Travis Industries 520-96 User manual

OWNER'S MANUAL
PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE
KEEP THIS MANUAL
November, 1992
¥ Residential Freestanding Stove
¥ Mobile Home Freestanding Stove
¥ Alcove
Model 520-96
(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 STOVE OR 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 INSTALL IN A SLEEPING ROOM
WHEN INSTALLING IN A MOBILE HOME.
¥ 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
FREESTANDING INSTALLATION
FREESTANDING OPTIONAL EQUIPMENT ...................................................................................................8
PREPARATION FOR INSTALLATION - FREESTANDING .................................................................................13
FREESTANDING INSTALLATION - SPECIFICATIONS ....................................................................................14
FREESTANDING INSTALLATION ...............................................................................................................16
Standard Ceiling Installation................................................................................................................16
Cathedral Ceiling Installation ...............................................................................................................17
Horizontal Installation Into Factory-Built Chimney....................................................................................18
Hearth Stove Installation Using a Positive Connection..............................................................................19
Hearth Stove Installation Using a Direct Connection.................................................................................21
Hearth Stove Installation Using a Horizontal Connection ...........................................................................23
Mobile Home Installation.....................................................................................................................25
Alcove Installation.............................................................................................................................26
INSTALLATION OF A FIREPLACE BLOCK-OFF PLATE ...................................................................................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 ................................................................................................................................49
SAFETY LABEL ......................................................................................................................................50

Page 4
FEATURES AND SPECIFICATIONS
* EPA Phase II Approved
* Large Firebox Capacity - 2.5 cu. ft.
* 3/16 and 5/16" Steel Plate Construction
* Long Burn time - Up to 12 Hours
* Heavy Duty Firebrick Lining
* Conveniently Located Single Push-Pull
Combustion Air Control
* 22" Log Length Capacity
CONVENIENT
HIGH HEAT OUTPUT
VERSATILE
CLOSE CLEARANCES
DURABLE
Heating Capacity ............................................................................1,500 to 2,250 sq. ft.
Maximum B.T.U.'s/hr ......................................................................72,300 (Cord Wood)
Overall Efficiency ............................................................................70.3 % (Oregon Method)
Emissions grams/hr........................................................................7.4 (EPA Method)
Maximum Burning Time (Hours)..................................................12
Flue Opening Diameter ................................................................6 in.
Height from floor to top of stove on:
Steel Legs..................................................................................30 7/8 in.
Brass Legs .................................................................................32 1/4 in.
Cast Legs ...................................................................................32 1/4 in.
Pedestal......................................................................................36 3/8 in.
Overall Width ...................................................................................29 in.
Overall Depth...................................................................................22 in. (Not Including Ashlip)
Weight...............................................................................................455 lbs. (On Legs)
Fuel....................................................................................................Solid Wood Only
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
FREESTANDING OPTIONAL EQUIPMENT
Your Lopi 520-96 appliance comes completely assembled. The options available for the freestanding
method of installation are listed below and require assembly.
1. Pedestal
2. Leg Kit, Steel
3. Leg Kit, Brass
4. Leg Kit, Cast
5. Blower, Rear
6. Outside Air (Available with Pedestal or Outside Air Boot and Legs)
1. Pedestal Assembly:
Open the box marked Pedestal and
remove the pedestal and the two
attachment bolts and washers (3/8"
diameter - 16 x 3/4" hex. head bolts).
Optional Air Intake Port
Attach the pedestal
to the stove here
Lift the stove onto the pedestal. Line up the threaded bolt holes in the bottom of the stove with the two
holes in the tabs that stick out of the side of the pedestal. Using an open-end or socket wrench, fasten the
pedestal to the stove with the supplied bolts and washers.
2. Steel Leg Kit Assembly:
Open the box marked Steel Leg Kit and remove the four 6 1/2" high black steel legs, complete with
rubber-tipped leveling bolts, the four attachment bolts (3/8" diameter - 16 x 3/4" hex. head bolts) and the
washers.
Raise the stove on some pieces of lumber to a height of about 7".
Line up the hole in the top of the leg with the threaded bolt hole
in each corner of the stove bottom. Using a 9/16" open end or
socket wrench, fasten the leg to the stove with the supplied
attachment bolts and washers, making sure the legs are flush
with the corners of the stove.
Attach Bolt (with
washer) to Stove
From Below
To level the stove, first make sure the leveling bolts with the rubber ends (some models come with steel
bolts -- the same directions apply) are screwed into position and backed off just enough to penetrate
below the steel portion of the leg. Unscrew each leveling bolt just enough so each leveling bolt is an
equal distance from the floor. You may wish to use a piece of wood or other spacer to measure this
distance. Next, lower the stove onto the ground and check for a level position. If slight adjustments need
to be made, make sure to first raise the stove before turning the leveling bolts or moving the stove. The
rubber tips of the leveling bolts will tear if they are adjusted or slid while weight is applied to them.

