New Buck Corporation Fan 91 User Manual

 
 
SECTION I  
The New Buck Corporation room heater Model 91 Bay 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 new room heater. Failure to follow instructions  
may result in property damage, bodily injury, or even death.  
Throughout the manual, you will see this symbol.  
Please make a special note of these areas.  
This indicates areas of importance regarding safety.  
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 Mobile Home.  
This unit has been safety tested by ITS (Warnock-Hersey) to UL Standards 737 and 1482.  
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.  
OPERATING CONTROLS  
WARNING: Model 91 Bay 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.  
It is 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 by OPEN before the door is opened.  
2. Blower Control: The blower control (Rheostat) is located on the side of the unit. The rheostat is used to  
vary the speed of the blower. It can be set at any position. It must be turned on to activate the automatic  
thermostat on the stove.  
3. Primary Air Controls: The primary air intake draft controls are located at the left and right bottom side of  
the hearth. They are operated by moving the handle out to open (to allow air into the firebox) or in (to  
control or close off) the air into the firebox. Right side primary air and air wash control (3A). Left side, (3),  
also called shot gun air control, allows air to the center of the firebox of the stove.  
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. Door: Provides an “airtight” feature. The door allows a much higher burning efficiency than can be  
obtained with an open firebox.  
8. Hearth Extension: Offers protection from spilled ashes and cinders.  
9. Power Cord: Provides electrical power to operate the blower.  
10. Catalyst: Enables the unit to burn cleanly and efficiently.  
11. Catalyst Probe: Probe is located to the right of the bypass damper rod. It is used to determine (catalyst)  
temperature.  
12. Automatic/Off/Manual Switch: Located at the bottom right corner of stove. In the “Manual” position, the  
blower operates continuously. In the “Automatic” position, the blower is controlled by the internal  
thermostat which reacts to the temperature of the air between the stove walls. (Not the same as the  
temperature showing on the Catalyst Probe.)  
SAFETY STANDARD COMPLIANCE  
The Model 91 Bay catalytic solid fuel (wood) burning combination room heater/fireplace stove manufactured by  
New Buck Corporation complies with US 1482-1994 and UL 737-1995 for residential freestanding and masonry  
fireplace insert installations when constructed and installed in accordance with ITS approved documentation.  
 
EPA COMPLIANCE STATUS  
This manual describes the installation and operation of the New Buck Corporation Model 91 Bay 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 10,000 to 54,500 BTU/hr for the Model 91 Bay.  
MODEL 91 WOOD STOVE IDENTIFICATION  
41  
11  
15  
4
20  
7
1
32  
16  
39  
5
37 & 38  
10  
13  
21  
14  
40  
18  
31  
33  
8
19  
3A  
3
12  
2
25  
26  
9
29  
35  
30  
36  
24  
23  
22  
6
34  
28  
20. Door Gasket  
21. Side Glass  
22. Leveling Screws  
23. Firebrick  
24. Motor  
25. Motor Mount Bracket  
26. Cover Door  
27. Cover Door Screws  
28. Shot Gun Air Box  
29. Ash Pan  
1. Bypass Damper & Brass Spring Handle  
2. Blower Control (Rheostat)  
3. Primary Air Control Air Wash Rod for Both  
Sides  
3a. Shot Gun Air Control  
4. Warm Air Outlets  
5. Baffles (Interior of Stove)  
6. Air Inlet  
7. Door  
8. Hearth Extension  
9. Power Cord  
10. Catalyst (Interior Firebox)  
11. Catalyst Probe  
12. Automatic / Off / Manual Switch  
13. Brass Cap  
30. Disc Thermostat  
31. Door Handle & Brass Spring Handle  
32. Air Wash Screen  
33. Glass Gasket  
34. Cover Door Hinge  
35. Magnet Holder  
36. Cover Door Magnet  
37. Door Latch  
38. Door Latch Screw  
39. Lower Heat Shield  
40. Hinge Pins  
14. Hinge Block  
15. Brass Overlays  
16. Brass Overlay Mounting Screws  
17. Door Glass & Logo  
18. Glass Clips  
19. Hearth Brass  
41. 8" Flue Exit  
 
