Installation & Operating Manual - Hearth N Homedownloads.hearthnhome.com/installManuals/30005295... · 2 Vermont astings • Encore® Fleburn nstallation ManualR3 • 0518 303000525

1 3-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R40 • 05/18

SAFETY NOTICE: IF THIS APPLIANCE IS NOT P R O P E R LY I N S TA L L E D , O P E R AT E D A N D MAINTAINED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY OR EVEN DEATH. CONTACT LOCAL BUILDING OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.

The French language version of this manual is available online:www.vermontcastings.comLa version française de ce manuel est disponible en ligne : www.vermontcastings.com

Please read this entire manual before installation and use of this wood-burning room heater. Failure to follow these instructions could result in property damage, bodily injury or even death.

• Donotstoreorusegasolineorotherflammablevaporsand liquids in the vicinity of this or any other appliance.

• Donotoverfire-Ifanyexternalpartstartstoglow,youareoverfiring.Closeaircontrols.Overfiringwillvoidyour warranty.

• Complywithallminimumclearancestocombustiblesasspecified.Failuretocomplymaycauseahousefire.

WARNING!

Testedandapprovedforusewithdry,seasonedcordwoodonly. Do Not Burn Wet or Green Wood. Burning any other type of fuel will void your warranty.

CAUTION!

Installation & Operating ManualInstallation and Appliance Setup - Care and Operation

INSTALLER: Leave this manual with party responsible for use and operation.OWNER: Retain this manual for future reference.Call your dealer for questions on Installation, Operation, or Service.

2425Encore NC Cover5/05

For use in the UnitedStatesandCanada

Encore® FlexBurn® Non-Catalytic/CatalyticWoodBurningStove

Model 2040

NOTICE: SAVE THESE INSTRUCTIONS


CongratulationsonyourchoiceofaVermontCastingsEncore® stove. With this purchase you have made a commitment to makethehearthaplaceofwarmth,beautyandcomfortinyourhome.AtVermontCastings,wesharethatjoyandappreciationforthehearth.Weassureyouthatyourcast-ironVermontCastingsstovehasbeenmadewiththeutmostcareandwillprovide you with many years of service. Asyoubecomeacquaintedwithyournewstove,youwillfindthatitsappearanceismatchedbyitsfunctionality,duetocastiron’s unique ability to absorb and radiate heat.Also,VermontCastingsproductsareamongthecleanest-burningwoodstovesavailable today.However,cleanburningdepends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate and maintain your stove.AtVermontCastings,weareequallycommittedtoyoursatisfactionasacustomer.Thatiswhywemaintainanexclusivenetworkofthefinestdealersintheindustry.Ourdealersarechosenfortheirexpertiseanddedicationtocustomerservice.Theyarefactory-trainedandknowledgeableabouteveryVermontCastingsproduct.FeelfreetocontactyourAuthorizedVermontCastingsDealeranytimeyouhaveaparticularquestionaboutyourstoveoritsperformance.ThismanualcontainsvaluableinstructionsontheinstallationandoperationofyourVermontCastingsEncore®.Italsocontainsuseful information on maintenance. Please read the manual thoroughly and keep it as a reference.

Thismanual describes the installation, operation, andmaintenanceoftheVermontCastingsEncore® Model 2040 Non-Catalytic/Catalyticwoodburningheater.ThisheatermeetstheU.S.EnvironmentalProtectionAgency’semissionlimitsforwoodheaterssoldonorafterMay15,2015.Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in propertydamage,bodilyinjury,orevendeath.

Table of Contents

Proposition 65 Warning: Fuels used in gas, woodburning or oil fired appliances, and the products ofcombustionof such fuels, contain chemicals known totheStateofCaliforniatocausecancer,birthdefectsandother reproductive harm.CaliforniaHealth&SafetyCodeSec.25249.6

Installation AccessoriesWarming Shelf 8” Flue Collar

#0200 ClassicBlack #0555 ClassicBlack#0205 Biscuit #0556 Biscuit#0199 Bordeaux #0560 Bordeaux#0208 BrownMajolica #0557 BrownMajolica#0198 Twilight #0561 Twilight

#3265* OutsideAirKit#3185 OutsideAirAdapter#0336* MobileHomeKit#0127 FirescreenFK26 FanKit#3190 ConnectorPipeHeatShield#0180 RectangularCeilingKit#0181 RoundCeilingKitA line of porcelain enamel stove pipe is available in Biscuit, Bordeaux, Brown Majolica colors.*If you order #3265 or #0336, you must also use #3185.

ListingsandCodeApprovals .................................3Stove Dimensions..................................................4Installation .............................................................5ClearancetoCombustibles .................................13MobileHomeInstallation .....................................17Assembly .............................................................18SmokeAlarm/SafetyTips ...................................21Operation .............................................................22Draft Management ...............................................28Maintenance ........................................................30TheCatalyticElement .........................................34Service Parts List.................................................36Warranty ..............................................................42

= Contains updated information


*An efficiency based on EPA historical data: 63% for non-catalytic stoves.**Maximum calculated efficiency using Douglas Fire dimensional lumber and data collected during EPA emissions test.***A range of BTU outputs based on EPA Default Efficiency and the burn rates from the low and high EPA tests, using Douglas Fir dimensional lumber.**** A peak BTU out of the unit calculated using the maximum first hour burn rate from the High EPA Test and BTU content of seasoned cordwood (8600) times the efficiency.This wood heater needs periodic inspection and repair for properoperation.Itisagainstfederalregulationstooperatethis wood heater in a manner inconsistent with operating instructions in this manual.

EPA Certification Number: 787Non-Catalytic InformationEPA Certified Emissions: 1.6g/hr*EPA Default Efficiency: 73.0%**Actual tested Efficiency: 67.6%***EPA BTU Output: 10,000-34,000****Peak BTU/Hour Output: 47,200Catalytic InformationEPA Certified Emissions: 1.1g/hr*EPA Default Efficiency: 80.0%**Actual tested Efficiency: 74.3%***EPA BTU Output: 13,400-33,200****Peak BTU/Hour Output: 45,500Other Important InformationVent Size: 6Inch(152mm)

8Inch(203mm)Firebox Size: 2.3 cu. ft.Max. Wood Length: 22"MaximumIdeal Wood Length: 18"(TopLoad)Fuel SeasonedCordwood

(20%moisture)

Area Heated...................................900-2,300SquarefeetLoading .......................................................... Front and topChimney Connector: ......................................................... for6"fluecollar ...........................6"(152mm)diameter for8"ovalfluecollar ....................8"(203mm)diameterFlue Exit Position ............................................Top or RearPrimary Air ............Manuallyset,thermostaticallymaintainedSecondary Air ...................................Fixed,self-regulatingAsh Handling System........................ Removable ash panGlass Panels .............................High-temperatureceramicWeight ......................................................475lbs.(215kg.)

Listings and Code Approvals

MODEL: Encore®,Model2040LABORATORY: OMNITestLaboratories,IncREPORT NO. 227-S-42-2TYPE: SolidFuelRoomHeater/Wood

Burning TypeSTANDARD(s): UL1482-2011,UL737-2011,

ULC-S627-00ELECTRICAL RATING:

115VAC,60Hz

Mobile Home ApprovedThis appliance is approved for Installation in mobile/manufactured homes in the United States and CanadaThestructuralintegrityofthemobilehomefloor,ceilingandwalls must be maintained. The appliance must be properly groundedtotheframeofthemobilehome,andmustneverbe installed in a room designated for sleeping. The unit must have provisions for an outside air source when installed in a mobile home.


Stove Dimensions

Figure 1-Encore® 2040 dimensions.

Drawing Not to Scale

5295Encore 2N1dimensions

1-3/4”44 mm)

3-3/4”(95 mm)

22-3/4”(578 mm)

25"(635 mm)Top exit

flue collarheight

27"(686 mm)

25-3/4”(654 mm)

18-1/2”(470 mm)

7-1/4”(184 mm)

27"(686 mm)

22-1/4”(565 mm)

15-1/2”(394 mm)

5"(127 mm)

2-7/8” (73 mm)

23-3/4”(603 mm)

15"(381 mm)


InstallationSAFETY NOTICE: IF YOUR ENCORE® IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.Beforeyoubeginaninstallation,besurethat:• Your stove and chimney connector will be far enough from

combustible material to meet all clearance requirements.• Thefloorprotector is largeenoughand is constructed

properly to meet all requirements.• You have all necessary permits from local authorities.Yourlocalbuildingofficialisthefinalauthorityforapprovingyour installation as safe and determining that it meets local and state codes.The metal label permanently attached to the back of every VermontCastings’stoveindicatesthatthestovehasbeentested to currentUL andULC standards, and gives thenameof the testing laboratory.Clearanceand installationinformation also is printed on the label. When the stove is installed according to the information both on the label and inthismanual,localauthoritiesusuallywillacceptthelabelas evidence that the installation meets codes and can be approved.However,codesvaryindifferentareas.Beforestartingtheinstallation,reviewyourplanswiththelocalbuildingauthority.Your local dealer can provide any additional information needed.Foranyunresolvedinstallationissues,refertotheNationalFireProtectionAssociation’s publicationANSI/NFPA211Standard forChimneys,Fireplaces,Vents andSolidFuelBurningAppliances.ForCanada,theequivalentpublicationisCSACAN-B365InstallationCodeforSolidFuelBurningAppliancesandEquipment.Thesestandardsarethebasisformanynationalcodes.Theyarenationallyrecognizedandareaccepted by most local authorities. Your local dealer or your localbuildingofficialmayhaveacopyoftheseregulations.IMPORTANT: Failure to follow these installation instructions may result in a dangerous situation, including a chimney or house fire. Follow all instructions exactly, and do not allow makeshift compromises to endanger property and personal safety.Outside AirIn some modern, super-insulated homes, there may beinadequateairsupplyforcombustionbecauseofinsufficientairinfiltrationintothebuilding.Suchairentersahomethroughunsealedcracksandopenings.Exhaustfansinkitchensorbathrooms can compete with the stove for available air and compound the problem.

ST241chimney types12/13/99 djt

Aprefabricateddouble-wall insulated chimney

Atile-linedmasonry chimney

Figure 2-Approvedchimneytypes.

