Travis Industries 616 GSR Green Smart Owner's Manual

616 GSR Insert

Owner's Manual

Tested and Listed by

ANSI Z21.88 CSA 2.33

 Direct Vent Fireplace Insert

 Masonry or Factory Built (Metal) Wood-

Burning Fireplace



Residential or Mobile Home

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

This appliance may be installed in an aftermarket permanently located, manufactured home (USA only) or mobile home, where not prohibited by local codes.

This appliance is only for use with the type(s) of gas indicated on the rating plate.

A conversion kit is supplied with the appliance.

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

 Copyright 2012, T.I. $10.00 100-01271_000 4051112

Travis Industries, Inc.

www.travisproducts.com

4800 Harbour Pointe Blvd. SW

Mukilteo, WA 98275

2 Introduction

Introduction

We welcome you as a new owner of a 616 GSR Insert. In purchasing this fireplace insert you have joined the growing ranks of concerned individuals whose selection of an energy system reflects both a concern for the environment and aesthetics. It is one of the finest home heaters the world over. This manual will explain the installation, operation, and maintenance of this heater. Please familiarize yourself with the

Owner's Manual before operating your heater and save the manual for future reference. Included are helpful hints and suggestions that will make the operation and maintenance of your new heater an easier and more enjoyable experience. We offer our continual support and guidance to help you achieve the maximum benefit and enjoyment from your heater.

Important Information

No other 616 GSR Insert has the same serial number as yours. The serial number is below and to the left of the gas control valve.

This serial number will be needed in case you require service of any type.

Model:

Serial Number:

Purchase Date:

Purchased From:

616 GSR

Register your warranty online at: traviswarranty.com

Or, mail your warranty card to:

Travis Industries House of Fire

4800 Harbour Pointe Blvd. SW

Mukilteo, WA 98275

Save Your Bill of Sale.

To receive full warranty coverage, you will need to show evidence of the date you purchased your heater. Do not mail your Bill of Sale to us.

We suggest that you attach your Bill of Sale to this page so that you will have all the information you need in one place should the need for service or information occur.

Listing Details

This appliance was listed by Intertek. The listing label is attached to the appliance near the gas control valve. A copy is shown on page 46.

Massachusetts Approval

This manual has been submitted to the Massachusetts Board of State Examiners of Plumbers and Gas

Fitters.

National Fireplace Institute

© Travis Industries 4051112 100-01271_000

Table of Contents 3

Introduction ...................................................... 2

Important Information ...................................... 2

Listing Details ................................................... 2

Features ............................................................ 6

Installation Options .......................................... 6

Heating Specifications ..................................... 6

Dimensions ....................................................... 6

Electrical Specifications (for blowers) ........... 6

Fuel .................................................................... 6

Installation Warnings ....................................... 7

Packing List ...................................................... 7

Additional Items Required ............................... 7

Order of Installation ......................................... 7

Fireplace Requirements .................................. 8

Fireplace Clearances to Gas Insert ....................... 8

Factory-Built (Metal) Wood-Burning Fireplace

Requirements ........................................................ 9

Hearth Requirements ....................................... 9

Leveling Bolts ................................................. 10

Electrical Requirements ................................ 11

Clearances ...................................................... 11

Mantel Clearances .............................................. 11

Gas Line Requirements ................................. 12

Gas Inlet Pressure .............................................. 12

Directions for Connecting a Gas Pressure Test

Gauge ................................................................. 12

Gas Line Installation ...................................... 13

Vent Requirements ........................................ 14

Altitude Considerations.................................... 14

Exhaust Restrictor ......................................... 15

Adjusting the Exhaust Restrictor ......................... 16

Diffuser Adjustment ....................................... 17

Adjusting the Diffuser .......................................... 17

Vent Installation ............................................. 18

Vent Location ...................................................... 19

Vent Configurations ............................................ 19

Vent Attachment – Tight Installations .................. 20

Vent Connector Attachment ................................ 21

Glass Frame Removal and Installation ........ 24

Steps for Finalizing the Installation ............. 25

Air Shutter Adjustment ........................................ 26

Burner Removal .................................................. 27

Before You Begin ........................................... 30

© Travis Industries

Remote Set-Up ............................................... 30

Verify the Fan Control Module Is On ................... 30

Synchronize the Transmitter to the Receiver ...... 30

Starting the Heater for the First Time .......... 31

Location of Controls ...................................... 31

Direct Operation ............................................. 32

Accent Lights ................................................. 33

Continuous/Intermittent Pilot Switch ........... 34

Remote Operation .......................................... 34

Display Overview ................................................ 34

Listen for the “Beep” ........................................... 34

Manual On-Off / Smart Thermostat / Standard

Thermostat .......................................................... 35

Mode Controls (Flame, Blower, Light, Comfort

Control) ............................................................... 36

Flame Height ................................................. 36

Blower Speed ................................................ 36

Mode Controls (continued) .................................. 37

Accent lights (Aux) ........................................ 37

Comfort Control (Rear Burner) ...................... 37

Low Battery Indicator .................................... 38

Transmitter Batteries ........................................... 38

Receiver Batteries ............................................... 38

Child-Proof Feature ....................................... 38

Power Outages ............................................... 39

Display Fahrenheit or Celsius ...................... 39

Normal Operating Sounds ............................ 39

Normal Operating Odors ............................... 39

Battery Replacement ..................................... 40

Receiver Battery Installation ............................... 40

Transmitter Battery Installation ........................... 40

Accent Light Replacement ............................ 41

Accent Light Installation ...................................... 41

Lower Accent Lights ...................................... 41

Upper Accent Lights ...................................... 41

Yearly Service Procedure ............................. 43

Replacement Parts ........................................ 44

Troubleshooting Table .................................. 44

Wiring Diagram .............................................. 45

Safety Label ........................................................ 46

CONDITIONS & EXCLUSIONS ...................... 47

IF WARRANTY SERVICE IS NEEDED: ......... 47

LP Conversion Instructions .......................... 48

4051112 100-01271_000

4 Safety

IF YOU SMELL GAS:

* Do not light any appliance

* Extinguish any open flame

* Do not touch any electrical switch or plug or unplug anything

* Open windows and vacate building

* Call gas supplier from neighbor's house, if not reached, call fire department

This unit must be installed by a qualified installer to prevent the possibility of an explosion.

Your dealer will know the requirements in your area and can inform you of those people considered qualified. The room heater should be inspected and cleaned before use and at least annually by a qualified service person. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc.

The instructions in this manual must be strictly adhered to. Do not use makeshift methods or compromise in the installation. Improper installation will void the warranty and safety listing.

This heater is either approved for natural gas (NG) or for propane (LP). Burning the incorrect fuel will void the warranty and safety listing and may cause an extreme safety hazard. Direct questions about the type of fuel used to your dealer.

Check for a label on the flame adjust knob on the gas control valve (this is the best place to check). You may also check for a label on the gas control valve body.

Ok

Contact your local building officials to obtain a permit and information on any installation restrictions or inspection requirements in your area.

Notify your insurance company of this heater as well.

It is imperative that control compartments, screens, or circulating air passageways of the heater be kept clean and free of obstructions. These areas provide the air necessary for safe operation.

Gas

Do not store or use gasoline or other flammable liquids in the vicinity of this heater.

If the flame becomes sooty, dark orange in color, or extremely tall, do not operate the heater. Call your dealer and arrange for proper servicing.

?

Do not operate the heater if it is not operating properly in any fashion or if you are uncertain.

Call your dealer for a full explanation of your heater and what to expect.

Do not operate if any portion of the heater was submerged in water or if any corrosion occurs.

Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system that has been under water.



• Do not place clothing or other flammable items on or near the heater. Because this heater can be controlled by a thermostat there is a possibility of the heater turning on and igniting any items placed on or near it.

