Travis Industries X-96 User manual

OWNER'S MANUAL
PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE
KEEP THIS MANUAL
November, 1992
¥ Masonry Fireplace
¥ Zero-Clearance (Metal) Fireplace
Model X-96
(E.P.A. Phase II Approved)
Tested to U.L. 127, U.L. 1482, U.L. 907 Standards by:
Warnock Hersey Professional Services, LTD
Manufactured by:
10850 117th Place N.E. Kirkland, WA 98033

Page 2
SAFETY PRECAUTIONS
¥ VIEWING DOOR MUST BE CLOSED AND
LATCHED DURING OPERATION.
¥ THE APPLIANCE IS DESIGNED AND
APPROVED FOR BURNING OF WOOD ONLY.
THE BURNING OF ANY TYPE FUEL OTHER
THAN WOOD WILL VOID ALL WARRANTIES
AND SAFETY LISTING OF THE APPLIANCE.
DO NOT ATTEMPT TO BURN ANY OTHER
FUEL THAN SPECIFIED IN THIS MANUAL.
¥ THIS APPLIANCE MUST BE PROPERLY
INSTALLED IN ORDER TO PREVENT THE
POSSIBILITY OF A HOUSE FIRE. FOR YOUR
SAFETY THE INSTALLATION
INSTRUCTIONS MUST BE STRICTLY
ADHERED TO. DO NOT USE MAKESHIFT
METHODS OR COMPROMISE IN
INSTALLATION.
¥ THE FLUE SYSTEM SHOULD BE CHECKED
TWICE A YEAR MINIMUM FOR ANY BUILD-
UP OF SOOT OR CREOSOTE.
¥ CONTACT YOUR LOCAL BUILDING
OFFICIALS TO OBTAIN A PERMIT AND
INFORMATION ON ANY INSTALLATION
RESTRICTIONS OR INSPECTION
REQUIREMENTS IN YOUR AREA. ALSO,
NOTIFY YOUR INSURANCE COMPANY THAT
YOU ARE INSTALLING YOUR WARNOCK
HERSEY LISTED INSERT.
¥ 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 MUST BE CONNECTED TO
A LISTED HIGH TEMPERATURE
RESIDENTIAL TYPE CHIMNEY OR AN
APPROVED MASONRY CHIMNEY WITH A
STANDARD CLAY, TILE, OR STAINLESS
STEEL LINER.
¥ NEVER BLOCK FREE AIRFLOW THROUGH
OPEN VENTS.
¥ ASHES MUST BE DISPOSED OF IN A METAL
CONTAINER WITH A TIGHT FITTING LID, AND
PLACED ON A NON-COMBUSTIBLE
SURFACE BEFORE FINAL DISPOSAL.
¥ NEVER TRY TO REPAIR OR REPLACE ANY
PART OF THE APPLIANCE UNLESS
INSTRUCTIONS ARE GIVEN IN THIS
MANUAL. ALL OTHER WORK SHOULD BE
DONE BY A TRAINED TECHNICIAN.
¥ DO NOT MAKE ANY CHANGES OR
MODIFICATIONS TO THE APPLIANCE OR AN
EXISTING MASONRY FIREPLACE OR
CHIMNEY TO INSTALL THIS APPLIANCE.
¥ WAIT UNTIL THE APPLIANCE HAS COOLED
BEFORE CARRYING OUT MAINTENANCE
PROCEDURES.
¥ TRAVIS INDUSTRIES, INC. GRANTS NO
WARRANTY, IMPLIED OR STATED, FOR THE
INSTALLATION OR MAINTENANCE OF YOUR
APPLIANCE, AND ASSUMES NO
RESPONSIBILITY FOR ANY
CONSEQUENTIAL DAMAGE(S).
¥ ALWAYS FOLLOW THE INSTRUCTIONS IN
THE OWNER'S MANUAL.
¥ KEEP THIS MANUAL FOR LATER USE.
¥ DO NOT CONNECT THIS APPLIANCE TO
ANY CHIMNEY SERVING ANOTHER
APPLIANCE.
¥ KEEP FURNITURE, DRAPES, CURTAINS,
WOOD, PAPER AND OTHER
COMBUSTIBLES A MINIMUM OF 36" AWAY
FROM THE APPLIANCE.

