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Travis Industries Flex-95 Owner's Manual

Residential freestanding stove and masonry fireplace insert
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OWNER'S MANUAL
PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE
KEEP THIS MANUAL
November, 1992
¥ Residential Freestanding Stove
¥ Masonry Fireplace Insert
Model Flex-95
(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

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Summary of Contents for Travis Industries Flex-95

  • Page 1: Introduction

    PREPARATION, INSTALLATION, OPERATION AND MAINTENANCE KEEP THIS MANUAL November, 1992 ¥ Residential Freestanding Stove ¥ Masonry Fireplace Insert Model Flex-95 (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:...

  • Page 2: Safety Precautions

    ¥ THE FLUE SYSTEM SHOULD BE CHECKED PROCEDURES. TWICE A YEAR MINIMUM FOR ANY BUILD- UP OF SOOT OR CREOSOTE. ¥ TRAVIS INDUSTRIES, INC. GRANTS NO WARRANTY, IMPLIED OR STATED, FOR THE ¥ CONTACT YOUR LOCAL BUILDING INSTALLATION OR MAINTENANCE OF YOUR...

  • Page 3: Table Of Contents

    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 ..........................

  • Page 4: Features And Specifications

    FEATURES AND SPECIFICATIONS * EPA Phase II Approved CONVENIENT * Firebox Capacity of 2.9 cu. ft. HIGH HEAT OUTPUT * 1/4 and 5/16" Steel Plate Construction * Long Burn time - Up to 12 Hours VERSATILE * Heavy Duty Firebrick Lining * Conveniently Located Single Push-Pull CLOSE CLEARANCES Combustion Air Control...

  • Page 5: Chimney Information & Regulations

    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.

  • Page 6: Factory-Built Chimneys

    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.

  • Page 7: Masonry Chimneys

    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.

  • Page 8: Freestanding Optional Equipment

    FREESTANDING OPTIONAL EQUIPMENT Your Lopi Flex-95 appliance comes completely assembled. The optional items available for the freestanding method of installation are listed below and require assembly. THE TOP KIT IS MANDATORY FOR FREESTANDING INSTALLATIONS. 1. Top Kit (Includes the top panel and a flue extender) 2.
  • Page 9 FREESTANDING OPTIONAL EQUIPMENT (Continued) 2. Pedestal Assembly: Attach the pedestal to the stove here Open the box marked Pedestal and Optional Air Intake Port remove the pedestal and the two attachment bolts and washers (3/8" diameter - 16 x 3/4" hex. head bolts). Included with the pedestal kit is a rodent screen and a roll of insulation.
  • Page 10 FREESTANDING OPTIONAL EQUIPMENT (Continued) 6. 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.
  • Page 11 FREESTANDING OPTIONAL EQUIPMENT (Continued) 7. Outside Air (Available with Pedestal or Outside Air Boot and Legs) The outside air option allows the stove to use outside air for combustion instead of room air. This is a requirement for mobile home installations. Both the outside air boot and pedestal (with outside air installed) work in the same fashion.

  • Page 12: Preparation For Installation

    PREPARATION FOR INSTALLATION - FREESTANDING 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.

  • Page 13: Freestanding Installation - Specifications

    FREESTANDING INSTALLATION - SPECIFICATIONS REQUIRED FLOOR PROTECTION: 6 " 6 " FRONT: 16" SIDE: 6" From BACK: 6" Faceplate 16" CLEARANCE TO COMBUSTIBLES: Single Wall Connector Inches Backwall A. Sidewall to unit ......B. Backwall to unit......C. Cornerwall to unit ......D.
  • Page 14 FREESTANDING INSTALLATION - SPECIFICATIONS (Cont.) TOP VIEW 29 7/8" 14 15/16" 6 3/4" 23 3/4" Edge of Faceplate 4 3/4" 26" SIDE VIEW Chart Below Overall Height With: Steel Legs.................. 29 3/4" Brass Legs ................. 31 1/4" Cast Legs ................... 31 1/4" Pedestal..................

