Travis Industries Small Flush User manual

Small Flush
Wood Insert
(Arched or Rectangular)
with Hybrid-Fyre™ Technology
Owner's Manual
•Masonry Fireplace Insert
•Zero-Clearance (Metal) 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.
Travis Industries, Inc.
4800 Harbour Pointe Blvd. SW
Mukilteo, WA 98275
www.travisproducts.com
©Copyright 2013, T.I.
$10.00 100-01342
4131101 Listed
Tested to: U.L. 1482 & ULC S628

2 Introduction
© Travis Industries 100-01342 4131101
Introduction
We welcome you as a new owner of a Small Flush Wood Insert. In purchasing a Small Flush Wood 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 Small Flush Wood 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: Small Flush Wood Insert
Serial Number:
Purchase Date:
Purchased From:
Register your warranty online at:
traviswarranty.com
Or, mail your warranty card to:
Travis Industries House of Fire
4800 Harbour Pointe Blvd. SW
Mukilteo, WA 98275
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 100-01342 4131101
Introduction ......................................................2
Important Information......................................2
Installation Options..........................................6
Features ............................................................6
Heating Specifications.....................................6
Dimensions.......................................................6
Emissions and Efficiency................................6
Planning the Installation..................................7
Preparation for Installation....................................7
Additional Accessories Needed for Installation.....7
Packing List...........................................................7
Additional Requirements for Canada....................7
Fireplace Requirements ..................................8
Fireplace Altered Tag.......................................8
Insert Placement Requirements .....................9
Hearth Requirements.....................................10
USA ....................................................................10
CANADA.............................................................10
Masonry Fireplace Requirements ................11
Zero-Clearance (Metal) Fireplace
Requirements .................................................11
Drafting Performance ....................................11
Leveling Bolt Installation...............................12
Flue Adapter Installation...............................13
Vent Overview ................................................17
Surround Panel Installation ..........................18
Face Removal.................................................18
Re-Routing the Electrical Cord to the Left
Side..................................................................19
Safety Notice ..................................................20
Before Your First Fire....................................20
Verify the Installation...........................................20
Curing the Paint..................................................20
Over-Firing the Stove..........................................20
Opening the Door...........................................21
Bypass Operation ..........................................22
Catalytic Combustor – Use and Cleaning....23
Inspecting & Cleaning the Combustor.................23
Starting a Fire.................................................24
Adjusting the Burn Rate................................25
Approximate Air Control Settings:.......................25
Ash Removal..................................................25
Blower Operation...........................................26
Re-Loading the Stove....................................26
Overnight Burn...............................................26
Normal Operating Sounds ............................26
Hints for Burning ...........................................27
Selecting Wood..............................................27
Why Dry Wood is Key.........................................27
Wood Cutting and Storage..................................27
Troubleshooting.............................................28
Daily Maintenance (while stove is in use)...29
Remove Ash (if necessary).................................29
Clean the Glass (if necessary)............................29
Monthly Maintenance (while appliance is in
use)..................................................................30
Door and Glass Inspection..................................30
Door Latch Adjustment .......................................30
Creosote - Formation and Need for Removal .....30
Cleaning the Catalytic Combustor.......................31
Yearly Maintenance .......................................32
Touch-Up Paint...................................................32
Cleaning the Air Duct and Blower (if applicable).32
Firebrick and Baffle Inspection............................32
Door Parts.......................................................33
Replacing the Glass............................................33
Replacing the Door Gasket.................................33
Blower and Electrical Parts ..........................33
Firebox Parts..................................................34
Baffle Parts .........................................................34
Baffle Removal....................................................34
Combustor ..........................................................34
Air Tube Removal & Replacement...............35
Brick Removal & Replacement ...........................36
Catalytic Combustor Temperature Probe
Installation Instructions ................................37
GreenStartTM Igniter – Firebrick and Housing
Installation......................................................38
Minimum Fireplace Size......................................38
Igniter Firebrick and Housing..............................38
Listing Label........................................................42