Page 9
FREESTANDING OPTIONAL EQUIPMENT (Continued)
3. & 4. Brass and Cast Legs Assembly:
Open the box marked Brass (or Cast) Leg Kit and remove the four 7 7/8" high legs, complete with rubber-
tipped leveling bolts, the four attachment bolts (3/8" diameter - 16 x 3/4" hex. head bolts) and the washers.
Use the same directions listed above for the steel legs assembly. The one difference is that the brass (or
cast) legs are taller, and the stove should be lifted approximately 8 1/2" above the floor before attachment.
Attach Bolt (with
washer) to Stove
From Below
5. Blower, Rear
The rear 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. The blower mounts to the back of the stove centered on the lower edge with three screws. It also
has a thermodisk assembly which turns the blower on and off automatically. Follow the directions below
to attach the blower.
1. Before installing the blower, first remove the two knock-outs on the bottom rear edge of the stove by
prying them out with a screwdriver. They are approximately 1" by 6" and are located near the rear
edge of the stove.
Do not remove. The front knock-out
is for the outside air connection.
Remove these knock-outs for the
universal rear blower.
2. Feed the two wires coming from the thermodisk assembly through the stove and out the left side
knock-out that was removed in step 1. Take the thermodisk assembly and insert it directly below the
ashlip into the left side of the air intake. The thermodisk assembly should be positioned just behind
the support tab that sits at an angle to the left front corner.
Support Tab
Feed wires through stove and
out the left knock-out
removed in step 1.
Front of Stove

Page 10
FREESTANDING OPTIONAL EQUIPMENT (Continued)
5. Blower, Rear (Continued)
The thermodisk must come in contact
with the bottom of the firebox when it is
installed. To insure this, bend the metal
portion of the thermodisk assembly up or
down to create a snug fit.
Thermodisk
Assembly
Bend metal up or down here to create a snug fit
Wires that
attach to
blower box
Thermodisk
Slide the wire clip
over the edge of the
strip of metal
between the two
knock-outs removed
in step 1. Insert the
two thermodisk wires
into the eye of the
wire clip and pull the
slack wire out of the
stove.
Slide the wire clip over the
edge of the strip of metal
between the two knock-outs.
Feed the two thermodisk
wires into the eye of the
wire clip.
NOTE: The wires coming from the thermodisk assembly must not have too much slack
Ð these wires pass near the firebox and can cause a short if the slack is not
taken in and held in place with the wire clip. Do not pull so hard on the wires
that you dislodge the thermodisk housing from its location.
There are two yellow wires coming out of the blower box. These two wires must exit the blower box
from the top, not through the small access hole in the back. Re-route these wires so they exit out of
the top of the blower box. Attach these two wires to the two wires coming from the thermodisk by
connecting the mating quick-connects. It does not matter which wire from the blower box connects to
which wire from the thermodisk assembly. Push all of the excess wire into the cavity inside the blower
box.
3. Place the blower box near the bottom
rear of the stove and push any slack
wire into the blower box so that when
the blower box is attached the excess
wire will not contact the stove.
4. Attach the blower box to the bottom
rear of the stove with the three screws
provided. Push the blower box up
against the stove while tightening the
screws.
The two yellow wires
attach to the thermodisk.
Three holes for attaching the blower
box to the back of the stove
Power Cord
(exits from back
of blower box)
FRONT