New Buck Corporation 20 Room Heater Installation And Operation Manual
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New Buck Corporation 20 Room Heater Installation And Operation Manual

Buck stove room heater
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"MEETS PHASE II EPA STANDARDS"
MODEL 20 Room Heater
FEATURES
PREPARATION
INSTALLATION
OPERATION MAINTENANCE
SAFETY
Contact your insurance company for coverage and installation inspection
SAFETY NOTICE
If this heater is not properly installed, a house fire may result. For your safety, follow the installation
directions. Contact local building or fire officials about restrictions and installation inspection requirements
in your area.
This product is listed by Warnock-Hersey International, Inc. to the UL Standard No. 1482 and 127.
Manufactured by New Buck Corporation, Spruce Pine, NC 28777
Revised
May/2001
PN-PI-200660
Tested by ITS

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Summary of Contents for New Buck Corporation 20 Room Heater

  • Page 1 Contact local building or fire officials about restrictions and installation inspection requirements in your area. This product is listed by Warnock-Hersey International, Inc. to the UL Standard No. 1482 and 127. Manufactured by New Buck Corporation, Spruce Pine, NC 28777 Revised May/2001...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1: Room Heater Features ... 3 Important Statements ... 4 SECTION II: Masonry Insert Installation ... 6 Minimum Clearances... 7 Required Fireplace Dimensions ... 8 Tools for Installation... 8 Installation Preparation: Fireplace ... 8 Installation Preparation: Heater ... 8 Installation Procedure—Direct Connect ...

  • Page 4: Room Heater Features

    SECTION I The New Buck Corporation room heater Model 20 is one of the safest and most efficient heating systems available when installed and operated as specified in these instructions and as stipulated on the operation and installation labels affixed to the unit. The unit is designed to burn wood fuel only.

  • Page 5: Important Statements

    EPA COMPLIANCE STATUS This manual describes the installation and operation of the New Buck Corporation, Model 20 wood heater. This heater meets the U.S. Environmental Protection Agency’s Emission limits for wood heaters sold after July 1, 1992. Under specific test conditions this heater has been shown to deliver heat at rates ranging from approximately 10,000 to 39,000 BTU/hr.

  • Page 6: Ash Removal

    CATALYST MONITORING It is important to periodically monitor the operation of the catalytic combustor to ensure that it is functioning properly and to determine when it needs to be replaced. A non-functioning combustor will result in a loss of heating efficiency, and an increase in creosote and emissions. Following is a list of items that should be checked on a periodic basis.

  • Page 7: Masonry Insert Installation

    SECTION II MASONRY INSERT INSTALLATION INSTALLATION PRECAUTIONS Extensive field and laboratory testing has shown that catalytic stoves perform best as fireplace inserts when: 1. A direct connect kit is used to connect the stove exhaust outlet directly to the masonry flue of the fireplace when flue liner size is approximately the same size as the heater flue gas exit.

  • Page 8: Minimum Clearances

    MINIMUM CLEARANCES: The Model 20 Fireplace Insert is intended for installation in accordance with the standard for chimneys, fireplaces, vents, and solid-fuel burning appliances, NFPA-211 Code. This model is not intended for installation into factory- built metal fireplaces or for use with a metal chimney (except as listed in Section V of this manual). 1.

  • Page 9: Required Fireplace Dimensions

    REQUIRED FIREPLACE DIMENSIONS Minimum and/or maximum fireplace dimensions: Height Min. Model 20 22” POSSIBLE TOOLS NEEDED FOR INSTALLATION If you decide to install your own stove, there are several hand tools you may need to do the job. If you do not already have them, they are readily available at most hardware stores.

  • Page 10: Installation Procedure-Direct Connect

    NOTE: Due to the redesign for the 2002 series of the Model 20/ZC20, starting with serial number 003908 . The following steps must be followed for proper in- stallation and operating. INSTALLATION MOUNTING TRIM PANELS FOR MASONRY INSTALLATION (Changes refer to pages 9 and 10 in your owners manual) FIGURE 2 POSITIONING POSITIONING THE HEATER...

  • Page 11: Mounting Trim Panels

    FIGURE 3 MOUNTING TRIM PANELS 8. Reinstall the top trim panel by sliding the rear lip of the top trim panel underneath the front lip of the mounting bracket already secured to top of unit. NOTE: Mount the top trim panel so that it sits in front of the top of the side trim panels. 9.

