Travis Industries DVL EF Insert User manual

DVL EF Insert
Owner's Manual
Featuring the
Burner
Tested and Listed by
OMNI-Test Laboratories, Inc.
Beaverton, Oregon
ANSIZ21.881998CSA2.33M98
CAN/CGA2.17M81,U.L.307b
• Direct Vent Fireplace Insert
• Masonry or Factory Built (Metal)
Fireplace
• Residential or Mobile Home
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Refer to this manual. For assistance or additional
information consult a qualified installer, service agency, or the gas supplier.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
- Installation mustbe performed by a qualified installer,service agency or the gas supplier
IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installer: After installation give this manual to the home-owner and
explain operation of this heater.
Copyright 2005, Travis Industries, Inc. $10.00 100-01151
Travis Industries, Inc.
4800 Harbour Pointe Blvd. SW
Mukilteo, WA 98275

2Introduction
Travis Industries 4041028 100-01151
Introduction
We welcome you as a new owner of a Travis DVL Insert. In purchasing a Travis DVL Insert you have
joined the growing ranks of concerned individuals whose selection of an energy system reflects both
a concern for the environment and aesthetics. The Travis DVL Insert is one of the finest home
heaters the world over. This manual will explain the installation, operation, and maintenance of this
heater. Please familiarize yourself with the Owner's Manual before operating your heater and save the
manual for future reference. Included are helpful hints and suggestions that will make the operation
and maintenance of your new heater an easier and more enjoyable experience. We offer our
continual support and guidance to help you achieve the maximum benefit and enjoyment from your
heater.
Important Information
No other Travis DVL Insert has the same serial number
as yours. The serial number is below and to the left of
the gas control valve.
This serial number will be needed in case you require
service of any type.
Model: Travis DVL Insert EF
Serial Number:
Purchase Date:
Purchased From:
Mail your Warranty Card
Today, and Save Your Bill of
Sale.
To receive full warranty coverage,
you will need to show evidence of
the date you purchased your
heater. Do not mail your Bill of
Sale to us.
We suggest that you attach your
Bill of Sale to this page so that you
will have all the information you
need in one place should the need
for service or information occur.

Table of Contents 3
Travis Industries 4041028 100-01151
Introduction & Important Info.
Introduction & Important Information.........................2
Safety Precautions
Safety Precautions...............................................4
Features & Specifications
Installation Options...............................................6
Heating Specifications...........................................6
Dimensions..........................................................6
Fuel....................................................................6
Compliance..........................................................6
Insert Installation
Installation Warning...............................................7
Items Required for Installation.................................7
Packing List.........................................................7
Items Packed with Face .........................................7
Order of Installation...............................................7
Insert Placement ..................................................8
Zero Clearance (Metal) Fireplace Requirements...........8
Hearth Requirements.............................................8
Insert Clearances .................................................9
Mantel Requirements.............................................9
Face Sizing..........................................................9
Gas Line Installation..............................................10
Vent Requirements................................................11
Altitude Considerations..........................................11
Vent Installation ...................................................11
Vent Location.......................................................12
Vent Configurations...............................................13
Installation Without Surround Panels ........................14
Surround Panel Installation.....................................15
Manifold Removal and Installation ............................16
Finalizing the Installation
Glass Removal.....................................................17
Log, Twig, and Ember Installation.............................19
Purge and Leak Test the Gas Line............................20
Pilot Flame Inspection............................................20
Air Shutter Adjustment...........................................21
Flame Inspection ..................................................21
Explain Heater Operation to Owner...........................21
Operating Your Heater
Before You Begin..................................................22
Location of Controls ..............................................22
Starting The Pilot Flame..........................................23
Starting the Heater for the First Time.........................24
Turning the Heater On and Off .................................24
Adjusting the Flame Height......................................24
Adjusting the Blower Speed.....................................25
Normal Operating Sounds.......................................25
Normal Operating Odors.........................................25
Maintaining Your Heater
Maintaining Your Heater's Appearance......................26
Cleaning Your Heater.............................................26
Yearly Service Procedure.......................................26
Troubleshooting Table............................................27
How this Stove Works............................................28
Wiring Diagram .....................................................29
Replacement Parts List..........................................29
Listing Information
Safety Label ........................................................30
Warranty
Warranty.............................................................31
Optional Equipment
LP Conversion Instructions.....................................32
Cast Aluminum Firebacks .......................................34
Ceramic Firebacks ................................................36
Index
Index..................................................................38