• Viewing glass should only be removed for service. Any safety screen or guard removed for servicing must be replaced prior to operating the heater. Do not operate with the glass removed or damaged. Replacement of the glass should be done by a licensed or qualified service person.

• Operate the heater according to the instructions included in this manual.

• If the main burners do not start correctly turn the gas off at the gas control valve and call your dealer for service.

• This unit is not for use with solid fuel

• Do not place anything inside the firebox (except the media).

• If the media becomes damaged, replace with Travis Industries media set.

 Young children should be carefully supervised when they are in the same room as the appliance.

Toddlers, young children and others may be susceptible to accidental contact burns. A physical barrier is recommended if there are at risk individuals in the house. To restrict access to a fireplace or stove, install an adjustable safety gate to keep toddlers, young children and other at risk individuals out of the room and away from hot surfaces.

This

Manual

5

• Light the heater using the built-in igniter. Do not use matches or any other external device to light your heater.

• Allow the heater to cool before carrying out any maintenance or cleaning.

• Never remove, replace, modify or substitute any part of the heater unless instructions are given in this manual. All other work must be done by a trained technician.

Don't modify or replace orifices.

Replace glass with Travis glass only.

• Instruct everyone in the house how to shut gas off to the appliance and at the gas main shutoff valve. The gas main shutoff valve is usually next to the gas meter or propane tank and requires a wrench to shut off.

• Do not throw this manual away.

This manual has important operating and maintenance instructions that you will need at a later time. Always follow the instructions in this manual.

• Plug the heater into a 120V grounded electrical outlet. Do not remove the grounding plug.

• Don’t route the electrical cord in front of, over, or under the heater

 Travis Industries, Inc. grants no warranty, implied or stated, for the installation or maintenance of your heater, and assumes no responsibility of any consequential damage(s).

4051112 100-01271_000

6 Features and Specifications

Features

- Works During Power Outages (battery backup system)

- Blowers and Remote Control Included

- Continuous or Intermittent (GreenSmart) Pilot

- Convenient Operating Controls

Installation Options

 Residential or Mobile Home

 Masonry or Factory Built (Metal) Wood-

Burning Fireplace

Heating Specifications

*

Approximate Heating Capacity (in square feet)*

Maximum BTU Input Per Hour

Natural Gas

600 to 2,000

39,000

Heating capacity will vary with floor plan, insulation, and outside temperature.

Dimensions

Propane

600 to 2,000

39,000

24" *

(610mm) *

Small 30-1/2"

(775mm)

Large 34"

(864mm)

23-5/16" *

(593mm) *

34" *

(864mm) *

Small 42" (1067mm)

Large 44" (1118mm)

* See "Fireplace Requirements"

for minimum fireplace sizing.

16" *

(407mm) *

Electrical Specifications (for blowers)

Electrical Rating ............................................................. 120 Volts, 1.8 Amps, 60 Hz (205 watt)

Fuel

This heater is shipped in natural gas (NG) configuration but may be converted to propane (LP) using the LP Conversion Kit (included) and the LP stepper motor (SKU 94400999, sold separately). The sticker on top of the gas control valve will verify the correct fuel.


Installation (for qualified installers only)

Installation Warnings

 Failure to follow all of the requirements may result in property damage, bodily injury, or even death.

 This heater must be installed by a qualified installer who has gone through a training program for the installation of direct vent gas appliances.

 The installation must conform with local codes or, in the absence of local codes, the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, or the National Gas and Propane Installation Code, CSA

B149.1.

 In Manufactured or Mobile Homes must conform with Manufactured Home Construction and

Safety Standard, Title 24 CFR, Part 3280, or, when such a standard is not applicable, the

Standard for Manufactured Home Installations, ANSI/NCSBCS A225.1. This appliance may be installed in Manufactured Housing only after the home is site located.

 The heater is designed to operate on natural gas, or propane (LP).

 All exhaust gases must be vented outside the structure of the living-area. Combustion air is drawn from outside the living-area structure.

 Notify your insurance company before hooking up this heater.

 The requirements listed below are divided into sections. All requirements must be met simultaneously. The order of installation is not rigid – the qualified installer should follow the procedure best suited for the installation.

Packing List

 Propane (LP) Conversion Kit  "Fireplace Altered" tag (attach to the fireplace)

Additional Items Required

 Faceplate

 3" and 4” Diameter Gas Liner with Termination (Kit – SKU 96200331)

 Gas Line Equipment (shutoff valve, pipe, etc.)

Kit

Kit

 Media

 Faceplate

 LP only: LP Stepper Motor (SKU 94400999)

Order of Installation

1. Run gas line to the fireplace

2. Remove the glass frame.

3. Run vent through fireplace chimney. On larger fireplaces, the vent connector may be left in place. For smaller fireplaces, remove the vent connector. See “Vent Connector Removal and Installation” for details.

INSTALLATION WARNING: If using a tall vent (over 25’) – you must open the diffuser before attaching the vent. See “Diffuser Adjustment” for details.

INSTALL THE LIGHT SHIELD (ALL FACES EXCEPT SHADOWBOX). The light shield (shipped with the face) prevents light from exiting the upper grill area. Install this prior to placing the insert.

4. Place insert into position and attach the gas line and vent.

7

NOTE: If using propane (LP), convert the appliance at this time.

6. Install the firebacks.

7. Replace the burner.

8. Install the media (logs, stones - see instructions included with the media).

9. Install the surround panel (see instructions included with surround panel).

10. Replace the glass.

11. Install the face (see instructions included with the face).

12. Follow the instructions under “Finalizing the Installation.”


8 Installation (for qualified installers only)

Fireplace Requirements

 Insert must be placed within a code-conforming masonry fireplace or tested and listed factory-built

(metal) wood-burning fireplace. Repair any fireplace damage prior to installation.

 Because the insert uses a circulation blower, clean the fireplace, smoke shelf, and chimney prior to installation.

 This heater may be placed in a bedroom. Please be aware of the large amount of heat this appliance produces when determining a location.

 Do not place insulation or any other material on top of the insert. This may block the upper accent light ventilation, leading to premature bulb failure. a f b g h

Fireplace Sizing a

Minimum Height b

Minimum Width

24-1/4” (616mm)

35” (889mm) c

Minimum Depth d

Hearth Depth (see

“Hearth Requirements” on the following page for full details)

16-1/2” (420mm)

12” (305mm) e The gas and electrical line should be installed prior to installing the heater. e c f For tight fits (under 28”) see the section

“Removing the Vent Connector” d g See “Leveling Bolts” for details on leveling the heater. h Attach the “This fireplace has been altered…” plate to the fireplace (use two screws or other suitable method). You may wish to place it in a location where it will be covered by the surround panels.

Fireplace Clearances to Gas Insert

Side of Insert to Inside of Fireplace

Back of Insert to Inside of Fireplace

Top of Insert to Inside of Fireplace

½” (13mm)

½” (13mm)

5/8” (18mm)



Factory-Built (Metal) Wood-Burning Fireplace Requirements

NOTE: Any parts that are removed must be removed in a way that would allow them to be re-installed if the insert is ever removed (removal of rivets or screws is acceptable).

The damper ("A") and grate (with log set) ("B") must be removed (see the illustration below)

The smoke shelf ("C"), internal baffles ("D"), screen ("E"), masonry lining or refractory ("G" & "I"), and metal or glass doors ("F") may be removed (if applicable)

The fireplace must be permanently marked to indicate that it has been altered and is no longer suitable for burning solid fuel (wood), unless the removed parts are re-installed. Cutting of any sheet metal parts is prohibited.

The metal floor (“J”) of the firebox may be removed in certain cases*.