  • Page 12: Final Check

    FINAL CHECK 1. Recheck the specified clearances. 2. Remove all foreign material from the firebox area. 3. Open the primary air draft and damper bypass. 4. Plug the power cord into a 115V AC outlet. Set switch to “Manual” position to ensure motor operates properly.

  • Page 13: Installation Precaution

    SECTION III RESIDENTIAL FREESTANDING ROOM HEATER INSTALLATION INSTALLATION PRECAUTION Extensive field and laboratory testing has shown that catalytic stoves perform best as freestanding stoves when vented into a masonry chimney if: 1. A rain cap is installed on the chimney. 2.

  • Page 14: Minimum Clearances

    MINIMUM CLEARANCES The New Buck Corporation Model 20 must be installed in compliance with the instructions contained in this manual. CLEARANCE FROM COMBUSTIBLE WALLS AND CEILINGS (Using single wall chimney connector) The minimum lateral distance between any part of the room heater and combustible walls is shown in Figures 1 and 2.

  • Page 15: Tools For Installation

    Close clearance installations using listed Close Clearance pipe and 2100 manufacturer’s list. (See page 18) 12” FIGURE 3 WALL INSTALLATION TOOLS FOR INSTALLATION Drop Cloth Electric Drill with 3/32” drill bit 5/16” combination wrench 5/16” magnetic socket chuck adapter, 5/16” wrench (box or socket) or adjustable wrench Socket Set Tape Measure Pencil...

  • Page 16: Determining The Chimney Location

    PREPARING THE ROOM HEATER LOCATION 1. Select an installation location that will give the best airflow from the front of the heater to the remainder of the home. 2. Place the protective floor pad in position. 3. Place the unit on the pad making sure the minimum clearance specifications are met. 4.
  • Page 17 NOT USE GALVANIZED PIPE. Connect each section so the crimped end faces downward, and secure each section to each other using at least three (3) steel sheet metal screws or rivets. 6. After securing New Buck Corporation Chimney Connector to heater, secure pipe to connector with three (3) screws or rivets.
  • Page 18 (b) Connect each section so the crimped end faces downward. (c) Secure each section to each other using at least three (3) sheet metal screws or rivets. (d) After securing New Buck Corporation Chimney Connector to heater secure pipe to connector with three (3) screws or rivets.

  • Page 19: Final Check

    FINAL CHECK 1. Recheck the specified clearances. 2. Remove all foreign material from the firebox area. 3. Open the primary air draft and damper bypass. 4. Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure motor operates properly.

  • Page 20: Mobile Home Installation

    Security Selkirk Metal Bestos Selkirk Metal Bestos Metal Fab Metal Fab Part Description / Part - • Model 20 Room Heater • Outside air pedestal kit #P21B • 6” Chimney Connector #MA-6CHIMCNB • 6” Double wall chimney connector type DVL •...

  • Page 21: Minimum Clearances

    Clearance from combustible walls using listed Close Clearance pipe and 2100 HT chimney system from approved manufacturer’s list. (See page 18) FIGURE 1 WALL INSTALLATION FIGURE 2 CORNER INSTALLATION FLOOR PROTECTION If the room heater is to be installed on a combustible floor, a non-combustible pad must be placed below it to protect the floor from burning material from the stove.

  • Page 22: Installation Preparation

    PREPARING THE HEATER FOR INSTALLATION 1. Inspect the unit for any obvious physical damage. 2. Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure motor operates properly. 3. Check the primary air draft control to ensure that it operates freely. 4.

  • Page 23: Determining The Chimney Location

    (b) Chimney pipe height is at least 2’ higher than any part of the roof within 10’ of the chimney. (See Figure 5.) 4. Next, install a New Buck Corporation Chimney Connector to the flue of the heater. (See Figure 4.) 5.

  • Page 24: Final Check

    RAIN CAP STORM COLLAR 2FT. FLASHING NEW BUCK CORP. FIRESTOP RADIATION SHIELD OUTSIDE AIR DUCT TROUGH UNDERPINNING FINAL CHECK 1. Recheck the specified clearances. 2. Remove all foreign material from the firebox area. 3. Open the primary air draft and damper bypass. 4.

  • Page 25: Pre-Fab Insert Installation

    Other models of those brands may also be acceptable for installation of the Model 20 unit into them. However, factory approval from New Buck Corporation and Warnock-Hersey Laboratories is required prior to installation. Installation must conform to New Buck Corporation installation instructions or addendums.