4Safety Precautions
Travis Industries 4041028 100-01151
• IF YOU SMELL GAS:
* Do not light any appliance
* Extinguish any open flame
* Do not touch any electrical switch or plug or unplug anything
* Open windows and vacate building
* Call gas supplier from neighbor's house, if not reached, call fire
department
• This unit must be installed by a qualified installer to prevent the possibility of an
explosion. Your dealer will know the requirements in your area and can inform you of
those people considered qualified. The room 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, etc.
• The instructions in this manual must be strictly adhered to. Do not use makeshift
methods or compromise in the installation. Improper installation will void the warranty
and safety listing.
For LPG only | Pout 11” W.C.
Look for this label:
If the label is present, the
heater is equipped for LP
(propane). If the label is
absent, the heater is equipped
for NG (natural gas).
•This heater is either approved for natural
gas (NG) or for propane (LP). Burning
the incorrect fuel will void the warranty
and safety listing and may cause an
extreme safety hazard. Direct questions
about the type of fuel used to your
dealer. Check the label and flame adjust
knob on the gas control valve.
Ok
•Contact your local building
officials to obtain a permit
and information on any
installation restrictions or
inspection requirements in
your area. Notify your
insurance company of this
heater as well.
•If the flame becomes sooty,
dark orange in color, or
extremely tall, do not
operate the heater. Call
your dealer and arrange for
proper servicing.
•It is imperative that control
compartments, screens, or
circulating air passageways
of the heater be kept clean
and free of obstructions.
These areas provide the air
necessary for safe
operation. ?•Do not operate the heater if
it is not operating properly in
any fashion or if you are
uncertain. Call your dealer
for a full explanation of your
heater and what to expect.
Gas
•Do not store or use gasoline
or other flammable liquids in
the vicinity of this heater.
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•Do not operate if any portion
of the heater was
submerged in water or if any
corrosion occurs.

Safety Precautions 5
Travis Industries 4041028 100-01151
• Do not place clothing or
other flammable items on or
near the heater. Because
this heater can be controlled
by a thermostat there is a
possibility of the heater
turning on and igniting any
items placed on or near it.
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• Light the heater using the
built-in piezo igniter. Do not
use matches or any other
external device to light your
heater.
• Never remove, replace,
modify or substitute any part
of the heater unless
• The viewing glass should be
opened only for lighting the
pilot or conducting service.
• Any safety screen or guard
removed for servicing must
be replaced prior to
operating the heater.
instructions are given in this
manual. All other work must
be done by a trained
technician. Don't modify or
replace orifices.
• Allow the heater to cool
before carrying out any
maintenance or cleaning.
• Operate the heater
according to the instructions
included in this manual.
• If the main burners do not
start correctly turn the gas
off at the gas control valve
and call your dealer for
service.
• The pilot flame must contact
the thermopile and
thermocouple (see the
illustration to the left). If it
does not, turn the gas
control valve to "OFF" and
call your dealer.
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• This unit is not for use with
solid fuel
• Do not place anything inside
the firebox (except the
included fiber logs).
• If the fiber logs become
damaged, replace with
Travis Industries log set.
This
Manual
•Do not throw this manual
away. This manual has
important operating and
maintenance instructions
that you will need at a later
time. Always follow the
instructions in this manual.
•Children and adults should
be alerted to the hazards of
high surface temperature
and should stay away to
avoid burns or clothing
ignition. Young children
should be supervised when
they are in the same room as
the heater.
•Plug the heater into a 120V
grounded electrical outlet.
Do not remove the
grounding plug.
•Don’t route the electrical
cord in front of, over, or
under the heater
•Instruct everyone in the
house how to shut gas off to
the appliance and at the gas
main shutoff valve. The gas
main shutoff valve is usually
next to the gas meter or
propane tank and requires a
wrench to shut off.
•Travis Industries, Inc.
grants no warranty,
implied or stated, for
the installation or
maintenance of your
heater, and assumes
no responsibility of any
consequential
damage(s).

6Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Features:
- Works During Power Outages (millivolt system)
- High Efficiency
- Optional Thermostat or Remote Control
- Ember Fyre™Burner for "Wood Fire" Look
- Quiet Blower for Effective Heat Distribution
- Convenient Operating Controls
- Variable-Rate Heat Output
- Low Maintenance
Installation Options:
- Residential or Mobile Home
- Fireplace Insert
- Masonry or Zero Clearance
(Metal) Fireplace
Heating Specifications: Natural Gas Propane
Approximate Heating Capacity (in square feet)* 600 to 2,000 600 to 2,000
BTU Input Per Hour (on high) 40,000 40,000
BTU Output on Low 20,700 17,900
Efficiency** (with blowers on) 78.9 % 81.0 %
AFUE (Annual Fuel Utilization Efficiency) 71.0 % 73.7 %
* Heating capacity will vary with floor plan, insulation, use of power heat vent, and outside temperature.
** Efficiency rating is a product thermal efficiency rating determined under continuous operation
independent of installed system.
44-3/16"* 8x10 Arch/Rect. Panels
48-3/16"* 10x13 Rect. Panels
* Includes trim & standoffs
17-3/8"
See the section "Vent Requirements"
for vent location.
32-1/4"
16"*
1-5/8"*
23-3/4"
33-3/8"* 8x10
Arch/Rect.
Panels
36-3/8"* 10x13
Rect. Panels
Fuel: This heater is designed either for natural gas or for propane. Check the sticker on top of
the gas control valve or check with the installer to verify gas use.
Compliance: This unit has passed the ANSI Z21.88 –1998, CSA 2.33 M98 Vented Gas Fireplace
Heater Standard as tested by OMNI-Test Laboratories, Inc. Beaverton, Oregon.

Installation (for qualified installers only) 7
Travis Industries 4041028 100-01151
Installation Warnings:
! Failure to follow all of the requirements may result in property damage, bodily
injury, or even death.
! This heater must be installed by a qualified installer who has gone through a
training program for the installation of direct vent gas appliances.
! This appliance must be installed in accordance with all local codes, if any; if not,
follow ANSI Z223.1 and NFPA 54(88) in the USA and B-149 in Canada.
! In Manufactured or Mobile Homes must confirm with: In USA, Manufactured Home
Construction and Safety Standard, Title 24 CFR, Part 3280; In Canada, CSA Z240.4
and Gas-Equipped Recreational Vehicles and Mobile Housing. This appliance may
be installed in Manufactured Housing only after the home is site located.
! The DVL Insert is designed to operate on natural gas (NG) or propane (LP).
! All exhaust gases must be vented outside the structure of the living-area.
Combustion air is drawn from outside the living-area structure.
! Notify your insurance company before hooking up this heater.
! The requirements listed below are divided into sections. All requirements must be
met simultaneously. The order of installation is not rigid – the qualified installer
should follow the procedure best suited for the installation.
Additional Items Required for Installation
• 6-5/8” to 3” & 4” Co-Linear Adapter – W/ Flashing (Travis Part # 98900124)
•Face
•Gas Hookup Equipment
•Surround Panels (Optional - see “Installation without Surround Panels”)
•3” and 4” Diameter Gas Liner
•Direct Vent Cap (Simpson Duravent Part # 991)
Packing List
• DVL Insert
• Log Set (Log Set, Coals, and Embers)
• Owner's Manual
• Two Leveling Bolts
• Propane Conversion Kit
• "Fireplace Altered" tag (attach to the fireplace)
• 8" Pipe Inlet (3/8" dia.)
• Door Latch Key
• Block Off Plate
• (2) Fireback Clips (for ceramic firebacks only)
Items Packed with the Face
•Face (with attachment hardware) • Face Installation Instructions
Order of Installation
1If the heater is to use propane, install the propane conversion kit (see page 32)
2Install gas line into the fireplace (do not connect to unit)
3Position the heater (see "Insert Placement")
4Connect the gas line and gas vent to the appliance.
5Install the optional surround panels and trim. Attach the on/off switch.
6Follow the instructions under "Finalizing the Installation" on pages 17 through 21.

8Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Insert Placement
•Insert must be placed within a code-conforming masonry fireplace or tested and listed zero-clearance
(metal) fireplace. Fix any fireplace damage prior to installation.
•Because the insert uses a circulation blower, clean the fireplace, smoke shelf, and chimney prior to
installation. We recommend painting the interior surface of the fireplace with latex paint to further
eliminate dust.
•This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance
produces when determining a location.
The DVL inserts 16" into the
fireplace.
Run the power cord to either
side of the insert along the face.
Min. 38-1/4" - Includes 6" for gas line installation
For tight fits (under 28"), you may remove the manifold. See the
section "Removing the Manifold"
Use the leveling bolts for
fireplaces with recessed floors.
Min. 23-3/4"
Run the on/off switch wires to the
right, behind the surround panels.
The gas line and shutoff
valve should be installed
prior to insert placement.
Attach the "This fireplace has been altered..." plate
to the fireplace (use two screws or other suitable
method). You may wish to place it in a location
where it will be covered by the surround panels.
Zero-Clearance (Metal) Fireplace Requirements:
•The damper ("A") and grate (with log set) ("B") must be removed (see the illustration below)
•The smoke shelf ("C"), internal baffles ("D"), screen ("E"),
masonry lining or refractory ("G" & "I"), and metal or glass doors
("F") may be removed (if applicable)
NOTE: If any internal baffle is cut, bent, or removed, the
fireplace must be permanently marked to indicate
that it has been altered and is no longer suitable
for burning solid fuel (wood).
•The insulation ("H"), and any structured rigid frame members
(metal sides, floor, door frame, face of the fireplace, etc.) must
not be removed or altered.
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Hearth Requirements
•The heater must be installed on a non-combustible hearth extending a minimum 12" from the fireplace
opening (local codes may require a larger hearth). The hearth must also extend to both sides of the
face (see page 9 for face sizing).

Installation (for qualified installers only) 9
Travis Industries 4041028 100-01151
Insert Clearances
• Due to the high temperature of the fireplace, it should be located out of traffic and away from furniture
and draperies.
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Min. 6”
Side
Wall
Combustible or Non-Combustible Mantel
Min. 6”
Combustible Top Facing
Min. 8-1/2”
Side Facing
Min. 10”
12”Min. (from fireplace opening)
Max. 8”See “Face
Sizing”Below
The non-combustible hearth
must be as wide as the face
and extend to both sides.
See “Face
Sizing”Below
Mantel Clearances
The mantel must be a minimum 10”above the face and a maximum 8”deep.
NOTE: The combustible area above the facing must not protrude more than 3/4" from the facing. If it
does, it is considered a mantel and must meet the mantel requirements listed in this manual.
Face Sizing
Lopi Discovery DVL
26”
35-3/4”
Avalon Rosario DVL
26”
35-3/4”
FPX Arched
FPX Artisan
NOTE: Artisan faces
vary in size.
26-1/2”
3-1/2"
34-3/4”Access
Door
Radius = 45”
FPX 34
Rectangular
Bevel
Access
Door
26-1/2”34-3/4”
Avalon
Cambridge
DVL
25-7/8”36-3/4”
37-5/8”
2”
27-7/8”
33-5/8”
FPX 34
Architectural
Faces
Access
Door
36”
27-1/2”
* The decorative braces protrude 1/4”
2-3/8”2-1/4”
27-1/2”
16-1/2”
Avalon
Craftsman
35-3/4”
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27”
Avalon
Victorian DVL
Avalon
Rawhide
27”
35-3/4”