CATALYST EQUIPPED  
This wood heater contains a catalytic combustor, which needs periodic inspection and replacement for proper  
operation. 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 set of (3) (2"x3-1/2"x6"x25" cells). 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  
For best results, this heater is designed to burn (dry), natural wood. Higher efficiencies and lower emissions  
generally result when burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut  
hardwoods. Green or freshly cut hardwoods (wood with high moisture content) will not product the BTU’s  
needed to heat your home. The result will be low temperature reading on the catalyst probe, thus low BTU  
output.  
DO NOT BURN:  
1) Treated Wood  
2) Coal  
3) Garbage  
4) Cardboard  
5) Solvents  
6) Colored Paper  
7) Trash  
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. (Not covered under  
warranty.)  
ACHIEVING CATALYTIC LIGHT-OFF  
The temperature in the stove and the gases entering the combustor must be raised to between 700o F to 900o F for  
catalytic activity to be initiated. The temperature can be determined by the Catalyst Monitor Probe. During the  
start up of a cold stove a medium to high firing rate must be maintained for about 20 minutes. This can be  
achieved by starting the fire with dry kindling, paper, and small split wood. Have the Bypass Damper fully open  
(pulled out). This ensures that the stove, catalyst, and fuel are all stabilized at proper operating temperatures.  
Even though it is possible (and likely) to have gas temperatures reach 600o 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.  
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 10 minutes to ensure that the catalyst reaches approximately 800o  
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.  
See Troubleshooting section for detailed  
instructions BEFORE attempting to remove catalyst.  
This catalytic heater is equipped with the means to monitor catalyst operation. Properly functioning combustors  
typically maintain temperatures in excess of 1000o F. If catalyst temperatures are not in excess of 500o refer to  
Catalyst Troubleshooting section of this owner’s manual.  
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. To  
remove ashes the dump is located at the left inner bottom. By lifting the dump door, place the ashes through the  
dump opening. The ashes fall directly into the ash pan. The ash pan is located at the left side under the hearth  
behind the cover door.  
NOTE: Be sure to turn the room air blower off before removing ashes. Open cover door and slide ash pan out.  
NOTE: Fueling and ash removal door (s) must remain closed when in operation.  
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.  
NOTE: Be sure to turn room air blower back on when job is completed.  
NOTE: The room heater is not to be connected to any air distribution duct.  
CREOSOTE - FORMATION AND NEED FOR REMOVAL  
When wood is burned slowly, it produces tar and other organic vapor, which combined with expelled moisture  
forms creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire. As a  
result, creosote residue accumulates on the flue lining. When ignited this creosote makes an extremely hot fire.  
NOTE: SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.  
 
OPTION (A)  
AIRTIGHT INSU-  
LATED CLEAN-  
STARTER PIPE  
OUT  
SEAL TRIM PANELS WITH INSULA-  
TION / AND OR HIGH TEMPERATURE  
CAULK  
REMOVE  
DAMPER  
OR WIRE  
IT OPEN  
NOTE: New Buck Corporation grants no  
warranty, implied or stated, for the installation  
or maintenance of your appliance, and assumes  
no responsibility of any consequential damage  
 
OPTION (B)  
OPTION (C)  
CAP(PREVENTS  
WATER FROM  
ENTERING)  
NOTE: Follow installation  
instruction with Positive  
Connection Kit.  
(Kit sold separately)  
NOTE: Follow installation instruction  
with Direct Connection Kit.  
(Kit sold separately)  
FLUE  
LINER  
INSTALL A NON-COMBUSTIBLE  
COVER PLATE TO PREVENT  
WATER FROM ENTERING THE  
CHIMNEY  
THE LINER MUST  
BE STAINLESS  
STEEL CONNEC-  
TOR OR FLEXIBLE  
VENT. FOLLOW  
THE LINER MANU-  
FACTURE’S IN-  
STRUCTIONS FOR  
INSTALLATION  
AND SUPPORT.  
STAINLESS  
STEEL  
CHIMNEY  
CONNEC-  
TOR MUST  
EXTEND 1’  
PAST THE  
BLOCK-OFF  
PLATE OR  
TO THE  
SEAL TRIM PANELS  
WITH INSULATION /  
AND OR HIGH TEM-  
PERATURE CAULK  
AIRTIGHT  
INSULATED  
CLEAN-OUT  
FLUE LINER  
AIRTIGHT  
INSULATED  
CLEAN-OUT  
TRIM PANELS  
REMOVE  
DAMPER  
OR WIRE IT  
OPEN  
REMOVE  
DAMPER  
OR WIRE  
IT OPEN  
BLOCK-OFF PLATE  
OR DAMPER  
ADAPTER  
INSTALLATION (Fireplace Insert)  
Minimum Clearances to Combustible Materials (in inches)  
MANTEL  
30"  
20"  
15"  
20"  
24"  
HEARTH EXTENSION  
8"  
FIGURE 1  
FIREPLACE INSERT  
 
