1080 CF Valve Replacement Instructions
(sku 250-00972)
Overview
This kit includes the newer American Flame gas control valve designed specifically for the 1080 CF gas fireplace.
If you have a 1080 CF fireplace, and you are uncertain as to whether this kit is required, please contact Travis
Industries with your serial number. The serial number can be found by removing the glass frame, and pulling out
the aluminum tag chained to the right side of the fireplace (see the illustration below). Travis Industries will keep
records of all 1080 CF fireplaces that have been modified to the new valve. By contacting Travis, you will be able
to verify if your fireplace has been updated.
The following serial number ranges have the older
valve:
1080 CF– serial number
3411-000001 through 3411-000075
NOTE: If you wish to verify the valve directly, the
American Flame gas control valve has a code stamped
on the back (see the photo to the right). If you have a
gas control valve with a code starting with “06”,
you must replace the gas control valve (for
example: “0643”). Gas control valves with a date
code of 0730 (or greater) are the newer design, and do
not require replacement.
Page 1 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
Packing List
•
Valve Assembly (includes valve, valve tray, pilot assembly, manifold, and gas connections)
•
Hex Key (used to remove the plugs from the burner manifold)
•
RMA Slip (very important –must be completed and shipped back with the old valve for credit and to
verify records)
•
UPS Pre-Paid Return Slip (attached to the outside of the box in a shipping envelope)
Installation
WARNING: Installation must be made by a qualified installer.
WARNING: Make sure gas has been shut off to the appliance. Turn off the key-valve (if applicable) or shut off the
main gas line to the residence.
1. Remove the glass frame, logs, embers, and firebacks from the fireplace (installation instructions are
included at the back of this instruction sheet). Remove the floor and ember tray following the directions
below.
Page 2 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
2. Remove the firebox floor following the directions below.
3. Remove the burner following the directions below.
Page 3 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
4. Remove the valve assembly following the directions below.
5. Reach behind the valve assembly and turn off the built in shutoff valve.
Page 4 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
6. Disconnect the flexible gas line from the gas control valve. Make sure to hold the elbow securely while
removing the flex line.
7. Bend the heat shield above the gas control valve up 90°. This allows access to the top of the valve.
8. Remove the pilot flame control connector from the valve (orange and white wire). HINT: A wiring
schematic is included on page 14 of these instructions for reference.
Page 5 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
9. Remove the burner flame control connector from the valve (green and white wire).
10. Remove the battery box connector from the receiver module (4 wire connector).
11. Remove the two power wires from the receiver module.
WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire.
Page 6 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
12. Reach in behind the valve assembly and disconnect the DCMD (red and black) wires leading from the
gas control valve to the battery box.
WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire.
13. At this time the valve assembly (gas control valve, receiver module, etc.) may be removed from the
fireplace. Place the valve assembly on a suitable work surface so the necessary components (receiver
module with bracket, orifices) may be switched from the old valve assembly to the new valve assembly.
14. Remove the igniter (“I” – orange) and sensor (“S” – white) wires from the receiver module.
WARNING: To prevent dislodging the wire from the connector, pull on the connector, not the wire.
Page 7 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
15. Remove the two screws that hold the receiver module plate to the bracket attached to the valve.
16. Remove the bracket attached to the valve.
NOTE: a grounding wire is attached to the bracket with one of the screws – take care to prevent damage
to the wire.
Page 8 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
Special Instructions for LP (Propane) Fireplaces
The replacement valve assembly is configured for natural gas. If you are installing this valve assembly into a
fireplace with LP (propane), you will need to do the following items.
Switch the Pilot Hood to LP
Install Rate Screw (from old valve assembly) and Adjust the Input Shaft
Page 9 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
17. Attach the receiver module bracket to the new valve assembly using the screws removed in step 16.
While attaching the bracket, insert the grounding wire under the screw and secure.
18. Attach the receiver module plate to the new valve assembly.
NOTE: Make sure to attach the receiver module in the correct orientation – see photo below.
Page 10 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
19. Re-attach the igniter (“I” – orange) and sensor (“S” – white) wires to the new valve assembly. NOTE: see
the wiring schematic on page 14 for further details.
20. Re-attach the burner and pilot flame control connectors to the new gas control valve. Both sets of wires
and connections on the gas control valve are labeled.
21. Bend the heat shield on the new valve assembly to the horizontal position.
Page 11 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
22. Place the valve assembly back into the firebox and re-attach the DCMD (red and black) wires. Re-attach
the connector from the battery box to the receiver module. Re-attach the power wires to the receiver
module.
23. Re-attach the flexible gas line to the gas control valve. Make sure to hold the elbow securely while
attaching the flex line. Turn the shutoff valve to the on position.
Page 12 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
Leak Testing the Appliance
Because of the unique configuration of this fireplace, the gas connection can not be leak-tested in a normal
manner. Follow the steps below to leak test the fireplace gas connection. We suggest that you have immediate
access to an external shutoff valve while conducting the leak test.
„
Disconnect the main burner control wire connection (white in green wires) from the gas control valve
WARNING: Failure to disconnect the main burner control wire will allow gas to flow to the main
burner orifices while leak testing – creating an extreme fire and gas-leakage hazard.
„
With the valve assembly inside the firebox, turn the fireplace on using the remote – stand back from the
pilot, it will light (it may take some time as the gas line purges air). If unit does not spark, check your
connections.
„
Once the pilot has lit, you may now start to leak test the gas control valve and gas line connections. Pay
close attention to the flexible gas line (both) sides and the gas connections leading from the valve. Any
leaks must be properly fixed prior to completing the installation. Replace the main burner control wire
after turning the pilot off.
