New Buck Corporation Fan Heater Model 80 User Manual

BUCK STOVE  
“MEETS PHASE II EPA STANDARDS”  
MODEL 80 HEATER  
FEATURES  
PREPARATION  
OPERATION MAINTENANCE  
INSTALLATION  
SAFETY  
SAFETY NOTICE  
If this heater is not properly installed, a house fire may result. For your safety, follow the installation directions.  
Contact local building or fire officials about restrictions and installation requirements in your area.  
Manufactured by New Buck Corp.—Spruce Pine, NC 28777—  
Revised 2/03  
PN-PI-8000660  
Tested by ITS  
 
TABLE OF CONTENTS  
SECTION I  
Room Heater Features ...................................................................................................3  
Important Statements.....................................................................................................5-6  
SECTION II  
Masonry Insert Installation............................................................................................7-10  
SECTION III  
Residential Freestanding Heater Installation.............................................................. 11-17  
SECTION IV  
Wood Heater Safety.....................................................................................................18  
SECTION V  
Operation .....................................................................................................................19-20  
SECTION VI  
Preventive Maintenance/Parts Replacement ...............................................................21-22  
SECTION VII  
Troubleshooting...........................................................................................................23-24  
WARRANTY .............................................................................................................25  
1
 
2
 
SECTION I  
The New Buck Corporation room heater Model 80 is one of the safest and most efficient heating systems  
available when installed and operated as specified in these instructions and as stipulated on the operation and  
installation labels affixed to the unit. The unit is designed to burn wood fuel only.  
Please read this entire manual before you install and use your new room heater. Failure to follow instructions  
may result in property damage, bodily injury, or even death.  
Throughout the manual, you will see this  
Please make a special note of these areas.  
symbol. 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 a  
Mobile Home.  
ROOM HEATER FEATURES  
Before attempting to install or operate your heater, it is a good idea to familiarize yourself with the features and  
operating controls of the unit.  
WARNING: Model 80 heater was not designed for fire grates.  
1. Bypass Damper: The bypass damper control is located in the top center of the heater front just under the  
top. 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 be open before the door is opened.  
2. Blower Control: The blower control (Rheostat) is located on the side of the unit. This switch controls  
the variable speed blower. For blower to operate turn switch from “OFF” position to either “LOW”,  
“MEDIUM” or “HIGH”. When stove temperature reaches 110o blower will automatically come on.  
3. Primary Air Controls: The primary air intake draft controls are located at the left and right side of the  
hearth. They are operated by moving in and out to control the amount of primary air entering the firebox.  
4. Warm Air Outlets: Provides heat extraction from the top of the firebox.  
5. Baffles: Directs air flow around the unit for maximum heat transfer.  
6. Air Inlet: Allows cool air near the floor to be circulated through the blower and back into the warm air  
chamber of the heater.  
7. Stand: Elevates heater above the floor for safety and a neat appearance.  
8. Door: Provides an “airtight” feature. The door allows a much higher burning efficiency than can be  
obtained with an open firebox.  
9. Hearth Extension: Offers protection from spilled ashes and cinders.  
10. Power Cord: Provides electrical power to operate the blower.  
11. Chimney Connector: Used to connect unit to chimney or direct connect kit.  
12. Catalysts: Enables the unit to burn cleanly and efficiently.  
13. Temperature Monitor: The location can be used for either a fireplace insert or freestanding installation.  
Monitor hole is located to the right of the damper rod on the front. Remove plug and insert probe provided  
by manufacturer.  
14. Cover Door: Conceals blower, blower controls and ash pan.  
15. Airway: Primary air is directed in such a way as to provide a “sweeping” air wash over the glass to assist  
in keeping it clean.  
16. Ash Pan: Provides for easy ash removal.  
3
 
Model 80  
Wood Stove  
40  
11  
4
5
20  
1
21  
32  
7
13  
14  
10  
15  
39  
38  
37  
&
18  
17  
33  
Buck  
23  
31  
27  
Stove  
15  
8
3
19  
12  
3A  
35  
2
28  
6
16  
9
34  
30  
22  
36  
26  
29  
25  
24  
21. Lower Heat Shield  
22. Leveling Screws  
23. Bottom Firebrick  
24. Motor  
25. Motor Mount Bracket  
26. Cover Door  
27. Cover Door Screws  
28. Shot Gun Air Box  
29. Ash Pan  
1. By Pass Damper & Brass Spring Handle  
2. Blower Control (Rheostat)  
3. Primary Air Control (Right Side)  
3a. Primary Air Control (Left Side)  
4. Warm Air Outlets  
5. Baffles (Interior of Stove)  
6. Air Inlet  
7. Door  
8. Hearth Extension  
9. Power Cord  
30. Disc Thermostat  
31. Door Handle & Brass Spring Handle  
32. Air Wash Screen  
33. Glass Gasket  
34. Cover Door Hinge  
35. Magnet Holder  
10. Catalyst (interior firebox)  
11. Catalyst Probe  
12. Automatic / Off / Man. Switch  
13. Brass Cap  
14. Hinge Block  
36. Cover Door Magnet  
37. Door Latch  
38. Door Latch Screw  
39. Hinge Pins  
15. Air Control Brass Knobs  
16. Shot Gun Air Control  
17. Door Glass  
18. Glass Clips  
40. 8" Flue Exit  
19. Hearth Brass  
20. Door Gasket  
4
 
