector or hearth extension material specified as one layer of 2" thick brick
with a K* factor of 5.0, you may use alternate materials as long as the K* factor (s) is calculated
as follows:
FORMULA: Required thickness = (K of alternate material/K of millboard) X (thickness
of millboard)
EXAMPLE: An alternate inorganic non-combustible millboard with a K* of .9375
would require a thickness as follows:
Required thickness = (.9375/5.0) x 2 in.
= 3/8 inch
K* FACTORS OF ALTERNATE MATERIALS
Material K Required Thickness
Ceroform 126 .21 1/8"
Limestone 8.0 3.2"
Concrete 8.0 3.2"
Sandstone 13.0 5.2"
Marble 18.0 7.2"
Hearth extension or floor protector thickness above four (4) inches are generally not acceptable
due to cost, floor load capacity, and look. The alternate we recommend is using Ceroform No.
126 millboard 1/8" minimum and putting any type decorative brick or stone (any thickness) on
top of it.
* The K* factor represents the thermal conductivity of a material and is the time rate of heat
flow through a homogeneous material under steady-state conditions, through unit area, per unit
temperature gradient in the direction perpendicular to a surface.
14

Chimney
These models are designed for connection to:
(1) Simpson Duravent - Dura Black
(2) Metal Fab
(3) Ameritec - BSR
NOTE: This Room Heater must be converted to (1) a chimney complying with the
requirements for Type HT chimneys in the Standard for chimneys, Factory-Built, Residential,
Type and Building Heating Appliance, UL 103, or (2) a code approved masonry chimney
with a flue liner. The chimney size should not be less than nor more than 3 times greater than
the cross-sectional area of the flue collar.
CAUTION
SPECIAL METHODS ARE REQUIRED WHEN PASSING THROUGH A
WALL OR CEILING. SEE INSTRUCTIONS AND BUILDING CODES.
DETERMINING THE CHIMNEY LOCATION
A. Ceiling Exits: (Using 6" Single Wall Pipe and UL 103 HT type chimney
system listed with manufacturer in this section of manual.)
1. Suspend a plumb bob from the ceiling above the unit so that the weight is hanging in the
center of the flue exit. (A small weight on a string will serve as a plumb bob.) Mark the
ceiling where the string is suspended to locate the center of the 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. Now connect the stove and ceiling support box using #24 ga. minimum blued or black
steel connector pipe. (DO NOT USE GALVANIZED PIPE.) Connect each section so
the crimped end faces downward, and secure each section to each other using at least
15

three (3) sheet metal screws or rivets. Next, install an optional New Buck Corporation
chimney connector to the flue exit of the heater or you may use “Ell” brackets to fasten the
pipe to the stove.
4. Install Single Wall Connector and chimney system per manufacturer’s written operating in-
structions. See manufacturer’s list of tested pipes in this manual.
Figure 5
Figure6
B. Wall Exit Into Metal Tee-Box
1. Mark the plumb line on the wall directly behind the center of the heater. (See Figure 6.)
NOTE: When using #24 ga. minimum blue or black steel pipe maintain 18" between pipe and
ceiling.
2. Place the vertical portion of the heater pipe and the elbow in position and project a point
onto the plumb line level with the center of the elbow.
3. Measure up so there will be at least 1/4" rise per foot of horizontal connector pipe,
16

maintaining clearances to the ceiling as noted in Figure 6. This will give you the center of
the hole for the chimney penetration.
4. After locating the center of the penetration, install the tee box and chimney as per the
chimney manufacturer's specifications.
5. Connect the chimney collar to the tee-box using #24 ga. minimum blued or black steel
connector pipe. (DO NOT USE GALVANIZED PIPE.) Connect each section so the
crimped end faces downward, and secure each section to each other using three (3) sheet
metal screws or rivets.
C. Wall Exit Into Masonry (Using Single Wall Pipe)
1. Before connecting these units to a masonry chimney, determine that the masonry fireplace
wall pass-through connector thimble meets the NFPA-211 Code and local building codes
and is a minimum of 18" from the ceiling. If the connector thimble does not meet
these codes, the pass-through connector must be modified. (See Figure 7.)
Figure 7
Connectors may pass through walls or partitions constructed of combustible material if the
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 the conditions of the listing.
(b) Selected or fabricated in accordance with the conditions and clearances as stated in
the 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.
17

NOTE: In addition, a connector to a masonry chimney shall extend through the 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 the chimney connector for
cleaning, in which case the thimble shall be permanently cemented in place with high-
temperature cement.
2. Once the through-the-wall thimble codes are met, simply connect the chimney collar to
the wall pass-through connector using #24 ga. minimum, blued or black steel
connector pipe as follows:
(a) Maintain 1/4" rise per foot (horizontal length) from the appliance to the chimney.
(b) Connect each section so the crimped end faces downward or back toward the unit.
(c) Secure each section to each other using at least three (3) sheet metal screws or rivets.
(d) Use three (3) sheet metal screws to fasten pipe to connector collar on heater.
D. Ceiling Exit-Close Clearance
1. Suspend a plumb bob from the ceiling above the unit so that the weight is hanging in the
center of the flue exit. (A small weight on a string will serve as a plumb bob.) Mark the
ceiling where the string is suspended to locate the center of the chimney hole.
2. After locating the center of the hole, install the ceiling support box, chimney flashing
and rain cap.
3. Now connect the stove and ceiling support box using #24 ga. minimum blued or black steel
connector pipe. (DO NOT USE GALVANIZED PIPE.) Connect each section so the
crimped end faces downward, and secure each section to each other using at least three (3)
sheet metal screws or rivets. Next, install an optional New Buck Corporation chimney
connector to the flue exit of the heater or you may use “Ell” brackets to fasten the pipe to
the stove.
4. Install Single Wall Connector and chimney system per manufacturer’s written operating
instructions. See manufacturer's list of tested pipes in this manual.
18