New Buck Corporation Heater Model 80 User's Manual
Contents
1. gr 16 HEARTH EXTENSION FIGURE 1 FIREPLACE INSERT MINIMUM CLEARANCES The Model 80 Fireplace Insert is intended for installation in accordance with the standard for chimneys fireplaces vents and solid fuel burning appliances NFPA 211 Code NOTE This model is not intended for installation into zero clearance or pre fabricated fireplace 1 The hearth must be of masonry construction and must extend a minimum of 16 in front of the firebox opening and a minimum of 8 to either side of the firebox opening 2 Floor protector must be 3 8 minimum thickness non combustible material or equivalent 3 If your fireplace has wood trim above it the wood trim must be at least 9 above the top of the unit 4 If your fireplace has a wood mantel the mantel or mantel supports must be located at a height of 24 above the top of the unit REQUIRED FIREPLACE DIMENSIONS Minimum and or maximum fireplace dimensions Height Width Min Max Min Max Model 80 23 1 2 32 1 2 29 46 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 Caulking gun Large adjustabl2. 24 1 By Pass Damper amp Brass Spring Hande 21 Lower Heat Shield 2 Blower Control Rheostat 22 Leveling Screws 3 Primary Air Control Right Side 23 Bottom Firebrick 3a Primary Air Control Left Side 24 Motor 4 Warm Air Outlets 25 Motor Mount Bracket 5 Baffles Interior of Stove 26 Cover Door 6 Air Inlet 27 Cover Door Screws 7 Door 28 Shot Gun Air Box 8 Hearth Extension 29 Ash Pan 9 Power Cord 30 Disc Thermostat 10 Catalyst interior firebox 31 Door Handle amp Brass Spring Handle 11 Catalyst Probe 32 Air Wash Screen 12 Automatic Off Man Switch 33 Glass Gasket 13 Brass Cap 34 Cover Door Hinge 14 Hinge Block 35 Magnet Holder 15 Air Control Brass Knobs 36 Cover Door Magnet 16 Shot Gun Air Control 37 Door Latch 17 Door Glass 38 Door Latch Screw 18 Glass Clips 39 Hinge Pins 19 Hearth Brass 40 3 Flue Exit 20 Door Gasket EPA COMPLIANCE STATUS This manual describes the installation and operation of the New Buck Corporation Model 80 wood heater These heaters meet 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 9 000 to 40 300 BTU hr for the Model 80 CATALYST EQUIPPED This wood heater contains a catalytic combustor which needs periodic inspection and replacement for proper operati
3. bak Move A as BRICK CLEARANCE REDUCTION SYSTEM ee a ILN A LEAVE 1 INCH CLEARANCE FOR AIR CIRCULATION AIR CIRCULATION FLOOR BRICK WALLS MAY BE ATTACHED TO COMBUSTIBLE WALLS USING WALL TIES IF BRICK IS USED BE SURE FLOOR CAN WITHSTAND THE WEIGHT OF THE BRICK COMBUSTIBLE WALL ZZZ lt r Rr WOOD STOVE pp CLEARANCE RE DUCTION SYSTEM SPACED OUT 1 INCH BRICK WALL SPACED OUT 1 INCH FROM PROTECTED SURFACE AIRSPACE P COMBUSTIBLE WALL NAIL OR SCREW ANCHOR MINIMUM 24 GAUGE SHEET METAL 1 INCH NON COMBUSTIBLE SPACER SUCH AS STACKED WASH ERS SMALL DIAMETER PIPE TUBING OR ELECTRICAL CON DUIT DO NOT USE FASTENERS DIRECTLY BEHIND CHIM NEY CONNECTOR OR STOVE COMBUSTIBLE TOPVIEW WALL p Y a a MONIMOM f NON COMBUSTIBLE SHEET METAL o SHEET METAL CLEARANCE REDUCTION SYSTEM FIGURE 12 ALTERNATIVES FOR WALL PROTECTION Example The rear clearance for the Model 80 from page 12 is 26 Measurement A This clearance may be reduced by 66 by using either of the wall protection devices mentioned below 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 condition exist 1 A dead air space or 1 separates the listed and tested wall protector fr
4. LIMITED WARRANTY FOR NBC RELATED PRODUCTS PLEASE READ THIS WARRANTY CAREFULLY PRODUCTS COVERED This warranty covers the new heating unit so long as it is owned by the original purchaser including optional and standard accessories purchased at the same time subject to terms limitations and conditions herein set out PRODUCTS NOT COVERED This warranty does not cover the following Glass Refractory material such as refractory cement or firebrick Gaskets This Warranty will also not cover any damage and or failure caused by abuse or improper installation of the Products Covered WARRANTY TIME PERIODS A Period I For one 1 year from the date of purchase NBC will replace or repair at its option any part defective in materials or workmanship The costs of parts only are included The customer pays any labor or transportation charges required Thereafter B Period II For the period after the first year from the date of purchase and extending for five 5 years as long as the related product is owned by the original purchaser NBC will repair or replace at its option any part defective in materials or workmanship with the exception of electrical motors wiring switches and components optional and standard accessories and all parts not permanently attached to the heating unit Parts not permanently attached to the heating unit are defined as those items designed to be removed from the unit including those