EPA COMPLIANCE STATUS  
This manual describes the installation and operation of the New Buck Corporation, Model 80 wood heater. These  
heaters meet the U.S. Environmental Protection Agency’s Emission limits for wood heaters sold after July 1, 1992.  
Under specific test conditions this heater has been shown to deliver heat at rates ranging from approximately 9,000  
to 40,300 BTU/hr for the Model 80.  
CATALYST EQUIPPED  
This wood heater contains a catalytic combustor, which needs periodic inspection and replacement for proper  
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 3 cell catalyst with an overall dimension of 2" x 6" x 7". Consult the  
catalytic combustor warranty also supplied with this heater. All warranty claims should be addressed to:  
Applied Ceramics  
Customer Service Department  
P.O. Box 29664  
Atlanta, GA 30359  
770-448-6888  
See enclosed catalyst warranty for instructions. New Buck Corporation does not handle catalyst replacements.  
Customer can order direct form Applied Ceramics.  
PROPER FUEL SELECTION  
This heater is designed to burn natural wood only. Higher efficiencies and lower emissions generally result when  
burning air dried seasoned hardwoods, as compared to softwoods or to green or freshly cut hardwoods.  
DO NOT BURN:  
Treated Wood  
Coal  
Garbage  
Cardboard  
Solvents  
Colored Paper  
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.  
ACHIEVING CATALYTIC LIGHT-OFF  
The temperature in the stove and the gases entering the combustor must be raised to between 500o F to 700o F for  
catalytic activity to be initiated. This can be determined with the use of a temperature monitor (TM-20). During the  
start up of a cold stove a medium to high firing rate must be maintained for about 20 minutes. This ensures that the  
stove, catalyst, and fuel are all stabilized at proper operating temperatures. Even though it is possible to have gas  
temperatures reach 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. If this happens open the damper to raise the  
temperature to activate the catalyst. Once the combustor starts working, heat generated in it by burning the smoke  
will keep it working.  
5
 
ACHIEVING CATALYTIC LIGHT-OFF WHEN REFUELING  
During the refueling and rekindling of a cool fire, or a fire that has burned down to the charcoal phase, operate the  
stove at a medium to high firing rate for about 15 minutes to ensure that the catalyst reaches approximately 600o F.  
CATALYST MONITORING  
It is important to periodically monitor the operation of the catalytic combustor to ensure that it is functioning  
properly, and to determine when it needs to be replaced. A non-functioning combustor will result in a loss of  
heating efficiency, and an increase in creosote and emissions.  
This catalytic heater is equipped with the means to install a temperature probe to monitor catalyst operation.  
Properly functioning combustors typically maintain temperatures in excess of 1000o F. If catalyst temperatures are  
not in excess of 500o F 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.  
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.  
6
 
SECTION II  
MASONRY INSERT INSTALLATION  
INSTALLATION PRECAUTIONS  
It is not necessary to direct connect this unit, but testing has shown that it is necessary for best performance in a  
poorly drawing flue, oversized flue liner or a short chimney.  
Use the following to complete the installation of the unit as an insert:  
Kit # PA FP80  
Note: Clearances to mantel may be reduced by using a tested or listed mantel shield.  
INSTALLATIONS (Fireplace Insert)  
Minimum Clearances to Combustible Materials (in inches):  
24"  
9"  
12"  
9"  
16"  
8"  
HEARTH EXTENSION  
FIREPLACE INSERT  
FIGURE 1  
MINIMUM CLEARANCES:  
The Model 80 Fireplace Insert is intended for installation in accordance with the standard for chimneys, fireplaces,  
vents, and solid-fuel burning appliances. NFPA-211 Code: NOTE: This model is not intended for installation into  
zero clearance or pre-fabricated fireplace.  
1. The hearth must be of masonry construction and must extend a minimum of 16" in front of the firebox opening  
and a minimum of 8" to either side of the firebox opening.  
2. Floor protector must be 3/8" minimum thickness non-combustible material or equivalent.  
3. If your fireplace has wood trim above it, the wood trim must be at least 9" above the top of the unit.  
4. If your fireplace has a wood mantel, the mantel or mantel supports must be located at a height of 24" above the  
top of the unit.  
REQUIRED FIREPLACE DIMENSIONS  
Minimum and/or maximum fireplace dimensions:  
Height  
Width  
Min.  
23 1/2"  
Max.  
32 1/2"  
Min.  
29"  
Max.  
46"  
Model 80  
7
 