4 Safety Precautions
© Travis Industries 100-01342 4131101
The viewing door must be
closed and latched during
operation.
Smoke from this appliance may
activate a smoke detector when
the door is open.
Never block free airflow through
the air vents on this appliance.
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 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.
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.
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.
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.
Gas
ASHES
36"
Ok
Type
HT Clay
Liner

Safety Precautions 5
© Travis Industries 100-01342 4131101
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.
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.
Over-firing the appliance may
cause a house fire. If a unit or
chimney connector glows, you
are over-firing.
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).
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This
Manual

6 Stove Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
Installation Options
•Masonry Fireplace Insert
•Zero-Clearance (Metal) Fireplace Insert
Features
•EPA Phase II Approved
•1.2 Cubic Foot Firebox Volume
•Single Air Control
•Accepts Logs Up to 18" 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)* 650 to 1,000
Maximum Burn Time Up to 7 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
(a) Measure clearances
from base of insert
(b) Fireplace Opening
(c) Extension Onto Hearth
(for hearth depth)
Emissions and Efficiency
0.89 Grams per Hour (EPA Phase II Approved) 76.5% Efficiency (B415 – EPA)
Tested for efficiency using B-415.1-10 using the HHV for the test fuel heating value.
a
265 Lbs. (118 Kg)
6" (153mm) Dia.
24.75" 629mm
18.75"
477mm
19.25"
489mm
19.625"
499mm
13.5"
343mm
b
1.5"
39mm
8.5"
216mm
b
2.25"
58mm
c

Fireplace Insert Installation (for qualified installers only) 7
© Travis Industries 100-01342 4131101
SAFETYNOTICE:
Please read this entire manual before you install and use your new room heater. Failure to
follow instructions may result in property damage, 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 and combustor is in
place).
The fireplace insert can be lightened by removing the firebricks (pg. 36) - replace before operation.
Additional Accessories Needed for Installation
•Face
•Surround Panels (see page18 for sizing)
Packing List
•Flue Attachment Gasket (with screws)
•Bypass Tool
•GreenStart Igniter FireBrick and Igniter Housing (used with GreenStart igniters only)
•Flue Alignment Tool
•Brush for Combustor
Additional Requirements for Canada
•Do not remove bricks or mortar from existing fireplace.
•This fireplace insert must be installed with a continuous chimney liner of 6” diameter extending from
the fireplace insert to the top of the chimney. The chimney liner must conform to the Class 3
requirements of CAN/ULC-S635, Standard for Lining Systems for Existing Masonry or Factory-Built
Chimneys and Vents, or CAN/ULC-S640, Standard for Lining Systems for New Masonry Chimneys.
•Permanently seal any opening between the masonry of the fireplace and the facing masonry.
•Fireplace insert, or surround panels, may be removed to inspect fireplace insert and fireplace.
•Lock existing dampers in the open position.

8 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
Fireplace Requirements
The table below details minimum size requirements for the fireplace.
Minimum Fireplace Size
a Height (front) 19" 483mm
b Height (rear) 19" 483mm
c Width (front) 27”* 686mm*
d Width (rear) 19.25” 489mm
e Depth 14” 356mm
f Hearth Depth
(measured from fireplace opening)
17.5” 445mm
(USA)
19.5” 496mm
(Canada)
g Hearth Width 40.75" 1036mm
h Facing Width 37.25" 947mm
i Facing Height Above Base of Insert 37.5" 953mm
j Mantel Height Above Base of Insert 37.5" 953mm
* Includes 2” (51mm) for power cord installation and face brackets.
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.
a
ce
f
b
d
h
i
j
g
Non-Combustible Hearth
Combustible Mantel
Non-Combustible Facing