  • Page 26: Heater Installation

    4. Thoroughly clean the fireplace of ashes and soot. 5. Check the chimney and smoke chamber for excessive buildup of creosote or soot. Also, check for obstructions, such as birds’ nest. If the chimney is excessively dirty, clean it, or have someone clean it professionally BEFORE installing or using the room heater.

  • Page 27: Minimum Clearance To Combustibles

    MINIMUM CLEARANCE TO COMBUSTIBLES C. Sealing Trim Kit 1. This third method of installation is to use the masonry fireplace trim kit to seal the stove to the Pre-Fab fireplace. CAUTION! Although this method is a tested and approved method, some codes may not allow this type installation so be sure to check local codes for approval prior to making this type of installation.
  • Page 28 2. To complete this installation, follow the basic masonry fireplace trim kit installation instructions except: The trim kit may have to be cut down in size so as not to block any cooling vents/chambers of the Pre- Fab Fireplace. 3. To complete methods 1 and 2: Position the heater into the Pre-Fab Fireplace and center the flue exit under the connector.

  • Page 29: Safety

    SECTION VI WOOD HEATER SAFETY Certain safety hazards are inherent in any wood heater installation. You should be aware of these so that a safe and proper installation can be made. 1. FAULTY CHIMNEY: An older masonry chimney should be thoroughly checked to be sure there are no holes or weak spots which could allow sparks or hot gases to escape.

  • Page 30: Operation

    SECTION VII OPERATION This section of the manual is to help you get the maximum efficiency and maximum smoke (particulate) reduction from your heater. If you should experience any difficulty or have any questions concerning your heater, contact your dealer for assistance. Build a fire for maximum efficiency.
  • Page 31 and door to rake the wood and coals into a pile near the front center of the firebox. (Be certain wood chunks are pulled out of the rear corners.) Close door and bypass damper. This step will assure continued combustion and thorough burning of the wood. D.

  • Page 32: Operating And Safety Hints

    OPERATING AND SAFETY HINTS: When preparing to refuel the heater, open the bypass damper (taking the heater out of catalytic mode) and wait for the smoke to clear out of the firebox before opening the door. Burn only natural wood in your catalytic heater. You should not burn trash or garbage, artificial or paper logs, gift wrapping, treated or painted wood, nor should you start a fire with lighter fluid or chemical starter.

  • Page 33: Section Viii

    SECTION VIII PREVENTIVE MAINTENANCE / PARTS REPLACEMENT Check Chimney A. The chimney should be cleaned as necessary to remove creosote, soot, leaves, birds’ nests, etc. (Refer to Page 27, #5 Creosote Formation.) B. A neglected chimney can eventually cause a draw restriction or can ignite and burn hot enough to cause damage to the chimney.

  • Page 34: Catalyst Replacement

    Properly functioning catalysts will be exhibiting a uniform glow from one end to the other (indicating ignition). b. Physically degraded catalysts will have cold places (areas not igniting) where plugging, crumbling, or other degradation has occurred. If this occurs, the monitor probe temperature will not increase at a normal rate.

  • Page 35: Door Gasket Replacement

    4. Using penetrating oil, generously lubricate the four (4) bolt threads holding the catalyst housing in place. Allow to penetrate. 5. Using a 9/16” wrench or 9/16” socket, loosen the four (4) bolts and remove the catalyst housing (drop down) and place in a suitable work area.

  • Page 36: Wiring Schematic

    OPERATION OF SWITCH With Power Cord Plugged Into 115V AC Outlet. (A) For Auto position push in top of switch. When the room heater becomes warm enough the Room Air Blower will come on and stay on until your room heater falls below the acti- vating temperature for the thermostat.

  • Page 37: Troubleshooting Guide

    SECTION IX CATALYTIC TROUBLESHOOTING Definitions Possible Problems Plugging Extreme Temperatures Flow Restrictions Creosote Build-up Chemical Deactivation Excessive Handling Condensation in Chimney Backpuffing Non-uniform flow Troubleshooting Heater Related Problems 1. Sluggish Heater Performance 2. Drop in Overall Efficiency 3. High Fuel Consumption 4.
  • Page 38 DEFINITIONS AIRTIGHT HEATER—In an airtight heater, all air enters in through the inlets. Generally, non-airtight stoves are not as efficient and their level of heat output is less controllable than that of an airtight. BURN CYCLE—Time span between refuelings in which the wood is reduced to a bed of hot coals. BYPASS—Movable door inside a woodstove that is opened when the stove door is opened to give a path of least resistance to smoke to prevent roll-out.
  • Page 39 Problems encountered with the operation of catalytic-combustor equipped wood heaters are usually the same as those experienced in the operation of traditional wood heaters. Our experience has shown that adoption of good operating practices will eliminate most of these problems. In addition, it should be noted that problems with catalytic combustors are rare-fewer than 1 percent of combustors are returned for any reason.