POSSIBLE TOOLS NEEDED FOR INSTALLATION  
If you decide to install your own stove, there are several hand tools you may need to do the job. If you do not  
already have them, they are readily available at most hardware stores.  
Caulking gun  
Large adjustable wrench (may not be needed)  
Drop cloths or newspapers  
Vacuum cleaner or whisk broom  
Flashlight  
1 tube of RTV silicone, Code 103 or 106, or high temperature rubber cement rated between 450o F- 600o F.  
7/32" drill bit and drill  
Socket/Rachet Set  
Insulation (Provided in trim kit package)  
INSTALLATION PREPARATION  
Fireplace  
1. Locate furniture and other materials away from the front of the fireplace to allow free access to the fireplace.  
2. Cover the hearth and adjacent floor areas with the drop cloths to protect from soiling or scarring the surface.  
3. Remove the existing fireplace damper plate.  
4. Thoroughly clean the fireplace of ashes and soot.  
5. Check the chimney and smoke chamber for excessive buildup of creosote or soot. Also, check for  
obstructions, such as birds’ nest. If the chimney is excessively dirty, clean it, or have someone clean it  
professionally BEFORE installing the room heater.  
6. If the fireplace has an ash dump or outside air provision, these must be sealed off with metal or tightly packed  
non-combustible insulation to prevent cold air from entering the fireplace chamber.  
Heater Preparation  
1. Inspect the unit for any obvious physical damage.  
2. Check the primary air draft controls to ensure that they slide freely.  
3. Check the operation of the damper control to ensure that it will open and close properly.  
It is not necessary to direct connect this unit unless installed in an improper drawing fireplace or oversized flue.  
POSITIONING THE HEATER  
When positioning the heater, the following conditions MUST be met! (See Figure 2)  
1. The front of the damper opening must be BEHIND the rear edge of the lintel to ensure proper draft. (See  
Figure 2)  
2. The vertical plane of the fireplace front must fall BEHIND the side panels of the unit. (In other words, it is  
possible to have the heater too far in as well as not far enough.)  
3. Center the heater in the fireplace opening.  
8
 
FIGURE 3  
MOUNTING TRIM PANELS  
FIGURE 2  
POSITIONING  
MOUNTING THE TRIM PANELS  
After the unit is positioned, as shown in Figure 2, mark the mounting position of the trim panels as follows:  
1. Set the side trim panels in place, flat against the face of the fireplace. Mark down the inside edge of the trim  
panel to make a vertical reference line.  
2. Set the top (long) trim panel in place on top of the unit. The panel should be flat against the outside face of the  
fireplace, and standing vertically. Mark along the lower edge of the trim panel with a pencil to make a  
reference line for mounting.  
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 the trim panel mounting brackets to allow for adjustment in and out if  
necessary.  
C) Mount the trim panel using self tapping screws provided.  
5. Mount top trim panel to the side panes with screws provided.  
6. Next slip the brass trim over the top edge of the trim panels and slide all the way down until sides and tops  
interlock.  
7. Slide the unit back into the fireplace. Check to be sure that the trim panels (and brass) are properly  
positioned and lie flat against the front of the fireplace. If one or more of the panels is out of position, slide  
the unit out and reset by loosening the mounting screws and repositioning in the slot. (See Figure 5)  
NOTE: If side and top panels gap due to unevenness of fireplace (normally on rock faced fireplaces), you will  
need to drill a 5/32" hole through both side and top panels near where the panels intersect and install a #10 self  
threading screw to eliminate the gap. (Paint screws to match.)  
8. Using insulation provided peel and stick to back of panels overlapping fireplace dimension by 1" each side  
on top. (See Figure 4)  
9. Next using high silicone or furnace cement run bead of caulking on backside of panel where they meet stove.  
(See Figure 4)  
10. Steps 10 and 11 will not be necessary when using direct connect or positive connect.  
9
 
FIGURE  
4
FIGURE  
5
11. Pull the unit back out of the fireplace and remove the brass and top trim panel to facilitate the installation of  
the direct connect or positive connect.  
12. Now, follow the installation procedures in the listed direct or positive connect kit you are using and install the  
heater and connector kit in the fireplace.  
13. Reinstall the top trim panel.  
14. Obtain the brass trim and slip over the top and sides.  
FINAL CHECK  
1. Recheck the specified clearances.  
2. Remove all foreign material from the firebox area.  
3. Open the primary air drafts and damper bypass.  
4. Plug the power cord into a 115 VAC outlet.  
5. Place crumpled pieces of newspaper in the stove. Light it and close the doors. Ensure that the stove draws  
properly through the primary drafts.  
6. Check for smoke leaks around the door.  
7. Open the doors and check for smoke escaping from the front of the stove. Smoking usually indicates a  
defective or poorly positioned chimney. Some chimneys with a marginal draft can be preheated by lighting  
newspaper and holding it near the open damper with a poker or fire tong. Once the chimney heats up, a proper  
draft can usually be obtained.  
If a thorough review of the Troubleshooting Guide in the rear of the manual does not reveal the problem contact  
your dealer for assistance.  
NOTE: The unit is painted with a specially formulated high temperature paint that cures during the first two or  
three firings. You may notice a slight smoking effect and an odor of burning paint when you build the first fires.  
This is normal and is not a cause for alarm. In some cases these fumes will activate a smoke alarm. Opening a  
window near the unit will allow these fumes to escape. DO NOT build a large, roaring fire until this curing is  
complete or the heater finish may be damaged.  
10  
 
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 pedestal kit as follows:  
Model 80 #4171B  
CAUTION: Do not connect this unit to a chimney flue serving another appliance.  
11  
 