10 Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Gas Line Installation
!This appliance must be installed in accordance with all local codes, if any; if not, follow ANSI Z223.1
and NFPA 54(88) in the USA and B-149 in Canada.
!The heater and gas control valve must be disconnected from the gas supply piping during any
pressure testing of that system at test pressures in excess of 1/2 psig (3.45 kPA). For pressures
under 1/2 psig (3.45 kPA), isolate the gas supply piping by closing the manual shutoff valve.
•Leak test all gas line joints and the gas control valve prior to and after starting the heater.
Gas Line Connection
•The location of the gas inlet is shown below
•A manual shutoff valve is required within 3’ of the fireplace. It should be placed upstream of
the flex line (if used) and may be installed behind the access door inside the heater. ). T-
Handle gas cocks are required in Massachusetts in compliance with code 248CMR.
Gas Control Valve
A 6" wide opening is provided on the left side, 3" behind the fireplace opening. It is 3" tall.
The gas inlet on the gas control valve is
located 3-5/8" behind the fireplace
opening, 7-3/4" to the left of the center,
and 1-7/8" above the base of the
appliance.
With the 8" pipe nipple installed,
the inlet is approximately 15"
from the center of the
appliance.
Shutoff Valve
8" Gas Inlet Pipe (shipped with the
insert in the accessory pack)
Shutoff Valve
Apply thread sealant to
both ends of the pipe prior
to installation.
Fuel
•This heater is designed for natural gas but can be converted to propane. Check the sticker on the top
of the gas control valve to make sure the correct fuel is used.
Gas Inlet Pressure
Standard Input Pressure
Natural Gas 7" W.C. (1.74 kPA)
Propane 13" W.C. (2.73 kPA)
•If the pressure is not sufficient, make sure the piping used is large enough and the total gas load for
the residence does not exceed the amount supplied.
•The supply regulator (the regulator that attaches directly to the residence inlet or to the propane tank)
should supply gas at the suggested input pressure listed above. Contact the local gas supplier if the
regulator is at an improper pressure.

