Travis Industries Flush Wood Plus Insert User manual

Flush Wood Plus Insert
Owner's Manual
•Masonry Fireplace Insert
Save these instructions for future reference
SAFETY NOTICE:
If this appliance is not properly installed, a house fire may
result. For your safety, follow the installation directions.
Contact local building or fire officials about restrictions and
installation inspection requirements in your area.
Dragon Wholesaling Pty. Ltd.
Unit 2, 16 Lexington Drive
Bella Vista NSW 2153
Australia
©Copyright 2011, T.I.
$10.00 100-01261
4110328
Tested By:
HRLTechnology–Victoria
Tramway Rd
Morwell Vic 3840
Australia
REPORT NUMBER: HCMG/11/004

2 Introduction
© Travis Industries 100-01261 4110328
Introduction
We welcome you as a new owner of a Flush Wood fireplace insert. In purchasing a Flush Wood fireplace
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. This insert is one of the finest appliances the
world over. This manual will explain the installation, operation, and maintenance of this appliance.
Please familiarize yourself with the Owner's Manual before operating your appliance and save the
manual for future reference. Included are helpful hints and suggestions which will make the installation
and operation of your new appliance an easier and more enjoyable experience. We offer our continual
support and guidance to help you achieve the maximum benefit and enjoyment from your appliance.
Important Information
No other Flush Wood fireplace insert appliance has
the same serial number as yours. The serial number
is stamped onto the label on the back of the
appliance.
This serial number will be needed in case you require
service of any type.
Model: Flush Wood Plus
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 100-01261 4110328
General Information
Introduction & Important Information.......................... 2
Safety Precautions..................................................... 4
Features & Specifications .......................................... 6
Fireplace Insert Installation
Planning The Installation............................................ 7
Preparation for Installation.................................... 7
Additional Accessories Needed for Installation..... 7
Fireplace Requirements............................................. 8
Fireplace Altered Tag................................................. 8
Insert Placement Requirements................................. 9
Hearth Requirements................................................. 9
Masonry Fireplace Requirements .............................. 9
Face Dimensions ....................................................... 10
Drafting Performance................................................. 10
Insert Rollers.............................................................. 11
Flue Installation.......................................................... 11
Surround Panel and Face Installation........................ 12
Re-Routing the Electrical Cord to the Left Side.......... 13
Operating Your Appliance
Safety Notice.............................................................. 15
Before Your First Fire................................................. 15
Opening the Door....................................................... 15
Bypass Operation....................................................... 17
Starting a Fire ............................................................ 17
Adjusting the Burn Rate............................................. 19
Ash Removal.............................................................. 19
Blower Operation ....................................................... 20
Re-Loading the Stove ................................................ 20
Overnight Burn........................................................... 20
Normal Operating Sounds.......................................... 20
Hints for Burning........................................................ 21
Selecting Wood.......................................................... 21
Troubleshooting ......................................................... 22
Maintaining Your Appliance
Daily Maintenance...................................................... 23
Remove Ash .............................................................. 23
Clean The Glass........................................................ 23
Monthly Maintenance................................................. 24
Door and Glass Inspection......................................... 25
Check For Creosote Buildup...................................... 24
Yearly Maintenance ................................................... 25
Touch Up Paint.......................................................... 25
Blower Cleaning......................................................... 25
Firebrick and Baffle Inspection................................... 25
Door Parts.................................................................. 26
Replacing the Glass................................................... 26
Replacing the Door Gasket........................................ 26
Blower and Electrical Parts ........................................ 26
Firebox Parts.............................................................. 26
Baffle Removal and Replacement.............................. 27
Air Tube Removal and Replacement ......................... 28
Brick Removal & Replacement .................................. 29
Listing Information.................................................... 30
Index.............................................................................. 32