  • Page 15: Freestanding Installation

    FREESTANDING INSTALLATION Standard Ceiling Installation When installing a freestanding stove into a residence with a standard ceiling, certain precautions should be taken to insure a safe installation. The directions below illustrate one way to install your freestanding stove into a standard ceiling with a factory-built chimney. There are several other alternative methods. Check with your dealer or installer for information on other options available to you.

  • Page 16: Cathedral Ceiling Installation

    FREESTANDING INSTALLATION (Cont.) Cathedral Ceiling Installation When installing a freestanding stove into a residence with a cathedral ceiling, certain precautions should be taken to insure a safe installation. The directions below illustrate one way to install your freestanding stove into a cathedral ceiling with a factory-built chimney. There are several other alternative methods. Check with your dealer or installer for information on other options available to you.

  • Page 17: Horizontal Installation Into Factory-Built Chimney

    FREESTANDING INSTALLATION (Cont.) Horizontal Installation Into Factory-Built Chimney When installing a freestanding stove into a residence with horizontal connection to a factory-built chimney, certain precautions should be taken to insure a safe installation. The directions below illustrate one way to install your freestanding stove with a horizontal installation into a factory-built chimney. This requires the use of an insulated tee, a wall support, wall closure plate, wall bands, roof flashing, storm collar and chimney cap.

  • Page 18: Hearth Stove Installation Using A Positive Connection

    FREESTANDING INSTALLATION (Cont.) Hearth Stove Installation Using a Positive Connection When installing a freestanding stove into a masonry fireplace that is using a positive connection, certain precautions should be taken to insure a safe installation. The advantages of this type of connection are excellent chimney draft and ease of cleaning.
  • Page 19 FREESTANDING INSTALLATION (Cont.) Hearth Stove with Positive Connection (Continued) Stainless Steel Chimney Liner System Follow Liner Manufacturer's Instructions on Installation and Support Combustible Mantle Airtight Insulated Clean-Out Remove Damper or Wire it Open 18" Min. Block-off Plate or Damper Adapter (Optional) Min.

  • Page 20: Hearth Stove Installation Using A Direct Connection

    FREESTANDING INSTALLATION (Cont.) Hearth Stove Installation Using a Direct Connection Using the direct connection between your hearth stove 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.
  • Page 21 FREESTANDING INSTALLATION (Cont.) (Continued) Hearth Stove with Direct Connection Stainless Steel Chimney Connector Must Extend 1' past the Block-off Plate or to the Flue Liner Airtight Insulated Clean-Out Combustible Mantle Remove Damper or Wire it Open Min. 18" Block-off Plate or Damper Adapter Min.

  • Page 22: Hearth Stove Installation Using A Horizontal Connection

    FREESTANDING INSTALLATION (Cont.) Hearth Stove Installation Using a Horizontal Connection When installing a freestanding stove into a masonry fireplace that is using a horizontal connection, certain precautions should be taken to insure a safe installation. A block-off plate is not needed for this type of installation because the seal can be maintained simply by closing the damper and sealing with a non- combustible material.
  • Page 23 FREESTANDING INSTALLATION (Cont.) Hearth Stove Installation Using a Horizontal Connection (Continued) Minimum Clearance from Chimney Flue Liner Connector to with 18" Unprotected Ceiling Required Airspace Listed or Approved Thimble Assembly Combustible Wall 1" Clearance for Airtight Completely Insulated Exterior Chimney Combustible Clean-Out or 2"...