The insulation ("H"), and any structured rigid frame members must not be removed or altered (side and top of door frame, side and top of the face of the fireplace, metal sides, etc.).

The surround panels should not seal ventilation openings on the fireplace.

F

E

H

C

B

I

J

A

D

G

*CAUTION: Firebox floor removal is not covered under the appliance safety standard (ANSI Z21.88 CSA 2.33

) used in the safety certification of this appliance. The Intertek safety certification does not apply to this method of installation. Before installing the appliance using this method, contact the Authority Having Jurisdiction to determine if this installation is acceptable in your area. The sheet metal base of the fireplace must be left in place and a minimum ½” cement board sheet placed under the entire length and width of the appliance.

If the factory-built fireplace has no gas access hole(s) provided, an access hole of 1.5 inch (37.5 mm) or less may be drilled through the lower sides or bottom of the firebox in a proper workmanship like manner.

This access hole must be plugged with non-combustible insulation after the gas supply line has been installed.

Hearth Requirements

 ½” of non-combustible material is required underneath the insert

 ½” of non-combustible material must extend 12” in front of the insert for the full width of the unit (34”).

RAISED INSERTS: If the insert is raised a minimum of 16” above the flooring (or other combustible material), a non-combustible hearth is not required in front of the insert.

9



Leveling Bolts

This heater includes front and rear leveling bolts to accommodate fireplaces with a step-down firebox.

NOTE: To access the rear leveling bolts, remove the burner (see page 48).

The leveling bolt holes are shown below.

1. Remove the cover and gasket to access the rear leveling bolt.


Installation (for qualified installers only) 11

Electrical Requirements

 Plug the power cord into a grounded 120 Volt outlet (do not remove the grounding pin).

 The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical

Code, CSA C22.1.

Clearances

Due to the high temperature of the heater, it should be located out of traffic and away from furniture and draperies.

S ide

W all k l

C omb ustib le or N

C om on

-C bus tibl om bu stible e T

M ante l op

F aci ng n p m x

No n-C omb ng us tible

Minimum

Clearances k Sidewall to Insert 6"

153mm l Side Facing

(non-combustible) m Top Facing*

(non-combustible) n 12” Mantel*

(combustible or non-combustible) n 4” Mantel*

(combustible or non-combustible)

5"

127mm

35.5"

902mm

36.5"

928mm

33"

839mm p Hearth Extension to the Front x Extension onto

Hearth

12"

305mm

0"

0mm

* Measured from the base of the insert.

NOTE: the non-combustible top facing must extend 35.5” (902mm) above the base of the insert or to the bottom of the mantel (whichever is less).

Mantel Clearances

The maximum mantel depth is 12” (305mm).

NOTE: The combustible area above the facing must not protrude more than 3/4" (20mm) from the facing.

If it does, it is considered a mantel and must meet the mantel requirements listed in this manual.

Maximum Mantel Depth

Mantel Height

Above Base of Insert (n)

37"+(940mm+)

36"(915mm)

35"(889mm)

34"(864mm)

33"(839mm)

32"(813mm)

31"(788mm)



Gas Line Requirements

MASSACHUSETTS INSTALLATIONS - WARNING:

THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR GAS FITTER WHEN INSTALLED WITHIN THE

COMMONWEALTH OF MASSACHUSETTS.

OTHER MASSACHUSETTS CODE REQUIREMENTS:



Flexible connector must not be longer than 36 inches.



Shutoff valve must be a “T” handle gas cock.



Only direct vent sealed combustion products are approved for bedrooms or bathrooms.



Fireplace dampers must be removed or welded in the open position prior to the installation of a fireplace insert or gas log.



A carbon monoxide (CO) detector is required in the same room as the appliance.

 The gas line must be installed in accordance with all local codes, if any; if not, follow ANSI 223.1 and the requirements listed below.

 A manual shutoff valve is required within 3’ of the heater. It should be placed upstream of the flex line

(if used) and may be installed behind the access door inside the heater. ).

 The heater and gas control valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 psig. For pressures under 1/2 psig, isolate the gas supply piping by closing the manual shutoff valve.

 Leak test all gas line joints and the gas control valve prior to and after starting the heater.

 This heater is designed either for natural gas or for propane (but not for both). Check the sticker on the top of the gas control valve to make sure the correct fuel is used (see illustration on page 4).

 Installation must be performed by a qualified installer, service agency or the gas supplier (In

Massachusetts a licensed plumber/gas-fitter).

Gas Inlet Pressure

Standard Input Pressure

Natural Gas 7" W.C. (1.74 kPA)

Propane 13" W.C. (2.73 kPA)

 If the pressure is not sufficient, make sure the piping used is large enough, the supply regulator is adequately adjusted, and the total gas load for the residence does not exceed the amount supplied.

 The supply regulator (the regulator that attaches directly to the residence inlet or to the propane tank) should supply gas at the suggested input pressure listed above. Contact the local gas supplier if the regulator is at an improper pressure.

Directions for Connecting a Gas Pressure Test Gauge

The gas control valve (shown to the left) has two accessible ports for testing line pressure and output pressure. Loosen the brass screw on either test port and place a 5/16” i.d. rubber or plastic tubing over the tapered test port.

Connect the tubing to the test gauge.

WARNING: The brass screw must be tightened after testing to prevent gas leakage.

Output pressure

Input pressure



Gas Line Installation

Route the included flex tube through the hole in the left side of the insert and out the front as shown below.

13

Bend the flex tube up as shown below.

Attach the included gas shutoff valve to the end of the flex tube and gas inlet as shown below. Position so the valve is on the right as shown.

Leak-test all gas line connections.



Vent Requirements

Travis Industries manufactures a vent kit specifically for this insert

(sku 96200331). It includes 30’

(10M) of vent, hose clamps, and a prairie cap. The flashing on the cap is 18” (458mm) by 18” (458mm).

 The gas appliance and vent system must be vented directly to the outside of the building, and never be attached to a chimney serving a separate solid fuel or gas-burning appliance. Each direct vent gas appliance must use its own separate vent system.

 Make sure the exhaust pipe on the heater connects to the exhaust portion of the cap. The illustrations below show how the flex liners should be attached.

 The exhaust vent must reline the entire length of the chimney and terminate above the chimney top

 Be careful not to crimp or rupture the liner when bending it into chimney offsets

 When installed, the vent must meet all of the vent manufacturer's requirements

 Use the following vent:

4” UL 441 or 1777 Gas Liner for Exhaust, 3” UL 441 or 1777 Gas Liner for Air Inlet

Simpson Duravent 6-5/8” to 3” & 4” Co-Linear Adapter and Flashing (Travis Part # 98900124).

Simpson Duravent High-Wind Vertical Termination Cap (46DVA-VCH) or Prairie Cap

(3” dia.)

(4” dia.)

Max. Ht. 40' (12.2M)

Min. Ht. 8' (2.5M)

Max. 2'

(610mm) offset

Altitude Considerations

 This heater has been tested at altitudes ranging from sea level to 6,000 feet (1,800 M). In this testing we have found that the heater, with its standard orifice, burns correctly with just an air shutter adjustment.

 Failure to adjust the air shutter properly may lead to improper combustion which can create a safety hazard. Consult your dealer or installer if you suspect an improperly adjusted air shutter.


Installation (for qualified installers only) 15

Exhaust Restrictor

Set the exhaust restrictor to the required position as shown in the table below.

NOTE: The exhaust restrictor position is determined by laboratory testing, optimum position may vary slightly.

Restrictor Settings

Traditional Logs


Driftwood Logs


Stones

Natural Gas Short Vent

(25’ or less)

Natural Gas Tall Vent

(25’ or more)

Propane Short Vent

(25’ or less)

Propane Tall Vent

(25’ or more)

#3 (stock)

#3 (stock)

#1 #1 #2

#3 (stock)

#1

#3 (stock)

#2

#4

Restrictor adjustment should only be done by a qualified installer.