Whenpoordraftiscausedbyalowinfiltrationrate,openingagroundfloorwindowonthewindwardsideofthehouseandnear the stove will usually alleviate the problem.Abettersolutionistoinstallapermanentoutsideairsupplytothestoveand/orroom.Infact,bringingairforcombustionfrom outside the home directly to the air inlet of the stove is required for new construction in some areas. Pressure variations within the house do not affect a stove equippedwith anoutside air supply, and improved stoveperformanceoftenresults.AnOutsideAirKitfortheEncore® is available from your local dealer. What Kind of Chimney to UseYou must connect the Encore®toacode-approvedmasonrychimneywithaflueliner,toarelinedmasonrychimneythatmeetslocalcodes,ortoaprefabricatedmetalchimneythatcomplieswiththerequirementsforTypeHTchimneysintheStandardforChimneys,Factory-Built,ResidentialTypeandBuildingHeatingAppliance,UL103.Figure2illustratesthetwo types. The chimney and chimney connector must be in good condition and kept clean.Ifyouuseanexistingmasonrychimney,itmustbeinspectedto ensure it is in a safe condition before the stove is installed. Yourlocalprofessionalchimneysweep,buildinginspector,orfiredepartmentofficialwillbeabletoinspectthechimneyor provide a referral to someone who can. Thechimneymustextendat least3’(914mm)abovethehighestpointwhereitpassesthroughorneararoof,andatleast2’(610mm)higherthananypartofabuildingwithin10’(3m)horizontally.(Figure3)Forproperdraftandgoodperformance,anychimneyusedwith a Encore®shouldextendatleast16’(5m)abovethefluecollarofthestove.


2' Min.

2' Min.

3'Min.

0 To 10'

3'Min.

0 To 10'

AC617RLTSKC8

2/11/98

Reference Point

Figure 3-The2’-3’10’ChimneyRule.

Masonry ChimneysAninspectionofthechimneymustconfirmthatithasalining.Do not use an unlined chimney. The chimney should have nocracks, loosemortar, other signsof deterioration, andblockage. Repair any defects before the chimney is used with your stove.Unusedopeningsinanexistingmasonrychimneymustbesealedwithmasonrytothethicknessofthechimneywall,andthechimneylinershouldberepaired.Openingssealedwith pie plates orwallpaper are a hazard and should besealedwithmortarorrefractorycement. In theeventofachimneyfire,flamesandsmokemaybeforcedoutoftheseunused thimbles.The chimney should be thoroughly cleaned before use.A newly-built masonry chimneymust conform to thestandardsofyourlocalbuildingcodeor,intheabsenceofalocalcode,toarecognizednationalcode.Masonrychimneysmustbelined,eitherwithcode-approvedmasonryorpre-castrefractory tiles, stainless steel pipe, or a code-approved,“poured-in-place”liner.Thechimney’sclean-outdoormustseal tightly.A looseor leaky clean-out door canweakenchimneydraft,causingperformanceproblems.Prefabricated ChimneysA prefabricated metal chimney must be one tested andlistedforusewithsolid-fuelburningappliancestotheHigh-Temperature(H.T.)ChimneyStandardUL-103-1985(2100°F)fortheUnitedStates,andHighTemperature(650°C)StandardULCS-629forCanada.DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.

Chimney SizeAnEncore®withan8"(203mm)fluecollarisapprovedforventing into amasonry chimneywith a nominal flue sizeof8"x8"(203x203mm)or8"x12"(203x305mm),andintoaroundfluewithnominalfluesizeof8"(203mm).AnEncore®witha6"(152mm)flueconnectorisapprovedforventingintoamasonrychimneywithanominalfluesizeof8"x8"(203x203mm),andintoaroundfluewithnominalflueof6"(152mm).NOTE: When installed with a 6" flue collar, the Encore® may not be operated with the front doors open.Whateverthefluecollarsize,anEncore® may be vented into largerchimneysaswell.However,chimneyswithlinerslargerthan8"x12"(203x305mm)mayexperiencerapidcoolingofsmokeandreductionindraft,especiallyifthechimneysare located outside the home. These large chimneys may needtobe insulatedorhavetheirfluesrelinedforproperstove performance. Accessoriestohelpmaketheconnectionbetweenstainlesssteel chimney liners and your Encore® are available through your local dealer.Chimney Connector GuidelinesAchimneyconnector is thesingle-wallpipethatconnectsthe stove to the chimney. The chimney itself is the masonry orprefabricatedstructure thatenclosestheflue.Chimneyconnectors are used only to connect the stove to the chimney. Single-wall connectors should bemade of 24 gauge orheaviersteel.Donotusegalvanizedconnector; it cannotwithstand the high temperatures that can be reached by smokeandexhaust gases, andmay release toxic fumesunderhighheat.Theconnectormaybe6"(152mm)or8"(203mm)indiameter.Ifpossible,donotpass thechimneyconnector throughacombustiblewallorceiling.Ifpassagethroughacombustiblewall is unavoidable, refer to the section onWall Pass-Throughs.Donotpasstheconnectorthroughanattic,aclosetor similar concealed space. The whole connector should be exposedandaccessibleforinspectionandcleaning.


Inhorizontalrunsofunshieldedchimneyconnector,maintainadistanceof30"(762mm)fromtheceiling.Keepitasshortanddirect as possible,with nomore than two90° turns.Slope horizontal runs of connector upward 1/4" per foot(6mmpermeter)goingfromthestovetowardthechimney.Therecommendedmaximumlengthofahorizontalrunis3’(1m),andthetotallengthshouldbenolongerthan8’(2.4m).Incathedralceilinginstallations,extendtheprefabricatedchimneydownwardtowithin8’(2.4m)ofthestove.Thiswillhelpmaintainagooddraftbykeepingthesmokewarm,sothat it rises readily.Wearglovesandprotectiveeyewearwhendrilling,cuttingorjoiningsectionsofchimneyconnector.Single-wall Chimney Connectors• Beginassemblyatthefluecollarofthestove.Insertthe

first crimpedend into thestove’s flue collar, andkeep each crimped end pointing toward the stove. (Figure4)Usingtheholesinthefluecollarasguides,drill1/8"(3mm)holesinthebottomofthefirstsectionofchimney connector and secure it to thefluecollarwiththree#10x1/2"sheetmetal screws. Lift off the griddle, and shield thestove’s surface between the griddle opening and the frontofthefluecollartoprotectthefinishwhenyoudrillthe front hole.

• Fasteneachjointbetweensectionsofchimneyconnector,includingtelescopingjoints,withatleastthree(3)sheetmetal screws.Thepre-drilled holes in the topof eachsection of chimney connector serve as guides when you drill1/8"(3mm)holesinthebottomofthenextsection.

• Fastenthechimneyconnectortothechimney.Instructionsfor various installations follow. Figure 5 illustrates the general layout of chimney connector parts.

• Be sure the installed stove and chimney connector are correct distances from nearby combustible materials.

NOTE: Special slip pipes and thimble sleeves that form telescoping jointsbetweensectionsofchimneyconnectorare available to simplify installations. They often eliminate theneedtocutindividualconnectorsections.Consultyourlocal dealer about these special pieces.

ST492Defiantfreestanding installation11/00

Chimney

Elbow

Slip Pipe

Standard Connector

FlueCollar

Thimble

FlueInner

Flue

Figure 5 -An exploded view of the chimney connection in afreestanding masonry installation.

ST242Chimney connector

12/13/99 djt

Flue Gas Direction

Toward Stove

Figure 4 -Chimneyconnector.

Securing the Single-wall Connector to a Prefabricated ChimneyFollow the installation instructions of the chimney manufacturer exactlyasyouinstallthechimney.Themanufacturerofthechimneywillsupplytheaccessoriestosupportthechimney,eitherfromtheroofofthehouse,attheceilingoftheroomwherethestoveisinstalled,orfromanexteriorwall.Special adapters are available from your local dealer to make the connection between the prefabricated chimney and the chimney connector. The top of such adapters attaches directly to the chimney or to the chimney’s ceiling support package,whilethebottomoftheadapterisscrewedtothechimney connector.Theseadaptersaredesignedsothetopendwillfitoutsidetheinnerwallofthechimney,andthebottomendwillfitinsidethefirstsectionofchimneyconnector.Securing the Single-wall Connector to a Masonry ChimneyBothfreestandingmasonrychimneysandfireplacemasonrychimneys may be used for your installation. Freestanding Installations Ifthechimneyconnectormustpassthroughacombustiblewall to reach thechimney, followtherecommendations intheWall Pass-Through section that follows. The openingthrough the chimney wall to the flue (the “breech”) mustbelinedwitheitheraceramicormetalcylinder,calledthe“thimble,”whichiscementedsecurelyinplace.Mostchimneybreechesincorporatethimbles,butthefitmustbesnugandthejointbetweenthethimbleandthechimneywallmustbecementedfirmly.


Figure 7-Inthisinstallation,thechimneyconnectorattachestothechimneyabovethefireplaceopening.

ST244Plymouthfplc over mantel12/99

*

*

CheckTheseClearances

Mantel

Seal ThisOff

ST243thinble connection

12/13/99 djt

Thimble Sleeve

ChimneyConnector

Flue

Keepsleeveendflushwithfluetile

Figure 6-Thethimble,madeofeitherceramicormetal,mustbecemented securely in place.

• Thefireplacedampermustbesealedtopreventroomairfromescapinguptheflue.However,itmustbepossibletore-openthedampertoinspectorcleanthechimney.

Through the FireplaceIfyourfireplaceopeningheightisatleast29"(737mm),youmay install a Encore® through the opening using a “positive connection” kit, available from your local dealer. Positiveconnectionkitsensureatightfitbetweenthestovefluecollarandthechimneyflue.(Figure8)Fireplaceinstallations,whetherconnectedtotheflueaboveor through the fireplace opening, have special clearancerequirementstoadjacenttrimandthemantel.You’llfindtherequired safe clearances for Encore®fireplaceinstallationson Page 12. Floor protection requirements also apply to fireplace installations. Refer to the "Floor Protection" section in this manual.Wall Pass-ThroughsWheneverpossible,designyourinstallationsotheconnectordoes not pass through a combustible wall. If you areconsideringawallpass-throughinyourinstallation,checkwithyourbuildinginspectorbeforeyoubegin.Also,checkwith thechimneyconnectormanufacturer foranyspecificrequirements.Accessoriesareavailableforuseaswallpass-throughs.Ifusingoneofthese,makesureithasbeentestedandlistedforuseasawallpass-through.