MODEL 80  
Minimum Clearances  
The New Buck Corporation Model 80 must be installed in compliance with the instructions contained in this  
manual.  
Clearance from combustible walls and ceilings. (Using single wall chimney connector)  
The minimum lateral distance between any part of the room heater and combustible wall is shown in Figures 6 and  
7.  
FIGURE 6  
FIGURE 7  
FLOOR PROTECTION  
If a freestanding model is to be installed on a combustible floor, a non-combustible pad must be placed below it to  
protect the floor from burning material from the stove. The pad must be 37" wide by 37 1/2" deep. Floor protector  
must be 3/8" in minimum thickness, non-combustible material or equivalent.  
The unit must be positioned on the pad so that there is a minimum of 16" from the front of the door opening to the  
front of the pad, and a minimum of 8" measured horizontally from the sides of the fuel loading and ash removal  
openings to the sides of the pad.  
NOTE: For clearance reductions using wall protectors, refer to the NFPA-211 Code.  
TOOLS FOR INSTALLATION  
Drop Cloth  
Electric Drill with 7/32" drill bit  
1/2" - 9/16" combination wrench  
3/8" magnetic socket chuck adapter, 3/8" wrench (box or socket) or adjustable wrench  
Socket Set  
Tape Measure  
Pencil  
Level  
Screw Driver  
12  
 
Preparing The Stove for Installation  
1. Inspect the unit for any obvious physical damage.  
2. Check the primary air draft controls to ensure that they slide freely.  
3. Check the operation of the bypass damper control to ensure that it will open and close properly.  
4. Remove any items from within the firebox. Spread the drop cloth on the floor behind the heater. Next, tilt the  
heater so that the back is on the drop cloth.  
5. Using a tape measure, make a line down 3" from the front of the heater.  
6. Open the corresponding box and obtain the pedestal. Place the pedestal against the bottom of the heater (angle  
side to heater) at the marked line. Center the pedestal left and right and mark screw locations on bottom  
through outer holes of pedestal mounting angles. Set pedestal aside and drill four 7/32" holes in heater bottom.  
7. Obtain four 1/4" self tapping screws and secure the pedestal to the heater.  
8. If you chose legs rather than a pedestal, open box, attach legs to pre-drilled holes in bottom of heater.  
9. Reposition the heater to the upright position.  
10. Obtain the chimney connector from your dealer. Position on top of stove at flue exit. Position the two “J” bolts  
in connector using lock washer and nuts provided. Lock in place.  
CHIMNEY  
Ceiling Exits (using Single Wall Pipe and UL 103  
HT type chimney system listed with manufacturer  
in this section of manual)  
The Model 80 is designed for connection to:  
(1) Simpson Duravent (2) Security (3) Selkirk  
Metalbestos (4) Metal Fab (5) Air Jet, listed as  
2100 degree pipe and parts.  
Follow the chimney and chimney connector manu-  
facturer’s instructions and local building codes for  
installation through combustible walls or ceilings.  
This room heater must be converted to (1) a chim-  
ney complying with the requirements for Type HT  
chimneys in the Standard for Chimneys, Factory-  
Built, Residential, Type and Building Heating Appli-  
ance, UL 103, or (2) a code approved masonry  
chimney with a flue liner.  
CEILING  
SUPPORT BOX  
SINGLE WALL  
PIPE  
BUCK STOVE  
CHIMNEY  
CONNECTOR  
Caution: Certain installation types require the use of  
certain chimney types. Please follow these  
instructions exactly.  
DETERMINING THE CHIMNEY  
LOCATION  
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 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 or chimney  
connector, flashing, and rain cap per the  
chimney manufacturer’s instructions, and local  
building codes for installation through  
combustible walls or ceilings.  
FIGURE 8  
13  
 
3. Now connect the stove to the ceiling support box by using #24 ga. minimum blued or black steel chimney  
pipe. (Do not use galvanized pipe.) Connect each section so the crimpled end faces downward, and secure  
each section to each other using at least three (3) sheet metal screws or rivets. (See Figure 8)  
Wall Exit Into Metal Tee-Box  
1. Mark the plumb line on the wall dir-  
ectly behind the center of the heater.  
(See Figure 9)  
NOTE: When using #24 ga. min. blue 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.  
3. Measure up so there will be at least  
1/4" rise per foot of horizontal  
connector pipe, maintaining  
clearances to the ceiling as noted in  
Figure 10. This will give you the  
center of the hole for the chimney  
penetration.  
4. After locating the center of the  
penetration, install the tee-box and  
chimney as per the chimney manu-  
facturer’s specifications and local  
building codes for installation  
through combustible walls or  
ceilings.  
FIGURE  
9
5. Connect the chimney collar to the tee-box using #24 ga. minimum blued or black steel connector pipe. DO  
NOT USE GALVANIZED PIPE. Connect each section so the crimped end faces downward, and secure each  
section to each other using at least three steel sheet metal screws or rivets.  
Wall Exit Into Masonry (using single wall pipe)  
1. Before connecting the Model 80 to a masonry chimney, determine that the masonry fireplace wall pass-  
through connector thimble meets the NFPA-211 Code and local building codes and is a minimum of 18" from  
the ceiling. If the connector thimble does not meet these codes, the pass-through connector must be modified.  
Connectors may pass through walls or partitions constructed of combustible material if the connector is:  
(a) either listed for wall pass-through or is routed through a device listed for wall pass-through and is  
installed in accordance with the conditions of the listing.  
(b) selected or fabricated in accordance with the conditions and clearances as stated in tables 5-7 of the 1988  
NFPA 211 Code. Any unexposed metal that is used as part of a wall pass-through system and is exposed  
to flue gases shall be constructed of stainless steel or other equivalent material that will resist corrosion,  
softening, or cracking from flue gases at temperatures up to 1800o F.  
In addition, a connector to a masonry chimney shall extend through the wall to the inner face or liner but not  
beyond, and shall be firmly cemented to masonry.  
EXCEPTION: A thimble may be used to facilitate removal of the chimney connector for cleaning, in which case  
the thimble shall be permanently cemented in place with high-temperature cement.  
14  
 