4 Safety Precautions
© Travis Industries 100-01261 4110328
The viewing door must be
closed and latched during
operation.
Smoke from this appliance may
active a smoke detector when
the door is open.
Never block free airflow through
the air vents on this appliance.
Gas
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.
This appliance is designed and
approved for the burning of cord
wood only. Do not attempt to
burn any other type of fuel other
than cord wood in this
appliance, it will void all
warranties and safety listings.
ASHES
Ashes must be disposed in a
metal container with a tight lid
and placed on a non-
combustible surface well away
from the home or structure.
Do not touch the appliance while
it is hot and educate all children
of the danger of a high-
temperature appliance. Young
children should be supervised
when they are in the same room
as the appliance.
36"
Keep furniture, drapes, curtains,
wood, paper, and other
combustibles a minimum of 36"
away from the front of the
appliance.
This appliance must be properly
installed to prevent the
possibility of a house fire. The
instructions must be strictly
adhered to. Do not use
makeshift methods or
compromise in the installation.
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 appliance as well.
Inspect the chimney connector
and chimney at least twice
monthly and clean if necessary.
Creosote may build up and
cause a house fire.
Do not connect this appliance to
any chimney serving another
appliance.
Type
HT Clay
Liner
This appliance must be
connected to a listed high
temperature (UL 103 HT)
residential type chimney or an
approved masonry chimney with
a standard clay tile, or stainless
steel liner.

Safety Precautions 5
© Travis Industries 100-01261 4110328
Never try to repair or replace
any part of this appliance unless
instructions are given in this
manual. All other work must be
done by a trained technician.
Do not place clothing or other
flammable items on or near this
appliance.
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Allow the appliance to cool
before carrying out any
maintenance or cleaning.
Do not make any changes or
modifications to an existing
masonry fireplace or chimney to
install this appliance.
Do not make any changes to the
appliance to increase
combustion air.
Maintain the door and glass seal
and keep them in good
condition.
Do not operate this heater with
broken or missing glass.
Avoid placing wood against the
glass when loading. Do not
slam the door or strike the glass.
Overfiring the appliance may
cause a house fire. If a unit or
chimney connector glows, you
are overfiring.
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.
Do not use a grate or other
device to elevate the fire off of
the firebox floor. Burn the fire
directly on the bricks.
Travis Industries, Inc. grants
no warranty, implied or
stated, for the installation or
maintenance of your
appliance,and assumes no
responsibility of any
consequential damage(s).

6 Stove Installation (for qualified installers only)
© Travis Industries 100-01261 4110328
Installation Options
•Masonry Fireplace Insert
Features
•2.2 Cubic Foot Firebox Volume
•Single Operating Control
•Accepts Logs Up to 24" Long
•Steel Plate Construction (Up to 5/16")
•Heavy Duty Refractory Firebrick
•Standard High-Tech Blower
Heating Specifications
Approximate Maximum Heating Capacity (in square feet)* 1,200 to 2,000
Maximum Burn Time Up to 10 Hours
* Heating capacity will vary depending on the home's floor plan, degree of insulation, and the outside
temperature. It is also affected by the quality and moisture level of the fuel.
Dimensions
6-3/8"
(162mm)
450 Lbs. (200 Kg)
1-1/4"
(32mm)
6" (153mm) Dia.
17-3/4"
(451mm)
21-1/2"
(547mm)
a
b
28-7/8" (734mm)
19-3/4"
(502mm)
18-7/8"
(480mm)
10"
(254mm)
Figure 1
(a) Measure clearances from base of insert (b) Fireplace Opening
Emissions
APPLIANCE EMISSION FACTOR BURNING HARDWOOD = 1.5 g/Kg

Fireplace Insert Installation (for qualified installers only) 7
© Travis Industries 100-01261 4110328
SAFETY NOTICE:
Please read this entire manual before you install and use your new room heater. Failure to
follow instructions may result in propertydamage, bodily injury, or even death. Contact
local building or fire officials about restrictions and installation inspection requirements in
your area.
Planning The Installation
We suggest that you have an authorized Travis Industries dealer install your fireplace insert. If you
install the fireplace insert yourself, your authorized dealer should review your installation plans.
Check with local building officials for any permits required for installation of this fireplace insert and
notify your insurance company before proceeding with installation.
Preparation for Installation
•Check for damage to the exterior of the fireplace insert (dents should be reported, scratches can be
fixed by applying touch up paint).
•Check the interior of the firebox (replace cracked firebrick and make sure baffle is in place).
The fireplace insert can be lightened by removing the firebricks and baffle (pg 29) - replace before
operation.
Additional Accessories Needed for Installation
•Face
•Surround Panels (see page12)

8 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01261 4110328
Fireplace Requirements
Figure 2 shows the minimum size requirements for the type of fireplace used.
a
ce
f
b
d
h
i
j
g
Non-Combustible Hearth
Combustible Mantel
Non-Combustible Facing
Minimum
Fireplace Size Masonry Fireplace
a Height (front) 21.5"
547mm
b Height (rear) 19.75"
502mm
c Width (front) 30.875” *
(785mm)
d Width (rear) 18.875”
(480mm)
e Depth 19”
(483mm)
f Hearth Depth
(includes insert
depth on hearth
plus required
hearth extension)
See “Insert
Placement
Requirements”
on the following
page-
g Hearth Width 38.125"
967mm
h Facing Width 36.875"
934mm
i Facing Height 29.5”
750mm
j Mantel Height 47.25"
1195mm
Figure 2 * Includes 2”(51mm) for power cord installation.
Fireplace Altered Tag
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.