Toinstallathimblesleeve,slideitintothebreechuntilitisflushwiththeinnerfluewall.Donotextenditintotheactualfluepassage,asthiscouldinterferewiththedraft.Thethimblesleeveshouldprotrude1-2"(25-50mm)intotheroom. Use furnace cement and thin gasketing to seal the sleeve in place in the thimble. Secure the chimney connector to the outer end of the sleeve with sheet metal screws.Withoutathimble,asuitable lengthofchimneyconnectorcanbeextendedthroughthebreechtotheinnerfaceoftheflueliner,andcementedsecurelyinplace.Additionalpiecesof connector are then attached with sheet metal screws. Fireplace InstallationsThe chimney connector may be connected to the chimney abovethefireplaceopeningorthroughthefireplace.Above the FireplaceThe Encore® may be connected to a chimney above a fireplaceopening.(Figure7)Insuchinstallations,thestoveispositionedonthehearthinfrontofthefireplaceandthechimney connector rises from the stove top and then angles ninety degrees back into the chimney. The chimney liner shouldextendtothepointatwhichthechimneyconnectorenters the chimney. If the chimney connector in your installation enters thechimneyaboveafireplace,followalltheguidelinesmentionedaboveforfreestandinginstallations.Inaddition,givespecialconsideration to the following points:• Check the clearance between themantel and thechimney connector, and any combustible trim or themantel.

• Checktheclearancebetweenthechimneyconnectorandtheceiling.Theclearanceshouldbeatleast30"(762mm)withunshieldedconnectors.Consulttheclearancecharts for other installation options.

Aspecialpiececalledthe“thimblesleeve,”slightlysmallerindiameter thanstandardconnectorsandmost thimbles,will facilitate the removal of the chimney connector system forinspectionandcleaning.(Figure6)Thimblesleevesareavailable from your local dealer.


ST245fireplace flex connector12/99

FlexibleConnector

Mantel Shield

FireplaceAdapterKit“PositiveConnection”

Figure 8-Throughthefireplaceinstallation.

ST493Brick pass thru11/00

Wall Stud

ChimneyConnector

Floor Protection

12" of Noncombustible Material

Figure 9-Anapprovedwallpass-throughfortheUnitedStates.

T

ST494steelwall pass thru11/00

18"(460mm)clearancebetween pipe and sides/top/bottomofopening

Figure 10-Anapprovedwallpass-throughforCanada.

Your local dealer or your local building inspector can provide details for other approved methods of passing a chimney connectorthroughacombustiblewallinyourarea.InCanada,this type of installationmust conform toCAN/CSA-B365,Installation Code for Solid Fuel Burning Appliances andEquipment. NOTE: Do not vent your Encore®intoafactory-built(zero-clearance)fireplace.Theseappliancesandtheirchimneysarespecificallydesignedasaunitforuseasfireplaces.Itmayvoidthelistingorbehazardoustoadaptthemforanyother use.DO NOT CONNECT THE Encore® TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.

ThreeothermethodsarealsoapprovedbytheNFPA:• Placing a section of chimney connector inside a ventilated

thimble,whichinturnisseparatedfromcombustiblesby6"(152mm)offiberglassinsulatingmaterial.

• Placing a section of chimney connector inside a section of 9" (230mm) diameter, solid-insulated, factory-builtchimney, with 2" (51mm) of air space between thechimney section and combustibles.

• Using a section of solid-insulated double-wall hightemperaturechimney,withaninsidediameterthesameasthechimneyconnector,atleastoneinchofsolidinsulation,andaminimumof9"(229mm)airspacebetweentheouter wall of the chimney section and combustibles.

In Canada, The Canadian Standards Association hasestablisheddifferentguidelinesforwallpass-throughs.Figure10showsonemethod,inwhichallcombustiblematerialinthewall iscutawaytoprovidetherequired18"(457mm)clearance for the connector. The resulting space must remain empty.Aflush-mountedsheetmetalcovermaybeusedononesideonly.Ifcoversmustbeusedonbothsides,eachcover must be mounted on noncombustible spacers at least 1"(25mm)clearofthewall.IntheUnitedStates,theNationalFireProtectionAssociation

(NFPA) has established guidelines for passing chimneyconnectors through combustible walls. Many building code inspectors follow these guidelines when approving installations. Figure 9 shows one NFPA recommendedmethod.Allcombustible material in the wall is cut away from the single-wallconnectortoprovidetherequired12"(305mm)clearance.Anymaterialusedtocloseuptheopeningmustbe noncombustible.


U.S. CanadaA 39" 43"(1092mm)B 45" 49"(1245mm)

C 12"10"

12"(305mm)8"Connector10"(250mm)6"Connector

D 6" 8"(203mm)E 6" 8"(203mm)F 16" 18"(460mm)

Floor ProtectionAtremendousamountofheatradiatesfromthebottomplateofyourstove.Thefloorareadirectlyunderandaroundthestove will require protection from radiant heat as well as from straysparksorembersthatmayescapethefirebox.HeatprotectionisprovidedwiththeuseoftheBottomHeatShield supplied with the stove. Most installations will require the bottom heat shield to be attached.Onlywhen thestove isplacedonacompletelynoncombustible surface such as unpainted concrete over earth may it be used without the heat shield. With the bottom heat shield installed the Encore® 2040 was tested using a 1/2" (13mm) non-combustible hearthmaterialwith a thermal conductivity, (k) = 0.47BTU - in/hr-ft2-°F,resultingintherequirementofprovidingatotalthermalresistance(R)of1.06.(Referto“How to Determine if Alternate Floor Protection Materials are Acceptable” section.)Thefloorprotectormaybecoveredwithadecorativenoncombustible material if desired. Do not obstruct the space under the heater.Whenusingafirescreenwithdoorsopen,UL737,StandardforFireplaceStoves,thisunitwastestedusinga1"(25mm)non-combustiblehearthpadwithathermalconductivity,(k)=0.47BTU-in/hr-ft2-°F,resultingintherequirementofprovidinga total thermal resistance (R)of2.12. (Refer to“How to Determine if alternate Floor Protection Materials are Acceptable” section.)Thefloorprotectormaybecoveredwith a decorative noncombustible material if desired. Do notobstructthespaceundertheheater.An8"chimneyandchimney connector is required and the bypass damper must be in the fully open position.Important: All installations on a combustible floor require the use of the supplied bottom heat shield.Protection requirements vary somewhat between the Untied StatesandCanadaasfollows:In U. S. installationsthefloorprotectorisrequiredunderthestoveandmustextendatleast16"(notincludingtheashlip)fromthefrontofthestove(“F,”Figure11),andatleast6"fromthesidesandrear.(“D”and“E,”Figure11)In rear venting configurations, floor protectionmust alsoextendunderthechimneyconnectorand2"toeitherside.(“C,”Figure11)Forthe8"(203mm)connector,theprotectormustbeaminimumof12"(305mm)wide.Forthe6"(152mm)connector,theprotectormustbe10"(254mm)wide.The protector must be centered under the connector.Tomeettheserequirements,afloorprotectormustbeatleast39"wideand45"deep.In Canada:A noncombustible floor protector is requiredunderthestoveaswell.Thefloorprotectormustextend18"(457mm)tothefront(“F,”Figure11),and8"(203mm)fromthesidesandrear.(“D”and“E,”Figure11)Tomeettheserequirements,afloorprotectormustbeatleast43"(1092mm)wideand49"(1245mm)deep.

D

E

A

B

A

E

C

ST500Defiantfloor protection1/31/02 djt

F

EE

F

Figure 11-Requiredfloorprotectiondimensions.

How to Determine if Alternate Floor Protection Materials are AcceptableAllfloorprotectionmustbenoncombustible(i.e.metals,brick,stone,mineralfiberboards,etc.).Anyorganicmaterials(i.e.plastics,woodpaper products, etc.) are combustible andmust not beused.The floor protection specified includessomeformofthermaldesignationsuchasR-value(thermalresistance)ork-factor(thermalconductivity).Procedure:1. ConvertspecificationstoR-value:

i.R-valuegiven-noconversionneeded.ii.K-factorisgivenwitharequiredthickness(T)ininches:

iii.K-factorisgivenwitharequiredthickness(T)ininches:

iv.R-factorisgivenwitharequiredthickness(T)ininches:R=rxT

2. Determine theR-value of the proposedalternate floorprotector:i. Use the formula in Step 1 to convert values not

expressedasR.ii. Formultiple layers, addR-values of each layer to

determineoverallR-value.3. If theoverallR-valueof thesystemisgreater than the

R-valueof thespecifiedfloorprotector, thealternate isacceptable.

R= xT1Kx12

R=xT1K


EXAMPLE:Thespecifiedfloorprotectorshouldbe1/2-inchthickmaterialwithk-factorof0.84.Theproposedalternateis4"brickwithanr-factorof0.2over1/8"mineralboardwithak-factorof0.29Stepa:UseformulaabovetoconvertspecificationtoR-value:

Stepb:CalculateRofproposedsystem. 4"brickofr=0.2,therefore: Rbrick=0.2x4=0.8 1/8"mineralboardofk=0.29,therefore

Rmineralboard= x0.125=0.431

Rtotal=Rbrick + Rmineralboard=0.8+0.431=1.231Stepc:CompareproposedsystemRtotalof1.231tospecified

Rof0.59.SinceproposedsystemRtotalisgreaterthanrequired,thesystemisacceptable.

Definitions

R=xT=x1.00=1.181k

10.84

10.29

r= =(ft2)(hr)(°F)(Btu)(in)

1k

(Btu)(ft)(ft2)(hr)(°F)K=

K= =kx12(Btu)(in)(ft2)(hr)(°F)R=(ft

2)(hr)(°F)Btu

Floor Protection for Fireplace InstallationDo not assume that your fireplace hearth is completelynoncombustible.Manyfireplacehearthsdonotsatisfythe“completelynoncombustible”requirementbecausethebrickorconcreteinfrontofthefireplaceopeningissupportedbyheavy wood framing. Because heat passes readily through brickorconcrete,itcaneasilypassthroughtothewood.Asaresult,suchfireplacehearthscanbeafirehazardandareconsideredacombustiblefloor.For all fireplace installations, follow the floor protectionguidelinesdescribedabove,includingtheneedforabottomshield.Keep inmindthatmanyraisedhearthswillextendless than the required clearance from the front of the heater. Insuchcases,sufficientfloorprotectionasdescribedabovemust be added in front of the hearth to satisfy the minimum floorprotectorrequirementfromthefrontofthestove:16"(410mm)intheUnitedStatesand18"(460mm)inCanada.Hearthrugsdonotsatisfytherequirementforfloorprotectionastheyarenotfireproof.Fireplace installations also have special clearance requirements to the side walls, side decorative trim andfireplacemantel.Refertotheinformationonfireplaceandmantel trim shields in this section.