Page 3
TABLE OF CONTENTS Page
IMPORTANT INFORMATION
INTRODUCTION......................................................................................................................................1
SAFETY PRECAUTIONS...........................................................................................................................2
FEATURES AND SPECIFICATIONS ............................................................................................................4
CHIMNEY INFORMATION & REGULATIONS .................................................................................................5
The 3-Foot, 2-Foot, 10-Foot Rule ..........................................................................................................5
Factory-Built Chimneys ......................................................................................................................6
Determining the Distance Between the Chimney and Combustibles..............................................................6
Masonry Chimneys............................................................................................................................7
INSERT INSTALLATION
OPTIONAL EQUIPMENT...........................................................................................................................8
PREPARATION FOR INSTALLATION ..........................................................................................................14
FIREPLACE INSERT - SPECIFICATIONS .....................................................................................................15
MASONRY FIREPLACE INSERT INSTALLATION ...........................................................................................17
Installation Using a Direct Connection ...................................................................................................17
Installation Using a Positive Connection ................................................................................................19
Installation Using a Face Seal Connection..............................................................................................21
INSTALLATION OF A FIREPLACE BLOCK-OFF PLATE ...................................................................................22
ZERO CLEARANCE (METAL) FIREPLACE INSTALLATION
PREPARATION FOR INSTALLATION ..........................................................................................................24
ZERO CLEARANCE (METAL) FIREPLACE - SPECIFICATIONS .........................................................................25
ZERO CLEARANCE (METAL) FIREPLACE INSTALLATION ..............................................................................27
OPERATING YOUR APPLIANCE
OPERATING YOUR APPLIANCE................................................................................................................29
Location and Use of Controls...............................................................................................................29
Burning Procedure.............................................................................................................................30
Burning Your Appliance Efficiently........................................................................................................31
Daily Use of Your Appliance.................................................................................................................31
Wood ..............................................................................................................................................32
Seasoning Wood...............................................................................................................................33
Storing Wood....................................................................................................................................35
CARE AND MAINTENANCE
CARE AND MAINTENANCE .......................................................................................................................38
Maintenance Schedule.......................................................................................................................38
Maintenance Instructions ...................................................................................................................38
BEFORE CALLING FOR SERVICE
BEFORE CALLING FOR SERVICE ..............................................................................................................41
REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS
Replacement Parts............................................................................................................................42
Removal Instructions.........................................................................................................................42
5-YEAR WARRANTY ................................................................................................................................48
SAFETY LABEL ......................................................................................................................................49

Page 4
FEATURES AND SPECIFICATIONS
* EPA Phase II Approved
* Large Firebox Capacity - 2.3 cu. ft.
* 3/16 and 5/16" Steel Plate Construction
* Long Burn time - Up to 10 Hours
* Heavy Duty Firebrick Lining
* Conveniently Located Single Push-Pull
Combustion Air Control
* 19 1/2" Log Length Capacity
CONVENIENT
HIGH HEAT OUTPUT
VERSATILE
CLOSE CLEARANCES
DURABLE
Heating Capacity ............................................................................1,200 to 1,800 sq. ft.
Maximum B.T.U.'s/hr ......................................................................71,300 (Cord Wood)
Overall Efficiency ............................................................................72.5 % (Oregon Method)
Emissions Grams/hr .......................................................................7.2 (EPA Method)
Maximum Burning Time (Hours)..................................................10
Flue Opening Diameter ................................................................6 in.
Height from Floor to Top of Appliance ........................................21 in. (Includes damper rod)
Overall Width in Fireplace.............................................................24 1/4 in.
Overall Depth in Fireplace ............................................................14 7/8 in.
Fuel....................................................................................................Solid Wood Only
Weight...............................................................................................400 lbs.
Emissions, Efficiency, Heating Capacity and Burn Times may vary depending on actual
home floor plan, type of fuel used, and moisture content of wood. Emissions and
efficiency numbers are those that have been certified by the U.S. E.P.A. and the Oregon
Department of Environmental Quality.