Adjusting the Exhaust Restrictor

Loosen the 4 screws holding the exhaust restrictor in place using a ¼” nutdriver.

Slide the exhaust restrictor to the desired position. The photo below shows the exhaust restrictor in position #1.



Diffuser Adjustment

Adjusting the Diffuser

Adjust the restrictor to the setting described in the table below.

Diffuser

Natural Gas Short Vent

(25’ or less)

Closed (stock)

Natural Gas Tall Vent

(25’ or more)

Open

Propane Short Vent

(25’ or less)

Closed (stock)

Propane Tall Vent

(25’ or more)

Open

The diffuser must be adjusted before attaching the vent (it is attached to the vent connector and is concealed once the vent is installed). Use a screwdriver or pliers to bend the diffuser to a vertical position.

17


Diffuser Closed (stock)

Diffuser Open

4051112 100-01271_000


Vent Installation

Secure the vent to the insert and termination kit using screws.

3" (76mm) dia.

4" (102mm) dia.

Duravent

Chimney Liner

Termination Kit

Inlet

Exhaust

NOTE: The appliance will slow down within 5 to 10 minutes due to the bi-metallic closing time. The restrictor position is based on laboratory testing. The optimum position may vary slightly.


Finalizing the Installation

Vent Location

 An Exhaust Restrictor is built into the appliance to adjust the flow rate of exhaust gases. This ensures proper combustion for all vent configurations. Depending upon the vent configuration, you may be required to adjust the restrictor position. See “Exhaust Restrictor” on page 15.

Vent Configurations

Inlet & Exhaust Re-Line

(recommended)

Exhaust Only Re-Line

(not recommended)

19

Direct Vent Cap

Exhaust

6-5/8" to 3" & 4" Colinear

Adapter & Flashing

Inlet

Recommended Block-Off

Plate (non-combustible metal and/or insulation).

Prevents odors from chimney entering room.

Exhaust

Any cracks or damage inside the chimney must be repaired.

A block-off plate must seal the intake to the chimney space. This way air is drawn down the chimney for combustion air.

Block-Off Plate

(non-combustible materials)

Inlet

Z.C. (Metal) Wood-Burning Fireplace

Masonry Fireplace

NOTE: You may use either re-line configuration with a masonry or zero-clearance fireplace.


20 Finalizing the Installation

Vent Attachment – Tight Installations

The vent connector is shipped attached to the insert, but must be removed to facilitate tight installations. See the directions below for installation.

1. Route the flex vent through the chimney from above (leave an extra 3' at the top). Make sure the flex is thoroughly stretched.

2. Remove the vent connector from the unit and attach it to the flex vent (see the instructions on the following page).

3. Pull on the flex vent until the vent connector is at the same height as the insert. Temporarily attach the flex vent to the top of the chimney (leave extra slack).

4. Slide the insert into place, guiding the vent connector into the guides on top of the insert.

5. Attach the vent connector to the appliance (see the following page for details).

6. Remove any excess slack in the flex line and attach the vent termination.

1

3

6

4

5

2

2



Vent Connector Attachment

1. Remove the exhaust restrictor to access the vent connector.

21

2. Remove these 2 nuts using a 3/8” nutdriver.

3. Tilt and remove the vent connector.



4. Make sure the gasket remains in place. Use silicone, if necessary, to secure the gasket.

5. Attach the 4” exhaust vent to the connector and secure with at least 3 screws.

6. Attach the 3” intake vent to the connector and secure with at least 3 screws.



7. Slide the insert into position. Reach up through the exhaust opening to guide the connector into place. Make sure the gasket remains in place.

23

8. Slide the vent connector into place, making sure it fits underneath the tab on top of the insert (see step 3 above for additional photos). Continue to pull down on the connector until it is fully seated.

9. Re-attach the nuts removed in step 2 to secure the vent connector.

10. Replace the exhaust restrictor. Make sure it is in the correct position (see “Exhaust Restrictor” on page 15 for details).



Glass Frame Removal and Installation

The appliance must be completely cool before removing the glass.

Do not strike or slam the glass.

1. The glass removal tool is located to the right of the glass frame and may be removed with a ¼” nutdriver.

Glass removal tool

Remove and discard this shipping screw

NOTE: Replace the tool in this location after removing the glass frame.

2. Remove the glass frame as shown below. The glass frame is held in place with three tabs inserted into three slots at the bottom of the insert.



Steps for Finalizing the Installation

1. Remove the glass (see page 21).

NOTE: If using propane (LP) convert the appliance prior to installing the media.

2. We recommend you purge the gas line at this time (with the glass removed). This allows gas to be detected once it enters the firebox, ensuring gas does not build up.

3. Make sure the accent light bulbs are in place and work correctly.

NOTE: Take care to not touch the bulb with your fingers – use a cloth or paper towel).

4. Install the four AA batteries in the remote receiver (included in the owner’s pack - see illustration below). The AA batteries act as a power backup in case the household (AC) power goes out and are required for operation. Install three AAA batteries into the remote (see illustration below).

Synchronize the transmitter to the receiver (see page 30).

T he remote receiver us es 4 AA batteries .

°F

AA

Ba tte ry

AA

Ba tt er y

AA

B at te ry

AA

Ba tte ry

25

T he remote us es 3 AAA batteries .

att ery

AAA B

AAA

B a tter y

B a tter y

AAA

5. Install the media (see the instructions included with the media kit).

6. Replace the glass.

7. Start the heater.

8. Leak test all gas joints.

9. Adjust the air shutter following the directions on the next page.

10. Attach the face following the directions included with the face.

11. Adjust the flame to its highest position - the flames should not contact the top of the firebox. Check the flame on low position. The flames should burn off of each burner hole. If the heater does not work correctly, contact your Travis dealer for a remedy.



12. Give this manual to the home owner for future reference and fully explain operation of this heater.

Air Shutter Adjustment

Rear air shutter (gold)

Left = More Air

Front air shutter (red)

Let the heater burn for fifteen minutes (make sure the media and glass are in place). The flames should be yellow with no sooting. Adjust the air shutter, if necessary, to achieve the correct looking flame.

Correct

Flames should be blue at the base, yellow-orange on the top.

Not Enough Air

If the flames are too tall or sooty on the ends, open the air shutter.

Too Much Air

If the flames are all blue and short, close the air shutter.


Burner Removal

1. Remove the burner attachment screws (there are 2 in the front and 1 in the rear) using a ¼” nutdriver.

27


28

2. Remove the rear burner.


3. Remove the front burner as shown below.

4. Install the firebacks. See the firebacks installation instructions for details.

5. Replace the front burner as shown.



6. Replace the rear burner as shown.

29

7. Re-attach the burner attachment screws (see step 1 above).


30 Operation

Before You Begin

 Read this entire manual before you use your new heater (especially the section "Safety Precautions" on pages 4 & 5). Failure to follow the instructions may result in property damage, bodily injury, or even death.

Remote Set-Up

Verify the Fan Control Module Is On

The fan control module has a power switch. Make sure it is in the ON (“-“) position (see Figure 1 ). This switch must remain in the ON position for the AC components to operate (Accent lights and Optional

Blower). The module also supplies low-voltage for the fireplace controller. By leaving it in the OFF position, the fireplace will operate off the receiver batteries, greatly diminishing battery life.

”

Figure 1

Synchronize the Transmitter to the Receiver

The transmitter will need to be synchronized to the receiver before the remote will work correctly.

Synchronizing is done in the following two steps below (see Figure 2 ): a) Press the PRG (Program) button on the receiver using a paperclip or equivalent device (receiver will beep 3 times). b) Press the “ON” button on the transmitter (receiver will beep 4 times).