Keep the Stove a Safe Distance From Surrounding MaterialsBoth a stove and its chimney connector radiate heat in all directionswhenoperating,andnearbycombustiblematerialscan overheat dangerously if they are too close to the heat source.Asafeinstallationrequiresthatadequateclearancebe maintained between the hot stove and its connector and nearby combustibles.Clearance is the distance between either your stove orchimneyconnector,andnearbywalls,floors,theceiling,andanyotherfixedcombustiblesurface.TheEncore®hasspecificclearance requirements that have been established after careful research and testing. These clearance requirements must be strictly observed.Inaddition,keepfurnishingsandothercombustiblematerialsaway from thestove. Ingeneral, adistanceof 48" (1219mm)mustbemaintainedbetweenthestoveandmovablecombustible items such as drying clothes, furniture,newspapers,firewood,etc.Keepingthoseclearanceareasempty assures that nearby surfaces and objectswill notoverheat. Safe Ways to Reduce ClearancesClearance requirements are established to meet everyinstallationpossibility,andtheyinvolvethecombinationofthese variables:

• When the stove pipe has no listed heat shield mounted on it.

• When the wall has no heat shield mounted on it.• When the wall has a heat shield mounted on it.• When the wall and stove pipe have heat shields.

Ingeneral,thegreatestclearanceisrequiredwhenyouplacea stove and its connector near a wall with no heat shield. Forexample,whentheEncore®isinstalledusing6"connectorpipe parallel to the rear wall and no connector shield is used,itmustbeatleast15"(381mm)fromthewallbehinditandatleast19"(483mm)fromwallsoneitherside.Thesedimensions are measured from the back of the rear shroud and the side edge of the cast iron top to the combustible wall.IftheEncore®isinstalledinacornerandnoshieldisused,thecornersofthestovetopmustbeatleast18-1/2"(470mm)fromnearbywalls.Clearancesmaybereducedonlybymeansapprovedbytheregulatoryauthority,andinaccordancewiththeclearanceslisted in this manual. Refer to the clearance chart for approved clearancereductionspecifications.NOTE: Installation of the Encore® is not permitted in alcoves.


N o n c o m b u s t i b l e s h i e l d s installed 1" (25mm)away fromthe combustible surface on noncombustible spacers, calledventilated shields,maybeusedto reduce clearances.To protect a mantel from the heat of a stove in a fireplace installation, usea custom-madeventilated mantel shield that is at least 48" (1220 mm) long,centeredoverthestove.(Figure13) Ventilated shields for sidetrimmust extend the full lengthof the trim.Anunprotectedmantel(“A,”Figure14)cannotbemorethan9"(230mm)deepandmusthaveaminimumclearanceof28"(711mm),measuredfromthestove’stopplate.Withaventilatedshield, thisclearancemaybereducedsafelyto15"(381mm).Unprotectedtoptrim(B)protruding3/4"(19mm)orlessfromthefaceofthefireplacemustbeaminimumof25"(635mm)fromthestove’stopsurface.Withaventilatedtrimshield,this clearance may not be reduced safely.Unprotectedsidetrim(C)thatprotrudes3/4"(19mm)orlessfromthefaceofafireplacemusthaveaminimumclearanceof22"(554mm),measuredfromthestove’stopsideedge.Ifthetrimextendsmorethan3/4"(19mm),itissubjecttothe requirements for wall clearance.The charts and sample installations that follow list all the clearancesrequiredforthevariousinstallationconfigurationsof the Encore®.

ST248wall shield construction12/14/99 djt

Stud Wall Framing

Wall Shield

Noncombustible Spacers and Fasteners

Drywall

AirFlow

AirFlow

Screen

Shield

Metal Spacer

Figure 12-Approvedwallshieldconstruction.

1" (25mm)

1/4" (6mm)

ST501mantel andtrim shield11/10/00 djt

Figure 13 - A custom-formed mantel shield.

Fireplace and Mantel Trim ClearancesUnprotected Protected

A Mantel Trim 28"(711mm) 15"(281mm)B Top Trim 25"(635mm) 15"(281mm)C Side Trim 22"(554mm) 11"(280mm)D Side Wall 22"(559mm) 11"(280mm)

Figure 14-Maintainclearancestocombustiblecomponentsofthemantel piece.

ST253bEncoretrim clearances02/01 djt

C C

A B

D

Side Wall

Theshieldmustbeaminimumof48"(1219mm)tall,andmustextendatleast19"(483mm)higherthanthetopofthestove,whicheverishigher.Theshieldbehindthechimneyconnectormustbe30"(760mm)wide,centeredbehindthepipe; for installations that use an approvedprefabricatedchimneytopassthroughtheceiling,theshieldbehindthechimneyconnectormuststop1"(25mm)belowtheceiling.With8"connectionsandchimneys,becauseofpotentiallyhigher pipe temperatures, the shieldmust extend the fullheightof thewall (up to9’ (2.7m))andstop1" (25mm)below the ceiling.Fireplace and Mantel Trim ShieldsAfireplaceinstallationrequiresspecialclearancebetweenthesideofthestoveandtherightandleftwalls,betweenthesideofthestoveandthedecorativesidetrimonthefireplaceface,andbetweenthetopofthestoveandthemantel.

Wall ShieldsOne way to reduce clearances is with a wall shieldconstructedof24gaugeorheaviersheetmetal,orofanothernoncombustiblematerial such as 1/2" (13mm) insulationboard such as Durock® or Wonderboard®,orcommonbrick“laidonflat,”withthe3-1/2"(90mm)sidedown.Shields must be spaced out from the combustible surface 1" (25mm)onnoncombustiblespacers,asinFigure12.Thespacers should not be directly behind the stove or chimney connector.Airmustbeabletoflowbetweenthewallandtheshield.Atleast50%ofthebottom1"(25mm)oftheshieldmustbeopen,andtheshieldmustbeopenatthetop.Metalscreeningacrossthetopwillkeepsmallstrayobjectsfrombeingtrappedbehindtheshield.(Figure12)


Clearance to CombustiblesForusewitheither6”or8”fluecollar/chimneyconnection

Theprovidedrearshroudmustbeusedinallinstallations.Thefluecollarheatshieldmustbeusedinallverticalinstallations.1. Aceilingheatshield24"(610mm)indiameterandsuspended1"(25mm)fromtheceilingmustsurroundthepipein

installations where chimney penetrates the ceiling.2. Theconnectorpipeheatshieldmustextend36"(914mm)abovefluecollar.3. Usinglisteddoublewallovaltoroundadapterwheninstallingoptional8"ovalfluecollar.4. Aminimumof58”(147cm)fromthetopofthestovetotheceiling,isrequiredforallinstallationsoftheEncore®

Unprotected Surfaces Protected SurfacesStove Clearance

Stove InstalledParallel to Wall

Stove In Corner

Stove InstalledParallel to Wall

Stovein Corner1

SideTo Rear Shroud Corners Side

To Rear Shroud Corners

TopExit,8”singlewall connector without shields,verticalfluecollar heat shield installed

(A)19"(483mm)

(B)20"(508mm)

(C)18-1/2"(470mm)

(D)5"(127mm)

(E)7"(178mm)

(F)12"(305mm)

Top Exit,single-wallchimney connector heat shield2,verticalfluecollar h.s. installed

(G)19"(483mm)

(H)10"(254mm) (I)18-1/2"

(470mm)(J)6"

(152mm)(K)6"

(152mm)(L)12"

(305mm)

Rear ExitNofluecollarheatshield

(M)22"(559mm)

(N)12"(305mm) N/A (P)11"

(279mm)(Q)12"(305mm) N/A

Top Exit,double-wallchimney connector3,verticalfluecollarheatshield installed

(G)18"(457mm)

(H)7"(178mm)

(I)12"(305mm)

(J)4"(102mm)

(K)5"(127mm)

(L)5"(127mm)

Clearance to Combustibles in Front of StoveAllInstallations(S)48"(1219mm)

6" Chimney Connector ONLYTop Exit,singlewall6"connectorwithoutshields,verticalfluecollarheat shield installed

(A)19"(483mm)

(B)15"(381mm)

(C)18-1/2"(470mm)

(D)5"(127mm)

(E)7"(178mm)

(F)12"(305mm)


Unprotected Surfaces Protected SurfacesStove InstalledParallel to Wall Stove in Corner

Stove Installed Parallel to Wall

Stove Installed Parallel to Wall

Top Exit Installations,NoStoveHeatShields,collarheatshieldinstalled.

D

E

F

F

C

C

A

B

J

K

L

L

I

I

G

H

ST628Encore ClearanceDiagrams02/01

P

Q

M

N

N/A N/A

Top Exit Installations,verticalcollarheatshield,andchimneyconnectorheatshieldsordouble-wallconnector.

Rear Exit Installations.

Forusewitheither6"or8"fluecollar/chimneyconnector


Distance from the Center of the Flue Collar to the Wall in Top-Exit Installations Theinformationonthispageishelpfulinplanningstoveplacementfortop-exitinginstallations,particularlythoseinstallationswithchimneysthatpassthroughtheceiling.However,thisisnotaclearancechart.Finalstoveclearancesmustadheretothe guidelines stated in the clearance chart on Page 13.Dimensionsindicatedarevalidforinstallationswitheither6"or8"fluecollars.

Encore®: WITH Chimney Connector Heat ShieldsUnprotected Surfaces Protected Surfaces

Parallel InstallationsCorner

Installations** Parallel InstallationsCorner

Installations**Side(A) Rear(B) Corner(C) Side(D) Rear(E) Corner(F)32-1/2"(826mm)

13-1/4"(337mm)

22-1/2"(572mm)

19-1/2"(495mm)

9-1/4"(235mm)

18-1/2"(470mm)

**Tolocatecenteroffluecollarforcornerinstallation,add6-1/2"(165mm)totheclearancedistancefromstovecornertowall.Markofftheresultingdistancefromthecorneralongbothwalls.Next,measurethesamedistancefromthesetwopointsoutfromthewalls.Theselasttwomeasurementswillmeetatapointrepresentingthecenterofthefluecollar.Refertothediagramsabove.

ST632aEncore flue centerlineDiagrams02/01

A B C E FD

Encore®: WITHOUT Chimney Connector Heat ShieldsUnprotected Surfaces Protected Surfaces

Parallel Installations Corner Installations** Parallel Installations Corner

Installations**Side(A) Rear(B) Corner(C) Side(D) Rear(E) Corner(F)32-1/2"(826mm)

23-1/4"(691mm)

22-1/2"(572mm)

18-1/2"(470mm)

10-1/4"(260mm)

18-1/2"(470mm)

*Thisdistance,fromthecenterofthefluecollartothefrontedgeofthehearth,isthesameforallinstallationsonthispage:35-1/4"intheUnitedStatesand37-1/4"(946mm)inCanada.