Page 5
CHIMNEY INFORMATION & REGULATIONS
Whether you install your wood heating appliance with a factory-built chimney or masonry chimney, there
are certain rules that must be followed. The following guidelines for chimney installation are included in
this manual to augment the information supplied with either the manufacturer's information for factory-built
chimneys or to insure that your present masonry chimney is suitable for this wood heating appliance. Do
not use makeshift methods or compromise in installation of any chimney equipment.
The 3-Foot, 2-Foot, 10-Foot Rule
The 3-foot, 2-foot, 10-foot rule states that all chimneys (factory-built or masonry) must be:
1. At least 3 feet higher than the highest part of the roof opening through which it passes;
2. And at least 2 feet higher than any part of the roof within 10 feet, measured horizontally. A chimney
must meet requirement #1 and requirement #2. This rule, required by all building codes, applies to
both factory-built and masonry chimneys.
Minimum Chimney Height on a Sloped Roof
2' Minimum
10' 3' Minimum
Ridge
Minimum Chimney Height on a Flat Roof
42"
24"
18"
Less
Than 10'
36"
6"
10' or Greater
Wall or
Parapet
"A" "B"
These minimum chimney heights are required by building codes for safety purposes, to allow time for
sparks exiting a chimney to cool before they land on the roof. In some problematic situations, additional
chimney height above the specified minimums may be necessary to reduce wind-induced down drafting
and back puffing, or to increase draft, thereby improving appliance operating characteristics.

Page 6
CHIMNEY INFORMATION & REGULATIONS (Cont.)
Factory-Built Chimneys
Depending on the manufacturer and where the chimney is to be installed, special supports, roof
assemblies, radiation shields, or locking bands may be supplied as a part of the chimney system. The
manufacturer's installation instructions, which are reviewed by the listing agency, specifies when and
where each of these components must be used.
There are three standard installations with factory-built chimneys. Each type of installation should use
flashing and an adjustable storm collar at the roof line to prevent water from entering the house.
Manufacturers require that chimneys extending beyond a certain height above the roof (frequently above
5 feet) must also be braced.
A chimney cap keeps out rain, birds and other animals, and may reduce down drafts. Spark arresters,
wire mesh devices designed to catch sparks and burning particles emitted with the smoke, may be
included with factory-built chimney caps. These spark arresters may become encrusted with creosote,
blocking the proper flow of flue gases out of the chimney. When burning wood, it is recommended that the
spark arrester be cleaned regularly, or removed entirely unless individual conditions or local codes
require their use.
Determining the Distance Between the Chimney and Combustibles
The chimney must be kept a minimum distance of 2" away from combustibles (e.g., drywall, wood framing,
etc.). The distance between the outside surface of a chimney and combustibles is measured horizontally,
at right angles to the chimney. The pitch of the platform (e.g., the roof) must be considered in calculating
the size of the hole that is cut.
Calculating the Cut-Out on a Slanted Roof
Combustible Roof
Factory-Built Chimney with
Required 2" Clearance
Length of Cut-Out in Roof
2" Min.
c
a
b
90û
Width of Cut-Out in roof
= 4" + chimney width
Length of Cut-Out in Roof
= "c" times 2 + chimney width
Width of
Cut-Out in Roof

Page 7
CHIMNEY INFORMATION & REGULATIONS (Cont.)
Determining the Distance Between the Chimney and Combustibles (Continued)
Installers may find it convenient to create hole cut-out templates for pitches common to their area rather
than performing the calculations or using a trial "cut and measure" system for each installation.
Carefully read the specifications, as minimum clearances other than 2 inches are sometimes required by
the manufacturer. Maintain a minimum clearance of 2" or what the manufacturer requires, whichever is
greater.
Masonry Chimneys
If you are going to use an existing masonry chimney for your wood heating appliance make sure the
chimney is inspected and found in good and safe condition. If the existing chimney is not in good
condition repairs should be made before installation.
WARNING:
Do not connect this unit to a chimney flue serving another appliance.
Do not use makeshift compromises in the installation.