2. Once the through-the-wall thimble  
codes are met, simply connect the  
chimney pipe to the wall pass-  
through connector using #24 ga.  
minimum, blued or black steel pipe  
as follows:  
(a) Maintain 1/4" rise per foot  
(horizontal length) from the  
appliance to the chimney.  
(b) Each section of pipe should fit  
into the section below or into  
the opening on the stove, for  
drip free operation.  
(c) Secure each section to each  
other using at least three (3)  
sheet metal screws or rivets.  
(d) Use three (3) screws to connect  
pipe to New Buck Corp.  
Chimney Connector.  
Ceiling Exit—Close Clearance  
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  
string will serve as a plumb bob.)  
Mark the ceiling where the string is  
suspended to locate the center of  
the chimney hole.  
2. After locating the center of the  
hole, install the ceiling support box,  
chimney or chimney connector,  
flashing, and rain cap.  
FIGURE 10  
CEILING SUPPORT  
BOX  
SINGLE WALL  
PIPE  
3. Next, install a New Buck Corp.  
Chimney Connector to the flue of  
the heater.  
4. Install Double Wall Connector and  
chimney system per manufacturer’s  
list of tested pipes  
BUCK STOVE  
CHIMNEY CONNECTOR  
Caution: Because of the high efficiency  
and low flue gas temperature,  
freestanding catalytic heaters connected  
to masonry chimneys with oversized  
flue lines may encounter drafting  
problems.  
FIGURE 11  
15  
 
AIRSPACE  
COMBUSTIBLE  
WALL  
BRICK  
CLEARANCE  
REDUCTION  
SYSTEM  
1”  
BRICK WALL SPACED  
OUT 1 INCH FROM  
PROTECTED SURFACE  
NAIL OR  
SCREW  
ANCHOR  
MINIMUM  
24 GAUGE  
SHEET  
METAL  
1 INCH NON-COMBUSTIBLE SPACER SUCH AS STACKED WASH-  
ERS, SMALL DIAMETER PIPE, TUBING, OR ELECTRICAL CON-  
DUIT.  
AIR CIRCULATION  
LEAVE 1 INCH  
CLEARANCE FOR AIR  
CIRCULATION  
FLOOR  
DO NOT USE FASTENERS DIRECTLY BEHIND CHIM-  
NEY CONNECTOR OR STOVE  
BRICK WALLS MAY BE ATTACHED TO COMBUSTIBLE WALLS  
USING WALL TIES. IF BRICK IS USED, BE SURE FLOOR CAN  
WITHSTAND THE WEIGHT OF THE BRICK.  
TOP VIEW  
COMBUSTIBLE  
COMBUSTIBLE WALL  
WALL  
MINIMUM  
24 GAUGE  
SHEET METAL  
NON-COMBUSTIBLE  
SPACERS  
WOOD STOVE  
CLEARANCE RE-  
DUCTION SYSTEM  
SPACED OUT 1  
INCH.  
FLOOR PROTECTOR  
SHEET METAL CLEARANCE REDUCTION SYSTEM  
FIGURE 12  
ALTERNATIVES FOR WALL PROTECTION  
Example: The rear clearance for the Model 80 from page 12 is 26". (Measurement A.) This clearance may be  
reduced by 66% by using either of the wall protection devices mentioned below.  
Tested and Listed Wall Protector  
Clearances to combustibles may be reduced if a tested and listed wall protector is installed over a combustible  
surface when the following condition exist:  
1. A dead air space or 1" separates the listed and tested wall protector from the combustible surface.  
2. The tested and listed wall protector extends from floor to ceiling with a 1" clearance for air circulation at both  
the floor and ceiling.  
3. The 1" spacers (preferable ceramic rather than metal) must be located at the corners rather than behind the  
heater or the chimney connector.  
Unlisted and Untested Wall Protector  
Wall protectors may be constructed of masonry, 24 gauge or thicker sheet metal, or non-combustible 1/2" thick  
insulation board. Conditions 2 and 3 above must be observed but the air space in condition 1 must be increased to 1  
1/2".  
FINAL CHECK  
1. Recheck the specified clearances.  
2. Remove all foreign material from the firebox area.  
16  
 