MINIMUM CLEARANCES:  
The Model 91 Bay 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 24" 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 musts be at least 20" above the top of the unit and may be a  
maximum of 1/2" thick.  
4. If your fireplace has a wood mantel, the mantel or mantel supports must be located at a height of 30" above the top  
 
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 positioned 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.  
CENTER  
LINE  
VERTICAL PLANE  
DAMPER  
OPENING  
LINTEL EDGE  
FIGURE 3 MOUNTING TRIM PANELS  
FIGURE 2  
POSITIONING  
MOUNTING THE TRIM PANELS  
After the unit is positioned, 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. (See Figure 3.)  
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.  
3. 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 trim panel mounting brackets to allow for adjustment in  
and out if necessary.  
c. Mount the trim panel using the self-tapping screws provided.  
5. Place top panel back on reference mark. Take top trim panel mounting bracket supplied with unit. Position  
bracket so it overlaps rear lip of top trim panel. Drill mounting holes in top of stove using holes in bracket as  
guide. Tighten down screws.  
6. Now, follow the installation procedures in the listed direct connect or positive connect kit you are using and  
 
7. Slide the unit back into the fireplace. Check to be sure that the trim panels 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.  
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. Obtain the brass trim kit provided with unit and slip over the top and sides of trim panels. (Top ends of brass  
may need to be trimmed to fit.)  
10. Insure that the starter pipe or connector is properly secure in the stove flue exit, and aligned with the chimney  
flue.  
11. Mount top trim panel by drilling mounting holes in center of trim panel mounting brackets, with top end side  
of top panel overlapping side panel.  
12. Using insulation provided, peel and stick to back of panels overlapping fireplace dimensions by 1" on each  
side and top. (See Figure 3.)  
13. Next using high heat silicone or furnace cement run heavy bead of caulking around where panels meet the  
stove. (See Figure 3.)  
14. 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 panels are out of position, slide the unit out and  
reset by loosening the mounting screws and repositioning in the slot. With bar lift stove up in front. Place  
insulation across front and the surface of hearth or bottom of fireplace to make complete seal.  
15. To check seal of panels, use candle flame and go around the entire area sealed by silicone and insulation. If  
flame leans toward inside of fireplace, add additional insulation. This ensures an airtight seal.  
FINAL CHECK  
1. Recheck the specified clearances.  
2. Remove all foreign material from the firebox area.  
3. Open the primary air draft; shot-gun air draft, and damper bypass, make sure ash drawer is sealed properly.  
4. Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure  
motor operates properly.  
5. Place 4 or 5 pieces of newspaper in the stove. Light paper and close the door. Ensure that the stove draws  
properly through the primary drafts.  
6. Check for smoke leaks around the door.  
7. Open the door (slowly) 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 us, a  
proper draft can usually by obtained.  
NOTE: A poor drafting chimney can lead to poor heater performance. This is not a defect of the heater, but  
with the chimney. Poor performance due to a poor drafting chimney is NOT a warranty problem.  
If a thorough review of the Troubleshooting Guide in the rear of the manual does not solve your problem,  
contact your dealer for assistance. If the homeowner installed the unit himself, there generally is a charge for  
dealer to service the stove and inspect the installation.  
8. The unit is painted with a specially formulated high temperature paint that cures during the first two or three  
firings. DO NOT BUILD A LARGE ROARING FIRE UNTIL THIS CURING IS COMPLETE OR THE  
HEATER FINISH MAY BE DAMAGED. (Paint may blister or peel off. This is not covered by warranty.)  
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.  
 
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 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 Leg Kit # FA FS2191 for Model 91  
CAUTION: Do not connect this unit to a chimney flue serving another appliance.  
 