Fireplace Insert Installation (for qualified installers only) 9
© Travis Industries 100-01342 4131101
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 (item “q” below).
•Insert and hearth must be installed on a level, secure floor
•The minimum clearances, facing, and hearth requirements listed below must be met.
Minimum Clearances
k Sidewall 11.625" 296mm
l Side Facing (non-combustible) 6.25" 159mm
m Top Facing (non-combustible) 37.5" 953mm
n Mantel (combustible – maximum 12” 305mm deep) 37.5" 953mm
o Front Hearth
16” 407mm
(USA)
18” 458mm
(Canada)
p Side Hearth 8" 204mm
q Front of Insert 36" 915mm
s Mantel Column (max. 8” 204mm deep) 6.25" 159mm
x Extension Onto Hearth 1.5" 39mm
Combustible Top Facing
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Side
Wall
Non-Combustible
Hearth
Facing
q
l
p
o
m
Combustible Mantel
n
k
s
x

10 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
Hearth Requirements
When installing into a masonry fireplace, the hearth must meet Uniform Building Code (UBC) standards.
USA
When installing into a zero-clearance fireplace, the hearth must extend 16” (407mm) to the front and 8”
(204mm) to the sides of the insert. The hearth must provide an R-value (thermal resistance) of 1.19 or
greater.
If the insert is a minimum 2” (51mm) above the combustible floor (carpet, wood, etc.) the hearth must
extend 16” (407mm) in front and 8” (204mm) on both sides of the insert. Hearth must be non-combustible
(cement board, tile, etc.). No R-value (thermal resistance) is required.
CANADA
When installing into a zero-clearance fireplace, the hearth must extend 18” (458mm) to the front and 8”
(204mm) to the sides of the insert. The hearth must provide an R-value (thermal resistance) of 1.19 or
greater.
If the insert is a minimum 2” (51mm) above the combustible floor (carpet, wood, etc.) the hearth must
extend 18” (458mm) in front and 8” (204mm) on both sides of the insert. Hearth must be non-combustible
(cement board, tile, etc.). No R-value (thermal resistance) is required.
Non-Combustible Hearth
(min. R-Value 1.19)
Combustible
Flooring
Non-Combustible Spark Protection
(Tile, Cement Board, Steel, etc.)
USA Min. 16" (407mm)
Canada Min. 18" (458mm)
Combustible
Flooring
Min. 2"
(51mm)
USA Min. 16" (407mm)
Canada Min. 18" (458mm)

Fireplace Insert Installation (for qualified installers only) 11
© Travis Industries 100-01342 4131101
Masonry Fireplace Requirements
•Must utilize a positive connection (full reline)
•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 UBC standards.
Zero-Clearance (Metal) Fireplace Requirements
•Must utilize a positive connection (full reline).
•Must be manufactured by one of the following manufacturers:
• Marco • Majestic • Heatilator • Preway • Tempco • Superior
• Heat N Glo • Lennox • Martin • Monesson
•Entire fireplace, including chimney, must be clean and undamaged. Any damage must be repaired
prior to installation of the insert.
•Entire fireplace, including chimney, must meet local building requirements.
•Chimney height: 15' (4.5M) minimum; 33' (10M) maximum (measured from base of insert). Minimum
cross section: 28.65 square inches (18626 sq. mm).
•The damper ("A") and grate ("B") must be removed (see Figure 1). The smoke shelf ("C"), internal
baffles ("D"), screen ("E"), and metal or glass doors ("F") may be removed (if applicable). The
masonry lining (masonry sides, floor, etc. - "G"), insulation ("H"), and any structured rigid frame
members (metal sides, floor, door frame, face of the fireplace etc. – "I") may not be removed or
altered.
Figure 1
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 cannot be responsible for external forces leading to less
than optimal performance.
C
B
F
I
D
E
A
G
H

12 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
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 “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.
Figure 2
a
b
c