5. adjustment in and out if necessary C Mount the trim panel using self tapping screws provided 5 Mount top trim panel to the side panes with screws provided 6 Next slip the brass trim over the top edge of the trim panels and slide all the way down until sides and tops interlock 7 Slide the unit back into the fireplace Check to be sure that the trim panels and brass are properly positioned and lie flat against the front of the fireplace If one or more of the panels is out of position slide the unit out and reset by loosening the mounting screws and repositioning in the slot See Figure 5 NOTE If side and top panels gap due to unevenness of fireplace normally on rock faced fireplaces you will need to drill a 5 32 hole through both side and top panels near where the panels intersect and install a 10 self threading screw to eliminate the gap Paint screws to match 8 Using insulation provided peel and stick to back of panels overlapping fireplace dimension by 1 each side on top See Figure 4 9 Next using high silicone or furnace cement run bead of caulking on backside of panel where they meet stove See Figure 4 10 Steps 10 and 11 will not be necessary when using direct connect or positive connect U GASKET WE FIGURE 4 FIGURE 5 11 Pull the unit back out of the fireplace and remove the brass and top trim panel to facil
6. control wide open for two minutes to charge wood It may be necessary to open shotgun air for 2 5 minutes After most of the wood is burned if you are not planning on reloading immediately it may be necessary to open the bypass damper and door to rake the wood and coals into a pile near the front corner 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 C Medium High Burn Rate Set the primary air control to the medium high setting Turn the rheostat to high Wood Loading During refueling open the bypass damper open the door and add wood Immediately close door and bypass damper Open primary air control wide open for two minutes to charge wood It may be necessary to open shotgun air for 2 5 minutes After most of the wood is burned if you are not planning on reloading immediately it may be necessary to open the bypass damper and door to rake the wood and coals into a pile near the front corner 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 High Burn Rate Set the primary air control to the medium high setting Turn the rheostat to high Wood Loading During refueling open the bypass damper open the door and add wood Immediately close door and bypass damper N ON You wi
7. floor behind the heater Next tilt the heater so that the back is on the drop cloth Using a tape measure make a line down 3 from the front of the heater Open the corresponding box and obtain the pedestal Place the pedestal against the bottom of the heater angle side to heater at the marked line Center the pedestal left and right and mark screw locations on bottom through outer holes of pedestal mounting angles Set pedestal aside and drill four 7 32 holes in heater bottom Obtain four 1 4 self tapping screws and secure the pedestal to the heater If you chose legs rather than a pedestal open box attach legs to pre drilled holes in bottom of heater Reposition the heater to the upright position Obtain the chimney connector from your dealer Position on top of stove at flue exit Position the two J bolts in connector using lock washer and nuts provided Lock in place CHIMNEY Ceiling Exits using Single Wall Pipe and UL 103 HT type chimney system listed with manufacturer in this section of manual The Model 80 is designed for connection to 1 Simpson Duravent 2 Security 3 Selkirk OO Metalbestos 4 Metal Fab 5 Air Jet listed as 2100 degree pipe and parts Follow the chimney and chimney connector manu CEILING facturer s instructions and local building codes for SUPPORT BOX installation through combustible walls or ceilings This room heater must be converted to 1 a chim ney complying with the requir
8. into the section below or into the opening on the stove for drip free operation c Secure each section to each other using at least three 3 sheet metal screws or rivets d Use three 3 screws to connect pipe to New Buck Corp Chimney Connector Ceiling Exit Close Clearance l Suspend a plumb bob from the ceiling above the unit so that the weight is hanging in the center of the flue exit A small weight on a string will serve as a plumb bob Mark the ceiling where the string is suspended to locate the center of the chimney hole After locating the center of the hole install the ceiling support box chimney or chimney connector flashing and rain cap Next install a New Buck Corp Chimney Connector to the flue of the heater Install Double Wall Connector and chimney system per manufacturer s list of tested pipes Caution Because of the high efficiency and low flue gas temperature freestanding catalytic heaters connected to masonry chimneys with oversized flue lines may encounter drafting problems VALL gt FIGURE 10 BUCK STOVE CHIMNEY CONNECTOR FIGURE 11 CEILING SUPPORT BOX ae SINGLE WALL eo PIPE
9. replace screws and or fasteners CAUTION NEVER use gasoline gasoline type lantern fuel kerosene charcoal lighter fluid or similar liquids to start or freshen up a fire in the heater Keep all such liquids well away from the stove when it is in use All fluids of this type give off volatile fumes and can and WILL EXPLODE Don t take a chance with the safety of your home and family SECTION V OPERATION This section of the manual is to help you get maximum efficiency and maximum smoke particulate reduction from your Model 80 heater If you should experience any difficulty or have questions concerning your heater contact your Model 80 dealer for assistance Manufacturer s recommendation for peak performance and long catalyst life is to burn seasoned hardwood wood dried 6 12 months and place wood from front to back position in the heater Build a fire for maximum efficiency Model 80 burns wood and extracts heat so efficiently a large fire is not necessary A large fire not only wastes energy it usually results in the home being too warm for comfort The following steps will serve as a guide for operating your stove GUIDE TO THE DIFFERENT BURNING QUALITIES OF WOOD Type of Ease of Coaling Amount of Wood Starting Qualities Sparks Apple Poor Excellent Few Ash Fair Good Few Beech Poor Good Few Birch Good Excellent Moderate Cherry Poor Excellent Few Cedar Excellent Poor Many Elm Fair Good Very Few Hemlock Good Low Ma