Fireplace Insert Installation (for qualified installers only) 9
© Travis Industries 100-01261 4110328
Insert Placement Requirements
•The insert must be placed so that no combustibles are within, or can swing within (e.g. drapes,
doors), 36" (915mm) of the front of the insert (Figure 3 “q”).
•Insert and hearth must be installed on a level, secure floor
•The minimum clearances, facing, and hearth requirements in Figure 3 must be met.
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Side
Wall
Combustible Mantel
Combustible Top Facing
Non-Combustible
Hearth
Facing
q
l
k
p
x
o
n
m
Minimum Clearances Masonry Fireplace
k Sidewall 9"
229mm
l Side Facing
(non-combustible) 4”
100mm
m Top Facing
(non-combustible) 29.5”
750mm
n Mantel (combustible) 47.25"
1195mm
o Front Hearth
(does not include
insert extension “x”)
12"
300mm
p Side Hearth 4.625"
118mm
q Front of Insert 36"
915mm
x Extension Onto
Hearth 1.25" 32mm
NOTE: May vary
depending upon face.
Figure 3
Mantel Leg (Column) Clearances
Mantel leg (column or upright) must maintain 4” (100mm) clearance to side of insert. The leg must not
protrude more than 2” (50mm) from the front of the insert (if it does, it must meet the side wall clearance –
9” 229mm).
Masonry Fireplace Requirements
•Chimney must have stainless steel liner
•Entire fireplace, including chimney, must be clean and undamaged. Any damage must be repaired
prior to installation of the insert.
•Chimney height: 15' (4.5M) minimum; 33' (10M) maximum (measured from base of insert).
•Entire fireplace, including chimney, must meet local building requirements.
•The fireplace insert must be placed on a masonry hearth built to code standards.

10 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01261 4110328
Hearth Requirements
•Non-combustible hearth must extend 12" (300mm) in front of the insert and 4.625" (118mm) from
both sides of the insert
•When installed over a timber floor:
Hearth must be a minimum of 75mm of non-
combustible masonry with 16mm of FC sheet
along with offcuts to provide air flow (see
illustration to the right).
NOTE: if using the “Lopi Flush Wood Zero
Clearance Box” (www.lopi.com.au) see the
instructions included with the zero clearance
box for hearth requirements.
•When installed over a cement floor:
Hearth must be non-combustible.
Face Dimensions
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33”
23-1/4”
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33-1/2”
23-1/4”
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33-3/8”
51-1/2”
Radius
23-7/8”
2-7/8”
Avalon Victorian Lace Fireplace Xtrordinair Arched Lopi Wilmington
Figure 4
Drafting Performance
This appliance relies upon natural draft to operate. External forces, such as wind, barometric pressure,
topography, or factors of the home (negative pressure from exhaust fans, chimneys, air infiltration, etc.),
may adversely affect draft. Travis Industries can not be responsible for external forces leading to less
than optimal performance.

Fireplace Insert Installation (for qualified installers only) 11
© Travis Industries 100-01261 4110328
Insert Rollers
Two rollers are built into the back edge of the insert. This
allows the insert to be rolled into position by lifting the front
of the insert and pushing it into position (see Figure 6).
Figure 6
Leveling Bolt Installation
MASONRY NOTE: Place a metal plate below the
bolts on masonry fireplaces to prevent damage to the
floor brick.
Two leveling bolts are pre-installed on the insert to
allow for proper leveling within the fireplace. To
access the bolts, remove the back corner firebricks
and cover plates (see Figure 7 “a” and “b”) The bolts
are pre-threaded to a weld-nut on the base of the
insert. Use a 3/4” socket wrench to screw the bolts
down (clockwise) until the insert is level (see “c”).
SEALING THE COVER PLATE: We recommend
sealing the cover plate with furnace cement (place on
underside of cover plate).
BOLT LENGTH: The included bolts allow
approximately 1” of rise. If additional rise is required,
use a longer 1/2-13 thread bolt. Make sure the
additional bolt length does not interfere with the cover
plate.
a
b
c
Figure 7
Flue Installation
Included in the owner’s pack are
three “flue brackets” and six self-
drilling screws. Use these
components to secure the flue to the
fireplace insert.
Flue Opening
Flue (flexible or rigid)
Flue Bracket
Self-Drilling Screws

