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MODEL 91
CATALYTIC UNIT
Buck Stove
FIREPLACE INSERT & FREESTANDING
FEATURES
PREPARATIONS
INSTALLATION
OPERATION
MAINTENANCE
SAFETY
SAFETY NOTICE
IF THIS HEATER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT.
FOR YOUR SAFETY, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT
THE AUTHORITY HAVING JURISDICTION ( SUCH AS MUNICIPAL
BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE PREVENTION BUREAU,
etc.) CONSULT BEFORE INSTALLATION TO DETERMINE THE NEED TO
OBTAIN A PERMIT. KEEP THESE INSTRUCTIONS FOR FUTURE USE.
LISTED BY:
PFS/TECO, COTTAGE GROVE, WI
MANUFACTURED BY NEW BUCK CORPORATION
200 ETHAN ALLEN DRIVE,
SPRUCE PINE, N.C. 28777
Revised February 2020
www.buckstove.com
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Related Manuals for BuckMaster 91 CATALYTIC UNIT
Summary of Contents for BuckMaster 91 CATALYTIC UNIT
- Page 1 MODEL 91 CATALYTIC UNIT Buck Stove FIREPLACE INSERT & FREESTANDING FEATURES PREPARATIONS INSTALLATION OPERATION MAINTENANCE SAFETY SAFETY NOTICE IF THIS HEATER IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT THE AUTHORITY HAVING JURISDICTION ( SUCH AS MUNICIPAL BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE PREVENTION BUREAU, etc.) CONSULT BEFORE INSTALLATION TO DETERMINE THE NEED TO OBTAIN A PERMIT.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION I Room Heater Features and safety .................. 3 Model 91 Stove Identification ..................4 Important Statements ..................... 5-6 Chimney Heights ......................7 SECTION II Masonry Insert Installation .................... 8-12 SECTION III Residential Freestanding Heater Installation ............... 13-20 Leg Installation ...................... -
Page 4: Section I
SECTION I When installed and operated as specified in these instructions, and as stipulated on operation and installation labels affixed to unit, The New Buck Corporation room heater Model 91 Bay is one of the safest and most efficient heating systems available. The unit is designed to burn wood fuel only. -
Page 5: Model 91 Stove Identification
EPA COMPLIANCE STATUS This manual describes installation and operation of the New Buck Corporation Model 91 Bay wood heater. This heater meets the U.S. Environmental Protection Agency’s Emission limits for wood heaters sold after May 15th 2020. Under specific test conditions, this heater has been shown to deliver heat at rates ranging from approximately 10,400 to 62,745 BTU/hr for the Model 91 Bay. -
Page 6: Important Statements
CATALYST EQUIPPED "This wood heater contains a catalytic combustor, which needs periodic inspection and replacement for proper operation. It is against federal regulations to operate this wood heater in a manner inconsistent with operating instructions in this manual, or if the catalytic element is deactivated or removed."... - Page 7 CATALYST MONITORING It is important to periodically monitor operation of 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. See Troubleshooting section for detailed instructions BEFORE attempting to remove catalyst.
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Page 8: Chimney Heights
CHIMNEY HEIGHTS GREATER LESS THAN THAN 10 FT. 10 FT. 10 FT. 2 FT. 3 FT. 2 FT. 3 FT. METAL CHIMNEY 2 FT. MINIMUM HEIGHT ABOVE THE ROOF WITHIN 10 FT. HORIZONTALLY CHIMNEY “10 FT.” RULE (MINIMUM HEIGHTS) MASONRY CHIMNEY NOTE: MINIMUM CHIMNEY HEIGHT 15 FT. -
Page 9: Masonry Insert Installation
SECTION II MASONRY INSERT INSTALLATION INSTALLATION OPTIONS This unit (appliance) may be installed into an all masonry fireplace, built in accordance with Uniform Building Code and National Fire Protection Association (NFPA 211). NOTE: Check with local building officials for any permits required for installation of this stove and notify your insurance company before proceeding with installation. - Page 10 OPTION (B) OPTION (C) CAP(PREVENTS NOTE: Follow installation WATER FROM ENTERING) instruction with Positive Connection Kit. (Kit sold separately) NOTE: Follow installation instruction FLUE with Direct Connection Kit. LINER INSTALL A NON-COMBUSTIBLE (Kit sold separately) COVER PLATE TO PREVENT WATER FROM ENTERING THE CHIMNEY THE LINER MUST BE STAINLESS...