"B eep"

"B eep"

"B eep"

°F

"B eep"

"B eep"

"B eep"

“B eep”

Figure 2

NOTE: If power is cut off to the receiver for an extended period of time, you may need to re-synchronize the remote.


Starting the Heater for the First Time

 Burn the heater at a high setting with the blower off for an extended period (up to 48 hours). This will cure the painted surfaces. Fumes from the paint curing and oil burning off the steel will occur. This is normal. We recommend opening a window to vent the room.

 Condensation may appear on the glass each time you start the heater - this is normal.

 Blue Flames will occur on the heater when it first comes on. After fifteen minutes the flames will turn a more realistic yellow and orange color.

 Verify the receiver and batteries are installed (see page 40).

Location of Controls

Most features will be controlled by the included remote control.

°F


32 Operation

Direct Operation

The fireplace may be operated directly from the receiver. To access the receiver, remove the face. The three positions are shown below:

ON – Burner turns on (regardless of transmitter settings).

OFF – Burner turns off (regardless of transmitter settings)

REMOTE – Burner is controlled by the transmitter.

ON

Remote

OFF

NOTE: When the receiver switch is turned to ON or OFF, the mode settings (Lights, Blower, Flame

Height, Comfort Control) will remain in the same state as before the switch was moved (i.e. the receiver

“remembers” the previous settings). If you wish to adjust the mode settings use the transmitter mode button to adjust the settings (see “Mode Controls” on page 27). The thermostat and burner ON/OFF operating functions will not work on the transmitter.


Accent Lights

This heater has built-in accent lights that may be turned on and off and dimmed to your preference. Turn the knob to achieve the desired light output.

Rheostat location

OFF LOW HIGH


34 Operation

Continuous/Intermittent Pilot Switch

This heater may run with the pilot continuously running or in intermittent mode. For most homeowners, the intermittent mode is preferred (this saves fuel, doesn’t give off unneeded heat). However, in some situations the homeowner may prefer to switch the heater to continuous pilot. The most typical reasons for switching to continuous pilot are:

 Very Cold Conditions – in very cold conditions you may notice that the burner does not light quickly, and the flames lift off the burner. If this is situation, we recommend you switch to continuous pilot.

This will create a slight draft in the vent, allowing for the burner to light quickly and draft correctly.

 Excessive Condensation on Glass After Startup – certain installations may encounter excessive fogging on the window after startup (not just the first time the heater was started). This is an aesthetic condition that may be remedied by switching the heater to continuous pilot.

 Cold Glass or Heater Front – in very cold conditions you may notice that the heater front and glass become very cold. To remedy this, switch the heater to continuous pilot.

 Frequent On / Off Operation – if you are frequently turning the heater on and off, you may wish to leave it in continuous pilot. This allows the burner to turn on more quickly, without pilot ignition delay.

Remote Operation

Once the receiver is switched to “REMOTE” the transmitter operates the fireplace. Once you understand how the transmitter works, you will be able to operate your fireplace quickly and easily.

Display Overview

The transmitter display has four main sections (see Figure 3 ).

Thermostat Display

Room Temperature Display

F

ON

Read-Out (Thermostat Setting, Function, etc.)

Mode Display (Flame Height, Blower, Light, Comfort Control)

MAX MAX AUX

Figure 3

Listen for the “Beep”

Each time you press a button on the transmitter that controls the fireplace, a “beep” will come from the fireplace. When you change thermostat target settings the fireplace will not beep.

NOTE: When the receiver batteries start to get low, the receiver will beep intermittently. When the batteries are nearly depleted, the receiver will no longer beep. See “Receiver Batteries” on page 38).


Manual On-Off / Smart Thermostat / Standard Thermostat

Use the thermostat button to cycle through the three thermostat settings (see Figure 4 ).

Look here for the thermostat setting.

Press the thermostat button to cycle through the thermostat settings.

F

OFF

ON

ON SMART

MAX AUX

Figure 4

 MANUAL ON/OFF – The burner will turn on and off using the remote (see

Figure 5 ). Press the

On/Off button to control the burner. When off, the display will only show the current temperature.

F

OFF

When in manual setting, the word “OFF” will appear here.

MAX MAX AUX

Figure 5

 SMART THERMOSTAT – While in Smart Thermostat mode, the transmitter will control the flame height to achieve the target temperature (“smart modulation”). If the temperature exceeds the target temperature the heater will shut off. This allows the heater to stay on longer and provide a more consistent temperature. To adjust the target temperature, press the Up and Down buttons until a suitable temperature is achieved. (See

Figure 6

below.)

F

When in smart thermostat

SMART

This is the target temperature setting, the word “SMART” on the read-out. Use the up will appear here.

or down buttons to adjust the target temperature.

MAX AUX

Figure 6

 STANDARD THERMOSTAT - While in standard thermostat setting, the transmitter will turn the burner on and off to achieve the target temperature (see

Figure 7

below). To adjust the target temperature, press the up and down buttons until a suitable temperature is achieved.

F

ON

When in standard thermostat setting, the word “ON” will appear here.

This is the target temperature on the read-out. Use the up or down buttons to adjust the target temperature.

MAX AUX

Figure 7

NOTE: If the transmitter batteries go dead while in thermostat setting (standard or smart), the appliance will shut off after approximately 24 hours.


36 Operation

Mode Controls (Flame, Blower, Light, Comfort Control)

Use the mode button to cycle through the four mode controls (see Figure 8 below).

Press the mode button to cycle through the mode settings.

F

OFF

Flame

Height

Comfort

Control

Look here for mode controls.

MAX AUX

Optional

Blower

AUX

Accent

Light

Figure 8

Flame Height

Flame height may be controlled using the up and down buttons when in Flame Height Mode (see Figure 9 below). The center display will display the 7 settings, from “OFF” to “HI” for full on.

NOTE: Flame height may not be adjusted if operating in Smart Thermostat setting.

F

High

OFF

When in flame height mode, this icon will appear darkened.

This is the flame height readout. Use the up or down buttons to adjust the flame height (7 settings).

Medium

Off

MAX MAX AUX

Figure 9

Blower Speed

The blower may be controlled using the up and down buttons when in Blower Speed Mode (see Figure 10 ).

The center display will display the 7 settings, from “OFF” to “HI” for full on.

F

When in blower mode, this icon will appear darkened.

OFF

This is the blower speed readout. Use the up or down buttons to adjust the blower speed (7 settings).

High

Medium

MAX AUX

Off

Figure 10

MANUAL MODE

When in Manual Mode the blower will remain on, even if the burner is turned off and the heater cools.

Either manually turn the blower off, or turn off the heater by pressing the On/Off button.


Mode Controls (continued)

Accent lights (Aux)

The Accent Light (night light) inside the heater may be turned on and off using the up and down buttons when in Accent Light (Aux) Mode (see

Figure 11

). The center display will display either “ON” or “OFF”.

F

On

OFF

This is the accent light read-

When in accent light mode, this icon will appear darkened.

out. Use the up button to turn on, down button to turn off (2 settings).

AUX

Figure 11

HINT: The rheostat on the heater must be turned on for remote operation to work correctly. You may wish to adjust the rheostat to a desirable light output prior to operating.

HINT: If you wish to leave the accent lights on while turning the burner off, adjust the Flame Height to

“OFF” (see the previous page).

Off

Comfort Control (Rear Burner)

The comfort control (rear burner) may be turned on and off using the up and down buttons when in

Comfort Control Mode (see

Figure 12

). The center display will display either “ON” or “OFF”.

F

On

OFF

When in comfort control mode, this icon will appear darkened.

AUX

This is the comfort control read-out. Use the up button to turn on, down button to turn off (2 settings).