ST632Encoreflue centerlineDiagrams2/01

A B C

*

E F

*

D


48" (1220 mm)

ST498 Defiant

Wall shield B 11/00

Figure 16 -Parallel installationwith rearwallpass-through, twowall shields. Reduced clearances to both rear and side walls. Wall shieldsmaymeet at corner if desired.Wall pass-throughmustcomply with codes. Referto“SpecialInstallations.”

48"

(1220 mm)

ST497 Defiant wall shield A 11/00

48" (1220 mm)

Figure 15 -Parallel installation,verticalchimneyconnector, twowall shields. Reduced clearances for both rear and side walls. Wall shields may meet at corner if desired. Shielding for connector is centered behind connector.

48" (1220 mm)

48" (1220 mm)

ST499 Defiant

Wall Shield C 11/00

Figure 17-Cornerinstallation,verticalchimneyconnector,twowallshields. Reduced side clearances. Wall shield MUST meet at corner.


Mobile Home Installation1. Anoutsideairinletmustbeprovidedforcombustionand

must remain clear of leaves, debris, ice and/or snow.Itmustbeunrestrictedwhilestove is inusetopreventroom air starvation which can cause smoke spillage and an inability tomaintainafire.Smokespillagecanalsoset off smoke alarms.

2. The appliance must be secured to the mobile home structurebyboltingittothefloor.

3. Stove must be grounded with #8 solid copper grounding wire or equivalent and terminated at each end with N.E.C.approvedgroundingdevice.

4. Stove must be installed with an approved UL103 HTventilated chimney connector,UL103HTchimneyandterminal cap with spark arrestor. Never use a single wall connector(stovepipe)inamobilehomeinstallation.Useonlydouble-wallconnectorpipe,Dura-VentDVL,SelkirkmetalbestosDS,SecurityDLdoublewall connectororany listed double wall pipe connector.

5. Refer to the clearance charts in this manual or the serial number label on the back of the stove for clearances to combustibles.

6. Floorprotectionrequirementsmustbefollowedprecisely.Refer to the "Floor Protection" section in this manual.

7. InCanada,thisappliancemustbeconnectedtoa6inch(152mm)factory-builtchimneyconformingtoCAN/ULC629M,STANDARDFORFACTORYBUILTCHIMNEYS.Refer to the "Floor Protection" section in this manual.

8. Use silicone to create an effective vapor barrier at the location where the chimney or other component penetratestotheexteriorofthestructure.

9. Follow the chimney and chimney connectormanufacturer’s instructions when installing the fluesystem for use in a mobile home.

NOTE: Offsets from the vertical, not exceeding 45°, areallowedperSection905(a)oftheUniformMechanicalCode(UMC).Offsetsgreaterthan45°areconsideredhorizontalandarealsoallowed,providingthehorizontalrundoesnotexceed75%oftheverticalheightofthevent.Construction,clearance and termination must be in compliance with the UMCTable9C.This installationalsocomplieswithNFPA211.NOTE: Top sections of the chimney must be removable to allowmaximumclearanceof13.5ft.(411cm)fromgroundlevel for transportation purposes.10.Burn wood only. Other types of fuels may generate

poisonousgases(e.g.carbonmonoxide).11. Ifunitburnspoorlywhileexhaustblowerisoninhome,

(i.e.kitchenrangehood)increasecombustionair.

ST1190mobile home install

Spark ArrestorCap

Roof Flashing

StormCollar

JointShield/Firestop ListedChimney

Connector

Floor Protection

OutsideAirKitConnector

OutsideAirFloorVent

Figure 18-Mobilehomeinstallation.

DO NOT INSTALL IN SLEEPING ROOM

WARNING!

CAUTION!THE STRUCTURAL INTEGRITY OF THE MOBILE HOME FLOOR, WALL AND CEILING/ROOF MUST BE MAINTAINED. (i.e., DO NOT CUT THROUGH FLOOR JOIST, WALL STUD, CEILING TRUSS, etc.).

NEVER DRAW COMBUSTIBLE AIR FROM A WALL, FLOOR OR CEILING CAVITY OR FORM ANY ENCLOSED SPACE SUCH AS AN ATTIC OR GARAGE.

WARNING!


Assembly

ST564handle holder12/13/00

BottomHeatShield

DoorHandleHolder

Leg Bolt and Washer

Figure 21-Handleholderandheatshieldpositions.

ST857abottom heat shield12/051/10

Figure 22-Attachthebottomheatshield.

BottomHeatShieldST516Attach griddle handle11/17/00 djt

Figure 20-Attachthegriddlehandle.

Install the Bottom Heat ShieldNOTE: TheBottomHeatShieldisrequiredinmostinstallations.RefertoFloorProtection,Page9,forfurtherdetails.1. Install(4)1/4-20x3/8"hexboltssuppliedinthemanual

bagintothefourholeslocatedunderthestove(Figure22).

2. Alignthebottomheatshieldkeyholestothefourhexboltspreviouslyinstalledintobase.(Figure22).Theoutsideaircutout hole should be toward the rear of the stove.

3. Attachtheheatshieldsidesbypassingtheslotsovertheboltheads.Tightenthehexheadbolts.Figure22.

Storing the HandleUsetheremovablehandletoopenorclosethedoors.Afterusingit,removethehandlesoitwillnotgethot.Storethehandle in the handle holder installed behind the right front leg.(Figure21)

CAUTION!Overtighteningcanstriptappedthreads.

Figure 19-Removeunitfromshippingbrackets.Removetheunitfromtheshippingbracketsbyremoving(2)1/4-20hexheadboltsfromeachshippingbracket,leavingbracketsattachedtotheskid.Figure19.(Savethe1/4-20hexheadboltsastheywillbeneededlatertoinstallheatshield.)NOTE:Whenmovingthestove,liftthestovetotakeweightoffthelegswheneverpossible.Draggingorslidingthestove,especially across rough surfaces can cause the legs to loosen or even break.Set Up Your StoveCastironstovesareheavy,anditwilltaketwotofourpeopleto move your Encore® into position.Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel. Install the handle on the griddle. First, place the griddleupside down at the edge of a flat surface and assemble the handle. Figure 20.With the handle pointing 45°fromitsfinalposition,tighten the nut as far as possible with the pliers. Move the handle to its final positionwhile stillholding the nut with the pliers.

1/4-20 Bolt


ST540Assemblyhandle11/00

Figure 26-Assemblethefrontdoorhandle.

ST635EncoreInstall thermostathandle2/01

Figure 25-Attachthethermostathandle.

ST1180�ue collar heat shield

Sheet Metal Screws

Sheet Metal Screws

FlueCollarHeatShield

Figure 23-Installfluecollarheatshield.

Attach the Damper Handle Usethe1/4"-20x3"screwtoattachthedamperhandletothe damper stub on the left side. Attach the Catalyst Temperature ProbeToinstallthecatalysttemperatureprobe,removetheholeplug from the cast iron wall behind the rear shield as shown (Figure24)use two#10sheetmetal screwsandbracketsupplied,securethebracketandprobetothebackofyourstove.(Figure24)

Assemble the Removable Insert HandleThe wooden removable insert handle opens and closes the frontdoors.Removeaftereachuse,andstoreitinthehandleholderbehind the right front leg.Assemble thehandlebypassingthe3-3/8"screwthroughthewoodenshaftandintothebrightmetalnub.(Figure26)Tightencarefullyuntilsnug.

Attach the Primary Air Thermostat Handle The primary air thermostat handle is the smaller of the two black handles. Secure the handle to the stub on the right sideofthestovewithan8-32x2"slotheadmachinescrew.(Figure25)

WARNING!Thefluecollarheatshieldmustbeinstalledinallverticalinstallations.Thefluecollarheatshieldisnotusedwhenthefluecollarisintherearexitposition.

Adjust the Leg Levelers Lift the stove slightly so there is no weight on the leg while makingtheadjustment.Reverse the Flue Collar (If necessary)Reversethefluecollarbyremovingthetwoscrewsthatattachit to the back of the stove. Be sure the gasket around the fluecollaropeningisinpositionwhenyouscrewthecollarback onto the stove.

Figure 24-InstalltheCatalystTemperatureProbe

1.4"

1.8"

Bracket mounting screw hole location

Fold bracket strap over catalyst probe shaft and secure with screw.

Insertcatalystprobethrough sheetmetal and castironbackandtwist&pushthroughfiberpanel.

Remove hold plug from cast iron back.

Insertcatalystprobebracketwithself-drillingscrew.


Fan Kit Installation1. Attachthefanassemblyatthebottomedgeoftheinner

backwithtwo(2)1/4-20x3/4"hexheadscrews.2. Attachsnapstattothemountingholesontheunderside

ofthebottomwithtwo(2)1/4-20panheadscrews.3. Attach the rheostat holder (provided with the stove)

under the right front wing of the bottom heat shield with two(2)#10sheetmetalscrews.

4. Attachtherheostattoitsholderbyinsertingtherheostatcontrolshaftthroughtheholderhole.Installtheretainingring and rheostat knob onto the shaft.

5. Secure the rheostat cable to the underside of the bottom heat shield using the wire tie provided and the hole at the right rear edge of the heat shield.

6. Fanwill notoperateuntil stove reachesapproximately109°F.

7. Plug blower cord into a grounded outlet. Do not remove ground prong from plug. Route power cord to avoid heat from the stove or other damage. Do not route cord under or in front of appliance.

Figure 27-Faninstallation(Kit#2767).

Rheostat Knob

RheostatSnapstat Screws

HoleforWireTie to Secure Cable

Rheostat Holder

Installing or Removing Catalyst1. Remove the access cover by gently lifting up and pulling

outfromthebottomedge.(Figure28)2. Removetheinnercoverbypullingitstraightout.(Figure

29)3. Remove the catalyst by gently pulling it straight out.

(Figure 30) Place the catalyst where the catalyst’sceramic components will not be damaged.

ST1187remove access cover

AccessCover

Figure 28-Removeaccesscover.

ST1188remove inner cover

InnerCover

Figure 29-Removeinnercover.

ST1189remove catalyst

RemoveCatalyst

Figure 30-Removecatalyst.