  • Page 40: Troubleshooting

    Backpuffing-A hot combustor (above 1400 ignitor). Usually the wood gas-to-air mixture is either too lean or too rich to form a highly flammable mixture. There are times when this mixture is just right within the firebox during the normal burning process. If the combustor is running at or above the ignition temperature of the mixture, spontaneous combustion will result, causing the stove to vent puffs of smoke.
  • Page 41 Problem 3. High Fuel Consumption 4. Backpuffing 5. Smoke Rollout When Heater Door Is Opened 6. Low Catalytic Temperature Possible Cause 1. Inexperience in catalytic operation 2. Improper regulation of draft or inlet air 3. Burning wet, unseasoned wood or pitchy spongy wood 4.
  • Page 42 Problem 7. Creosote Running From Draft Inlet Openings CHIMNEY-RELATED PROBLEMS 1. Creosote Accumulation 2. Tar and Liquid Creosote Leaking From Metal Flue Joints Possible Cause 6. Heater dampered down too much 7. Combustor not functioning 1. Burning wet, pitchy woods 2.
  • Page 43 Problem 3. Heavy Concentration of Smoke Leaving Chimney 4. Rusted or Corroded Flue Parts 5. Odor-Both Inside and Outside The Home 6. Poor-Drafting Chimney Possible Cause 1. Water vapor. (On cold, still days water vapor may be mistaken for smoke. The difference is that water vapor appears white and will tend to rise vertically and...
  • Page 44 LESS THAN 10 INCHES 2 FT. 3 FT. METAL CHIMNEY CHIMNEY “10 FT.” RULE (MINIMUM HEIGHTS) GREATER THAN 10 FT. 2 FT. MINIMUM HEIGHT ABOVE THE ROOF WITHIN 10 FT. HORIZONTALLY 10 FT. 2 FT. 3 FT. MASONRY CHIMNEY Stack wood in criss-cross pattern under a shelter to allow air flow to dry the wood and to keep wood from rain.

  • Page 45: Combustor-Related Problems

    COMBUSTOR-RELATED PROBLEMS Problem 1. Plugging 2. Catalyst Peeling 3. Chemical Deactivation 4. Catalyst Masking—a catalyst with a layer of fly ash or soot which prevents catalytic activity 5. Substrate Cracking-Thermal Possible Cause 1. Burning materials that produce a lot of char and fly 2.
  • Page 46 Problem 6. Substrate Cracking— Mechanical 7. Substrate Crumbling 8. Color Variations Possible Cause 1. Mishandling or abuse 1. Extreme thermal shock 2. High draft 1. Variation in color from combustor to combustor or within a combustor can occur (new combustors) Solution 1.

  • Page 47: Zero-Clearance Cabinet Model Zc20

    Do not attempt to build a fire in this product. It has been designed and safety tested for use only with Model 20 manufactured by New Buck Corporation. Read and follow the installation and operating instructions for this model. Do not remove or cover this label.