- Page 11 MINIMUM CLEARANCES: The Model 91 Bay Fireplace Insert is intended for installation in accordance with standard for chimneys, fireplaces, vents and solid-fuel burning appliances. NFPA-211 Code: NOTE-This model is not intended for installation into Zero Clear- ance or pre-fabricated fireplace. The hearth must be of masonry construction and must extend a minimum of 24"...
- Page 12 POSITIONING THE HEATER When positioning heater, the following conditions MUST be met! (See Figure 8.) The front of damper opening must be positioned BEHIND back edge of lintel to ensure proper draft. (See Figure 8.) The vertical plane of fireplace front must fall BEHIND side panels of the unit. (In other words, it is possible to have heater too far in as well as not far enough.) Center the heater in fireplace opening.
- Page 13 Slide unit back into fireplace. Check to be sure that trim panels are properly positioned and lie flat against front of fireplace. If one or more of panels is out of position, slide unit out and reset by loosening mounting screws and repositioning in slot.
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Page 14: Residential Freestanding Heater Installation
SECTION III RESIDENTIAL FREESTANDING ROOM HEATER INSTALLATION INSTALLATION PRECAUTION Select an installation location that will give best airflow from front of heater to remainder of home. Extensive field and laboratory testing has shown that catalytic stoves perform best as freestanding stoves when vented into a masonry chimney that include the following: A rain cap is installed on the chimney. -
Page 15: Leg Installation
Inspect unit for any obvious physical damage. Remove any items from within firebox. Plug power cord into a 115V AC outlet to test motor. Do not run power cord under unit or in high traffic areas. Check primary air and control to ensure that it slides freely. LEG INSTALLATION Use Leg Kit # FA FS9151 for Model 91 1. -
Page 16: Minimum Clearances To Combustibles Single Wall Chimney Connector
MINIMUM CLEARANCES The New Buck Corporation Model 91 Bay must be installed in compliance with instructions contained in this manual. Clearance from combustible walls and ceilings. (Using single wall chimney connector) The minimum lateral distance between any part of room heater and combustible walls is shown in (Figures 14 and 15). BACK WALL BACK WALL 50”... - Page 17 MINIMUM CLEARANCES FLOOR PROTECTION Floor protector must be 3/8" minimum thickness non-combustible material or equivalent. How to use alternate materials and how to calculate equivalent thickness An easy means of determining if a proposed alternate floor protector meets requirements listed in the appliance manual is to follow this procedure: 1.
- Page 18 PREPARING THE STOVE FOR INSTALLATION Inspect unit for any obvious physical damage. Check primary air draft controls to ensure that they operate freely. Check operation of bypass damper control to ensure that it will open and close properly. To attach legs, remove any items within firebox. Spread drop cloth on floor behind heater. Tilt heater so that back is on drop cloth.
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Page 19: Minimum Clearances To Combustibles Double Wall Chimney Connector
CLOSE CLEARANCE INSTALLATIONS (in inches) Close clearance installation is possible by using the following brands of black, double-wall chimney pipe. (See Figure 17 and Figure 18 for clearances.) Simpson Dura-Vent double wall chimney connector “Type DVL” and 8" Simpson Dura-Vent 2100 HT “Type DP”... - Page 20 Wall Exit Into Masonry (Using Single Wall Pipe) Before connecting Model 91Bay to a masonry chimney, determine if masonry fire-place wall pass-through connector thimble meets NFPA-211 Code and local building codes and is a minimum of 18" from ceiling. See Figure 20. If connector thimble does not meet these codes, the pass-through connector must be modified.
- Page 21 Ceiling Exit - Close Clearance Suspend a plumb bob from ceiling above unit so that weight is hanging in the center of flue exit. CEILING (A small weight on a string will serve as a plumb SUPPORT BOX bob.) Mark ceiling where string is suspended to locate center of chimney hole.
- Page 22 Tested and Listed Wall Protector Clearances to combustibles may be reduced if a tested and listed wall protector is installed over a combustible surface when the following conditions exist: A dead air space of 1" separates listed and tested wall protector from combustible surface. The tested and listed wall protector extends form floor to ceiling with a 1"...
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Page 23: Wood Heater Safety
SECTION IV 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. 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 24: Operation
SECTION V OPERATION This section of the manual is to help you get maximum efficiency and maximum smoke (particulate) reduction from your Model 91 heater. If you should experience any difficulty or have questions concerning your heater, contact your Model 91 dealer for assistance. 1.“To maximize the efficiency of your wood stove make sure it is sized properly for the space you plan to heat. - Page 25 BUILDING A FIRE: Place “Manual/Off/Automatic” switch in “Automatic” (bottom) position for thermostat control operation. Turn rheostat knob clockwise (it will click from “Off” position to “On”) so you can vary the speed of motor. Open door. While looking inside firebox, operate damper bypass plate in and out observing movement. This should operate freely and close completely.