Page 8
OPTIONAL EQUIPMENT
Your X-96 comes assembled and only needs the panels or bay kit attached. The options available for the
appliance are listed below and require some assembly.
1. Surround Panels - 8", 10", and 12" Sizes (Includes Insulation)
2. Surround Panel Brass Trim (Included with Surround Panels)
3. Bay Kit
4. Blower, Front
1. Surround Panels
The surround panels for your insert are sold separately and come in the three sizes listed below. It is very
important that you choose the surround panels that will adequately suit your installation. For direct or
positive connections the surround panels do not require insulation for an airtight seal. For face seal
connections the surround panels must overlap the fireplace at least 2" on the top and sides and require
insulation to insure an airtight seal.
SURROUND PANEL SIZES SIZE ON APPLIANCE (INCLUDING TRIM)
8" 40 1/2" width by 27 3/4" height
10" 44 1/2" width by 29 3/4" height
12" 48 1/2" width by 31 3/4" height
NOTE: For a Face Seal Connection it is recommended that you have at least 2" of
overlap. On brick or stone facing an overlap of 2 1/2" may be necessary for an airtight
seal due to the rough surface.
It is very important that your surround panels overlap the fireplace opening by 1/4" or more. This will
insure a good seal and provide a more attractive facade. When determining your surround panel size,
remember that the panels must overlap the fireplace opening in both width and height. The surround
panels may overlap the fireplace opening by more than the 1/4" recommendation if it is to allow for a
complete seal. Any questions on selection of the surround panels should be directed towards your
dealer. To install the surround panels, first refer to the type of installation you are using (e.g. Face Seal
Connection, Direct Connection, etc...).
Follow the directions listed for the type of installation you are doing, and follow the directions below when
they are referred in that section. The insert should be placed on the hearth one foot away from the
fireplace opening to install the surround panels. After the side surround panels are installed, the insert
can be placed into position.
1. Place the side panels against the side of the insert so the inward flange of the side panel goes inside
the panel on the side of the insert. Line up the slots in the panel with the holes in the side of the
insert. Attach each panel with two screws and nuts included with the panel kit. The screws should
pass through the insert and side panel from the inside out. Do not tighten all the way at this point.
See the illustration on the following page.
2. Slide the top panel onto the offset on top of the side panels. The top panel must also slide over the
mounting flange that is on the insert. The top panel has four joggle clips that hold the top panel in
place against the insert and the side panels. The best way to insert the top panel is to hold it at an
angle and insert one side first and gradually lower it until the opposite side is inserted. Adjust the top
panel so its edges are flush with the side edges of the side panels.

Page 9
OPTIONAL EQUIPMENT (Continued)
1. Surround Panels (Continued)
3. Adjust the position of the side panels so they are: 1) flush with the bottom of the insert; 2) both the
same distance back from the front of the insert; 3) perpendicular to the floor. Tighten the screws and
nuts that hold the panels in place to complete the surround panel installation.
NOTE: If using a positive or direct connection, the top panel should be installed after the
flue is connected to the appliance.
Side Panel Side Panel
Top Panel
Joggle clips
Mounting
Flange
The damper rod
must line up
with the channel
in the center of
the top panel.
Attach the side
panels with two
screws and nuts
as shown here.
The inward flange
on the side panel
goes inside the
panel on the side
of the insert.
INSULATION INSTALLATION INSTRUCTIONS
The installation of the insulation is required only for face seal connections. Direct and positive
connections do not require the insulation to be installed. Refer to the installation instructions for more
details on the type of installations available and the items that are required for each type of installation.
1. With the insert drawn at least 6" away from the fireplace, glue the insulation strip included with the
surround panel kit to the back of the panels using RTV silicon or stove gasket cement. The insulation
should be installed so it overlaps the fireplace opening to form a seal between the panels and the
fireplace face.
2. Push the insert into the fireplace, insuring a seal is made with the insulation between the panels and
the fireplace face. Use a screwdriver to tuck any exposed insulation behind the panels.