3. Open the primary air drafts and damper bypass.  
4. Plug the power cord into a 115 VAC outlet.  
5. Place crumpled pieces of newspaper in the stove. Light and close the door. Make sure that stove draws  
properly through the primary drafts.  
6. Check for smoke leaks around the door.  
7. Open the door and check for smoke escaping from the front of the stove. Smoking usually indicates a  
defective or poorly positioned chimney. Some chimneys with a marginal draft can be preheated by lighting  
newspaper and holding it near the open damper with a poker or fire tong. Once the chimney heats up, a proper  
draft can usually be obtained.  
If a thorough review of the Troubleshooting Guide in the rear of the manual does not reveal your problem, contact  
your dealer for assistance.  
NOTE: The unit is painted with a specially formulated high temperature paint that cures during the first two or  
three firings. You may notice a slight smoking effect and an odor of burning paint when you build the first fires.  
This is normal and is not a cause for alarm. In some cases, these fumes will activate a smoke alarm. Opening a  
window near the unit will allow these fumes to escape. DO NOT build a large, roaring fire until this curing is  
complete or the heater finish may be damaged.  
17  
 
SECTION IV  
WOOD HEATER SAFETY  
Certain safety hazards are inherent in any wood heater installation. You should be aware of these so that a safe and  
proper installation can be made.  
1. FAULTY CHIMNEY: An older masonry chimney should be thoroughly checked to be sure there are no  
holes or weak spots which could allow sparks or hot gases to escape.  
2. HEAT CONDUCTION: Placing combustible materials too close to a heater or chimney can be a fire hazard.  
By keeping these particular hazards in mind as you install and use your room heater you can ensure a safe, reliable  
installation.  
The connector and/or chimney should be inspected at least once a month during the heating season to determine if  
a creosote buildup has occurred. Any buildup of soot should be removed to prevent the risk of a chimney fire. To  
remove chimney or chimney connector, remove screws and/or fasteners. Remove pipe and clean with a steel wire  
brush. Replace chimney or chimney connector and 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.  
18  
 
SECTION V  
OPERATION  
This section of the manual is to help you get maximum efficiency and maximum smoke (particulate) reduction  
from your Model 80 heater. If you should experience any difficulty or have questions concerning your heater,  
contact your Model 80 dealer for assistance.  
Manufacturer’s recommendation for peak performance and long catalyst life is to burn seasoned hardwood (wood  
dried 6-12 months) and place wood from front to back position in the heater.  
Build a fire for maximum efficiency. Model 80 burns wood and extracts heat so efficiently a large fire is not  
necessary. A large fire not only wastes energy, it usually results in the home being too warm for comfort. The  
following steps will serve as a guide for operating your stove.  
GUIDE TO THE DIFFERENT BURNING QUALITIES OF WOOD  
Type of  
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.  
19  
 
Building a Fire:  
1. By-pass damper must be open (pulled out) when starting fire or adding wood to fire.  
2. Open the door.  
3. While looking inside the firebox, operate the damper bypass door in and out observing the movement. If the  
door does not operate freely and seal to the door opening, then the door has jumped out of its track during  
shipping and/or installation.  
4. Open the primary air control located on each side of the hearth. Also, open shotgun air control located in front  
center of hearth.  
5. Twist 4 or 5 pieces of non-colored newspaper in a roll and place on the floor of the firebox.  
6. Lay several pieces of dry kindling on top of the newspaper.  
7. Place three or four small pieces of firewood, 2-3" in diameter, on top of the kindling.  
8. Light the newspaper in the front, 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 cracked. Once the draft has started, close and lock the door.  
9. After embers and a coal bed have been established, load the heater with wood.  
A. Low Burn Rate: Set primary air control to the low setting. Close the shotgun air control. Turn the  
rheostat to low. Wood Loading-During refueling, open (pull-out) the bypass damper to allow smoke in  
the firebox to escape, open the door, and add wood. Immediately close door and bypass damper. Open  
primary air control wide open for two minutes to charge wood. It may be necessary to open shotgun air  
for 2 to 5 minutes also. Close and latch door. After most of the wood is burned, if you are not planning on  
reloading immediately, it may be necessary to open the bypass damper and door to rake the wood and  
coals into a pile near the front corner of the firebox. (Be certain wood chunks are pulled out of the rear  
corners.) Close door and bypass damper. This step will assure continued combustion and thorough  
burning of the wood.  
B. Medium-Low Burn Rate: Set the primary air control to the medium-low setting. Turn the rheostat to  
medium. Wood Loading-During refueling, open the bypass damper, open the door, and add wood.  
Immediately close door and bypass damper. Open primary air control wide open for two minutes to  
charge wood. It may be necessary to open shotgun air for 2-5 minutes. After most of the wood is burned,  
if you are not planning on reloading immediately, it may be necessary to open the bypass damper and  
door to rake the wood and coals into a pile near the front corner of the firebox. (Be certain wood chunks  
are pulled out of the rear corners.) Close door and bypass damper. This step will assure continued  
combustion and thorough burning of the wood.  
C. Medium-High Burn Rate: Set the primary air control to the medium-high setting. Turn the rheostat to  
high. Wood Loading-During refueling, open the bypass damper, open the door and add wood.  
Immediately close door and bypass damper. Open primary air control wide open for two minutes to  
charge wood. It may be necessary to open shotgun air for 2-5 minutes. After most of the wood is burned,  
if you are not planning on reloading immediately, it may be necessary to open the bypass damper and  
door to rake the wood and coals into a pile near the front corner of the firebox. (Be certain wood chunks  
are pulled out of the rear corners.) Close door and bypass damper. This step will assure continued  
combustion and thorough burning of the wood.  
D. High Burn Rate: Set the primary air control to the medium-high setting. Turn the rheostat to high. Wood  
Loading-During refueling, open the bypass damper, open the door, and add wood. Immediately close  
door and bypass damper.  
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 door and windows, and atmospheric conditions all influence which setting you must  
have. It may take you several firings to learn the setting necessary for your installation.  
Although the catalytic stoves decrease the ash residue, routine removal of excess ash is still necessary.  
20  
 
