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"

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.

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

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