Off

Figure 12


38 Operation

Low Battery Indicator

Transmitter Batteries

The transmitter has a battery-level indicator. When it indicates low battery voltage (see Figure 13 below), install three new AAA alkaline batteries into the transmitter (see “Transmitter Battery Installation” on page 40).

Low Battery Indicator

F

ON

MAX AUX

Figure 13

Receiver Batteries

The receiver will “beep” periodically when the receiver batteries go low. Install four new AA alkaline batteries into the receiver when this occurs (see “Receiver Battery Installation” on page 40). In applications where the appliance is required to provide heat, we recommend replacing the batteries before each heating season.

Child-Proof Feature

The child-proof feature disables the control buttons, preventing unwanted use of the remote.

 Press both the MODE and UP buttons simultaneously to turn this feature on and off (see

Figure 14 below).

HINT: This feature is especially useful while using the thermostat setting.

Child Proof Indicator

F

ON

MAX AUX

Figure 14


Power Outages

The remote will work if household current (AC power) is disconnected. The batteries inside the receiver will continue to power the heater but the accent lights and blower will not operate.

Display Fahrenheit or Celsius

 With the system in the “OFF” position, press both the MODE and THERMOSTAT buttons simultaneously to toggle between Fahrenheit (F) and Celsius (C) (see the illustration below).

F

F

C

Figure 15

Normal Operating Sounds

The appliance may creak with change of temperature -- THIS IS NORMAL.

Extinction Pops

It is not unusual, especially on Propane

(LP) appliances, to experience a "pop" when the burner is shut off.

Blower(s)

The blower(s) push heated air into the room. You will hear the sound of air movement that increases as the speed is increased.

Pilot Assembly

The pilot flame will make a clicking sound when starting up. If left on, it will make a slight whisper sound.

Gas Control Valve

As the gas control valve is turned on and off you will hear a dull clicking sound. This is the valve opening up and shutting down.

Normal Operating Odors

This appliance has several areas that reach high temperatures. Dust or other particles on these areas may burn and create an odor. This is normal during start-up. You may notice the smell is more acute if the appliance was left idle for a long period.


40 Maintenance

Battery Replacement

Receiver Battery Installation

Install four AA batteries into the receiver (see illustration below). You can use the batteries from the battery backup tray on the appliance. See the installation instructions for details. These batteries control the comfort control and act as a power-backup in case the household (AC) current goes out.

Transmitter Battery Installation

Install the three included AAA batteries into the remote (see illustration below).

T he remote receiver us es 4 AA batteries .

°F

AA

Ba tte ry

AA

Ba tt er y

AA

B at te ry

AA

Ba tte ry

T he remote us es 3 AAA batteries .

att ery

AAA B

AAA

B a tter y

B a tter y

AAA


Accent Light Replacement

Accent Light Installation

Accent lights are included in your heater to provide additional lighting. These bulbs will burn out over time. To replace, follow the directions below:

 Shut off gas to the heater and let it cool for 15 minutes.

 Remove the glass (see page 21) and media.

 Replace the halogen bulbs with the following bulbs:

NOTE: Take care to not touch the bulbs with your fingers – use foam packing or paper towel to hold the bulbs:

35 Watt 120 Volt T4 Halogen Bulb (G6.35 Base)

Lower Accent Lights

The lower accent lights are located at the back of the firebox behind the hoods shown below. They can be removed by pulling them out vertically.

Upper Accent Lights

The upper accent light can be accessed by removing the 4 screws with a ¼” nutdriver, as shown below.


42 Maintenance

The upper accent light assembly drops down to expose the accent light.

When replacing the assembly, carefully insert the wiring into this cavity to ensure the wiring is not pinched.

The upper accent light is secured with two small screws. Loosen the lower screws (NOT the upper screws) to disengage the accent light.

CAUTION:

Do not over-tighten the screws when replacing the accent light.


Yearly Service Procedure



Failure to inspect and maintain the heater may lead to improper combustion and a potentially dangerous situation. We recommend the following procedures be done by a qualified technician.

1. Turn the pilot flame to continuous. It should touch approximately 3/8" of the top of the flame sensor. If it does not, contact your dealer for service.

2. Shut off gas to the heater and let it cool for 15 minutes. Remove the glass (see page 21). Glass may be cleaned with glass cleaner and a soft cloth (do not use abrasive cleaners).

3. Remove the media (NOTE: The media may be fragile). If severely deteriorated, replace. Check the media for sooting. A small amount of soot along the bottom of the media is normal. If excessive sooting is found, the heater will require adjustment. Contact your dealer.

4. Inspect the burner and remove any debris.



Make sure the burner is not warped, cracked, or damaged.



Check the firebox and area around the pilot to make sure there is no warping or damage.



If any problem is found, discontinue use and contact your dealer for service.

5. Replace the media. Clean and replace the glass. If the glass is damaged, replace. Make sure the gasket along the perimeter of the glass contacts the face of the firebox and forms an air-tight seal. If it does not, re-align or replace the gasket to insure an air-tight seal.

6. Inspect the area behind the access door. Clean if necessary. Check the gas control valve and the gas lines.

If damage is found, discontinue use and contact your dealer for service. Clean the air channels, ducts, and blower (if applicable).

7. Start the main burner. Inspect the main burner and pilot flame. After 15 minutes the flames should be orange/yellow and not touch the top of the firebox. If the pilot or main burners do not burn correctly, contact your dealer for service. Monitor blower operation.

8. Remove any debris or vegetation near the vent termination. Contact your dealer if any sooting or deterioration is found near the vent termination. Venting system should be examined by a qualified agency.


44 Maintenance

Replacement Parts

Caution: Use only Travis Industries replacement parts. Do not use substitute materials.

Warning: Do not operate appliance with the glass front removed, cracked, or broken. Replacement of the glass should be done by a licensed or qualified service person.

Contact your local Travis Industries Dealer for a Replacement Parts List

Troubleshooting Table

Problem: Possible Cause:

Main Burners Will

Not Start

The ON/OFF switch is turned to "OFF"

The remote control is not working correctly

The thermostat is disconnected or set too low

No propane in tank

Fireplace Controller

Beeps

The power backup batteries are dead

(heater will beep once repeatedly)

The heater encountered an error when trying to start

(heater beeps 3 times repeatedly)

The heater encountered a pilot error

(heater beeps 2 times repeatedly)

Don't Call for Service

Until You:

Turn the ON/OFF switch to "ON".

See the remote control instructions.

See "Thermostat Operation".

Check Tank Level.

Replace the batteries (see page 40).

Make sure gas is turned on. Turn heater off for 5 seconds (make sure standing pilot is off) – then turn back on.

Contact your dealer if this occurs.

Thermostat Does Not

The ON/OFF switch is turned to "OFF"

The thermostat is set too low

Work

Turn the ON/OFF switch to "ON".

Check thermostat.

Fireplace Will Not

Distribute Heat

The fireplace is not getting electricity

The fireplace is not up to temperature

Flames Are Too Blue

The fireplace has just been started

Improper air shutter adjustment

Check the breaker switch.

Let the fireplace burn for at least 15 minutes.

This is normal - see "Starting the

Fireplace for the First Time".

Adjust Air Shutter - contact your dealer.

Turn the flame height to "HI" -

See "Adjusting the Flame Height".

Rear Flames Are Too

Short (Under 6")

The flame height may be turned too low

Thin Layer of Soot

Covers the Glass

The media or coals are placed incorrectly

Improper air shutter adjustment

See "Media Installation".

Adjust air shutter - contact your dealer.