10. should start quickly If not it may be necessary to preheat the chimney to get the draft started To do this open the door and add newspaper to the top rear of the wood Light or let this paper ignite and allow to burn while holding the door slightly cracked Once the draft has started close and lock the door 9 After embers and a coal bed have been established load the heater with wood A Low Burn Rate Set primary air control to the low setting Close the shotgun air control Turn the rheostat to low Wood Loading During refueling open pull out the bypass damper to allow smoke in the firebox to escape open the door and add wood Immediately close door and bypass damper Open primary air control wide open for two minutes to charge wood It may be necessary to open shotgun air for 2 to 5 minutes also Close and latch door After most of the wood is burned if you are not planning on reloading immediately it may be necessary to open the bypass damper and door to rake the wood and coals into a pile near the front corner of the firebox Be certain wood chunks are pulled out of the rear comers Close door and bypass damper This step will assure continued combustion and thorough burning of the wood B Medium Low Burn Rate Set the primary air control to the medium low setting Turn the rheostat to medium Wood Loading During refueling open the bypass damper open the door and add wood Immediately close door and bypass damper Open primary air
11. BUCK STOVE MEETS PHASE II EPA STANDARDS Lo MODEL 80 HEATER FEATURES PREPARATION INSTALLATION OPERATION MAINTENANCE SAFETY 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 requirements in your area Manufactured by New Buck Corp Spruce Pine NC 28777 Revised 2 03 PN PI 8000660 Tested by ITS Way ae TABLE OF CONTENTS SECTION I Room Heater P Catures salt ad il ta lla tt 3 Important Statements A A ia 5 6 SECTION II Masonry Insert Installation ii a e da di ated 7 10 SECTION III Residential Freestanding Heater Installation ia id 11 17 SECTION IV Wood Heater Safety a dd dtaateande ye 18 SECTION V Operation O O deanads 02 19 20 SECTION VI Preventive Maintenance Parts Replacement ooonoccnnoccnoccnonncoonaconnconn nono ccoo nccon occ nocnnnos 21 22 SECTION VII a O E 23 24 WARRANTY sii A iS 25 SECTION I The New Buck Corporation room heater Model 80 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 Please read this entire manual before you install and use your n
12. STIBLE VALL DN q ME PERN fe BS ff SS R Pa S N HE A ES ES HA 1 any ZN gt MINIMUM E ye Ue z CLEARANCES TO SOE T 4BUSTIBLE Fl CAER WALL PROTECT 2 AS MIN SIZE FIGURE 6 FIGURE 7 FLOOR PROTECTION If a freestanding model 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 The pad must be 37 wide by 37 1 2 deep Floor protector must be 3 8 in minimum thickness non combustible material or equivalent The unit must be positioned on the pad so that there is a minimum of 16 from the front of the door opening to the front of the pad and a minimum of 8 measured horizontally from the sides of the fuel loading and ash removal openings to the sides of the pad NOTE For clearance reductions using wall protectors refer to the NFPA 211 Code TOOLS FOR INSTALLATION Drop Cloth Electric Drill with 7 32 drill bit 1 2 9 16 combination wrench 3 8 magnetic socket chuck adapter 3 8 wrench box or socket or adjustable wrench Socket Set Tape Measure Pencil Level Screw Driver Preparing The Stove for Installation 1 2 3 4 Dn OS Inspect the unit for any obvious physical damage Check the primary air draft controls to ensure that they slide freely Check the operation of the bypass damper control to ensure that it will open and close properly Remove any items from within the firebox Spread the drop cloth on the
13. cally maintain temperatures in excess of 1000 F If catalyst temperatures are not in excess of 500 F refer to Catalyst Troubleshooting Section of this owner s manual A CAUTION AGAINST OVER FIRING Do Not Over fire This Heater Attempts to achieve heat output rates that exceed heater design specifications can result in permanent damage to the heater and to the catalytic combustor ASH REMOVAL Whenever ashes build up in the firebox and when the fire has burned down and cooled remove excess ashes Leave an ash bed approximately 1 inch deep on the firebox bottom to help maintain a hot charcoal bed Ashes should be placed in a metal container with a tight fitting lid The closed container of ashes should be placed on a non combustible floor or on the ground away from all combustible materials pending final disposal The ashes should be retained in the closed container until all cinders have thoroughly cooled SECTION II MASONRY INSERT INSTALLATION INSTALLATION PRECAUTIONS It is not necessary to direct connect this unit but testing has shown that it is necessary for best performance in a poorly drawing flue oversized flue liner or a short chimney Use the following to complete the installation of the unit as an insert Kit PA FP80 Note Clearances to mantel may be reduced by using a tested or listed mantel shield INSTALLATIONS Fireplace Insert Minimum Clearances to Combustible Materials in inches
