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...).