Wiring Diagram

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

Spark Rod

Pilot

Sensor

Pilot Ground

Comfort Control

Valve

CN4

CN3

PILOT

SENSOR DIGITAL

FIREPLACE

SPARK ROD

BURNER

CONTROL

DIAGNOSTIC

CN0

CN2

GROUND

VALVE COMMAND POWER

CN1

Yellow / Green

Orange

CONTINUOUS

PILOT

Green

INTERMITTENT

PILOT

Blue

White

IPI / CPI

FAN CONTROL

Fan Controller

POWER

110V OUT FAN AUX OUT COM

Optional

Blower(s)

4 Amp Fuse

RECEIVER

(4) AA Batteries

Remote Receiver

4 Amp Fuse

Accent Light

Rheostat

120 VAC

Power In

Accent

Light (s)

Black

POWER SUPPLY

Red

Black

Red

Green

White

COMFORT CONTROL

ON / OFF


46 Safety

Safety Label

The safety (listing) label is attached to the operating tag (chained to the heater near the gas control valve). A copy is shown below.


Limited 7 Year Warranty 47

Register your TRAVIS INDUSTRIES, INC. Limited 7 Year Warranty online at traviswarranty.com, or complete the enclosed Warranty card and mail it within ten (10) days of the appliance purchase date to: TRAVIS INDUSTRIES, INC., 4800 Harbour Pointe Blvd. SW, Mukilteo, WA 98275. TRAVIS INDUSTRIES, INC. warrants this gas appliance (appliance is defined as the equipment manufactured by Travis Industries, Inc.) to be defect-free in material and workmanship to the original purchaser from the date of purchase as follows:

Check with your dealer in advance for any costs to you when arranging a warranty call.

Mileage or service charges are not covered by this warranty. This charge can vary from store to store.

Component

Years 1 & 2

Parts & Labor

Years 3 Through 5

Parts & Labor

Years 6 & 7

Parts Only

Burner Assembly

Burner Pan Assembly, Air Shutter Assembly, Main Burner Orifice

Electrical Assembly (within heater structure):

Wiring harness, snap discs, rheostat speed control

Gas Control Assembly ustable control valve, fireplace controller, pilot assembly and pilot wiring

Glass

Glass (breakage from thermal shock)

Media

Log Set, Stones, etc.

Gold, Nickel & Copper Plating

Face & Door (see “Conditions and Exclusions” # 9)

Accessories

Firebacks, Power Heat Ducts, Andirons, etc…

One-Way Freight Allowance

One-way freight allowance on pre-authorized repair done at factory is covered.

Convection Heat Exchanger

Convection heat exchanger assembly

Firebox Assembly

Adjustable Air Restrictor, Pressure Relief Mechanisms, Glass Attachment Mechanism

EXCLUDED COMPONENTS:

Paint, Gasketing, and Accent Light Bulbs

CONDITIONS & EXCLUSIONS

1. This new gas appliance must be installed by a qualified gas appliance technician. It must be installed, operated, and maintained at all times in accordance with the instructions in the Owner’s

Manual. Any alteration, willful abuse, accident, neglect, or misuse of the product shall nullify this warranty.

2. This warranty is nontransferable, and is made to the ORIGINAL purchaser, provided that the purchase was made through an authorized TRAVIS dealer.

3. Discoloration and some minor expansion, contraction, or movement of certain parts and resulting noise, is normal and not a defect and, therefore, not covered under warranty. The installer must ensure the appliance is burning as per the rating tag at the time of installation. Over-firing (operation above the listed BTU rate) of this appliance can cause serious damage and will nullify this warranty.

4. The warranty, as outlined within this document, does not apply to the chimney components or other Non-Travis accessories used in conjunction with the installation of this product. If in doubt as to the extent of this warranty, contact your authorized TRAVIS retailer before installation.

5. Travis Industries will not be responsible for inadequate performance caused by environmental conditions such as nearby trees, buildings, roof tops, wind, hills or mountains or negative pressure or other influences from mechanical systems such as furnaces, fans, clothes dryers, etc.

6. This Warranty is void if: a. The unit has been operated in atmospheres contaminated by chlorine, fluorine or other damaging chemicals. b. The unit is subject to submersion in water or prolonged periods of dampness or condensation. c. Any damage to the unit, combustion chamber, heat exchanger or other components due to water, or weather damage which is the result of, but not limited to, improper chimney/venting installation.

7. Exclusions to this 7 Year Warranty include: injury, loss of use, damage, failure to function due to accident, negligence, misuse, improper installation, alteration or adjustment of the manufacturer's settings of components, lack of proper and regular maintenance, damage incurred while the appliance is in transit, alteration, or act of God.

8. This 7 Year warranty excludes damage caused by normal wear and tear, such as paint discoloration or chipping, worn or torn gasketing, corroded or cracked logs, embers, etc. Also excluded is damage to the unit caused by abuse, improper installation, modification of the unit, drilling of the orifices, or the use of fuel other than that for which the unit is configured. Units are shipped for natural gas and must be converted to propane using the included conversion kit. Confirm fuel configuration with your installer.

9. Damage to gold or nickel surfaces caused by fingerprints, scratches, melted items , or other external sources left on the gold or nickel from the use of cleaners other than denatured alcohol is not covered in this warranty.

10. TRAVIS INDUSTRIES, INC. is free of liability for any damages caused by the appliance, as well as inconvenience expenses and materials. Incidental or consequential damages are not covered by this warranty. In some states, the exclusion of incidental or consequential damage may not apply.

11. This warranty does not cover any loss or damage incurred by the use or removal of any component or apparatus to or from the gas appliance without the express written permission of TRAVIS

INDUSTRIES, INC. and bearing a TRAVIS INDUSTRIES, INC. label of approval.

12. Any statement or representation of TRAVIS products and their performance contained in TRAVIS advertising, packaging literature, or printed material is not part of this 7 year warranty.

13. This warranty is automatically voided if the appliance’s serial number has been removed or altered in any way. If the appliance is used for commercial purposes, it is excluded from this warranty.

14. No dealer, distributor, or similar person has the authority to represent or warrant TRAVIS products beyond the terms contained within this warranty. TRAVIS INDUSTRIES, INC. assumes no liability for such warranties or representations.

15. Travis Industries will not cover the cost of the removal or re-installation of hearths, facing, mantels, venting or other components.

16. If for any reason any section of this warranty is declared invalid, the balance of the warranty remains in effect and all other clauses shall remain in effect.

17. THIS 7 YEAR WARRANTY IS THE ONLY WARRANTY SUPPLIED BY TRAVIS INDUSTRIES, INC., THE MANUFACTURER OF THE APPLIANCE. ALL OTHER WARRANTIES, WHETHER

EXPRESS OR IMPLIED, ARE HEREBY EXPRESSLY DISCLAIMED AND PURCHASER’S RECOURSE IS EXPRESSLY LIMITED TO THE WARRANTIES SET FORTH HEREIN.

IF WARRANTY SERVICE IS NEEDED:

1. If you discover a problem that you believe is covered by this warranty, you MUST REPORT it to your TRAVIS dealer WITHIN 30 DAYS, giving them proof of purchase, the purchase date, and the model name and serial number.

2. Travis Industries has the option of either repairing or replacing the defective component.

3. If your dealer is unable to repair your appliance’s defect, he may process a warranty claim through TRAVIS INDUSTRIES, INC., including the name of the dealership where you purchased the appliance, a copy of your receipt showing the date of the appliance’s purchase, and the serial number on your appliance. At that time, you may be asked to ship your appliance, freight charges prepaid, to TRAVIS INDUSTRIES, INC. TRAVIS INDUSTRIES, INC., at its option, will repair or replace, free of charge, your TRAVIS appliance if it is found to be defective in material or workmanship within the time frame stated within this 7 year warranty. TRAVIS INDUSTRIES, INC. will return your appliance, freight charges (years 1 to 5) prepaid by TRAVIS INDUSTRIES, INC., to your regional distributor, or dealership.