Fireplace Insert Installation (for qualified installers only) 13
© Travis Industries 100-01342 4131101
Flue Adapter Installation
The flue adapter may be removed, attached to the liner, then re-attached while the insert is placed in
position.
1. Remove the two bolts that secure the flue adapter to the insert (7/16” Nutdriver).
NOTE: Flue adapter is tight and will need to be knocked loose with a hammer.
2. Prepare the liner connector for attachment to the flue adapter. Notch the liner around the bypass rod
and check fit.
3. The liner adapter will fit loose in the flush wood insert flue collar and must be sealed with the gasket
tape provided in the hardware pack with the insert. Start above the bypass rod notch and wrap the
gasket twice around the liner adapter overlapping the second wrap over the top edge of the first wrap
(shown below).

14 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
4. Attach the liner adapter to the insert flue adapter and then locate correct connection position in the
fireplace and attach to the liner. Make sure the adapter is centered, 8-1/2” behind the fireplace
opening, and approximately 18” from the floor of the fireplace.
HINT: Placing the flue connector near its final position is key to an easy installation.
5 Slide the insert into place. Make sure the adapter fits over the opening for the flue.
6 A flue adapter pull-stick is included to help position the flue adapter in place. Insert the pull stick
through one of the holes for the flue adapter bolt.

Fireplace Insert Installation (for qualified installers only) 15
© Travis Industries 100-01342 4131101
7 Thread the pull stick into the flue adapter and turn 4 to 6 times.
8 Use the pull stick to guide the flue adapter into position. Push the insert slightly, then pull on the pull
stick.
9 Repeat step 8 until the insert is in position.

16 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
10 Remove the pull stick and place it aside (behind surround panels, inside the fireplace for future use).
11 Replace the two bolts removed in step 1. Tighten the bolts fully, making sure the flue adapter is
seated.

Fireplace Insert Installation (for qualified installers only) 17
© Travis Industries 100-01342 4131101
Vent Overview
This insert utilizes a catalytic combustor to increase efficiency and decrease emissions. This increases
the air resistance inside the firebox, making the flue connection especially important. To insure proper
draft, and to prevent smoke spillage during re-loading, it is crucial for the flue to be sealed. Use the
included gasket to seal the liner connector to the flue adapter.
In addition, we recommend using non-combustible fiberglass insulation to seal the fireplace enclosure.
By sealing the top and bottom of the chimney, and the surround panels, you will be ensuring outside air is
not pulled into the chimney.
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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
Seal the flue connection with the
included gasket.
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We recommend using non-combustible
fiberglass insulation to seal the fireplace
enclosure (chimney top and bottom, and
surround panels)
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18 Fireplace Insert Installation (for qualified installers only)
© Travis Industries 100-01342 4131101
Surround Panel Installation
Width Height Part#
Standard Size 38” (966mm) 25” (635mm) 96100409
The surround panel is installed after the
insert is in place with the flue attached.
Make sure to route the power cord and
rheostat wires through the notch in the
panel.
NOTE: The surround panel is not required.
If the fireplace opening is small enough, you
may wish to use the face only (see
dimensions below).
Face Removal
WARNING: Unplug or disable power
to the appliance prior to removing the
face.
1) Open the door and lift it off its
hinges.
2) Pull the bypass all the way
forward. Unscrew the bypass rod
from the bypass yoke (make sure
to detach the handle and rod as
one piece).
3) Unscrew the air control rod from
the air control.
4) The face uses hooks to hang in
place. Lift the face up and pull
back to remove. Take care to
prevent damage to the wiring
(disconnect if necessary).
See the instructions included with the
face for full details.
FACE SIZING: 30” Wide, 21.5” Tall
When installing, lift the panel over this flange.
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Fireplace Insert Installation (for qualified installers only) 19
© Travis Industries 100-01342 4131101
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.
1 Disconnect the Molex connector and remove the power cord following the directions below.
2 Connect the power cord to the left side 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.
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.

20 Operating Your Appliance
© Travis Industries 100-01342 4131101
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.
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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2 to 4 hours