Smoke and CO DetectorsThe use of smoke and carbonmonoxide (CO) detectorsthroughout the home is strongly advised, even if notrequired by building codes or insurance regulations. It is a good idea to install a smoke detector in the livingareasandeachbedroom.Follow the smoke/COdetectormanufactures placement and installation instructions and maintain regularly.You may not, however, wish to install a detector in theimmediate vicinity of the stove. Depending on the sensitivity oftheunit,thealarmcanbesetoffwhileyouaretendingthefireoremptyingtheashes.Ifyouinstalladetectorinthesameroom,locateitasfarawayfromthestoveaspossible.Safety TipsConvenientlylocatea"ClassA"fireextinguishertocontendwith small fires. Be sure the fire extinguisher works andisclearlyvisible.Alloccupantsof thehouseshouldknowwhereitis,andhowitoperates.Haveheavystoveglovesavailablenear thestove.Havespecialsafetyaccessories(e.g.,ChildGuardScreen)availableforuseifsmallchildrenwill be in the home.Intheeventofastovepipeorchimneyfire….• Evacuate the house immediately• Notifythefiredepartment• If the fire isn't too threatening, closingdown the stove

tight,(damper,primaryair,alldoors)willhelptosmotherthefire.

• Inspect your stove, stove pipe and chimney for anydamage caused by the fire and correct any damagebefore using your stove again.


The Encore® Controls Two controls regulate the performance of the Encore®: a primary air control suppliesoxygenforthefire,andadamper directsairflowwithinthestovetoactivateanddeactivatethecombustionsystem.(Figure31)Symbols cast into the stove are reminders of the correct directions for using the controls. The words ‘Left’ and ‘right’ in these directions are facing the stove.

Figure 31 -TheEncore® controls are conveniently located and easy to operate.

ST633Encorecontrols2/01

GriddleHandleDamperHandle

AirControlLever

DoorHandleHolder(Behindleg)

AshdoorHandle

Andirons

DoorHandle

ST637encoreAir control2/01

Low Heat

High Heat

Figure 32 - The handle may be positioned anywhere between the twoextremesfordifferentheatlevels.

Damper Positions

ST638Encoredamper control 2/01

Open(UpdraftMode)

Closed(HighEfficiencyMode)

Figure 33 -Thedamper iseitheropenorclosed.Therearenointermediate positions.

A Damper Directs Air Flow Within the StoveThe damper handle on the left side of the stove operates thedampertodirectairflowwithinthestove.The damper is open when the handle points to the rear,enabling smoke to pass directly into the chimney. The damper mustbeopenwhenstartingorrevivingafire,andwheneverthe griddle or doors are opened.The damper is closed when the handle points forward. Smoke travels through the secondary combustion system where it can be further burned, before passing up thechimney.(Figure33)The damper should always be either fully open or fully closed. There are no intermediate positions. When closing the damper, be sure to pull firmly enough to snap the handle into the locked position.

Thiswoodheaterhasamanufactured-setminimumlowburn rate thatmustnotbealtered. It isagainst federalregulations to alter this setting or otherwise operate this wood heater in a manner inconsistent with operating instructions in this manual.

WARNING!

A Single Air Control Regulates Heat Output and Burn TimeThe primary air control lever,ontherightsideofthestove,controlstheamountofincomingairforstarting,maintaining,andrevivingafire.Oncetheaircontrolismanuallyset,abi-metallicthermostatautomatically maintains the heat output at a constant level for a more even heat over the life of the burn.Moreairenteringthestovemakesthefireburnhotterandfaster,whilelessairprolongstheburnatalowerheatoutputlevel.(Figure32)Forthegreatestairsupplyandmaximumheatoutput(buttheshortestburntime),movethelevertowardthefrontofthestove.Forafirethatwilllastlongerwithlessheat,movethe lever toward the rear of the stove.

Operation


Conditioning Your StoveCast iron isextremelystrong,but itcanbebrokenwithasharp blow from a hammer or from the thermal shock of rapidandextremetemperaturechange.The cast plates expand and contract with changes intemperature. When you first begin using your Encore®,minimizethermalstressbylettingtheplatesadjustgraduallyduringthreeorfourinitialbreak-infiresfollowingSteps1-3below.Wood Burning OperationBurnonlysolidwoodintheEncore®,andburnitdirectlyonthe grate. Do not elevate the fuel. Do not burn coal or other fuels.IntheUnitedStates,it isagainstthelawtooperatethis wood heater in a manner inconsistent with operating instructions in this manual.The bypass damper must be open when starting a fire or when refueling. Do not use chemicals or fluids to start the fire. Do not burn garbage. Never use flammable fluids such as gasoline, gasoline type lantern fuel, kerosene, charcoal lighter fluid, naptha, engine oil or similar liquids to start or “freshen up” a fire in this heater. Keep all such liquids well away from the heater while it is in use. 1. Openthestovebypassdamper,andopentheprimaryair

control fully.2. Place several sheets of crumpled newspaper in the

stove.Placesixoreightpiecesofdrykindlingsplittoafinger-widthsizeonthepaper.Onthekindling,laytwoorthree largersticksofsplitdrywoodapproximately1-2"(25-51mm)indiameter.(Figure34)

NOTE:Somechimneysmustbe“primed,”orwarmedup,beforetheywilldrawsufficientlytostartafire.Tocorrectthissituation,rollupacouplepiecesofnewspaper,placethemontopofthekindlingandtowardthebackofthestove,lightthem,andclosethedoors.Thiswillencouragethesmoketoriserapidly,makingiteasiertoestablishagooddraft.Oncethedraftisestablished,openthefrontdoorandlighttherestof the fuel from the bottom. Do not light the main bed of fuel untilthechimneybeginsdrawing,andrepeattheprocedureas often as necessary if the initial attempt is unsuccessful.NOTE:Effectivenessofa“top-down”methodtostartafire.Smoke emissions when starting a fire can be difficult tocontrol because the stove is not yet heated to its optimum temperature.Onemethodof reducingemissionsduringacoldstart-upistheuseofa“top-down”kindlingprocedure.Inthis,placelargerpiecesofkindlingonthebottomofthekindling pile followed by smaller and smaller pieces as the pile isadded to.Veryfinelysplitpiecesshouldbeon thetop. Light the kindling pile with a match at the top and allow the kindling to burn downward into the larger pieces. This reduces smoke by slowly increasing the fire sizewithoutcreatinganair-starvedcondition.4. If your Encore® has been broken-in previously using

Steps1-3,continuetobuildthefiregradually.Addlargerwood with a diameter of 3-4" (75-100 mm). Continueadding split logs of this size to the briskly-burning fireuntilthereisaglowingemberbed2-3"(51-75mm)deep.(Figure38)Agoodemberbed isnecessary forproperfunctioning of the combustion system.

5. Closethedamperwhenthegriddletemperaturereaches450°F(230°C)andsufficientemberbedisestablished.This will force the smoke into the secondary combustion chamber where the smoke and gases will ignite if the stove is sufficiently hot. Even though it is possible forthefiretogetquitehotwithinafewminutesafterafireisstarted,secondarycombustionmaystoporthefiremaygooutifthefirediesdownimmediatelyasaresultofthedamper being closed too early.

6. Adjusttheaircontrolforyourdesiredheatoutput.NOTE: Stove installations vary widely, and the operatingguidance given here is only a starting point. The "Draft Management" section in thismanualwill explain in detailhow the features of your installation may help or hinder good draft,andhowyoumayneedtovaryyourfiringtechniqueifyour installation doesn’t encourage a good draft.High-Efficiency Wood Burning with the Catalytic CombustorYour Encore stove was shipped from the factory with a separately packaged catalytic combustor. When operating the stove with the catalytic combustor, use the sameoperation instructions as outlined in the previous section.

ST263starting a fire12/99

Figure 34-Startthefirewithnewspaperanddrykindling.

3. Light the newspaper and close the door. Gradually build upthefirebyaddingafew3-5"(80-120mm)diameterpiecesofsplitfirewood. If this is one of the first few “break-in” fires, let the fire burn brightly, and then let it die out.During the break-in fires, do not let thestove get hotter than 500°F. (260°C) asmeasured onanoptionalstove-topthermometer.Adjusttheaircontrolleverasnecessary tocontrol thefire.Someodor fromthestove’shotmetalandthepaintisnormalforthefirstfewfires.


Whilenotrequired,operatingyourstovewiththecatalyticcombustor installed creates optimum conditions for secondarycombustionandwillincreaseyourefficiencyupto 15%on low burn,making sure you get themost heatout of each load of wood. Refer back to the "Installing or Removing Catalyst" section of this manual.The catalytic element is a ceramic “honeycomb” coatedwith the catalytic material. The element sits at the bottom of the secondary combustion chamber. Smoke, gasesand particulates that are not fully combusted during the secondarycombustionprocesspass through thecatalyst,creatingatertiaryburn.Thisresultsinhigherefficiencyandlower emissions.The catalyst will initiate combustion of smoke and particulates at500°-600°F(260°-315°C),halfthetemperaturenormallyrequiredforunaidedsecondarycombustion.Ifyoufollowedthe startup operation steps in the previous section the stove willbesufficientlyhottoallowthecombustortowork.Oncethe combustor startsworking, heat generated by burningthe smoke will keep it working.Todeterminewhetherthecombustor isoperating,refertothe temperature probe which shows the operating range of the catalytic combustor. This is located on the back of the stove and is viewed from the top. NOTE: It will takeseveral minutes after closing the bypass damper for the temperatureprobetofullyadjusttothenewtemperature.Iftheprobeindicatorisbelowtheoperatecatalystrange,addfueloropenthebypassdampertoallowthefiretofurtherbuild before engaging the catalyst again. If theprobe indicator isabovetheoperatecatalystrange,the catalytic combustor is running too hot and may be damaged. Inmanycases,decreasing theprimaryaircanreduce the catalyst temperature and adding less wood with each loading can also help if overheating is persistent. Do not add wood to the stove if the probe reads above the operate catalyst range. Avoidusingafullloadofverydrywoodinthefirebox,suchas dry slab wood or wood with below 14% moisture content. This may result in continuous very high temperatures in the secondary combustion area and damage the combustor.Never kindle a fire with colored paper or paper that hascoloredinkoraglossysurface.Neverburntreatedwood,garbage, solvents or trash. All of these may poison thecatalyst and prevent it from operating properly. Never burn cardboard or loose paper except for kindling purposes.Neverburncoal;doingsocanproducesootorlargeflakesofcharorflyash thatcancoat thecombustorandcausesmoketospill intotheroom.Coalsmokecanalsopoisonthe catalyst so that it won’t operate properly. NOTE: The ceramic catalytic combustor is fragile and will crack if subjected to thermal shock. Thermal shock canoccur when refueling with wet wood or closing the bypass damper too early after refueling. Hairline cracks will notaffect the performance of the combustor, but repeatedthermal shocks can result in cells falling out, somewhatreducing the effectiveness of the combustor.