Page 10
INSERT OPTIONAL EQUIPMENT (Continued)
2. Surround Panel Brass Trim (Included with Surround Panels)
The surround panel brass trim is an item included with your panels that greatly enhances the appearance
of your insert and is easy to install.
1. Lay the three pieces of brass trim on the floor in front of the insert. Arrange the brass trim so that it
resembles the illustration below. The rounded edge of the trim that will be facing outwards when
installed should be facing down.
Lay the trim on the floor in
front of the insert with the
rounded portion facing down.
Insert
CROSS SECTION OF BRASS TRIM
Set-screw that
holds the larger "L"
bracket in place
Groove where the
larger "L" bracket
fits into
Groove Where
Surround Panels
Slide
Groove where the
smaller "L" bracket
fits into
Front Side
Larger "L"
Brackets
Top Trim
Left Trim Right Trim
Smaller "L"
Brackets
2. Insert a large and small "L" bracket leg into the groove in the 45ocut end of each side piece. Slide the
other leg of each "L" bracket into the groove in each end of the top piece.
3. With the allen wrench included with the trim, tighten the set-screws into the "L" brackets, insuring that
the 45ocuts are butted together to form a neat joint.
4. Lift the complete brass trim assembly and slide the side pieces down over the edge of the side panels
until the bottom edge of the brass trim is flush with the bottom of the side panels and the top panel is
in the groove of the top brass trim piece.
3. Bay Kit
The bay kit for your insert is sold separately and offers an attractive facade for your installation. It is very
important that your installation is adequately suited for the bay kit before deciding on that type of
installation. For direct or positive connections the bay kit does not require insulation for an airtight seal.
For face seal connections the bay kit must overlap the fireplace at least 2" on the top and sides and
requires insulation to insure an airtight seal (See "Surround Panel Insulation Installation").
BAY KIT DIMENSIONS: 37" Wide 28" Height
NOTE: For a Face Seal Connection it is recommended that you have at least 2" of
overlap. On brick or stone facing an overlap of 2 1/2" may be necessary for an airtight
seal due to the rough surface.
It is very important that the bay kit overlaps the fireplace opening by 1/4" or more. This will insure a good
seal and provide a more attractive facade. The bay kit must overlap the fireplace opening in both width
and height. The bay kit may overlap the fireplace opening by more than the 1/4" recommendation if it is
to allow for a complete seal. Any questions on the use of the bay kit should be directed towards your
dealer. To install the bay kit, first refer to the type of installation you are using (e.g. Face Seal Connection,
Direct Connection, etc...).

Page 11
INSERT OPTIONAL EQUIPMENT (Continued)
3. Bay Kit (Continued)
Follow the directions listed for the type of installation you are doing, and follow the directions below when
the surround panels are referred to in that section. The insert should be placed on the hearth one foot
away from the fireplace opening to install the bay kit. After the bay kit has been installed, the insert can be
placed into position.
1. Place one of the side bays against the side of the insert so the inward flange goes inside the panel on
the side of the insert. Line up the slots in the side bay with the holes in the side of the insert (see the
illustration below). Attach the side bay with two of the screws and nuts included with the kit, leaving
the screws loose enough to adjust the side bay. Repeat for the the other side.
Attach
each side
bay to the
insert with
two of the
included
screws and
nuts.
Line up each side bay
and place it so the
inward flange goes
inside the panel on the
side of the insert.
2. Un-screw the handle on the damper rod before installing the bay kit top panel. Slide the top panel
onto the flange on top of the side bays. The top panel has four joggle clips that hold the top panel in
place against the insert and the side bays. The best way to insert the top panel is to hold it at an
angle and insert one side first and gradually lower it until the opposite side is inserted. Adjust the top
panel so its edges are flush with the side edges of the side panels. Before replacing the damper rod
handle make sure the top panel does not interfere with the movement of the bypass damper. Re-
adjust its position if necessary.
Un-screw the damper
control handle before
installing the top panel
of the bay kit. Re-install
the handle after the top
panel is in place
Place the top panel for the bay
kit over the insert. There are four
joggle clips on the top panel
that slide over the side bays
and top flange that hold the top
panel in place.
The brass trim fits over the top
portion of the top panel.

Page 12
INSERT OPTIONAL EQUIPMENT (Continued)
3. Bay Kit (Continued)
5. Adjust the position of the side bays so they are: 1) flush with the bottom of the insert; 2) both the same
distance back from the front of the insert; 3) perpendicular to the floor. Tighten the screws and nuts
before sliding the insert into place. Slide the pre-assembled brass trim over the top panel to complete
the bay kit installation.
NOTE: If using a positive or direct connection, the top panel should be installed after the
flue is connected to the appliance.
6. Follow the directions for installing insulation in the surround panel section of this manual if insulation
is needed.
4. Blower, Front
The front blower is designed to improve the natural convection of the stove by pushing air through the
convection chamber of the stove and causing the heated air to exit through the vents along the top of the
stove. It also has a thermodisk which turns the blower on and off automatically. Refer to the illustration
below while following the directions to attach the blower.
The front
blower fits
underneath
the ashlip.
Use a 3/8" nutdriver to attach
the two screws that hold the
front blower to the appliance.
Plug the
blower into
a 110 volt
grounded
outlet.
1. Remove the two screws below the ashlip with a 3/8" nutdriver.
2. Place the blower under the ashlip and align the two slots in the back mounting bar with the two holes
in the face of the appliance.