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Page 26: Preventive Maintenance
SECTION VI PREVENTIVE MAINTENANCE / PARTS REPLACEMENT THE CATALYSTS Warring: This product can expose you to chemicals including aluminosilicate. Which is knoen to the stat of California to cause Cancer. For more information, go to www.P65Warning.ca.gov The catalysts in your stove are designed for many years of use. If after several years of use, the efficiency of stove decreases or if a notable amount of smoke is observed, catalysts may need to be replaced. -
Page 27: Catalyst Replacement
MAINTENANCE CATALYST REPLACEMENT (Off-Season Replacement Recommended) Spread a drop cloth in front of stove. Open door and clean out any ash. You will have to remove lower stainless steel heat shield. Remove the four cotter pins holding shield in place. Lay shield aside. -
Page 28: Motor Replacement
MAINTENANCE MOTOR ASSEMBLY REPLACEMENT (Motor, Thermostat, Rheostat, Wiring Harness) Unplug heater from 115V AC outlet. To replace motor you must first take bottom cover door off. Do this by removing two screws holding it in place. See Figure 27. Next, you will find a wire screen protecting you from electrical components of this unit. See Figure 28. By looking to right of ash pan, you will find screen cover. -
Page 29: Wiring Schematic
MAINTENANCE WIRING SCHEMATIC Figure 30 THERMOSTAT AUTO SWITCH MANUAL RHEOSTAT GROUND Page 26 Page 28... -
Page 30: Brick Layout
MAINTENANCE BRICK LAYOUT TOP VIEW SIDE VIEW Page 29... -
Page 31: Door Gasket Replacement
MAINTENANCE DOOR GASKET REPLACEMENT (COLD HEATER) 1. To replace deteriorated gaskets, following steps must be taken to ensure proper installation of gaskets. 2. Using pliers, remove any worn and deteriorated gaskets. 3. Obtain proper gaskets and silicone glue from your local dealer. 4. -
Page 32: Check Chimney / Cleaning Heater / Care Of Glass Door
MAINTENANCE CHECK CHIMNEY A. Chimney should be inspected twice a year. B. The chimney should be cleaned as necessary to remove creosote, soot, leaves, birds’ nests, etc. NOTE: A chimney cap should be installed to prevent moisture from entering chimney, to prevent sparks and burning materials from escaping chimney and to keep birds and foreign materials from entering. -
Page 33: Replacement Parts
REPLACEMENT PARTS FOR MODEL 91 Description Quantity Part Number Door Handle Assembly PA 910096 Door Latch PC 910098 Door Handle Washer PH316916FW Front Door Bushing PO 910102 Door Handle Bushing Washer PO910104 Door Black PA 912651B Door Gold PA 912651G Door Pewter PA 912651P Carling Fan Auto/Man Switch... -
Page 34: Troubleshooting
SECTION VII TROUBLESHOOTING Operation of any wood heater can create problems. While use of a catalytic-combustor equipped stove will substantially lessen some of these problems– such as creosote formation– other traditional wood heater problems may remain. The following guidelines apply to operation of all wood heaters, with problems related to catalytic heater addressed where appropriate. - Page 35 Backpuffing Gusts of wind / windy day If flue cap not on chimney, install one. Hot combustor. (Above 1400 Increase the amount of combustion air slowly Bypass damper is closed Open bypass damper Opened door too soon after Open bypass damper– wait 15 opening bypass damper -30 seconds before slowly Smoke Rollout when Heater...
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Page 36: Warranty
NEW BUCK CORPORATION (NBC) “LIMITED WARRANTY” FOR NBC RELATED PRODUCTS If for any reason you are dissatisfied with the PLEASE READ THIS WARRANTY CAREFULLY suggested procedures, you may contact us in writing PRODUCTS COVERED This warranty covers heating unit so long as it is NEW BUCK CORPORATION owned by original purchaser, including optional and Customer Service Department... - Page 37 To be completed by selling distributor/ dealer/ customer: OWNER REGISTRATION CARD Name _________________________________________________________________________________ (Last) (First) Address _______________________________________________________________________________ City ______________________________________ State ________________ Zip_____________ CUSTOMER EMAIL::_________________________________________________________ Model 91 Bay _________ Insert: Residential _________ Model 91 Bay _________ Freestanding: Residential _________ Serial No. ________________________ Date of Installation: Day _________ Month ________________ Year _____________...