  • Page 24: Insert Optional Equipment

    INSERT OPTIONAL EQUIPMENT Your Lopi Flex-95 appliance comes completely assembled. The options for insert installation are listed below and require assembly. THE SURROUND PANELS ARE NECESSARY FOR INSTALLATION AS AN INSERT, ALL OTHER EQUIPMENT IS OPTIONAL. 1. Surround Panels - 8", 10" or 12" Sizes 2.
  • Page 25 INSERT OPTIONAL EQUIPMENT (Continued) 1. Surround Panels (Continued) IF USING THE FLUSH KIT, FOLLOW STEP 2A, FOR EXTENDED, FOLLOW 2B 2A. Slide the inside flange of one of the side panels into the space between the side extender and insert, lining up the slots in the panel with the holes in the side of the extender.
  • Page 26 INSERT OPTIONAL EQUIPMENT (Continued) 1. Surround Panels (Continued) 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.
  • Page 27 INSERT OPTIONAL EQUIPMENT (Continued) 3. Flush Kit The flush kit is used to extend the surround panels towards the front of the insert, making the insert extend much less onto the hearth. The flush kit must be used in conjunction with one of the surround panel sizes listed in this manual.
  • Page 28 INSERT OPTIONAL EQUIPMENT (Continued) 4. 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.
  • Page 29 INSERT OPTIONAL EQUIPMENT (Continued) 4. Bay Kit (Continued) 3. Un-screw the handle on the damper rod before installing the bay kit top panel. Slide the top panel onto the top of the side bays. The top panel has joggle clips that hold the top panel in place against the insert and the side bays.
  • Page 30 INSERT OPTIONAL EQUIPMENT (Continued) 6. Blower, Front (Continued) 4. Tighten both screws securely. 5. Insert the plug into a grounded outlet. The front Plug the blower fits blower into underneath a 110 volt the ashlip. grounded outlet. Use a 3/8" nutdriver to attach the two screws that hold the front blower to the appliance.

  • Page 31: Preparation For Installation

    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.

  • Page 32: Fireplace Insert - Specifications

    FIREPLACE INSERT - SPECIFICATIONS LOCATION OF FLUE COLLAR DIMENSIONS REQUIRED FOR INSTALLATION INTO FIREPLACE AND PANEL SIZING. TOP VIEW 29 7/8" 14 15/16" 3/4" 13 5/8" 19" (Extended (Flush) & Bay) 23 3/4" Edge of 4 3/4" Faceplate 26" FIREPLACE SIZING Measure and center the appliance into the fireplace based on the provided measurements.
  • Page 33 FIREPLACE INSERT - SPECIFICATIONS (Continued) FLOOR PROTECTION: Hearth of 42" width and 18" depth when the insert is in place (see "E" and "F" below). CLEARANCE TO COMBUSTIBLES: (NOTE: Measures for the bay kit should be taken before the side bays are put on or to the edge of the firebox.) A.

  • Page 34: Masonry Fireplace Insert Installation

    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.
  • Page 35 MASONRY FIREPLACE INSERT INSTALLATION (Cont.) Installation Using a Direct Connection (Continued) 9. To install the surround panels, follow the directions listed in the section "INSTALLING SURROUND PANELS" . NOTE: Surround panels are not required for a direct connection if a block-off plate is used.

  • Page 36: Installation Using A Positive Connection

    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.
  • Page 37 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.

  • Page 38: Installation Using A Face Seal Connection

    MASONRY FIREPLACE INSERT INSTALLATION (Cont.) Installation Using a Face Seal Connection 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.

  • Page 39: Installation Of A Fireplace Block-Off Plate

    INSTALLATION OF A FIREPLACE BLOCK-OFF PLATE A block-off plate is used to prevent the exhaust going into a masonry fireplace from entering the inside of the house. It insures a tight seal between the masonry fireplace and the stove pipe leading through it. A properly made block-off plate, coupled with either a positive or direct connection, provides the wood heating appliance with a vacuum draw that pulls the flue gases out of the appliance and out the top of the chimney.
  • Page 40 INSTALLATION OF A FIREPLACE BLOCK-OFF PLATE (Continued) Measurement "A" Measurement "C" } 2 " Measurement "B" 5. Bend the sheet metal as indicated on the template at a 45 degree angle on each side after cutting the sheet metal (This 2" lip will allow you to screw this plate into the smoke chamber inside your fireplace).