Page 13
INSERT OPTIONAL EQUIPMENT (Continued)
4. Blower, Front (Continued)
3. Insert one of the screws in each hole. Pull the blower assembly up as far as it will go to eliminate any
space between the blower and ashlip.
4. Tighten both screws securely.
5. Insert the plug into a grounded outlet.
FRONT BLOWER OPERATION
The blower controls are located on
the switch box that is connected by a
cord to the blower. There are two
rocker switches that determine the
speed and mode (automatic or
manual) of the blower. The two
speeds are RUN (slower) and
STARTUP (faster). The two modes
are AUTO (the thermodisk controls
the switch and the temperature of the
firebox will determine when the
blower starts or stops) and MAN
(manual Ð the blower will run on the
speed setting selected). The blower
should be switched "OFF" for
approximately 30 minutes after each
reload of the stove. This is to allow
the stove to reach operating
temperature.
Speed Control Rocker Switch
(If OFF is selected, the blower
will always be off, even if on
automatic)
Mode Rocker Switch (If OFF
is selected, the blower will
always be off, no matter what
the speed setting is at)
RUN OFF STARTUP
AUTO OFF MAN

Page 14
PREPARATION FOR INSTALLATION -
MASONRY FIREPLACE INSERT
READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE YOUR NEW APPLIANCE. FAILURE TO
FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.
PREPARATION:
1. Remove all tape and packaging.
2. Remove the wood shipping frame from around and under the appliance.
3. Check that no parts have become loose and the appliance has not been damaged during shipping.
4. Remove the hardware pack from the appliance.
5. READ THE OWNER'S MANUAL BEFORE PROCEEDING.
* Appliance should be located such that no doors, drapes, furniture or other combustibles can be
placed close or swing closer than the minimum 36" clearance.
* The appliance must be installed in a level, secure position.
REQUIRED FLOOR PROTECTION:
NOTE: Minimum hearth extension of 36 1/4" width by 18" depth from fireplace opening is required.
CHIMNEY LENGTH Maximum Minimum
Vertical 33 Feet 15 Feet
OPTIONS
Your fireplace insert comes completely assembled. Options available for your fireplace insert are:
1. Surround Panels - 8", 10", and 12" Sizes (Includes Insulation)
2. Surround Panel Brass Trim (Included with Surround Panels)
3. Bay Kit
4. Blower, Front
SAFETY
For your safety, examine the fireplace and chimney prior to installation of the insert to determine that they
are free from cracks, loose mortar, creosote deposits, blockages, or other signs of deterioration. If
evidence of deterioration is noted, the insert should not be installed until after repairs have been made.
Any opening between the masonry of the fireplace and the facing masonry must be permanently
sealed.Your fireplace insert is listed for installation into masonry fireplaces, and is approved to be
installed with one of the following connections:
1. Positive
2. Direct
3. Face Seal NOTE: It is recommended your chimney have a minimum 28 and a
maximum of 144 square inch cross-sectional area to use a face seal
connection, otherwise your chimney may not have sufficient draw for the
fireplace insert to operate correctly. If your chimney does not fit within these
parameters it is recommended you install a direct or positive connection.
When lifting the appliance, you may choose to remove the interior components to make it lighter. Refer to
the section "REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS" for the proper sequence of
removal and replacement of internal components.