SECTION VI  
PREVENTIVE MAINTENANCE / PARTS REPLACEMENT  
Disassembly Inspection and Catalytic Replacement  
The catalysts in your stove are designed for many years of use. If after several years of use, the efficiency of the  
stove decreases or if a notable amount of smoke is observed, the catalysts may need to be replaced. See the  
Catalyst Warranty prior to replacement.  
CATALYST REPLACEMENT (Off-Season Replacement Recommended)  
1. Spread a drop cloth in front of the stove.  
2. Open the door and clean out any ash.  
3. Using penetrating oil, generously lubricate the four (4) bolt threads holding the catalyst housing in place.  
Allow to penetrate.  
4. Using a 9/16" wrench or 9/16" socket, loosen the four (4) nuts and remove the catalyst housing (drop down)  
and place in a suitable work area.  
5. Using needle nose pliers, grasp the front edge of the stainless steel “can” which houses the catalytic element  
and pull upward. Reposition pliers to another position and pull upward. Repeat procedure until the catalyst can  
be removed from the housing.  
6. Using a small putty knife or scraper, remove any gasket that may have adhered to the catalyst housing.  
7. Now, obtain the new catalyst and wrap the stainless steel can with interam gasket and tape ends together using  
scotch tape or masking tape.  
8. Insert the new catalyst into the catalytic housing and push down until they are seated on the top of the stainless  
steel wire mesh supports.  
9. Reinstall the catalyst housing into the stove and secure in place with the bolts.  
10. The stove is now ready for use.  
GASKET REPLACEMENT (Cold Heater)  
To replace deteriorated gaskets, the following steps must be taken to ensure proper installation:  
1. Obtain the proper gaskets and silicone glue from your local dealer.  
2. Using pliers, remove any worn and deteriorated gaskets.  
3. Using a scraper, wire brush, and sand paper or steel wool, clean glue and gasket residue from the door frame.  
4. Measure and cut gaskets to length. Care should be taken not to stretch the gaskets. What you want is a full and  
loose gasket weave after attached to the framing.  
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.  
21  
 
22  
 
SECTION IV  
TROUBLESHOOTING  
Operation of any wood heater can create problems. While the use of a catalytic-combustor equipped stove will  
substantially lessen some of these problems-such as creosote formation-other traditional wood heater problems  
may remain.  
The following guidelines apply to operation of all wood heaters with problems related to catalytic heater addressed  
where appropriate.  
HEATER RELATED PROBLEMS  
Solution  
Problem  
Possible Cause  
1. Check for and remove  
obstruction  
1. Sluggish Heater Performance  
1. Obstruction in chimney  
2. Check trim kit gasketing or  
direct connect kit seal to  
fireplace and gasket as  
necessary to seal unit. Gasket  
under stove if needed. Check  
seal of direct connect and  
correct.  
2. Improperly sealed trim kit or  
direct connect kit  
3. Open manual damper and  
wire shut with stainless steel  
wire or remove damper  
4. Follow New Buck  
instructions for proper firing  
procedures  
3. Manual damper in chimney is  
closed  
4. Closing bypass or exhaust  
damper too soon  
5. Improper chimney height or  
wrong size flue being used.  
Cooler temperatures caused  
by external chimney.  
5. Poor chimney draft  
6. See section in “Combustor  
Related Problems”  
6. Combustor is plugged  
7. Burn dry, seasoned wood  
7. Wet or unseasoned wood  
being burned  
1. Operate stove with desired  
heat output in mind. Do not  
be overly concerned with  
maintaining light-off  
2. High Fuel Consumption  
1. Inexperience in catalytic  
operation  
temperatures  
2. Close inlet air control as  
much as possible to maintain  
desired heat output. Check  
gaskets. Reinstall fiberglass  
gasketing around doors and  
glass as necessary.  
2. Improper Regulation of draft  
or inlet air  
3. Check door gasket. Check  
adjustment of door latch.  
4. Put combustor in operating  
position in retrofit or close  
bypass damper in stove  
3. Improper Door Fitting  
4. Combustor not engaged  
23  
 