Installation (for qualified installers only) 11
Travis Industries 4041028 100-01151
Vent Requirements
!The gas appliance and vent system must be vented directly to the outside of the building, and never
be attached to a chimney serving a separate solid fuel or gas-burning appliance. Each direct vent gas
appliance must use it's own separate vent system.
!Make sure the exhaust pipe on the heater connects to the exhaust portion of the cap. The
illustrations below show how the flex liners should be attached.
•The exhaust vent must reline the entire length of the chimney and terminate above the chimney top
!Be careful not to crimp or rupture the liner when bending it into chimney offsets
•When installed, the vent must meet all of the vent
manufacturer's requirements
•Make sure to order the following:
-4”UL 441 Gas Liner for Exhaust, 3”UL 441 Gas Liner
for Air Inlet
- 6-5/8”to 3”& 4”Co-Linear Adapter & Flashing
(Travis Part # 98900124).
- Vertical Termination Cap (Dura-Vent pt # 991)
Altitude Considerations
This heater has been tested at altitudes ranging from sea
level to 8,000 feet (2,400 M). In this testing we have
found that the heater, with its standard orifice, burns
correctly with just an air shutter adjustment. If local codes
require resizing the orifice, in the U.S.A. refer to ANSI
223.1, Appendix P, in Canada B-149.1 or B-149.2
! Failure to adjust the air shutter properly may lead to
improper combustion which can create a safety hazard.
Consult your dealer or installer if you suspect an
improperly adjusted air shutter.
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Max. 1'
offset
Max. Ht. 35'
Min. Ht. 8'
Inlet
(3" dia.)
Exhaust
(4" dia.)
Vent Restrictor
WARNING: Restrictor adjustment should
only be done by a qualified installer.
Only those installations determined to
be over-drafting require this
adjustment. The best indication of
over-drafting is a hyper-active flame
pattern (flames that move too quickly).
If the air shutter is constricted, the
flames become short and yellow, yet
still very active. Over-drafting may
affect the pilot, but this is not the best
way to determine over-drafting. Over-
drafting is most likely in tall venting
configurations (especially if using an
“Exhaust Only Re-Line”). Do not
over-restrict the vent (this leads to
ghosting or lifting flames - reduce
restrictor setting).
To Adjust the Restrictor:
1
2
3
4
NOTE:
Position #1 is the
fully open position
Determine a restrictor position. Start low(move
the restrictor a maximum two positions at a time)
and thoroughly test the heater before adjusting further.
Remove the screw with a 1/4" nutdriver (or screwdriver).
Rotate the adjustment plate clockwise until the correct index hole is below the pivot point.
Insert the screw into the correct index hole and tighten.
1/4" Nutdriver
2
3
4
5
6
7
8
9
10
11
1
Adjustment
Plate
Index Holes Pivot Point
Screw
Rotate the
adjustment
plate to change
the restrictor
position.
This restrictor is in
Position #3.

12 Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Vent Installation
Inlet (3”)
Exhaust (4”)
Inlet
Exhaust
Termination Cap
(Simpson Part # 991)
6-5/8”to 3”& 4”Co-
Linear Adapter (Travis
Part # 98900124)
High-Temp.
Silicone
Apply high-temperature
silicone to the liners on
both ends and secure
with 2 screws.
High-Temp.
Silicone
3”dia. Gas
Liner
4”dia. Gas
Liner
Vent Location
2”
Center Line Inlet (3”Dia.)
Exhaust (4”Dia.)
Fireplace
Opening
2-1/4”13-7/8”
16”
13-1/4”
Vent
Configurations
Z.C. (Metal) firebox
Inlet & Exhaust Re-Line
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Exhaust Only Re-Line
(recommended)
Direct Vent Cap
(part # 991)
Recommended Block-Off
Plate (non-combustible
metal and/or insulation).
Prevents odors from
chimney entering room.
6-5/8" to 3" & 4" Colinear
Adapter & Flashing
(Travis Part # 98900124)
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The block-off plate mus
seal the intake to the
chimney space. This
way air is drawn down
the chimney for
combustion air.
Block-Off Plate
(non-combustible
materials)
NOTE: You may use either re-line configuration with a masonry or zero-clearance fireplace.
Inlet
Masonry Fireplace
Suggestion:
Paint the fireplace cavity
with latex paint to eliminate
the possibility of odors from
the fireplace circulating into
the room.
Any cracks or
damage inside the
chimney must be
repaired.
Exhaust
4" dia.
Gas Liner
Inlet
3" dia. Gas Liner
Exhaust
4" dia. Gas Liner