Page 15
FIREPLACE INSERT - SPECIFICATIONS
LOCATION OF FLUE COLLAR DIMENSIONS REQUIRED FOR INSTALLATION INTO FIREPLACE AND
PANEL SIZING.
TOP VIEW
Edge of
Faceplate
24 1/4"
5 1/4"
24 7/8"
4 3/4"
12 1/8"
14 7/8"
Surround Panels
or Bay Sides
20 1/4"
10" Extension onto hearth
FIREPLACE SIZING
Measure and center the insert into the fireplace based on the provided measurements.
A. Minimum Height (Front) 21"
B. Minimum Height (Back) 21"
C. Minimum Width (Front) 24 1/4"
D. Minimum Width (Back) 24 1/4"
E. Depth into Fireplace 14 7/8"
F. Extension onto Hearth 10"
(From Face of Fireplace)
A
D
C
B
E
F

Page 16
FIREPLACE INSERT - SPECIFICATIONS (Continued)
FLOOR PROTECTION:
Hearth of 45 1/4" width and 18" depth when the insert is in place (see "E" and "F" below).
CLEARANCE TO COMBUSTIBLES:
A. Adjacent Sidewall to
Insert 19"
B. Side Facing 13"
C. Top Facing 28 1/2"
With Shield 20 1/2"
D. Mantle to Insert 30 1/2"
With Shield 22 1/2"
E. Minimum Floor
Protection-Front 18"
F. Minimum Floor
Protection-Side 8"
COMBUSTIBLE SIDEWALL
COMBUSTIBLE MANTLE
A
D
E
F
Fireplace Facing
Combustible Surface
Combustible Surface
Surround Panel
B
C
Edge of
Firebox
NOTE: For clearances, use this clearance diagram or the clearance diagram on the safety label attached
to the back of the appliance.
LEVELING BOLTS
If your fireplace is stepped down from the hearth, you will be required to use the leveling bolts located
within the hardware package.
Prior to placing the insert
in the fireplace opening,
measure the step-down.
Screw the 1/2" bolts
provided into the threaded
holes in the back corners
of the insert body and
adjust them to match the
step-down measurement.
As you install the insert the
leveling bolts may need
further adjustment. This
may be done by tilting the
insert slightly and turning
the bolts.
BOTTOM VIEW
Leveling
Bolts

Page 17
MASONRY FIREPLACE INSERT INSTALLATION
Installation Using a Direct Connection
Using the direct connection between your insert and masonry chimney allows you to use your existing
chimney with a minimum of installation work. An airtight seal must be made with a block-off plate to insure
that your chimney will draw the smoke out of the appliance. The directions below illustrate one way to
install your insert into a direct connection masonry chimney. There are other alternative methods. Check
with your dealer or installer for information on other options available to you. The directions below should
be followed in the order listed.
1. Inspect the masonry chimney and follow all the rules outlined in the section titled "CHIMNEY
INFORMATION & REGULATIONS".
2. Follow the directions for making a block-off plate in the section titled "INSTALLATION OF A
FIREPLACE BLOCK-OFF PLATE".
3. Follow all of the regulations and guidelines specified in the sections titled "FIREPLACE INSERT -
SPECIFICATIONS" and "PREPARATION FOR INSTALLATION - MASONRY FIREPLACE INSERT".
4. The chimney connector that connects to the insert must either be a 6" flue adapter (See the section
titled "OPTIONAL EQUIPMENT") or a connector that has been notched 1 1/4" above the bottom edge
of the connector (1/2" wide). See the illustration to the left below.
5. Once the plate is in position, slide the pipe into the plate up through the damper. It must extend up to
the flue liner or at least one foot past the block-off plate.
Top
6"
Notch for
bypass
damper rod
(1/2" wide)
1 1/4"
Block-off Plate
6. Install the surround panels by following the directions in the section titled "OPTIONAL EQUIPMENT".
You may now place your new appliance into the fireplace opening and position the connector pipe so
that it can be easily pushed into the flue opening on top of the insert. You may want to use a towel or
blanket to protect the floor while positioning the insert.
7. Once this has been accomplished, reach in and pull the connector pipe down into the flue of the
insert. If ample room between the top of the insert and the fireplace opening does not exist, you will
need to remove the top firebricks by following the directions in the section "REPLACEMENT PARTS
AND REMOVAL INSTRUCTIONS". Then reach inside the appliance and pull the connector down by
placing your hand up through the flue opening of the appliance. The chimney connector should fit
tight and secure into the flue opening.
8. With the connector in place, you have now completed the direct connection for your insert. It is a good
idea to check your connection by trying to rock the chimney connector back and forth. If it feels snug,
a good connection is established. If you can feel some play when you rock it back in forth, make sure
that the insert is properly aligned and that the connector fits tight into the flue collar on the top of the
insert.
9. Take a look at the figure on the following page. Make sure all of the items listed are complete.