Page 13 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
24. Re-install the valve assembly, taking care to prevent pinching any wires or gas lines.
25. Remove the plug from the manifold on new valve assembly (use the included hex key). Remove the
orifice from the old valve assembly, apply thread-sealant, and attach to the new valve assembly.
Orifice Sizing for 1080 CF:
NG
LP
Rear
# 33
# 50
22. Replace the burner and restore the fireplace to the correct configuration.
Page 14 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
Re-packing and Shipping the Old Valve Assembly
(a) Complete the RMA/ Service form. No credit will be issued if the form does not include: Serial Number;
Date of Service; and, Customer Name and Address. If the fireplace is still in dealer inventory, substitute
the dealer name for customer name.
(b) Place the old valve assembly into the box the new valve assembly was shipped in. Make sure to place
the foam along the bottom, sides, and top of the box as shown below.
(c) Attach the pre-paid shipping label over the old shipping label and ship via UPS to Travis Industries.
NOTE: The shipping label is shipped inside a shipping envelope attached to the outside of the box.
Page 15 of 16
Printed 10/24/07
© Travis Industries, Inc.
1080 CF Valve Replacement Instructions
(sku 250-00972)
Wiring Schematic
Page 16 of 16
Printed 10/24/07
© Travis Industries, Inc.
Finalizing the Installation
(for qualified installers only)
43
Log Set Installation
Overview
Below is a picture detailing log placement for this fireplace. Follow the directions on the following
pages to place the logs correctly.
Lower Rear Log
Left Twig
© Travis Industries
Upper Rear Log
Front Log
4070824
Right Twig
Center Ember
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44
Finalizing the Installation
(for qualified installers only)
Lower Rear Log
The lower rear log has
two holes that insert
over pins on the grate
and log bracket.
© Travis Industries
4070824
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Finalizing the Installation
(for qualified installers only)
45
Upper Rear Log
The upper rear log
has two holes that
insert over pins on the
lower rear log.
NOTE: With the upper rear log
in place, the logs may tend to
tilt backward slightly. Once
the twigs are installed, the
logs will remain in place.
© Travis Industries
4070824
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46
Finalizing the Installation
(for qualified installers only)
Center Ember
Note how the pointed
end faces inwards.
Push the ember back so
it rests against the air
channel (and not over
any burner holes).
© Travis Industries
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Finalizing the Installation
(for qualified installers only)
47
Upper Left Log
Place the upper left log as shown below.
The front log has a hole that fits
over the pin on the grate.
This flat portion rests on
the left side of the grate.
This bracket is for the front
log. Slide the log back until
the back edge of the log rests
against the bracket.
When in place, the
front log should
look like this.
© Travis Industries
4070824
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48
Finalizing the Installation
(for qualified installers only)
Left Twig
The left twig has a
hole for the pin on the
front log.
This notch fits
over the grate.
Note how the left twig
fits directly over the
grate.
© Travis Industries
4070824
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Finalizing the Installation
(for qualified installers only)
49
Right Twig
The right twig has a
hole for the pin on the
rear log.
This notch
fits over the
grate
Note how the notch in
the right twig fits over
the grate.
© Travis Industries
4070824
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50
Finalizing the Installation
(for qualified installers only)
Ember Placement
Place the embers along the firebox floor and burner to help conceal the burner. Make sure none of
the embers are directly over the burner holes. See the photo below.
Note how the embers do not
cover any burner holes. Place
the embers around the burner
to create a realistic effect.
Rock Wool Placement
The rock wool must be pulled apart and made into a thin gauze prior to placing over the burner.
See the illustration below for details.
NOTE: Propane (LP) units use a lighter amount of rock wool than natural gas units.
Preparing the Rock Wool:
AAA
A
The rock wool comes in one
clump. Tear off “dime” sized
clumps and flatten. Then pull on
Place small pieces of rock wool next to the burner holes in
visible locations. Place the rock wool sparingly so it does
not cover large areas of the burner.
the wool to create gauze-like
pieces. The wool glows best
when very thin and porous.
WARNING: If the rock wool is too thick or placed so it
obstructs the flow of gas, sooting will occur.
© Travis Industries
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56
Finalizing the Installation
Fireback Installation
(for qualified installers only)
(Rectangular 96100172)
WARNING
Turn off gas to the appliance and make sure it has fully cooled prior to conducting service.
WARNING
The firebacks are fragile (especially after being burned) – handle with care.
NOTE
The firebacks are 2-sided. When installing, use the desired pattern. Also make
sure the rear brick is correctly positioned.
Herringbone Pattern
Brick Pattern
UP
UP
1
Remove the glass frame, logs, and grate.
2
Remove and discard the ember tray and burner tray cover..
Loosen the screw and remove the clips located on
the firebox ceiling (both sides).
a
Remove this clip on
the firebox floor.
b
c
Remove and discard
the ember tray and
the burner tray cover.
Remove this clip on the firebox
floor. Bend the clip upwards to
d
form a 90° angle.
Figure 38
© Travis Industries
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Finalizing the Installation
3
(for qualified installers only)
57
Install the firebacks following the directions below.
b
Up
pe
Fir r Re
a
eb
ac r
k
Place the rear firebacks in
place. The lower fireback
rests on the tabs on the back
wall of the firebox. Hold
Re
them in place while installing
the side firebacks.
ar
Lo
we
Fir r
eb
ac
k
Le
ft F
loo
rF
Place the floor
firebacks in place.
ire
ba
ck
a
Rig
ht
Flo
or
Fir
eb
ac
k
Slide the side
firebacks into place
c
and replace the clip to
secure (both sides).
Side
Fireb
ack
d
Replace these clips.
Figure 39
4
Restore the fireplace to the correct configuration.
© Travis Industries
4070824
100-01193_000