Installation (for qualified installers only) 13
Travis Industries 4041028 100-01151
Installation Without Surround Panels
a
b
c
Keep the jumper wire in
place while installing.
Disconnect the on/off switch from
the red and brown wires. Insert
the switch into the hole until it
locks in place. Re-attach the red
and brown wires (orientation does
not matter).
Use a knife to cut out the on/off switch hole
(the label covers a square hole in the bracket).
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Use a lock tie or
other device to
bundle the
excess wire.
Then tuck it
below the piezo
igniter to keep it
from coming in
contact with the
burner pan.
The insert may be installed without surround panels if a 3/8" gap is
allowed between the sides and top of the face and the fireplace (for
ventiliation). Wire mesh screen may be placed over this gap.
Min. 3/8"
Face Dimensions
See “Face Sizing”on page 9.
Surround Panel Installation
PANEL SIZE WIDTH HEIGHT
8" x 10" Rectangular 44-3/16" 33-3/8"
Arched (8”x 10”)44-3/16" 33-3/8"
10”x 13”Rectangular 48-3/16" 36-3/8"
1 Follow the
instructions
to the right
for installing
the side
panels.
Line up each side surround
panel and insert two screws from
the inside to secure in place.
b
a
5/16" Nutdriver
Pre-thread the holes on the surround
panels with the screws included in the
surround panel kit.
Run the wires from
the on/off switch and
the power cord
behind the surround
panel (cut the lock-
tie holding the on/off
switch in place).

14 Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Surround Panel Installation (continued)
2Follow the instructions below for installing the top panel, insulation, and trim.
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Install the top panel so
the two tabs insert into
the slots on the side
panels.
Top
Panel
Top Trim
"L" Bracket
Double-Back
Tape
Right Side Trim Construct the panel trim. Insert one leg of
each "L" bracket into the top and side trim
piece. Align the trim to form a precise corner,
then tighten the two set screws with a small
standard screwdriver. Slide the trim over the
panels. Attach a piece of included double-
back tape to the bottom of each side trim to
keep it from flaring at the bottom.
Tighten the set screws from the
back side with a small standard
screwdriver
"L" Bracket
Right Side
Trim
Top Trim
c
b
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Tuck the included insulation between
the top panel and the facing below
the rheostat (not along the sides).
Cut off excess insulation.
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Slot for on/off
switch
(rectangular or
arched)
WARNING: The insulation must be installed
along the top of the insert and should cover or
be below the rheostat (to protect it from heat).
Failure to install the insulation will invalidate
facing and mantel clearances, creating a fire
hazard.
NOTE:
On arched
panels make
sure these
stand-offs are
perpendicular
and not bent
over or
flattened.
3Install the on/off switch following the directions below.
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Upper
Right
of Trim
Keep the jumper wire in
place while installing.
Disconnect the on/off switch from the red and brown
wires leading from the heater. Insert the switch into
the hole in the upper right of the panel trim until it locks
in place. Re-attach the red and brown wires
(orientation does not matter).

Installation (for qualified installers only) 15
Travis Industries 4041028 100-01151
Manifold Removal and Installation
•The manifold is shipped attached to the insert, but may be removed to facilitate especially tight
installations. See the directions below for installation.
1Remove the manifold and place it within the fireplace (see the instructions on the following page).
2Route the flex vent through the chimney from above (leave an extra 3' (914 mm) at the top).
3Attach the flex vent to the manifold (seal with silicone and attach with screws).
4Place the manifold in an upright position (so it rests on the manifold legs) and have a partner pull on
the excess flex vent. Temporarily attach the flex vent to the top of the chimney (leave extra slack).
5Slide the insert into place, guiding the convection top over the insert until fully in place.
6After removing any slack from the flex vent, attach the manifold to the appliance.
7Remove any excess slack in the flex line then attach the vent termination.
4
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16 Installation (for qualified installers only)
Travis Industries 4041028 100-01151
Manifold Removal and Installation (Continued)
Remove the glass (see the instructions on page 17). Follow the directions below to remove the
manifold.
NOTE:When replacing the manifold, use the convection top to guide the manifold. You may also reach
through the exhaust ducts to guide the manifold forward to the appropriate location.
Remove the four bolts
inside the firebox.
7/16”
Socket
5/16" Nutdriver
Remove the three screws holding
the convection top to the insert.
Convection Top Manifold
Slide the
manifold
back.
NOTE: when installing the
manifold, make sure the
gaskets sealing the inlet and
exhaust ducts are in place. If
a gasket is loose, use high-
temperature silicone to
secure it to the manifold.
Shim the manifold legs if
installing into a fireplace
with a raised hearth.
Electrical Connection
•Plug the power cord into a grounded 120 Volt outlet (do not remove the grounding pin).