14. e wrench may not be needed Drop cloths or newspapers Vacuum cleaner or whisk broom Flashlight 1 tube of RTV silicone Code 103 or 106 or high temperature rubber cement rated between 450 F 600 F 7 32 drill bit and drill Socket Rachet Set Insulation Provided in trim kit package INSTALLATION PREPARATION Fireplace Locate furniture and other materials away from the front of the fireplace to allow free access to the fireplace Cover the hearth and adjacent floor areas with the drop cloths to protect from soiling or scarring the surface Remove the existing fireplace damper plate Thoroughly clean the fireplace of ashes and soot 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 the room heater 6 Ifthe fireplace has an ash dump or outside air provision these must be sealed off with metal or tightly packed non combustible insulation to prevent cold air from entering the fireplace chamber PUE Di Heater Preparation 1 Inspect the unit for any obvious physical damage 2 Check the primary air draft controls to ensure that they slide freely 3 Check the operation of the damper control to ensure that it will open and close properly It is not necessary to direct connect this unit unless installed in an improper drawing fireplace or oversi
15. ements for Type HT chimneys in the Standard for Chimneys Factory Se Built Residential Type and Building Heating Appli BUCK STOVE eee WALL ance UL 103 or 2 a code approved masonry CHIMNEY chimney with a flue liner CONNECTOR Caution Certain installation types require the use of certain chimney types Please follow these instructions exactly DETERMINING THE CHIMNEY LOCATION L Suspend a plumb bob from the ceiling above the unit so that the weight is hanging in the center of the flue exit A small weight on a string will serve as a plumb bob Mark the ceiling where the string is suspended to locate the center of the chimney After locating the center of the hole install the EZ ceiling support box chimney or chimney connector flashing and rain cap per the O D chimney manufacturer s instructions and local building codes for installation through mers combustible walls or ceilings 3 Now connect the stove to the ceiling support box by using 24 ga minimum blued or black steel chimney pipe Do not use galvanized pipe Connect each section so the crimpled end faces downward and secure each section to each other using at least three 3 sheet metal screws or rivets See Figure 8 Wall Exit Into Metal Tee Box om 1 Mark the plumb line on the wall dir ATTI ectly behind the center of the heater TIITII See Figure 9 VM NOTE When using 24 ga m
16. ew room heater Failure to follow instructions may result in property damage bodily injury or even death Throughout the manual you will see this A symbol This indicates areas of importance regarding safety Please make a special note of these areas Install and use only in accordance with the manufacturer s installation and operating instructions Do not connect this unit to a chimney flue serving another appliance This unit is not designed for installation into a Mobile Home ROOM HEATER FEATURES Before attempting to install or operate your heater it is a good idea to familiarize yourself with the features and operating controls of the unit WARNING Model 80 heater was not designed for fire grates 1 Bypass Damper The bypass damper control is located in the top center of the heater front just under the top Itis operated by pushing or pulling the rod The damper is fully open when the handle is pulled out and fully closed when it is pushed in The damper must be open before the door is opened 2 Blower Control The blower control Rheostat is located on the side of the unit This switch controls the variable speed blower For blower to operate turn switch from OFF position to either LOW MEDIUM or HIGH When stove temperature reaches 110 blower will automatically come on 3 Primary Air Controls The primary air intake draft controls are located at the left and right side of the hearth They are opera
17. g place Extreme temperatures at combustor surface can cause the catalyst to peel Over firing and flame impingement are primary cause Not maintaining light off temperature 24 NR Solution Install Buck draft inducer Increase the amount of combustion air slowly Open bypass damper In retrofit place combustor in bypass position before opening stove door Install Buck draft inducer Wait a few seconds after opening bypass damper be fore opening heater door to give smoke a chance to exit heater Once light off temperatures have been reached and unit is stabilized close bypass damper Follow manufacturer s oper ating instructions Refuel as necessary for com bustor operation See section on Combustor Related Problems Ensure that proper air mix ture and draft are available for wood pyrolysis to con tinue Do not burn materials such as garbage gift wrap or cardboard Burn dry seasoned wood Don t place the combustor in the operating position until high temperatures are high enough to initiate light off It may be possible to burn the accumulated soot or creosote off by putting the combustor in a partially open partially closed position after a hot fire has been started If peeling is severe remove and replace combustor Avoid extreme temperatures Place combustor in a partially closed position after a hot fire has been started to burn soot off NEW BUCK CORPORATION NBC