4. Check with your dealer in advance for any costs to you when arranging a warranty call. Mileage or service charges are not covered by this warranty. This charge can vary from store to store.


48 Optional Equipment

(for qualified installers only)

LP Conversion Instructions

WARNING

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer’s instructions supplied with the kit.

Packing List

LP

Orifices

(2) LP Seal Plates

Convert the appliance prior to installing the gas line to ensure proper gas use.

Note: This change is only applicable for NG units. On LP, any orifice gaskets are removed and discarded.

1. Access the firebox.

2. Remove the burners (see “Remove the Burner,” in the owners manual).

3. Remove and discard the two existing orifice gaskets (see “a” below).

4. Install the new 1”x1” gasket (see “b” below).

NOTE: The hole in the shorter gasket is not in exact center. Make sure to install the shorter gasket with the longer end at the bottom.

5. Bend and install the new 2¾” gasket (see “c” below).

© Travis Industries c b

4051112 100-01271_000

Optional Equipment (for qualified installers only)

6. Remove and discard the stock seal plates. Install the LP seal plates.

49

Stock Seal Plate


50 Optional Equipment

(for qualified installers only)

7. Install the LP (propane) orifices.

ORIFICE SIZE (ID) Natural Gas

Front Burner Orifice #44 DMS

Rear Burner Orifice #45 DMS

LP (Propane)

#54 DMS

1.25mm DMS

Rear Orifice

Front Orifice

8. Remove the pilot orifice following the instructions below. Replace with the propane pilot orifice

(included with stepper motor). a Lift the pilot hood off the pilot assembly.

c Remove the orifice and replace with the LP orifice. Screw the orifice all the way in and replace the pilot hood.

Orifice Identification:

LP (Propane) Orifice

35 b

Use a hex wrench to unscrew the orifice.

35

NG (Natural Gas) Orifice

62

5/32" Hex

NOTE: when re-attaching, this pin lines up with the notch in the pilot hood.


Optional Equipment (for qualified installers only)

9. Replace the firebox components. Restore the fireplace to the correct configuration. Install the firebacks before re-installing the burner.

10. Access the stepper motor (shown below). The stepper motor (adjustable regulator) has an installation sheet included with it – make sure to follow all of the directions. Disconnect the wiring from the stepper motor. Remove the stock stepper motor and replace with the LP version. – MAKE

SURE IT IS CORRECTLY ORIENTED. Secure using the screws included with the motor – tighten to

25 Lb-inches. Leak test this area after installation to verify proper installation. Re-attach the wiring.

51

11. Restore the appliance to the correct configuration. Make the gas line connection, bleed the gas line

(if applicable), start the heater and thoroughly leak-test all gas connections and the gas control valve.


52 Index

Accent Light Installation ................................... 41

Accent Light Replacement ............................... 41

Accent Lights .................................................... 33

Additional Items Required .................................. 7

Adjusting the Diffuser ....................................... 17

Adjusting the Exhaust Restrictor ...................... 16

Air Shutter Adjustment ..................................... 26

Altitude Considerations .................................... 14

Battery Replacement ........................................ 40

Before You Begin ............................................. 30

Burner Removal ............................................... 27

Child-Proof Feature .......................................... 38

Clearances ....................................................... 11

Continuous/Intermittent Pilot Switch ................ 34

Diffuser Adjustment .......................................... 17

Dimensions ........................................................ 6

Direct Operation ............................................... 32

Display Overview ............................................. 34

Electrical Requirements ................................... 11

Electrical Specifications (for blowers) ................ 6

Exhaust Restrictor ............................................ 15

Factory-Built (Metal) Wood-Burning Fireplace

Requirements ................................................. 9

Features ............................................................. 6

Fireplace Clearances to Gas Insert ................... 8

Fireplace Requirements ..................................... 8

Fuel .................................................................... 6

Gas Inlet Pressure ........................................... 12

Gas Line Installation ......................................... 13

Gas Line Requirements ................................... 12

Glass Frame Removal and Installation ............ 24

Hearth Requirements ......................................... 9

Heating Specifications ........................................ 6

Important Information ......................................... 2

Installation Options ............................................. 6

Installation Warnings .......................................... 7

Introduction ........................................................ 2

Leveling Bolts ................................................... 10

Listen for the “Beep” ........................................ 34

Listing Details ..................................................... 2

Location of Controls ......................................... 31

Low Battery Indicator ....................................... 38

Lower Accent Lights ........................................ 41

LP Conversion Instructions .............................. 49

Mantel Clearances ........................................... 11

Manual On-Off / Smart Thermostat / Standard

Thermostat ................................................... 35

Mode Controls (Flame, Blower, Light, Comfort

Control) ......................................................... 36

Normal Operating Odors .................................. 39

Normal Operating Sounds ............................... 39

Order of Installation............................................ 7

Packing List ........................................................ 7

Power Outages ................................................ 39

Receiver Batteries ............................................ 38

Receiver Battery Installation ............................ 40

Remote Operation ............................................ 34

Remote Set-Up ................................................ 30

Replacement Parts .......................................... 44

Safety Label ..................................................... 46

Starting the Heater for the First Time .............. 31

Steps for Finalizing the Installation .................. 25

Synchronize the Transmitter to the Receiver .. 30

Transmitter Batteries ....................................... 38

Transmitter Battery Installation ........................ 40

Troubleshooting Table ..................................... 44

Upper Accent Lights ........................................ 41

Vent Attachment – Tight Installations .............. 20

Vent Configurations ......................................... 19

Vent Connector Attachment ............................. 21

Vent Installation ............................................... 18

Vent Location ................................................... 19

Vent Requirements .......................................... 14

Verify the Fan Control Module Is On ............... 30

Wiring Diagram ................................................ 45

Yearly Service Procedure ................................ 43


Travis Industries 616 GSR Green Smart Owner's Manual

616 GSR Insert

Owner's Manual

 Direct Vent Fireplace Insert

 Masonry or Factory Built (Metal) Wood-

Burning Fireplace

Residential or Mobile Home

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Travis Industries, Inc.

Introduction

Important Information

Listing Details

Massachusetts Approval

National Fireplace Institute

IF YOU SMELL GAS:

Features

Installation Options

Heating Specifications

Dimensions

Electrical Specifications (for blowers)

Fuel

Installation Warnings

Packing List

Additional Items Required

Order of Installation

Fireplace Requirements

Fireplace Clearances to Gas Insert

Factory-Built (Metal) Wood-Burning Fireplace Requirements

I

J

Hearth Requirements

Leveling Bolts

Electrical Requirements

Clearances

Mantel Clearances

Gas Line Requirements

Gas Inlet Pressure

Directions for Connecting a Gas Pressure Test Gauge

Gas Line Installation

Vent Requirements

Altitude Considerations

Exhaust Restrictor

Adjusting the Exhaust Restrictor

Diffuser Adjustment

Adjusting the Diffuser

Vent Installation

Vent Location

Vent Configurations

Inlet & Exhaust Re-Line

(recommended)

Exhaust Only Re-Line

(not recommended)

Vent Attachment – Tight Installations

Vent Connector Attachment

Glass Frame Removal and Installation

Steps for Finalizing the Installation

T he remote receiver us es 4 AA batteries .

T he remote us es 3 AAA batteries .

Air Shutter Adjustment

Correct

Not Enough Air

Too Much Air

Burner Removal

Before You Begin

Remote Set-Up

Verify the Fan Control Module Is On

Synchronize the Transmitter to the Receiver

Starting the Heater for the First Time

Location of Controls

Direct Operation

Accent Lights

Continuous/Intermittent Pilot Switch

Remote Operation