MODEL 91 BAY  
MINIMUM CLEARANCES  
The New Buck Corporation Model 91 Bay 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.  
FIGURE 2  
FIGURE 1  
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 50 inches wide. NOTE: The floor must  
extend 16" from door opening in front of the stove, 8" from the door opening on each side, and should be under  
the chimney connector. Floor protector must by 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. 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. You cannot check the motor when the switch is in the “Off” or “Automatic”  
position, unless a heat gun is used to heat the internal thermostat.  
3. Check the primary air draft controls to ensure that they operate freely.  
4. Check the operation of the bypass damper control to ensure that it will open and close properly.  
5. To attach legs, remove any items within firebox. Spread drop cloth on the floor behind the heater. Tilt the  
heater so that back is on the drop cloth. Attach legs to pre-drilled holes in bottom of heater. If using optional  
pedestal, mounting holes will need to be drilled.  
6. Reposition the heater to the upright position.  
CHIMNEY  
Ceiling Exits:  
The Model 91 Bay is designed for connection to: 1)  
Simpson Dura-Vent, 2) Security, 3) Selkirk Metal  
Bestos, 4) Metal Fab, 5) Air Jet, listed as 2100o pipe and  
CEILING  
SUPPORT BOX  
parts.  
“Follow chimney and chimney connector manufacturers  
instructions and local building codes for installation  
through combustible walls or ceilings.” This heater can  
only be installed freestanding by using one of the  
following requirements: 1) must use a brand of chimney  
pipe, as listed above, complying to the requirements for  
Type HT chimneys in the standard code for chimneys,  
Factory-Built, Residential Type and Building Heating  
Appliance, UL 103 or 2) a code approved masonry  
chimney with a flue liner.  
SINGLE WALL  
PIPE  
OPTIONAL NBC  
CAST CHIMNEY  
CONNECTOR  
CAUTION: Certain installation types require the use of  
certain chimney types. Please follow these instructions  
exactly.  
DETERMINING THE CHIMNEY  
LOCATION  
A. Ceiling Exit (Using Single Wall Pipe and UL 103  
HT type chimney system listed with manufactur-  
er in this section of manual)  
1. 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  
FIGURE 3  
string will serve as a plumb bob.) Mark the ceiling where the string is suspended to locate the center of  
the chimney.  
2. After locating the center of the hole, install the ceiling support box, chimney, flashing, and rain cap per  
the chimney manufacturer’s instructions.  
3. Connect the stove to the ceiling support box by using #24 ga. minimum blued or black steel chimney  
pipe. (DO NOT use galvanized pipe.) Each section should fit into the section below or into the opening  
on the stove, for drip-free operation. Secure each section together by using at least three (3) sheet metal  
screws or rivets.  
4. You may secure chimney pipe to stove two (2) different ways.  
a. With Optional NBC Cast Chimney Connector, See Figure 3.  
b. Mounting clips attached to heater and chimney pipe, See Figure 7 on Page 15.  
 
CLOSE CLEARANCE INSTALLATIONS (in inches)  
Close clearance installation is possible by using the following brands of black, double-wall chimney pipe. (See  
Figure 4 and Figure 5 for clearances.)  
1. Simpson Dura-Vent double wall chimney connector “Type DVL” and 8" Simpson Dura-Vent 2100o HT  
“Type DP” chimney  
2. 8" Security Type DL double wall connector and 8" Security Type “ASHT” High Temp Chimney.  
3. 8" Selkirk Metal Bestos Model “DS” double wall connector-8" Selkirk Metal Bestos Model SSII type HT  
Chimney System.  
4. 8" Metal Fab type “DW” double wall connector - 8" Metal Fab 2100o HT chimney.  
5. 8" Air Jet  
FIGURE 4  
FIGURE 5  
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  
1/4” Rise Per. FT.  
Pencil  
Socket Set  
Level  
Tape Measure  
Screw Driver  
Wall Exit into Metal Tee-Box (Using  
Single Wall Pipe)  
1. Mark the plumb line on the wall directly  
behind the center of the heater. (See Figure  
6.)  
NOTE: When using #24 ga. min. blued or black  
steel pipe, maintain 18" between pipe and  
ceiling.  
2. Place the vertical portion of the heater pipe  
and the elbow in position and project a point  
onto the plumb line level with the center of  
the elbow.  
FIGURE 6  
 