18. he housing Using a small putty knife or scraper remove any gasket that may have adhered to the catalyst housing 7 Now obtain the new catalyst and wrap the stainless steel can with interam gasket and tape ends together using scotch tape or masking tape 8 Insert the new catalyst into the catalytic housing and push down until they are seated on the top of the stainless steel wire mesh supports 9 Reinstall the catalyst housing into the stove and secure in place with the bolts 10 The stove is now ready for use D GASKET REPLACEMENT Cold Heater To replace deteriorated gaskets the following steps must be taken to ensure proper installation 1 Obtain the proper gaskets and silicone glue from your local dealer 2 Using pliers remove any worn and deteriorated gaskets 3 Using a scraper wire brush and sand paper or steel wool clean glue and gasket residue from the door frame 4 Measure and cut gaskets to length Care should be taken not to stretch the gaskets What you want is a full and loose gasket weave after attached to the framing Obtain the silicone glue and run a 3 16 bead inside the door frame 6 Obtain the gasket s and place in the gasket channel areas Use a technique which assures that the gasket is applied in a loose like manner DO NOT STRETCH GASKETS 7 After gasket s are applied to the glue use your finger and go over all the gasket gently pressing the gasket to the channel Use the same pressure again
19. in blue or black steel pipe maintain 18 between j pipe and ceiling of 7 2 Place the vertical portion of the to Ht _ heater pipe and the elbow in position 4 and project a point onto the plumb line level with the center of the JALL elbow i 3 Measure up so there will be at least i 1 4 rise per foot of horizontal l NNEC TO TEE connector pipe maintaining clearances to the ceiling as noted in ALL SEMBL Figure 10 This will give you the center of the hole for the chimney penetration 4 After locating the center of the penetration install the tee box and chimney as per the chimney manu facturer s specifications and local building codes for installation through combustible walls or ceilings FIGURE 9 5 Connect the chimney collar to the tee box using 24 ga minimum blued or black steel connector pipe DO NOT USE GALVANIZED PIPE Connect each section so the crimped end faces downward and secure each section to each other using at least three steel sheet metal screws or rivets Wall Exit Into Masonry using single wall pipe 1 Before connecting the Model 80 to a masonry chimney determine that the masonry fireplace wall pass through connector thimble meets the NFPA 211 Code and local bui
20. itate the installation of the direct connect or positive connect 12 Now follow the installation procedures in the listed direct or positive connect kit you are using and install the heater and connector kit in the fireplace 13 Reinstall the top trim panel 14 Obtain the brass trim and slip over the top and sides FINAL CHECK 1 Recheck the specified clearances 2 Remove all foreign material from the firebox area 3 Open the primary air drafts and damper bypass 4 Plug the power cord into a 115 VAC outlet 5 Place crumpled pieces of newspaper in the stove Light it and close the doors Ensure that the stove draws properly through the primary drafts Check for smoke leaks around the door Open the doors and check for smoke escaping from the front of the stove Smoking usually indicates a defective or poorly positioned chimney Some chimneys with a marginal draft can be preheated by lighting newspaper and holding it near the open damper with a poker or fire tong Once the chimney heats up a proper draft can usually be obtained If a thorough review of the Troubleshooting Guide in the rear of the manual does not reveal the problem contact your dealer for assistance Na NOTE The unit is painted with a specially formulated high temperature paint that cures during the first two or three firings You may notice a slight smoking effect and an odor of burning paint when you build the first fires This is normal and is not a cause fo
21. lding codes and is a minimum of 18 from the ceiling If the connector thimble does not meet these codes the pass through connector must be modified Connectors may pass through walls or partitions constructed of combustible material if the connector is a either listed for wall pass through or is routed through a device listed for wall pass through and is installed in accordance with the conditions of the listing b selected or fabricated in accordance with the conditions and clearances as stated in tables 5 7 of the 1988 NFPA 211 Code Any unexposed metal that is used as part of a wall pass through system and is exposed to flue gases shall be constructed of stainless steel or other equivalent material that will resist corrosion softening or cracking from flue gases at temperatures up to 1800 F In addition a connector to a masonry chimney shall extend through the wall to the inner face or liner but not beyond and shall be firmly cemented to masonry EXCEPTION A thimble may be used to facilitate removal of the chimney connector for cleaning in which case the thimble shall be permanently cemented in place with high temperature cement Once the through the wall thimble codes are met simply connect the chimney pipe to the wall pass through connector using 24 ga minimum blued or black steel pipe as follows a Maintain 1 4 rise per foot horizontal length from the appliance to the chimney b Each section of pipe should fit