  • Page 41: Operating Your Appliance

    OPERATING YOUR APPLIANCE Location and Use of Controls NOTE: The Bypass Damper Control becomes hot during operation. Use the included adjustment tool to adjust this control while the appliance is hot. Combustion Air Control The Combustion Air Control is located in the center under the door and is operated by pushing or pulling the control.

  • Page 42: Burning Procedure

    Do not open the door of your appliance when the air control inlet is fully closed. There is a possibility with a solid fuel burning appliance that doing so could result in a sudden flash of flames as the fire ignites with oxygen. However, your Lopi Flex-95 has been thoroughly safety tested to reduce this possibility.

  • Page 43: Maintaining Catalytic Light-Off

    Maintaining Catalytic Light-Off Your Lopi Flex-95 is equipped with a catalytic combustor which increases the efficiency of your appliance. It is located along the roof of the firebox and is accessed from within. Its purpose is to re-ignite the flue gases before they exit up the chimney.

  • Page 44: Burning Your Appliance Efficiently

    OPERATING YOUR APPLIANCE (Continued) Burning Your Appliance Efficiently Your Lopi Flex-95 is designed to heat your home efficiently with the lowest amount of creosote build-up and pollutants emitted. The following steps provide a guideline to efficient burning: On cold days, when you wish for high heat output from your appliance, load the appliance fully after the fire has been established and burn at a medium-high to high burn mode.

  • Page 45: Wood

    OPERATING YOUR APPLIANCE (Continued) Wood This appliance is designed to burn natural wood only. Higher efficiencies and lower emissions generally result when you burn air dried, seasoned hardwoods as compared to softwoods or to green or freshly cut hardwoods. DO NOT BURN treated wood, garbage, solvents, trash, coal, cardboard, colored paper, or wax impregnated logs (i.e.

  • Page 46: Seasoning Wood

    OPERATING YOUR APPLIANCE (Continued) Wood (Continued) Wet wood not only causes more work for you due to the increase in weight making it more burdensome to carry, but most importantly it will not burn as efficiently. You will receive less heat output from a wet piece of wood because it wastes energy evaporating the water, energy that should be used for heating your home.
  • Page 47 OPERATING YOUR APPLIANCE (Continued) Seasoning Wood (Continued) Place firewood in an open area to obtain rapid drying and to prevent deterioration. Preferably, put a cover on the top tier of wood. If you cut trees in summer, let them lie for a week. The leaves will draw moisture from the wood and dry it more quickly than if you limb the tree immediately.

  • Page 48: Storing Wood

    OPERATING YOUR APPLIANCE (Continued) Seasoning Wood (Continued) The bathroom scales can be used to check if firewood is still seasoning. Weigh a basket or bag of a few pieces of firewood. Place them back in the wood pile as an identified unit. Then weigh them again in about a month.
  • Page 49 OPERATING YOUR APPLIANCE (Continued) Storing Wood (Continued) If sufficient space is available under a roof, seasoning and storage can be accomplished in one handling. This practice eliminates the extra handling of moving wood that has been dried outside into a covered storage area.
  • Page 50 OPERATING YOUR APPLIANCE (Continued) SAFETY IN OPERATION The Following Safety Rules Should Be Followed Whenever Using Your Appliance: Do not use this appliance for any purpose other than heating. Burn solid wood fuels only. Never use gasoline, gasoline-type lantern fuel, kerosene, engine oil, charcoal lighter fluid, or similar liquids to start or "freshen up"...

