Travis Industries 96400539 User manual

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539, 96400539A)
Page 1 of 7 17601689 - Printed 7/19/12 © Travis Industries, Inc.
Installation Notes
Before installing, make sure to install the one-piece panel, and disconnect the power cords making sure the Molex
connector and two wires are routed in front of the insert.
WARNING: Make sure all wiring is inserted into the cavity between the insert and the fireplace.
Failure to do this may cause the wiring to become damaged.
Figure1:Molexconnector Figure2:Twowires
This face and panel set extends the insert 19” into the fireplace (this is 1-1/4” more than the Flush Wood Arched).
Compatibility
•Large Flush Wood Hybrid-Fyre Rectangle
Sizing
Height Width Depth
26.25” 40” 4.875”
Packing List
•Face (Upper, Lower, Left and Right sections)
(not shown)
•(5) Lock-Ties
•(4) 10-24 Keps Nuts
•Bypass Rod (5 ½” x 3/8”)
•Air Control Rod (4 ½” x 3/8”)
•Bypass Ring

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 2 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
Installation
1. Lay the face upside down on a non-scratching flat surface. Align the sides with the top of the face and secure
with the 4 nuts. Use a 3/8” wrench to tighten the nuts.
Figure3:Nutlocation Figure4:Tighteninganut
2. Secure the wires to the face using lock-ties. Make sure the wires are secured at all 3 locations. Tighten the
lock-ties and cut off excess tie. Do not over-tighten.
Figure5:Lock‐tie Figure6:Securingthelock‐tie
Figure7:Wiressecuredwithlock‐tie Figure8:Wiresrouted

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 3 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
3. Remove the bypass rod from the fork in the insert, and set aside for later use.
4. Attach the face to the insert by inserting the tabs located on the face into the vertical slots located in the
1-piece panel.
Figure9:Attachingtheface
5. On the left side, connect the Molex connector from the face to the Molex connector on the insert.
Figure10:ConnectingtheMolexconnectors
6. Tuck excess wires into the cavity near the blower. Make sure they do not contact hot (the bottom of the
firebox) or moving components.
Figure11:Tuckexcesswires

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 4 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
7. Attach the shorter extension rod from this kit to the back of the existing air control rod assembly.
NOTE: If the power cord is routed onto the hearth, make sure to remove the tab on the face, as shown below
(either side may be used).
Figure12:Cut‐awayinface Figure13:Bendingthetabontheface
Figure14:Removingthecut‐awaycovering
8. Place the bottom section of the face near the insert. Connect the wires at the bottom left and right sides of the
face.
Figure15:Connectingthebottomleftwires Figure16:Connectingthebottomrightwires

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 5 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
9. Attach the lower face to the fireplace by inserting the tabs on the bottom into the slots provided in the insert.
The face should be aligned flush with the insert. Tilt the front of the assembly up slightly as you guide it into
place.
Figure17:Attachingthelowerface Figure18:Facealignedflushwiththeinsert
NOTE: If the power cord is routed on the hearth, make sure it is routed through the cut-away in the bottom of the
face.
Figure19:Routingthepowercord Figure20:Routingthepowercord
10. Attach the air control rod extension to the air control rod on the unit.
Figure21:Attachingtheaircontrolrod Figure22:Tighteningtheaircontrolrod

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 6 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
11. Attach the extension rod shipped with this kit to the bypass rod that was removed in Step 3, and attach to the
bypass yoke.
Figure23:Extensionrod Figure24:Attachingtheextensionrod
HINT: While installing the bypass extension, reach into the firebox and hold the bypass plate and yoke.
See the manual for a detailed view.

Large Flush Wood Hybrid-Fyre Insert:
Cypress Face Installation
(96400539)
Page 7 of 7 17601689 - Printed 4/10/12 © Travis Industries, Inc.
Light Bulb Replacement
Take care not to touch the new bulb with your fingers – use foam packing or paper towel to hold the bulb.
Note the location of the light bulb under the top left corner of the face.
1. Remove the two screws securing the cover plate and screen that conceal the light. Set the screws, plate, and
screen aside.
2. Remove the spent bulb. Wrap the new bulb in foam packing or paper towel and insert it into the socket.
3. Before replacing the cover plate and screen, insert the screws through the plate into the screen (see picture
below. This makes it easier to attach the screen and cover plate.
4. Attach the screen and cover plate using the screws removed in step 1.