22. ll have to experiment with the fire rate until you find the particular setting for heating your home Chimney drafts tightness of the house door and windows and atmospheric conditions all influence which setting you must have It may take you several firings to learn the setting necessary for your installation Although the catalytic stoves decrease the ash residue routine removal of excess ash is still necessary 20 SECTION VI PREVENTIVE MAINTENANCE PARTS REPLACEMENT Disassembly Inspection and Catalytic Replacement The catalysts in your stove are designed for many years of use If after several years of use the efficiency of the stove decreases or if a notable amount of smoke is observed the catalysts may need to be replaced See the Catalyst Warranty prior to replacement CATALYST REPLACEMENT Off Season Replacement Recommended 1 Spread a drop cloth in front of the stove 2 Open the door and clean out any ash 3 Using penetrating oil generously lubricate the four 4 bolt threads holding the catalyst housing in place Allow to penetrate 4 Using a 9 16 wrench or 9 16 socket loosen the four 4 nuts and remove the catalyst housing drop down nd place in a suitable work area 5 Using needle nose pliers grasp the front edge of the stainless steel can which houses the catalytic element nd pull upward Reposition pliers to another position and pull upward Repeat procedure until the catalyst can be removed from t
23. n an authorized service representative are not covered under this warranty In addition these unauthorized repairs may result in additional malfunctions the correction of which is not covered by warranty C Ne OTHER RIGHTS This warranty gives you specific legal rights and you may also have other rights which vary from state to state OWNER REGISTRATION CARD The attached Owner Registration Card must be completed in its entirety and mailed within 30 days from the date of purchase or from the date of installation if installed by a factory certified installer to New Buck Corporation in order for warranty coverage to begin PLEASE NOTE The Owner Registration Card must contain the Authorized Dealer Code Number and the Certified Installer s number if applicable for warranty coverage to begin
24. ny Hickory Fair Excellent Moderate Locust Poor Excellent Very Few Maple Poor Excellent Few Oak Poor Excellent Few Pine Excellent Poor Moderate The Main Audubon Society recently charted the heat produced by a wood fire They noted that the heat produced by a wood fire varies greatly with the kind of wood burned Beech is considered the best wood for a fire A cord of well seasoned Beech will produce as much heat as 169 gallons of fuel oil Sugar Maple and Red Oak produce as much heat as 166 gallons of fuel oil followed by White Ash 154 American Elm 130 White Birch 124 and White Pine 94 Building a Fire By pass damper must be open pulled out when starting fire or adding wood to fire Open the door 3 While looking inside the firebox operate the damper bypass door in and out observing the movement If the door does not operate freely and seal to the door opening then the door has jumped out of its track during shipping and or installation 4 Open the primary air control located on each side of the hearth Also open shotgun air control located in front center of hearth Twist 4 or 5 pieces of non colored newspaper in a roll and place on the floor of the firebox Lay several pieces of dry kindling on top of the newspaper Place three or four small pieces of firewood 2 3 in diameter on top of the kindling Light the newspaper in the front close and latch the door Don t leave the fire unattended at this point The draft
25. om the combustible surface 2 The tested and listed wall protector extends from floor to ceiling with a 1 clearance for air circulation at both the floor and ceiling 3 The 1 spacers preferable ceramic rather than metal must be located at the corners rather than behind the heater or the chimney connector Unlisted and Untested Wall Protector Wall protectors may be constructed of masonry 24 gauge or thicker sheet metal or non combustible 1 2 thick insulation board Conditions 2 and 3 above must be observed but the air space in condition 1 must be increased to 1 1 2 FINAL CHECK 1 Recheck the specified clearances 2 Remove all foreign material from the firebox area 16 3 Open the primary air drafts and damper bypass 4 Plug the power cord into a 115 VAC outlet 5 Place crumpled pieces of newspaper in the stove Light and close the door Make sure that stove draws properly through the primary drafts 6 Check for smoke leaks around the door 7 Open the door and check for smoke escaping from the front of the stove Smoking usually indicates a defective or poorly positioned chimney Some chimneys with a marginal draft can be preheated by lighting newspaper and holding it near the open damper with a poker or fire tong Once the chimney heats up a proper draft can usually be obtained If a thorough review of the Troubleshooting Guide in the rear of the manual does not reveal your problem contact your dealer for as