1/4” Rise Per. FT.  
FIGURE 7  
 
CEILING  
SUPPORT BOX  
SINGLE WALL  
PIPE  
OPTIONAL NBC  
CAST CHIMNEY  
CONNECTOR  
(COLLAR)  
FIGURE 8  
AIR SPACE  
1"  
COMBUSTIBLE WALL  
BRICK CLEAR-  
ANCE REDUC-  
TION SYSTEM  
NAIL OR  
SCREW  
ANCHOR  
BRICK WALL  
SPACED OUT I  
INCH FROM  
PROTECTED  
SURFACE  
1 INCH NON-COMBUSTIBLE SPACER SUCH AS  
STACKED WASHERS, SMALL DIAMETER PIPE, TUBING  
OR ELECTRICAL CONDUIT.  
MINIMUM  
24 GAUGE  
SHEET  
AIR CIRCULATION  
FLOOR  
LEAVE I INCH  
CLEARANCE FOR  
AIR CIRCULATION  
METAL  
DO NOT USE FASTENERS DIRECTLY BEHIND CHIMNEY  
CONNECTOR OR STOVE.  
BRICK WALLS MAY BE ATTACHED TO COMBUSTIBLE WALLS USING WALL TIES  
IF BRICK IS USED. BE SURE FLOOR CAN WITHSTAND WEIGHT OF BRICK.  
TOP VIEW  
COMBUSTIBLE WALL  
COMBUSTIBLE WALL  
MINIMUM 24 GAUGE  
SHEET METAL  
CLEARANCE REDUC-  
TION STEM SPACED  
OUT 1 INCH  
NON-COMBUSTIBLE  
SPACERS  
WOOD STOVE  
FIGURE 9  
FLOOR PROTECTOR  
 
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:  
1. A dead air space of 1" separates the listed and tested wall protector from the combustible surface.  
2. The tested and listed wall protector extends form floor to ceiling with a 1" clearance for air circulation at both  
the floor and ceiling.  
3. The 1" spacers (preferably 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.  
3. Open the primary air draft; shot-gun air draft, and damper bypass. Make sure ash drawer is sealed properly.  
4. Plug the power cord into a 115V AC outlet. Set switch to “Manual” and rheostat to “High” position to ensure  
motor operates properly.  
5. Place 4 or 5 pieces of newspaper in the stove. Light paper and close the door. Ensure that the stove draws  
properly through the primary drafts.  
6. Check for smoke leaks around the door.  
7. Open the door (slowly) 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.  
NOTE: A poor drafting chimney can lead to poor heater performance. This is not a defect of the heater, but  
with the chimney. Poor performance due to a poor drafting chimney is NOT a warranty problem.  
If a thorough review of the Troubleshooting Guide in the rear of the manual does not solve your problem,  
contact your dealer for assistance. If the homeowner installed the unit himself, there generally is a charge for  
dealer to service the stove and inspect the installation.  
8. The unit is painted with a specially formulated high temperature paint that cures during the first two or three  
firings. DO NOT BUILD A LARGE ROARING FIRE UNTIL THIS CURING IS COMPLETE OR THE  
HEATER FINISH MAY BE DAMAGED. (Paint may blister or peel off. This is not covered by warranty.)  
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.  
 
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. If any of these are present, a  
positive liner should be installed before heater is installed.  
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 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.  
WARNING: Hot while in operation. Keep children, clothing and furniture away from stove. Contact may cause  
skin burns.  
HELPFUL HINTS  
CURING THE PAINT ON YOUR HEATER: During the first several firings, burn small fires to cure the paint  
and to prevent damage to the finish. It is a good idea to flip the toggle switch to “Manual” position during these  
first firings so the blower will run continuously. This will allow the paint to cure at a slower rate and creates a  
better overall finish.  
CAUTION: Never remove ashes from your heater with the blower running.  
TIPS ON FIRE BURNING  
GREEN WOOD vs. SEASONED WOOD-Green wood has a high moisture content, and therefore requires a  
hotter ignition temperature. Seasoned wood-cut at least one year before use-allows for a quicker, prolonged burn  
and more complete combustion.  
SPLIT WOOD vs. ROUND WOOD-Split wood burns easier and more rapidly, whether it’s seasoned or green.  
If used after starting a fire, it should be packed tightly to achieve a longer burn.  
Round wood burns longer, but requires more effort to start. Inserting a round piece over a bed of red coals with  
the damper and drafts open will help it catch fire. Round wood should be used to accomplish an all-night burn.  
 