Page 18
MASONRY FIREPLACE INSERT INSTALLATION (Cont.)
Installation Using a Direct Connection (Continued)
Follow the installation instructions in reverse order for periodic inspection and cleaning.
SIDE VIEW OF FIREPLACE INSERT DIRECT CONNECTION
Non-Combustible
Material
Optional Surround
Panel
Block-off Plate
Remove Damper or
Wire it Open
Stainless Steel
Chimney Connector
Must Extend to Clay
Flue Liner or at least
one foot beyond
Block-off Plate
Insulation
(Optional)
Airtight Insulated
Clean-Out
Clay Flue Liner with
Required Air Space
Block-off Plate
Insulation
18" Min.
Follow the directions on the previous page for installation.

Page 19
MASONRY FIREPLACE INSERT INSTALLATION (Cont.)
Installation Using a Positive Connection
Using a positive connection between your insert and masonry chimney allows you to use your existing
masonry chimney to support a new factory-built chimney liner. The advantages of a positive connection
are excellent chimney draft and ease of cleaning. A block-off plate is not needed for this type of
installation because the positive connection provides sufficient draft. If one is used, it need not be airtight.
The directions below illustrate one way to install your positive connection. There are several other
alternative methods. Check with your dealer or installer for information on other options available to you.
1. Install the positive connection (full reline) through the masonry chimney according to the
manufacturer's instructions for installation and support. Make sure to follow all of the manufacturer's
safety precautions during assembly. Inspect the masonry chimney and positive connection so that all
of the rules outlined in the section titled "CHIMNEY INFORMATION & REGULATIONS" are met.
2. If a block-off plate is desired (optional), follow the directions for making a block-off plate in the section
titled "INSTALLATION OF A FIREPLACE BLOCK-OFF PLATE".
3. Follow all of the regulations and guidelines specified in the sections titled "FIREPLACE INSERT -
SPECIFICATIONS" and "PREPARATION FOR INSTALLATION - MASONRY FIREPLACE INSERT".
4. The chimney connector that connects to the insert must either be a 6" flue adapter (See the section
titled "OPTIONAL EQUIPMENT") or a connector that has been notched 1 1/4" above the bottom edge
of the connector (1/2" wide). See the illustration to the left below.
5. If you are using a block-off plate, slide the pipe into the plate up through the damper. If you are not
using a block-off plate, make sure the last segment of the positive connection will reach the insert
once it is inserted into the fireplace.
Top
6"
Notch for
bypass
damper rod
(1/2" wide)
1 1/4"
Block-off Plate
6. Install the surround panels by following the directions in the section titled "OPTIONAL EQUIPMENT".
You may now place your insert into the fireplace opening and position the connector pipe so that it
can be easily pushed into the flue opening on top of the insert. You may want to use a towel or
blanket to protect the floor or panel finish while positioning the insert.
7. Once this has been accomplished, reach in and pull the connector pipe down into the flue of the
insert. If ample room between the top of the insert and the fireplace opening does not exist, you will
need to remove the top firebricks by following the directions in the section "REPLACEMENT PARTS
AND REMOVAL INSTRUCTIONS". Then reach inside the appliance and pull the connector down by
placing your hand up through the flue opening of the appliance. The chimney connector should fit
tight and secure into the flue opening.

Page 20
MASONRY FIREPLACE INSERT INSTALLATION (Cont.)
Installation Using a Positive Connection (Continued)
8. With the connector in place, you have now completed the positive connection for your insert. It is a
good idea to check your connection by trying to rock the chimney connector back and forth. If it feels
snug, a good connection is established. If you can feel some play when you rock it back in forth,
make sure that the insert is properly aligned and that the connector fits tight into the flue collar on the
top of the insert.
9. Take a look at the figure below. Make sure all of the items listed below are completed.
Non-Combustible
Material
Remove Damper or
Wire it Open
Insulation
(Optional)
Airtight Insulated
Clean-Out
Stainless Steel
Chimney Liner System
Follow Liner
Manufacturer's
Instructions on
Installation and
Support
Optional Face Seal
Must be sealed at
the top (preferable)
or with a block-off
plate
18" Min.
Follow the installation instructions in reverse order for periodic inspection and cleaning.