Two Ways to Add FuelThe Encore®’s griddle lifts for convenient top-loading oflogs,andistheeasiestwaytoaddfuel.(Figure35)However, the front doors open as well for adding anoccasionallogtoafire.Ifthestoveisequippedwith8"(203mm)stovepipe, the frontdoorsmaybeopened (orevenremoved) and the optional Encore® spark screen placedin the opening for open-fire viewing.TheEncore® is notapproved for operation with the front doors open if equipped witha6"(152mm)chimneyconnectororchimney.

Defiant

ST521Intrepidloading11/00

Figure 35-Toploadingisthebestwaytoaddfuelduringregularuse.Frontloadingisusefulforkindlingafire.

Toopenthefrontdoors,insertthehandleintothedoorlatchstubandturnittotheleftandup.(Figure36)To close them, always close the left door first. Turn thehandle in the right door to the left and up (to the openposition)andcloseit.Finally,pushonthedoorasyouturnthe handle to the right and down. The doors will draw in slightly,andthehandleshouldoffersomeresistanceasyouturn it to the closed position. Toreducetheriskofbreakingtheglass,avoidstrikingtheglass or slamming the doors.When you are not using the door handle, store it in theholder behind the right front leg of the stove.

ST544door open11/00

ClockwisetoOpen

CounterclockwisetoClose

Figure 36-Toopenthefrontdoors,turnthehandleclockwise.

WARNING!Fireplace stoves equipped with doors should be operated only with doors fully open or doors fully closed. If doors are left partly open, gas and flame may be drawn out of the fireplace stove opening, creating risks from both fire and smoke.


WARNING!For safety and greatest efficiency, operate your stove only with all doors/griddles fully closed. The test standard for your stove when it is operated in this mode is UL 1482.

The Encore® may be used as a fireplace with the front doors open or removed, BUT only when it is equipped with 8" (203 mm) stove pipe and only when the optional spark screen is secured correctly in the opening to protect against the possibility of sparks and embers leaving the stove. The test standard for your stove when it is operated in this mode is UL 737. 1" floor protection is also required. Refer to the “Floor Protection” section in this manual.Use only the Encore® spark screen, Item #0127, with your Encore®. Encore® SPARK SCREENS ARE AVAILABLE FROM YOUR VERMONT CASTINGS DEALER.Refuel While the Embers Are Still HotWhenreloading,bestresultswillbeachievedifyoufirstde-ash the stove by stirring the fuel bed to allow ash to fall through the grate into the ash pan. Do not break the charcoal into very small pieces or pound or compressthecharcoalbed.Checktomakesureairholesatthebottomofthefirebackarenotblockedbyashorembers(blockagewillreduceperformanceofthestove).Itisimportantthataircancirculatethroughthecharcoalbedduring the burn. Larger pieces of charcoal allow more air to circulateunderthewood,resultinginthefirerevivingmorequickly.(Figure37)

ST264aadd wood fire11/00

Figure 37-Addfullsizelogsaftertheemberbedis3"(75mm)deep.

1. Openthedamperandturntheprimaryaircontroltohigh.2. De-ash the stove as described above. Open the ash

door and check the level of ash in the ash pan. Empty thepan ifnecessaryandreplace it in thestove.Closethe ash door.

3. Open the griddle top, load the wood (smaller piecesfirst),andclosethegriddletop.

4. Wait several minutes for the new wood to fully ignite and for the stove top surface temperature to reach 450°F(230°C).

5. Close the damper. And adjust the air control for theamount of heat your desire.

NOTE:Iftheremainingcharcoalbedisrelativelythick(2-3"/51-75mm)andifyourfueliswellseasoned,itispossibletoaddfreshfuel(smallerpiecesfirst),closethedooranddamper, and reset the primary air control for the desiredheatoutputwithinfiveminutes.

For best results when refueling, wear long-cuffed stoveglovestoprotectyourhandsandforearms.Addfuelwhilethestovestillhasplentyofglowingemberstore-kindlethefireand includesomesmallerpiecesofwood in thenewfuel load to help the stove regain its operating temperature quickly. Use this sequence as a guide to successful refueling:

WARNING!DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN. OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVER-FIRING CONDITION TO OCCUR. OVER-FIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE, INJURY OR LOSS OF LIFE.

Andirons Help Protect the GlassYour stove has andirons to keep logs away from the glass panels. The andirons are essential to maintain clear fireviewing, and should be left permanently in place. Sincethe andirons may slightly hinder refueling through the front doors,moststoveownerswillprefertheconvenienceoftoploading through the griddle. Do not place fuel between the andirons and the doors.Burn Only High-Quality WoodTheEncore®isdesignedtoburnnaturalwoodonly;donotburn fuels other than that for which it was designed. IMPORTANT: Do not burn any type of artificial or synthetic materials such as fire starter logs (containing wax) in this appliance. Never burn liquid-based fuels such as kerosene, gasoline or alcohol. Burninganymaterialsnotallowedintheseinstructions,orover-firingthestove,mayvoidthewarranty.You’ll enjoy thebest resultswhenburningwood that hasbeenadequatelyair-dried.Thewoodshouldbe18” -20”(457-508mm) in length.Avoidburning “green”wood thathas not been properly seasoned. Do not burn construction materials;theyoftencontainchemicalsandmetalsthatcandamage the inside surfaces of the stove and pollute the air.Donotburnoceandriftwood;whenitburns,thesalt itcontains will attack the cast iron.


Thebesthardwoodfuels includeoak,maple,beech,ash,and hickory that has been split, stacked, and air-driedoutside under cover for at least one year. Ifhardwood isnotavailable,youcanburnsoftwoodsthatincludetamarack,yellowpine,whitepine,Easternredcedar,fir,andredwood.Theseshouldalsobeproperlydried.Storesplitwoodundercovertokeepitdry.Evenforshort-termstorage,besuretokeepwoodasafedistancefromtheheater and keep it out of the areas around the heater used for refueling and ash removal.Surface Thermometer is a Valuable Guide to OperationAnoptionalsurface thermometer tellsyouwhen toadjusttheaircontrol,andwhentorefuel.(Figure38)

Figure 38-Taketemperaturereadingswithathermometerlocatedin the middle of the griddle.

For example, when the thermometer registers at least450°F(230°C)onthestovetopafterstart-upyouknowthestove is hot enough and it may be time to close the damper ifasufficientemberbedhasalsobeenestablished.Notethatthestovewillwarmupmuchsoonerthanthechimney,though;awarmchimneyisthekeytoeasy,effectivestoveoperation. Please review the "Draft Management" section of thismanualtoseehowthesize,type,andlocationofyourchimney will affect your stove operation. When thermometer readingsdropbelow350°F.(175°C) it’s timetoadjust theaircontrol forahigherburn rateor to reload thestove.Atemperaturereadingover650°F.(340°C)isasigntoreducethe air supply to slow the burn rate.Use the following temperature ranges as a guide:• Readingsinthe350°-500°F.(175°-260°C)rangeindicate

low to medium heat output.• 500°-600°F. (260°-315°C) readings indicate medium

heat output.• Readingsof600°-650°F.(315-340°C)indicatehighheat

output.OperatingyourEncore®continuouslyatgriddletemperatureshigherthan650°F(340°C)maydamagethecastironorenamelfinish.

Use the Air Control Settings that Work Best for YouNo single air control setting will fit every situation. Eachinstallationwilldifferdependingon thequalityof the fuel,theamountofheatdesired,andhowlongyouwishthefiretoburn;outdoorair temperatureandpressurealsoaffectdraft.

The control setting also depends on your particular installation’s “draft,” or the force that moves air from thestove up through the chimney. Draft is affected by such thingsasthelength,type,andlocationofthechimney,localgeography,nearbyobstructions,andotherfactors.Seethe"Draft Management" section of this manual for details on how the installation affects performance.Toomuchdraftmaycauseexcessive temperatures in theEncore®,andcouldevendamagethestove.Ontheotherhand, too little draft can causebackpuffing into the roomand/orthe“plugging”ofthechimney.Howdoyouknowifyourdraft isexcessivelyhighorlow?Symptoms of too much draft include an uncontrollable burnoraglowing-redstovepart.Signsofweakdraftaresmoke leaking into the room through the stove or chimney connectorjointsorlowheatoutput.Insomenewerhomesthatarewell-insulatedandweather-tight, poor draftmay result froman insufficient air supplyinthehouse.Insuchinstances,anopenwindownearthestove on the windward side of the house can provide the combustion air supply needed. Anotheroptionforgettingmorecombustionairtothestoveis to duct air directly from outside to the stove. In someareas provisions for outside combustion air are required in all new construction.The Encore® is equipped to deliver outside air for combustionandoutsideairkit#3265isavailable.When first using the stove, keep track of the air controlsettings.Youwillquicklyfindthataspecificsettingwillgiveyouafixedamountofheat. Itmaytakeaweekor twotodetermine the amount of heat and the length of burn you shouldexpectfromvarioussettings.Most installations do not require a large amount of combustion air, especially if adequate draft is available.Donotforanyreasonattempttoincreasethefiringofyourheaterbyalteringtheaircontroladjustmentrangeoutlinedin these directions.Use the following air control settings as a starting point to help determine the best settings for your installation. Each is described as a fraction of the total distance the lever may be moved from right to left.


Encore® Control Settings (RefertothefirstpageoftheOperationsection.)DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN. OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVER-FIRING CONDITION TO OCCUR. OVER-FIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE, INJURY OR LOSS OF LIFE. Ash DisposalRoutineashremovalisimportantforeaseofmaintenance,and is important for the stove’s durability. Remove ash beforeitreachesthetopoftheashpan.Checkthelevelatleastonceaday.Every fewdays,clearanyashfromtheouteredgesofthefirebox.Mostoftheashwillfallthroughthe grate. Stir the ash with a shovel or poker so that it falls through the grate slots. IMPORTANT:Checkthelevelofashintheashpanbeforereloadingthestove.Iftheashlevelisclosetothetopedgeofthepan,emptythepanaccordingtothisprocedure:• Openthedamper.• Open the griddle or front doors, and use a shovel or

pokertostirexcessashthroughtheashslotsinthegratedown into the ash pan.

• Close the griddle or doors, and unlatch the ash door.(Figure39)Itwillpivot,swingingtheashpanoutofthestove.

Figure 39- Turn the ashdoor handle clockwise to open andcounterclockwise to close.

ST545ashdoor11/00

Open

Close

• Removetheashpan,makingsuretokeepitlevel.• To keep the cover from sliding off and to keep ash from

fallingonthefloor,donottilttheashpanforward.• If the stove is in operation, close the ash door while

disposing of the ash. You may need to lift the latch end of the door slightly to align the latch with the mating part on the stove bottom.