Problem  
3. Backpuffing  
Solution  
Possible Cause  
1. Gusts of wind  
1. Install Buck draft inducer  
2. Increase the amount of  
combustion air slowly.  
2. Hot combustor  
(Above 1400 o F)  
4. Smoke Rollout when heater  
door is opened  
1. Open bypass damper. In  
retrofit place combustor in  
bypass position before  
1. Bypass damper is closed, or  
combustor is in operating  
position  
opening stove door.  
2. Install Buck draft inducer  
2. Wind gusts blowing down  
chimney  
3. Wait a few seconds after  
opening bypass damper be-  
fore opening heater door to  
give smoke a chance to exit  
heater  
3. Opening heater door too fast  
5. Low Catalytic Temperature  
1. Once light-off temperatures  
have been reached and unit is  
stabilized, close bypass  
damper  
1. Bypass damper is open  
2. Follow manufacturer’s oper-  
ating instructions  
3. Refuel as necessary for com-  
bustor operation  
2. Light-off not obtained  
3. Fuel charge is spent  
4. See section on “Combustor  
Related Problems”  
4. Combustor coated with fly ash  
or soot  
5. Ensure that proper air mix-  
ture and draft are available  
for wood pyrolysis to con-  
tinue  
5. Heater dampered down too  
much  
COMBUSTOR-RELATED PROBLEMS  
1. Plugging  
1. Do not burn materials such as  
garbage, gift wrap or  
1. Burning materials that produce  
a lot of char and fly ash  
cardboard  
2. Burn dry, seasoned wood.  
Don’t place the combustor in  
the operating position until  
high temperatures are high  
enough to initiate light-off. It  
may be possible to burn the  
accumulated soot or creosote  
off by putting the combustor  
in a partially open-partially  
closed position after a “hot”  
fire has been started.  
2. Burning wet, pitchy wood or  
burning large loads of small-  
diameter wood with the  
combustor in the operating  
position without light-off  
taking place  
2. Catalyst Peeling  
3. Catalyst Masking  
1. If peeling is severe, remove  
and replace combustor.  
1. Extreme temperatures at  
combustor surface can cause  
the catalyst to peel. Over-  
firing and flame impingement  
are primary cause  
Avoid extreme temperatures.  
1. Place combustor in a partially  
closed position after a “hot”  
fire has been started to burn  
soot off  
1. Not maintaining light-off  
temperature  
24  
 
NEW BUCK CORPORATION (NBC)  
“LIMITED WARRANTY” FOR NBC RELATED PRODUCTS  
If for any reason you are dissatisfied with the sug-  
PLEASE READ THIS WARRANTY CAREFULLY  
PRODUCTS COVERED  
gested procedures, you may contact us in writing at:  
NEW BUCK CORPORATION  
Customer Service Department  
P. O. Box 69  
This warranty covers the new heating unit so long as it  
is owned by the original purchaser, including optional  
and standard accessories purchased at the same time,  
subject to terms, limitations, and conditions herein set  
out.  
Spruce Pine, NC 28777  
CONDITIONS AND EXCLUSIONS  
PRODUCTS NOT COVERED  
(A) Replacement of parts may be in the form of new  
or fully reconditioned parts, at NBC’s option.  
(B) There are no other warranties express or implied  
including warranties of Merchantability, Fitness  
for Purpose or Otherwise except those warranties  
expressly stated herein.  
This warranty does not cover the following:  
Glass;  
Refractory material such as refractory cement or  
firebrick  
Gaskets;  
(C) New Buck Corporation is not liable for indirect,  
incidental, or consequential damages in  
This Warranty will also not cover any damage and/or  
failure caused by abuse or improper installation of the  
Products Covered.  
connection with the use of the product including  
any cost or expense or providing substitute  
equipment or service during periods of mal-  
function or non-use. Some states do not allow the  
exclusion of incidental or consequential  
WARRANTY TIME PERIODS  
(A) Period I  
damages, so the above exclusion may not apply  
to you.  
For one (1) year from the date of purchase, NBC  
will replace or repair, at its option, any part defective in  
materials or workmanship. The costs of parts only are  
included. The customer pays any labor or transportation  
charges required.  
(D) All warranty repairs under this warranty must be  
performed by an authorized Buck Stove service  
representative. Repairs or attempted repairs by  
anyone other than an authorized service  
representative are not covered under this  
warranty. In addition, these unauthorized repairs  
may result in additional malfunctions, the  
correction of which is not covered by warranty.  
Thereafter  
(B) Period II  
For the period after the first year from the date of  
purchase and extending for five (5) years as long as the  
related product is owned by the original purchaser,  
NBC will repair or replace, at its option, any part  
defective in materials or workmanship, with the  
exception of: electrical motors, wiring, switches, and  
components; optional and standard accessories; and all  
parts not permanently attached to the heating unit.  
Parts not permanently attached to the heating unit are  
defined as those items designed to be removed from the  
unit, including those removable with common hand  
tools. The cost of parts only are included. The customer  
pays any labor or transportation charges required.  
OTHER RIGHTS  
This warranty gives you specific legal rights, and  
you may also have other rights, which vary from state  
to state.  
OWNER REGISTRATION CARD  
The attached Owner Registration Card must be  
completed in its entirety and mailed within 30 days  
from the date of purchase or from the date of  
installation, if installed by a factory certified installer,  
to New Buck Corporation, in order for warranty  
coverage to begin.  
PROCEDURE  
PLEASE NOTE: The Owner Registration Card must  
contain the Authorized Dealer Code Number and the  
Certified Installer’s number (if applicable) for  
warranty coverage to begin.  
Should you feel that your heater is defective, you  
should contact any NBC dealer for the name of your  
nearest authorized heater service representative, who  
will instruct you on the proper procedure, depending on  
which Warranty Time Period (Period I or Period II)  
applies.  
25  
 

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