SECTION V  
OPERATION  
This section of the manual is to help you get maximum efficiency and maximum smoke (particulate) reduction  
from your heater. If you should experience any difficulty or have questions concerning your heater, contact your  
dealer for assistance.  
Manufacturer’s recommendation for peak performance and long catalyst life is to burn seasoned hardwood (wood  
dried 6-12 month) and place wood from front to back position in the heater.  
Build a fire for maximum efficiency. This model 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  
Wood  
Apple  
Ash  
Ease of  
Starting  
Poor  
Coaling  
Qualities  
Excellent  
Good  
Amount of  
Sparks  
Few  
Fair  
Few  
Beech  
Birch  
Cherry  
Cedar  
Elm  
Hemlock  
Hickory  
Locust  
Maple  
Oak  
Poor  
Good  
Poor  
Excellent  
Fair  
Good  
Fair  
Poor  
Poor  
Poor  
Excellent  
Good  
Few  
Moderate  
Few  
Many  
Very Few  
Many  
Moderate  
Very Few  
Few  
Few  
Moderate  
Excellent  
Excellent  
Poor  
Good  
Low  
Excellent  
Excellent  
Excellent  
Excellent  
Poor  
Pine  
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:  
1. Place the “Manual/Off/Automatic” switch in the “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.  
2. Open the door.  
3. While looking inside firebox, operate the damper bypass plate in and out observing the movement. This  
should operate freely and close completely. Open the damper bypass.  
4. Open the air controls on each side of stove (pull out).  
5. Twist 4 or 5 pieces of non-colored newspaper in a roll and place on the floor of the firebox.  
6. The Model 91 Bay is not designed for use with grates, andirons or other methods of supporting the fuel.  
7. Lay several pieces of dry kindling on top of the newspaper.  
8. Place three or four small pieces of firewood, 2-3" in diameter, on top of the kindling.  
9. Light the newspaper, close and latch the door. Don’t leave the fire unattended at this point. The draft 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 open. Do not leave the stove unattended with the door open! Once the draft has  
started, close and lock the door. A direct connect (option) usually solves this problem. Check with your  
dealer.  
10. After embers and a coal bed have been established, load the heater with wood. DO NOT BUILD A LARGE  
ROARING FIRE! Initially, build 2-3 small fires in order to cure the paint on your stove.  
11. Within the 20 minute time frame, you can begin to add your wood. Remember—DO NOT FILL firebox  
during your first 2 to 3 fires!  
12. Once your fire is burning well, close the bypass damper completely (push in). Gradually close the primary air  
controls (push in). You will have to experiment with the primary air controls to accommodate your draft. If  
you close them too soon, your fire may die down too quickly and go out. Close them gradually, a little at a  
time, until you can close completely.  
BURN RATES  
A. Low Burn Rate: Set primary air controls (both) almost closed - leave open about 1/8". Set the rheostat  
for fan control between the low to medium speed. This burn rate is the most desired and most efficient,  
but can only be achieved after a fire has been established and burning on its own controlled air. Close  
the bypass damper (push in).  
B. Medium-Low Burn Rate: Partially close primary air controls (push halfway in). Close the bypass  
damper (push in). Set the rheostat for the fan control halfway between low and high.  
C. Medium-High Burn Rate: Set the primary air controls almost fully open. Close the bypass damper.  
Set the rheostat for the fan control between the medium position and the high position.  
D. High Burn Rate: Set primary air controls wide open. Have the damper closed. Set the rheostat for the  
fan control all the way on high. USE CAUTION! Close shotgun air control after 5 minutes.  
E. Wood Loading: During refueling, open (pull out) the bypass damper to allow smoke in the firebox to  
escape - wait a few seconds, slowly add wood. Immediately close door and bypass damper. Open  
primary air control wide open for 2 minutes to charge the wood. After most of the wood has burned and  
if you are not planning on reloading immediately, it may be necessary to open damper bypass, then the  
door, and 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 the door and the damper bypass. This step will assure  
continued combustion and thorough burning of the wood.  
You will have to experiment with the fire rate until you find the particular setting for heating your home.  
Chimney drafts, tightness of the house, doors, windows, insulation in the house, and atmospheric conditions all  
influence which setting you must have, so it may take several firings to learn the setting necessary for your  
installation. Heating capacity is based on BTU output and the conditions listed above. These conditions will  
affect the heating capability of your heater.  
Although the catalytic stoves decrease ash residue, routine removal of excess ash is still necessary.  
 