  • Page 51: Care And Maintenance

    BRASS CLEANING Your Lopi Flex-95 may come with a solid brass door, ashlip trim and panel trim, which will require periodic attention to retain its luster. Use a non-abrasive polish, such as "FLITZ" on the solid brass door and clean it only when it is cool.
  • Page 52 CARE AND MAINTENANCE (Continued) DOOR AND GLASS GASKET INSPECTION A damaged or deteriorated glass or door gasket will allow air to enter the appliance through the space between the door and firebox. This will allow smoke to enter the room and hamper efficient burning. Inspect the door gasket to make sure it is flexible and completely intact.
  • Page 53 CARE AND MAINTENANCE (Continued) CHECK FOR CREOSOTE (Continued) 2. Burn the appliance with the combustion air control wide open for about 20 minutes every time you add fresh wood. This allows the wood to achieve the charcoal stage faster and burns the wood vapors which might otherwise be deposited within the system.
  • Page 54 CARE AND MAINTENANCE (Continued) CATALYTIC COMBUSTOR INSPECTION & CLEANING It is important to periodically monitor the operation of the catalytic combustor to insure that it is functioning properly and to determine when it needs to be cleaned or replaced. A non-functioning combustor will result in a loss of heating efficiency and an increase in creosote and emissions.

  • Page 55: Before Calling For Service

    BEFORE CALLING FOR SERVICE SAVE TIME AND MONEY - CHECK THIS LIST BEFORE YOU CALL FOR SERVICE To eliminate unnecessary service calls, first read all the instructions in this manual carefully. The following checklist provides possible solutions to common occurrences that are not the result of defective workmanship or materials in this appliance.

  • Page 56: Replacement Parts And Removal Instructions

    REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS Several components inside your appliance are serviceable by you. These components are usually easy to remove and replace without special tools. Before you attempt to carry out any of these steps, be sure to read through the entire section. To order new parts, use the chart below to order the appropriate part number through your dealer.
  • Page 57 Unscrew the ten screws on the glass bracket with a 5/16" nut driver. Pull the glass retainer, glass, and glass gasket away from the door. Replace the glass with Travis Industries Inc. replacement glass (available at your dealer). The replacement glass is high temperature, high shock ceramic glass. When re-installing, make sure the gasket is properly aligned ..
  • Page 58 REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS (Continued) Removing and Replacing the Catalytic Combustor Before replacing the catalytic combustor, make sure it is Catalytic Combustor (Slides into the holder inoperable by conducting the from the front) steps for testing the catalytic combustor in the section "CARE Temperature Gage &...
  • Page 59 REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS (Continued) Removing and Replacing the Firebricks The firebricks inside your wood-burning appliance are used to store the radiating heat and create a more thorough combustion inside the firebox. Occasionally one of them will crack and require replacement. The directions below are divided into three sections, each section addressing either the baffle (top) firebricks, side and back firebricks, or floor (bottom) firebricks.
  • Page 60 REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS (Continued) Removing and Replacing the Firebricks (Continued) REMOVING THE SIDE FIREBRICKS 1. Follow the directions for removing Metal clips that hold the back and floor firebricks. the side firebricks in place. 2. Once the floor firebricks are removed, the side firebricks can be pivoted out from behind the metal clips that hold the firebricks in...
  • Page 61 REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS (Continued) Removing and Replacing the Firebricks (Continued) REMOVING THE BAFFLE (TOP) FIREBRICKS & COMPONENTS (Cont.) TOP VIEW OF REAR BAFFLE FIREBRICKS Back Row of Baffle Firebrick Rear Baffle Support First, slide Twist the brick so Rotate the the firebrick that it is on end and...
  • Page 62 REPLACEMENT PARTS AND REMOVAL INSTRUCTIONS (Continued) Removing and Replacing the Secondary Air Tube The secondary air tube has holes and runs along the top of the firebox. Over time it may wear and become ineffective. The secondary air tube should be replaced if it cracks or shows severe deterioration, because it supplies air to the firebox that allows for a more efficient fire.

  • Page 63: 5-Year Warranty

    At that time, you will be asked to ship your appliance, freight charges prepaid, to TRAVIS INDUSTRIES, INC. TRAVIS INDUSTRIES, INC., at its option, will repair or replace, free of charge, your LOPI appliance if it is found to be defective in material or workmanship within the time frame stated within this limited warranty.

  • Page 64: Safety Label

    SAFETY LABEL The following is a safety label that is attached to your appliance for installation purposes. It is included here in case it is removed or becomes unreadable. For discrepancies in listings between the label and this manual, follow the listings in this manual. Page 64...

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