  • Page 48: Section I

    SECTION I RESIDENTIAL INSTALLATIONS Listed NEW BUCK CORP. Model ZC20 UL Listed and factory approved Chimney Systems Simpson Dura Vent Security Selkirk Metal Bestos Metal Fab CAUTION: Read through all of these instructions carefully. Follow approved Chimney Manufacturer’s Installation exactly. Failure to install the Cabinet Fireplace, Stove and Chimney as described in the instructions will void the manufacturer’s warranty and may have an effect on your Homeowner’s Insurance.
  • Page 49 F. DO NOT build a fire directly inside the ZC Cabinet. It is designed solely for housing the Model 20 Stove. G. WARNING: This fireplace has not been tested for use with a chase above the roof. H. Do not connect this unit to a chimney serving another appliance. SELECTING A CHIMNEY INSTALLATION AND LOCATION There are two basic types of chimney installations possible with the ZC20;...
  • Page 50 NOTE: Chase Installation: (See Figure 3.) A chase is an enclosure built specifically to house a chimney. The interior of a chase is open from the ZC20 to the roof, eliminating the need to cut through ceilings and the roof. Normally, a chase is built outside and against the exterior wall of a home.
  • Page 51 6. Obtain the listed and approved chimney installation instructions and follow exactly. a) Obtain the starter section of pipe and install on the ZC20 cabinet. It may be necessary to crimp the inside of the starter pipe to ease installation into the ZC20 cabinet. b) Obtain the two short sheet metal “ell”...
  • Page 52 7. The ZC20 cabinet is now ready for framing as follows: a) Frame the ZC20 using 2”x4” studs or local building code framing. Some minor framing restrictions are required: 1. Adjacent side walls must be at least 16” from the outer edge of the ZC20 trim panel 2.
  • Page 53 8. Next construct the hearth extension out of non-combustible inorganic building materials as follows: a) The hearth extension must extend 17” in front of the rough framed opening on the ZC20. b) The hearth extension width must be at least 37 15/16”. c) The hearth extension must be made of brick 2”...
  • Page 54 TOP FRONT TRIM PANEL HEATER POWER CORD 10. Now, finish the wall around the ZC20 using brick, rock, sheetrock, paneling, or any type finishing material. CAUTION: Do not block any openings designed into the unit. 11. Install a mantel above the unit if desired. Note that a combustible mantel must be positioned at least 12” above the top of the ZC20 cabinet.

  • Page 55: Mobile Home Installations

    SECTION II MOBILE HOME INSTALLATIONS Listed NEW BUCK CORP. Model ZC20 UL Listed and Factory Approved Chimney Systems Simpson Dura Vent Security Selkirk Metal Bestos Metal Fab CAUTION: Read through all of these instructions carefully. Follow approved Chimney Manufacturer’s Installation exactly. Failure to install the Cabinet Fireplace, Stove and Chimney as described in the instructions will void the manufacturer’s warranty and may have an effect on your Homeowner’s Insurance.
  • Page 56 F. DO NOT build a fire directly inside the ZC20. It is designed solely for housing the Model 20. G. WARNING: Do not install in sleeping room. H. CAUTION: The structural integrity of the mobile home floor, wall, and ceiling/roof must be maintained. Do not connect this unit to a chimney serving another appliance.
  • Page 57 Obtain the Listed and Approved Chimney Installation instructions and follow exactly. a) Obtain the starter section of pipe and install on the ZC20 cabinet. It my be necessary to crimp the inside of the starter pipe to ease installation into the ZC20 cabinet. b) Obtain the two short sheet metal “ell”...
  • Page 58 Optional Fire Code Sheet Rock And Metal Fire Stop RADIATION SHIELD Ceiling NOTE: Follow Chase building and fire Enclosure codes for each indi- vidual state. FIGURE 10 CHASE ENCLOSURE AND CORNER LOCATION FRAMING 7. Next construct the hearth extension out of non-combustible inorganic building materials as follows: a) The hearth extension must extend 17”...
  • Page 59 K Factors of Alternate Materials: Material Ceroform 126 Limestone Concrete Sandstone Marble Hearth extension or floor protector thickness above four (4) inches is generally not acceptable due to cost, floor load capacity, and look. The alternate we recommend is using Ceroform No. 126 millboard 1/8” thick minimum and putting any type decorative brick or stone (any thickness) on top of it.

  • Page 60: Safety Precautions

    CLEANING THE UNIT A. The unit should be lightly sanded with fine sandpaper or steel wool, then repainted or touched up with high temperature black paint. B. If the unit is located in a moist or damp location, check thoroughly for signs of condensation during times when the unit is not in use.

  • Page 61: Preventive Maintenance

    PREVENTIVE MAINTENANCE/ CHIMNEY A. The chimney should be cleaned as necessary to remove creosote, soot, leaves, birds’ nests, etc. CREOSOTE-FORMATION AND NEED FOR REMOVAL When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote.
  • Page 62 Merchantability, Fitness for Purpose or Otherwise except those warranties expressly stated herein. (C) New Buck Corporation is not liable for indirect, incidental, or consequential damages in connection with the use of the product including any cost or expense of providing substitute equipment or service during periods of mal- function or non-use.

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