SECTION VI  
PREVENTIVE MAINTENANCE / PARTS REPLACEMENT  
THE CATALYSTS  
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. The following points are some general guidelines from the catalyst  
manufacturer.  
1. Do not “hot fire” the stove. For many years retailers and installers have advised customers to build an extra  
hot fire to burn creosote deposits in the fire system. This advice may be acceptable for non-cat stoves, but  
can be death to a catalyst. Why? Because the catalyst is reducing the particulate, or creosote buildup,  
therefore the need to “hot fire” is eliminated. Proper chimney cleaning procedure should be followed.  
2. Direct Flame contact is death to a catalyst. A catalyst burns the by-products in the smoke. The gases such as  
CO, HC, and O2 ignite with each other in a chemical reaction in the presence of the catalyst (while passing  
through the honeycomb configuration). Direct flame inhibits this reaction by changing the chemical make-up  
of the catalyst breaking down the substrate or ceramic. This problem is called flame impingement. Today’s  
modern stoves are designed so that flame impingement is unlikely. However, a strong, fast draft can pull the  
flame into the catalyst. Or, a hot fire, with all the air controls and/or the ash door open can literally torch the  
catalyst. The remedy for the hot fire related flame is to advise customers not to “hot fire” the stove. The  
customer will enjoy their catalysts longer and with better performance if these guidelines are followed. Fly  
ash problems also can be reduced by controlling the draft.  
3. The “Glow” Misconception: A catalyst can glow during certain stages of combustion. The determination  
that a catalyst is not working simply because it does not glow is inaccurate. During the low burn cycle, when  
the catalyst is doing the bulk of its work, it usually does not glow. Also, extremely dry wood (oak, ash, etc.)  
can burn clean enough not to produce a glow in the converter. In most new stoves, you cannot see the  
catalyst.  
4. Light Off Temperature: CO conversation in the Applied Ceramics catalyst begins at a very low  
temperature. Usually, a normal start up to produce a coal bed will produce more than sufficient temperatures  
to begin catalytic combustion.  
5. The catalyst is not consumed or “used up”. The nature of a catalytic reaction is defined as follows, by the  
American Heritage Dictionary, Second College Edition: cat.a.lyst n “1. Chem. A substance, usually present  
in small amounts relative to the reactants, that modifies and especially increases the rate of a chemical  
reaction without being consumed in the process.” This means your catalyst is always there. This also means  
that gases that would normally go out the flue system and pollute the environment are being burned to create  
more heat from less wood.  
6. Why does a catalyst stop working? Most catalyst that are returned are either destroyed by flame  
impingement, broken due to accidents or mishandling, or have nothing wrong with them but fly ash build-up.  
A catalyst can be “saturated” with by-products of wood burning such as potassium. This is chemical  
saturation. The prohibitive chemical will fill in the chemical “holes” that the gases normally use for reaction.  
This process of saturation can be slowed by regular maintenance of the catalyst. Saturation can take several  
years since there are units in use for over five years. Burning garbage, painted woods, or large amounts of  
colored paper can poison your unit. Poisoning, however, is very difficult to do. Burning colored paper  
causes more of a fly ash problem than a risk of poisoning. NEVER BURN RUBBER OR PLASTIC.  
7. Burn only seasoned dried wood. Wood should be dried for at least 12 months prior to burning. The wood  
should be FREE of any moisture such as RAIN or SNOW. Wet wood creates water vapor which can drop the  
temperature of the catalyst. The results can be plugging, clogging, and thermal shock to the catalyst. When a  
catalyst has ceased to be effective, you will notice increased fuel usage and your chimney sweep will notice  
increased creosote in your system. Before you replace the unit, review this section. If you find that your  
catalyst should be replaced, follow the instructions for warranty replacement that were provided when your  
unit was purchased.  
 