26. on It is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual or if the catalytic element is deactivated or removed CATALYST WARRANTY The combustor supplied with this heater is a 3 cell catalyst with an overall dimension of 2 x 6 x 7 Consult the catalytic combustor warranty also supplied with this heater All warranty claims should be addressed to Applied Ceramics Customer Service Department P O Box 29664 Atlanta GA 30359 770 448 6888 See enclosed catalyst warranty for instructions New Buck Corporation does not handle catalyst replacements Customer can order direct form Applied Ceramics PROPER FUEL SELECTION This heater is designed to burn natural wood only Higher efficiencies and lower emissions generally result when burning 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 Burning treated wood garbage solvents colored paper or trash may result in release of toxic fumes and may poison or render the catalytic combustor ineffective Burning coal cardboard or loose paper can produce soot or large flakes of char or fly ash that can coat the combustor causing smoke spillage into the room and rendering the combustor ineffective ACHIEVING CATALYTIC LIGHT OFF The temperature in the stove and the gases entering the combustor must be raised to be
27. r alarm In some cases these fumes will activate a smoke alarm Opening a window near the unit will allow these fumes to escape DO NOT build a large roaring fire until this curing is complete or the heater finish may be damaged SECTION HI 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 that include the following 1 A rain cap is installed on the chimney 2 Height of chimney is at least 15 feet high 3 Location of chimney is interior not on an outside wall Satisfactory results have been reported with installations other than listed above However draft problems are possible if a hot chimney is not maintained Use pedestal kit as follows Model 80 4171B A CAUTION Do not connect this unit to a chimney flue serving another appliance MODEL 80 Minimum Clearances The New Buck Corporation Model 80 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 wall is shown in Figures 6 and 7 MINIMUM ALL CLEARANCES TO BU
28. r and wire shut with stainless steel wire or remove damper Follow New Buck instructions for proper firing procedures Improper chimney height or wrong size flue being used Cooler temperatures caused by external chimney See section in Combustor Related Problems Burn dry seasoned wood Operate stove with desired heat output in mind Do not be overly concerned with maintaining light off temperatures Close inlet air control as much as possible to maintain desired heat output Check gaskets Reinstall fiberglass gasketing around doors and glass as necessary Check door gasket Check adjustment of door latch Put combustor in operating position in retrofit or close bypass damper in stove Problem 3 Backpuffing 4 Smoke Rollout when heater door is opened 5 Low Catalytic Temperature ha 1 Possible Cause Gusts of wind Hot combustor Above 1400 F Bypass damper is closed or combustor is in operating position Wind gusts blowing down chimney Opening heater door too fast Bypass damper is open Light off not obtained Fuel charge is spent Combustor coated with fly ash or soot Heater dampered down too much COMBUSTOR RELATED PROBLEMS 1 Plugging 2 Catalyst Peeling 3 Catalyst Masking Burning materials that produce a lot of char and fly ash Burning wet pitchy wood or burning large loads of small diameter wood with the combustor in the operating position without light off takin
29. removable with common hand tools The cost of parts only are included The customer pays any labor or transportation charges required PROCEDURE Should you feel that your heater is defective you should contact any NBC dealer for the name of your nearest authorized heater service representative who will instruct you on the proper procedure depending on which Warranty Time Period Period I or Period II applies 25 If for any reason you are dissatisfied with the sug gested procedures you may contact us in writing at NEW BUCK CORPORATION Customer Service Department P O Box 69 Spruce Pine NC 28777 CONDITIONS AND EXCLUSIONS A Replacement of parts may be in the form of new or fully reconditioned parts at NBC s option B There are no other warranties express or implied including warranties of Merchantability Fitness for Purpose or Otherwise except those warranties expressly stated herein 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 or providing substitute equipment or service during periods of mal function or non use Some states do not allow the exclusion of incidental or consequential damages so the above exclusion may not apply to you D All warranty repairs under this warranty must be performed by an authorized Buck Stove service representative Repairs or attempted repairs by anyone other tha
30. sistance NOTE The unit is painted with a specially formulated high temperature paint that cures during the first two or three firings You may notice a slight smoking effect and an odor of burning paint when you build the first fires This is normal and is not a cause for alarm In some cases these fumes will activate a smoke alarm Opening a window near the unit will allow these fumes to escape DO NOT build a large roaring fire until this curing is complete or the heater finish may be damaged 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 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 2 HEAT CONDUCTION Placing combustible materials too close to a heater or chimney can be a fire hazard By keeping these particular hazards in mind as you install and use your room heater you can ensure a safe reliable installation The connector and or chimney should be inspected at least once a month during the heating season to determine if a creosote buildup has occurred Any buildup of soot should be removed to prevent the risk of a chimney fire To remove chimney or chimney connector remove screws and or fasteners Remove pipe and clean with a steel wire brush Replace chimney or chimney connector and