12 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01261 4110328
Surround Panel and Face Installation
The surround panel and face should be installed in the following order. Detailed installation instructions
are included in the surround panel and face installation instructions.
1. With the insert in place, and flue connected, attach the surround panel brackets.
2. Slide the surround panel into place, making sure the four pins hold it into place. NOTE: While
installing, route the power cord to the side of the panel, out the slot (if using a wiring kit, disregard
this step).
3. Remove the air control and bypass handles.
4. Place the face near the fireplace. Attach the rheostat wires (and power wires, if applicable).
Tuck all excess wire under the fireplace, away from hot or moving components.
5. Attach the face to the surround panels.

Fireplace Insert Installation (for qualified installers only) 13
© Travis Industries 100-01261 4110328
Re-Routing the Electrical Cord to the Left Side
The power cord is connected to the right side of the insert when it leaves the factory. It may be re-routed
to the left side following the directions below. Do this procedure before installing the surround panels.
•Disconnect the molex connector and remove the power cord following the directions below.
NOTE: An additional knockout is
provided if using the insert wiring kit.
Route the power through one hole,
the rheostat through the other.
Power
Cord
Rheostat Wires
Disconnect the molex connector
leading from the power cord.
Use pliers to compress the strain relief
from the top and bottom while pulling it
out of the hole in the side of the insert.
Remove the power cord.
Leave the rheostat
wires in place.
Make sure the power cord is
disconnected prior to
conducting these steps.
•Connect the power cord to the left side following the directions below.
Remove the button plug from the left side.
Re-attach the strain relief to the left side (use
pliers to compress the strain relief from the top
and bottom while pushing it into the hole).
Power
Cord
Attach the molex connector on the
power cord to the molex connector
on the left side of the insert.

14 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01261 4110328
Installation Overview
The liner must be
stainless steel
connector or flexible
vent. Follow the liner
manufacturer's
insturctions for
installation and
support.
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Remove damper
or wire it open
Airtight Insulated
Clean-Out
Combustible Mantle
Flue Liner
See the section "Insert
Placement Requirements" for
minimum clearances and
hearth required.
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Cap (prevents water
from entering)
Install a non-combustible
cover plate to prevent water
from entering the chimney
Surround Panels
Figure 8

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Safety Notice
If this appliance is not properly installed, a house fire may result. For your safety, follow the installation
directions. Contact local building or fire officials about restrictions and installation inspection
requirements in your area.
Read and follow all of the warnings on pages 4 and 5 of this manual.
Before Your First Fire
Verify the Installation
Before starting the stove, verify that the stove is properly installed and all of the requirements in this
manual have been followed.
Keep all flammable materials 36" away from the front of the stove (drapes, furniture, clothing, etc.).
Curing the Paint
This heater uses a heat-activated paint that will emit some fumes while
starting the first fire. Open doors and windows to the room to vent these
fumes. This typically lasts two to four hours. You may also notice oil burning
off of the interior of the heater. This rust-stopping agent will soon dissipate.
Door Gasket - The door gasket might adhere to the paint on the front of the
heater. Leave the door slightly ajar for the first fire and be careful when
opening the door after the first fire.
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2 to 4 hours
Over-Firing the Stove
This stove was designed to operate at a high temperature. But due to differences in vent configuration,
fuel, and draft, this appliance can be operated at an excessive temperature. If the stove top or other area
starts to glow red, you are over-firing the stove. Shut the air control down to low and allow the stove to
cool before proceeding.
Over-firing may lead to damage of plated surfaces. If any portion of the heater glows red, it is
considered over-firing and will void the warranty.

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Opening the Door
The door becomes hot during use. Use a glove to open the door if the handle is hot.
To prevent smoke from entering the room, open the bypass before opening the door (see following
page for directions). You can also open the door a small amount and let air enter the firebox.
Rotate the handle up.
Swing the door open.
Opening the Doors
Closing the Doors
Rotate the handle down to secure
the door.
Lift the handle and close the door.