8. Cleaning the catalyst with plain water can reduce build-up of the catalyst-retarding chemicals. Nothing but a  
soft brush, low pressure air or plain water should be used to clean a catalyst. The ceramic unit is fragile in  
comparison to the rest of the stove, so it should be handled with care. A soak in warm or hot (not boiling)  
water for 20 minutes is ideal. Then, allow the unit to cool at room temperature and rinse under medium  
pressure under a faucet. Allow the unit to thoroughly dry before reinstalling it or you will damage it. Finally,  
reinstall the unit. A cleaning once every year is sufficient for most users. Clean it when you have your flue  
system cleaned.  
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.  
4. Using penetrating oil, generously lubricate the eight (8) bolt threads holding the catalyst housing in place.  
Allow oil to penetrate.  
5. Using a 9/16" wrench or 9/16" socket, loosen the eight (8) nuts and remove the catalyst housing (drop down)  
and place in a suitable work area. BE CAREFUL removing the 8 nuts. If you break the bolt, you will have to  
drill out the bolt (difficult) and wait for your dealer to order one! You do not want this to happen during the  
cold weather!  
6. Using needle nose pliers, grasp the front edge of the stainless steel “cans” which houses the catalytic element  
and pull upward. Reposition pliers to another position and pull upward. Repeat procedure until the catalyst  
can be removed from the housing.  
7. Using a small putty knife or scraper, remove any gasket that may have adhered to the catalyst housing.  
8. Now, obtain the new catalysts and wrap the stainless steel “can” with interam gasket and tape ends together  
using scotch tape or masking tape. IMPORTANT: BEFORE STARTING TO REPLACE CATALYST,  
contact your dealer and order the INTERAM gasket and the CATALYST HOUSING Gasket. Gaskets not  
covered under warranty. It may take your dealer several days to receive the gaskets.  
9. Insert the new catalysts into the catalytic housing and push down until they are seated on the top of the  
stainless steel wire mesh supports.  
10. Reinstall the catalyst housing into the stove and secure in place with the bolts.  
11. The stove is now ready for use.  
DOOR GASKET REPLACEMENT (Cold Heater)  
To replace deteriorated gaskets, the following steps must be taken to ensure proper installation of gaskets.  
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 sandpaper 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 attachment to the framing.  
5. 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 against the gasket so that the final result is an evenly applied gasket.  
8. 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.  
10. This should be done annually. Allowing gaskets to deteriorate can cause over-firing and shorten the burn  
time.  
 
MOTOR ASSEMBLY REPLACEMENT  
(Motor, Thermostat, Rheostat, Wiring Harness)  
1. Unplug the heater from the 115V AC outlet.  
2. To replace the motor you must first take the cover door off. Do this by removing the two screws holding it in  
place.  
3. Next, you will find a wire cage protecting you from the electrical components of this unit. By looking to the  
right of the ash pan, you will find the two screws that hold the wire cage in place. Remove the two screws.  
You will also find a screw at the bottom right of the wire cage. Remove this screw. It will be easier to  
remove the cage if you first take the knob and nut from the rheostat that is hooked to the cage. Lay the cage  
aside.  
4. To remove the motor simply unhook the wire servicing the motor. Take the two screws holding the motor  
bracket out.  
5. Gently slide the motor out, and while pulling it out moving the rear of the motor facing you from right to left  
in a counterclockwise motion.  
6. To replace the thermostat follow steps 1 through 3 and then gently push the thermostat up out of the bracket.  
7. To rewire the motor, rheostat, and thermostat see Figures 10.  
8. To replace the motor turn the motor so that the 4"x4" air discharge opening is pointing toward the rear of the  
stove. The flat part of the motor housing is turned up. With the air discharge opening pointing in the 2  
o’clock position, start in toward the unit rotating the rear of the motor clockwise. The air discharge opening  
of the motor housing fits in a cavity in the rear of the unit that will direct the air flow to the proper location.  
Make sure the air discharge opening is located firmly in the opening. Replace motor bracket to the motor.  
9. Hook up the wiring to all three components if you have replaced or unhooked them.  
10. Replace rheostat on to the screen housing. Fasten the screen housing to the vertical bar to the right of the ash  
pan. Also fasten the motor bracket to the bar at the same time.  
11. Replace screw at the bottom of the screen guard. Replace cover door.  
12. Plug heater back into a 115V AC outlet.  
 
WIRING SCHEMATIC  
OFF  
AUTO/MAIN  
SWITCH  
 
 
 
 

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