Finalizing the Installation 17
Travis Industries 4041028 100-01151
1Remove the glass following the directions below.
Warning: The appliance must be completely cool before removing the glass.
Warning: Do not strike or slam the glass.
Note: If using an Victorian Lace face, attach the arch covers after installing the glass.
Open the four latches holding the glass
frame in place (start with the two below
the glass) - follow the directions shown
to the right.
a
Twist 1/4 turn.
The spring pin will
disengage from the
latch bracket,
opening the latch.
Latch Bracket
Insert the 1/4”key
into the spring
pin.
Glass
Top of
Firebox
Spring Pin
Glass Frame
Lift the glass
frame up and
pull it forward to
remove.
b
Re-Attaching the Glass Frame:
a) Hang the glass frame on the firebox.
b) While holding in place, attach the upper latches
(follow the instructions to the right in reverse).
c) Lift the glass frame slightly and attach the lower latches.
NOTE:
You may need to lift the glass
frame while re-attaching.

18 Finalizing the Installation
Travis Industries 4041028 100-01151
Glass Frame Removal and Installation (continued)
The spring pin can come loose from the latch assembly. This occurs when it is turned 1/4 turn when it is
disengaged. Follow the directions below to re-install the spring pin if it becomes loose.
To re-install the spring pin, first
insert this end into a 1/4”key.
Insert the spring pin into
this bracket with the pins
aligned vertically.
Push in slightly and
twist 1/4 turn.
With this pin horizontal, the
spring pin will remain in place.
NOTE: The spring pins
can be installed with the
glass frame in place or
removed.

Finalizing the Installation 19
Travis Industries 4041028 100-01151
•If converting this unit to propane, do so now (see the instructions on page 32).
2Install the log set, kibbles (optional), and embers (if using the decorative fireback, install it prior to the
log set - page 36).
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aPlace the rear log on the two
platforms at the rear of the
firebox.
bPlace the left and right logs.
The pins on the burner insert
into the holes on the logs.
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These pins
insert into the
holes in the
log.
cPlace the twig over the rear
log. The pins on the log insert
into the holes on the twig.
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Place the embers over the front and
side edges of the burner (do not place
them over the burner holes). Place
them in a random pattern.
d
On newer untis, an ember chunk is
included with the heater (instead of
cast into the burner). Place it in the
location shown (it should not cover
any burner holes).
e

20 Finalizing the Installation
Travis Industries 4041028 100-01151
!We recommend you purge the gas line at this time (with the glass removed). This allows gas to be
detected once it enters the firebox, ensuring gas does not build up.
3Turn on gas to the heater. Leak test all gas joints prior to starting the appliance. Start the pilot (see
page 23).
Warning: When lighting or re-lighting the pilot, the glass must be removed (see
page 23 for the full set of instructions on starting the pilot).
4Replace the glass (see page 17). Start the main burner. Leak test all gas joints again.
5Install the faceplate following the instructions included with the face (shut off the insert if necessary).
!ACID WASH WARNING : Before installing the faceplate, make sure any masonry that has been
treated with acid wash has been properly neutralized (this is used primarily with brick faces). Acid wash
(muriatic acid) is used to remove excess mortar. If not properly neutralized with an ammonia solution,
the gold or nickel face may develop a permanent tarnish when the acid evaporates over time. Contact
your dealer if uncertain your facing has been properly neutralized.
6Check the pilot flame to make sure it looks like the illustration below. Adjust the pilot flame if
necessary.
Standard
Screwdriver
The pilot flame must contact the thermocouple and
thermopile (see the illustration below). Adjust the pilot up or
down as necessary.
To adjust the pilot flame, turn this screw. Clockwise
lowers the flame while counter-clockwise raises it.