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© Travis Industries 100-01261 4110328
Bypass Operation
The bypass controls the flow of smoke inside the heater. When pulled out, smoke goes directly up the
flue, creating more draft. When pushed in, the smoke goes around the baffle, utilizing the secondary
combustion and making the heater more efficient.
•When starting or re-loading, pull the bypass out.
•During normal operation, push the bypass in.
Bypass Pushed In
Used for normal operation
Bypass Pulled Out
Used for starting and re-loading
Use the included pull tool
to operate the bypass rod
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Starting a Fire
Since the dawn of time man has debated the best way to start a fire. Some use the boy-scout "tee-pee",
some prefer the "tic-tac-toe" stack. Either way, review the hints and warnings below to ensure proper fire
starting.
•Make sure the air control is pushed in and the by-pass pulled out. If additional air is needed, open
the doors 1/4" during the first five minutes of start-up.
Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter fluid, or similar liquids to start
or "freshen up" a fire in this stove. Keep all such liquids well away from the stove while it is in use.
DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. DO NOT BURN GARBAGE OR
FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPHTHA OR ENGINE OIL. Do not place such fuel
within space heater installation clearances or within the space required for charging and ash removal.
If using a firestarter, use only products specifically designed for stoves - follow the manufacturer's
instructions carefully.
HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. CONTACT
MAY CAUSE SKIN BURNS.
If the smoke does not pass up the chimney, ball up one sheet of newspaper, place it in the center of the
firebox and light it. This should start the chimney drafting (this eliminates "cold air blockage").
Use plenty of kindling to ensure the stove reaches a proper temperature. Once the kindling is burning
rapidly, place a few larger pieces of wood onto the fire.
Starting a “Top-Down Fire”
One particularly successful method for starting a fire is to
stack several large pieces of wood in the center of the stove
(see the illustration to the right). Then place a several wads
of newspaper in the center with kindling on top. When you
light the newspaper this “top-down” fire will burn its way to
the center, igniting the larger pieces. With some practice,
this method should work for you.

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© Travis Industries 100-01261 4110328
Adjusting the Burn Rate
Use the air control slider to control the burn rate of the stove. See the illustration below for details.
Low Burn
(air control closed)
High Burn
(air control open)
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Use the air control to
change the burn rate.
Approximate Air Control Settings:
Overnight Burn Pulled Fully Out to 1/32" In
Medium Burn 1/32" to 1/16" In
Medium High Burn 1/16" to 3/16" In
High Burn 3/16" to Pushed All the Way In
The air control becomes hot during operation - use gloves or a tool to prevent burns.
The air control may take several minutes to influence the burn rate. When making adjustments, you
may wish to let the stove burn for 10 minutes to gauge performance.
Ash Removal
ASHES
Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes
should be placed on a noncombustible floor or on the ground, away from all combustible
materials, pending final disposal. If the ashes are disposed of by burial in soil or otherwise locally
dispersed, they should be retained in the closed container until all cinders have thoroughly
cooled.

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Blower Operation
The blower will turn on once the stove is up to temperature. This is typically 15 to 30 minutes after
starting the fire. Follow the directions below to alter the blower speed.
OFF
Turn the dial all the
way counter-clockwise
until it clicks off.
HIGH
The high position is all the
way counter-clockwise,
without clicking off.
LOW
Turn the dial all
the way
clockwise.
The blower may be used to affect heat output (i.e.: to reduce heat output, turn the blower down).
Route the power cord in a location where it will not come in contact with the appliance or become hot.
Re-Loading the Stove
Follow the directions below to minimize smoke spillage while re-loading the stove.
1 Open the air control all the way (push it in). Open the bypass (pull it out).
2 Open the door slightly. Let airflow inside the firebox stabilize before opening the doors fully.
3 Load wood onto the fire.
Overnight Burn
Follow the steps below to achieve an overnight burn.
1 Move the air control to high burn and let the stove become hot (burn for approximately 15 minutes).
2 Load as much wood as possible. Use large pieces if possible.
3 Let the stove burn on high for 15 minutes to keep the stove hot, then turn the air control to low.
4 In the morning the stove should still be hot, with embers in the coal bed. Stir the coals and load
small pieces of wood to re-ignite the fire, if desired.
Differences in chimney height and draft may lower overall burn times.
Normal Operating Sounds
Creaks and Clicks:
The steel may creak or click when the stove heats up
and cools down - this is normal.
Blower Sounds:
The blower will make a slight "humm" as it
pushes air through the stove.