31. st the gasket so that the final result is an evenly applied gasket Leave door open and allow at least one hour for the glue to dry 9 Once gaskets are checked the heater is ready for use wa ge 21 THERMUSTAI ES 22 SECTION IV TROUBLESHOOTING Operation of any wood heater can create problems While the 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 HEATER RELATED PROBLEMS Problem 1 Sluggish Heater Performance 2 High Fuel Consumption Possible Cause Obstruction in chimney Improperly sealed trim kit or direct connect kit Manual damper in chimney is closed Closing bypass or exhaust damper too soon Poor chimney draft Combustor is plugged Wet or unseasoned wood being burned Inexperience in catalytic operation Improper Regulation of draft or inlet air Improper Door Fitting Combustor not engaged 23 Solution Check for and remove obstruction Check trim kit gasketing or direct connect kit seal to fireplace and gasket as necessary to seal unit Gasket under stove if needed Check seal of direct connect and correct Open manual dampe
32. ted by moving in and out to control the amount of primary air entering the firebox 4 Warm Air Outlets Provides heat extraction from the top of the firebox 5 Baffles Directs air flow around the unit for maximum heat transfer 6 Air Inlet Allows cool air near the floor to be circulated through the blower and back into the warm air chamber of the heater 7 Stand Elevates heater above the floor for safety and a neat appearance 8 Door Provides an airtight feature The door allows a much higher burning efficiency than can be obtained with an open firebox 9 Hearth Extension Offers protection from spilled ashes and cinders 10 Power Cord Provides electrical power to operate the blower 11 Chimney Connector Used to connect unit to chimney or direct connect kit 12 Catalysts Enables the unit to burn cleanly and efficiently 13 Temperature Monitor The location can be used for either a fireplace insert or freestanding installation Monitor hole is located to the right of the damper rod on the front Remove plug and insert probe provided by manufacturer 14 Cover Door Conceals blower blower controls and ash pan 15 Airway Primary air is directed in such a way as to provide a sweeping air wash over the glass to assist in keeping it clean 16 Ash Pan Provides for easy ash removal Model 80 Wood Stove G q YM a
33. tween 500 F to 700 F for catalytic activity to be initiated This can be determined with the use of a temperature monitor TM 20 During the start up of a cold stove a medium to high firing rate must be maintained for about 20 minutes This ensures that the stove catalyst and fuel are all stabilized at proper operating temperatures Even though it is possible to have gas temperatures reach 600 F within two to three minutes after a fire is started if the fire is allowed to die down immediately it may go out or the combustor may stop working If this happens open the damper to raise the temperature to activate the catalyst Once the combustor starts working heat generated in it by burning the smoke will keep it working ACHIEVING CATALYTIC LIGHT OFF WHEN REFUELING During the refueling and rekindling of a cool fire or a fire that has burned down to the charcoal phase operate the stove at a medium to high firing rate for about 15 minutes to ensure that the catalyst reaches approximately 600 F 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 This catalytic heater is equipped with the means to install a temperature probe to monitor catalyst operation Properly functioning combustors typi
34. zed flue POSITIONING THE HEATER When positioning the heater the following conditions MUST be met See Figure 2 1 The front of the damper opening must be BEHIND the rear edge of the lintel to ensure proper draft See Figure 2 2 The vertical plane of the fireplace front must fall BEHIND the side panels of the unit In other words it is possible to have the heater too far in as well as not far enough 3 Center the heater in the fireplace opening VERTICAL PLANE FIREPLACE CUTAWAY LINTEL EDGE DAMPER u SIDE TRIM PANEL FIGURE 2 POSITIONING FIGURE 3 MOUNTING TRIM PANELS MOUNTING THE TRIM PANELS After the unit is positioned as shown in Figure 2 mark the mounting position of the trim panels as follows 1 Set the side trim panels in place flat against the face of the fireplace Mark down the inside edge of the trim panel to make a vertical reference line 2 Set the top long trim panel in place on top of the unit The panel should be flat against the outside face of the fireplace and standing vertically Mark along the lower edge of the trim panel with a pencil to make a reference line for mounting Slide the unit out of the fireplace far enough to work behind the trim panel reference lines 4 Mount the side trim panels See Figure 3 A Position the trim panel on the reference line B Drill mounting holes in center of the trim panel mounting brackets to allow for
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