• Properly dispose of the ash in a metal container with a tight-fitting lid.Store thecontaineroutdoorsaway fromall combustible material.

• Returntheashpanto itsoriginalposition in thestove,andcloseandlatchtheashdoor.(Figure41)

• Do not operate the stove with the ash door open. This will result in over-firing, and could cause damage to the stove, void the warranty, or even lead to a house fire.

Empty theashpan regularly, typically every one to threedays. The frequency will vary depending on how you operate your Encore®: ash will accumulate faster at higher heat outputs.Removed ash should be placed outdoors in a metal containerwithatight-fittinglid.Keeptheclosedcontainerofashonanoncombustiblefloororontheground,wellawayfrom all combustible materials, pending final disposal. Ifthe ash is disposed of by burial in soil or otherwise locally dispersed,itshouldbekeptintheclosedcontaineruntilallcinders have thoroughly cooled.• Slidethecoverontothepan,makingsureitissecurely

closed.(Figure40)

ST566remove ashpan7/05

Figure 40-Besurethecoverissecurelyattachedbeforeremovingthe ash pan.

CAUTION!Never use your household or shop vacuum cleaner to removeashfromthestove;alwaysremoveanddisposeof the ash properly.


A stove is part of a system,which includes the chimney,theoperator,thefuel,andthehome.Theotherpartsofthesystem will affect how well the stove works. When there is agoodmatchbetweenalltheparts,thesystemworkswell.Wood stove or insert operation depends on natural (unforced)draft.Naturaldraftoccurswhen theexhaust ishotter(andthereforelighter)thantheoutdoorairatthetopofthechimney.Thebiggerthetemperaturedifference,thestrongerthedraft.Asthehotgasesrisethroughthechimneythey provide suction or ‘draw’ that pulls air into the stove for combustion.Aslow,lazyfirewiththestove’sairinletsfullyopenindicatesaweakdraft.Abriskfire,supportedonlybyairenteringthestovethroughthenormalinlets,indicatesagooddraft.Thestove’sairinletsarepassive;theyregulatehowmuchaircanenterthestove,buttheydon’tmoveairintoit.Depending on the features of your installation - steel ormasonrychimney,insideoroutsidethehouse,matchedtothestove’soutletoroversized-yoursystemmaywarmupquickly,oritmaytakeawhiletowarmupandoperatewell.Withan‘airtight’stove,onewhichrestrictstheamountofairgettingintothefirebox,thechimneymustkeepthestove’sexhaustwarmall theway to theoutdoors inorder for thestove to work well. Some chimneys do this better than others. Here’salistoffeaturesandtheireffects.Masonry ChimneyMasonry is a traditionalmaterial for chimneys, but it canperform poorly when it serves an ‘airtight’ stove. Masonry isaveryeffective‘heatsink’-itabsorbsalotofheat.Itcancool the chimney gases enough to diminish draft. The bigger thechimney,thelongerittakestowarmup.It’softenverydifficulttowarmupanoutdoormasonrychimney,especiallyanoversizedone,andkeepitwarmenoughtomaintainanadequate draft. Steel ChimneyMostfactory-madesteelchimneyshavealayerofinsulationaround the inner flue. This insulation keeps the chimneywarm.Theinsulationislessdensethanmasonry,soasteelchimney warms up more quickly than a masonry chimney. Steeldoesn’thavethegoodlooksofmasonry,butitperformsmuch better. Indoor/Outdoor LocationBecausethechimneymustkeepthesmokewarm,it’sbesttolocate it inside the house. This uses the house as insulation fortheflueandallowssomeheatreleaseintothehome.Anindoorchimneywon’tloseitsheattotheoutdoors,soittakesless heat from the stove to heat it up and keep it warm.

Chimney HeightThecommonwisdomtellsusthatatallerfluedrawsbetterthanashortone.Thisisn’tnecessarilyso.Ifachimneyistallenoughtomeetthesafetyrequirementsofthe2/3/10footrule,thenaddingmoreheightisn’ttherightanswertoadraftproblem.Infactitcouldmaketheproblemworsebyaddingmoremasstothechimneysystem,whichmustbewarmedup,adistancefromtheheatsource(thestove).Don’tmakeachimneytallerunlessyoumustinordertomeetthesafetyrules,or unless there’s some nearby feature causing a downdraft. Even then, there are downdraft-preventing chimney capsavailable,whichareprobablythesmarterchoice.Flue Sizing The insidesizeofachimney foran ‘airtight’stoveshouldmatchthesizeofthestove’sflueoutlet.Whenachimneyservesanairtightstove,moreisnotbetter;infact,itcanbeadisadvantage.Hotgasesloseheatfasterastheytravelslowerthroughachimney;ifweventastovewithasix-inchfluecollar(28squareincharea)intoa10x10"flue,thegasesslowtoone third their original speed. This allows the gases to cool morerapids,whichweakensdraftstrength.Ifanoversizedflueisalsooutsidethehouse,theheatitabsorbsgetstransferredtotheoutdoorairandtheflueusuallystayscool.It iscommonforamasonryflue,especiallyoneservingafireplace,tobeoversizedforthestove.Itcantakequiteawhiletowarmupsuchaflue,andtheresultscanbedisappointing.Thebestsolutiontoanoversizedflueisaninsulatedsteelchimneyliner,thesamediameterasthestoveorinsertsflueoutlet;thelinerkeepstheexhaustwarm,andtheresultisastrongerdraft.Annon-insulatedlinerisasecondchoice-thelinerkeepstheexhaustrestrictedtoitsoriginalsize,butthehot gases still must warm up the air around the liner. This makesthewarm-upprocesstakelonger.Pipe & Chimney LayoutEveryturntheexhaustmusttakeasittravelstothechimneytop will slow it down. The ideal pipe and chimney layout is to vent vertically into a completely straight and vertical chimney. Ifyouarestartingfromscratch,usethislayoutifpossible.Ifthestovepipemustelbowtoenterachimney,locatethethimble about midway between the stove top and the ceiling. This achieves several goals: it allows the gases to speed up beforetheymustturn,itleavessomepipeintheroomforheattransfer,anditgivesyoulong-termflexibilityforinstallinga different stove without relocating the thimble. Thereshouldbenomorethaneightfeetofsingle-wallstovepipebetweenthestoveandachimney;longerrunscancooltheexhaustenoughtocausedraftandcreosoteproblems.Withprefabricatedchimney,bringitdowntosixtoeightfeetfromthestove.Withamasonrychimney,arrangethepipeso that it turns into the chimney within eight feet of the stove.

Draft Management


Back-puffingBack-puffingresultswhenthefireproducesvolatilegasesfasterthanthechimneydraftpullsthemoutofthefirebox.Thegasesbackupinthefireboxuntiltheyareconcentratedenoughandhotenoughtoignite.Ifyourstoveback-puffs,the stove needs to cool down. You should open the damper toletthesmokerisetothefluemorequickly,allowmoreairintothefirebox,avoidbigloadsoffirewoodandcheckthatthe wood moisture is not too low. Draft TestingAneasywaytotestyourchimneydraftistoclosethestove’sdamper,waitafewminutestolettheairflowstabilize,thenseewhetheryoucanvarythestrengthofthefirebyswingingtheaircontrolopenandclosed.Resultsarenotalwaysinstant;you may need to wait a few minutes for a change in the aircontrolsettingtohaveaneffectonthefire.Ifthere’snochange,thenthedraftisn’tstrongenoughyettoletyouclosethedamper,andyou’llneedtoopenitforawhilelongerandmanagethefirewiththeairinletuntilthedraftstrengthens.Ifyoukeeptrackofyourburninghabitsandrelatethemtotheireffectsonthestove’soperation,you’llberewardedwithgood performance and a safe system. Negative PressureGooddraftalsodependsonasupplyofairtothestove;achimney can’t pull in more air than is available to it. Sluggish draft results when a house is tight enough to prevent the readyflowofairtothestove,orbycompetitionbetweenthestoveandotherequipmentthatsendsindoorairoutside-especiallypower-drivenequipmentlikerangehoods,clothesdryers,etc.Ifthechimneydrawswellwithallotherequipmentturnedoff(orsealed,inthecaseoffireplacesand/orotherstoves),thenyousimplyneedtobecarefulwithtimingtheuseof theotherairconsumingequipment. Ifyouneed tocrackanearbywindowordoortoenablethechimneytoflowwell,itmaybeagoodideatoinstallanoutside-airintaketobringcombustionairdirectlytothestove.Anoutsideairkitisavailable to connect the stove directly to a source of outdoor combustion air.ConclusionWood-burning is an art rather than a science. Once thestoveandchimneysystemareinplace,youcanonlyvaryyourtechnique,mostlyyourtiming,toachievegoodresults.Ifyoukeeptrackofyourburninghabitsandrelatethemtotheireffectsonthestove’soperation,you’llberewardedwithgood performance and year of reliable heating.

Single VentingEach‘airtight’stoverequiresitsownflue.Ifanairtightstoveis vented to a flue that also serves an open fireplace, ora leakierstove, it’seasier for thechimneydraft topullairin through those channels and performance of the stove suffers.Imagineavacuumcleanerwithaholeinthehosetounderstandtheeffecthere.Insomecasestheotherappliancecanevencauseanegativedraftthroughthestove,andresultin a dangerous draft reversal.CreosoteCreosote is a by-product of slow wood-burning. It’s anorganictarthatcancondenseintheflueifitispresentintheexhaust,slow-moving,andcoolstolessthan290°F(130°C).Condensedcreosoteisvolatile,andcangeneratechimneyfiresifitgetshotenough.Allthefeaturesthataffectchimneydraftalsoaffectcreosotecondensation-sousewhatevercombination of installation features and operational steps that willencouragegooddraftandminimizecreosoteproduction.Becauselettingtheexhaustcooloffandslowdownisoneofthekeystocreosoteaccumulation,itmakessensetolineachimneytomatchthestove’soutletsize,forsafetyreasonsaswellasperformance.Canadianlawrequiresamatchinglinertoserveanystoveorinsertventedthroughafireplacechimney;intheUS,theNationalFireProtectionAssociation(NFPA)recommendsachimneylineriftheflueismorethanthree timesbigger (insquarearea) than theoutleton thestoveorinsert.SomelocalitiesenforcetheNFPAguidelinesas part of their building codes.FuelEven the best stove installation will not perform well with poorfuel.Thebestfuelishardwoodthathasair-dried12-18months.Softwoodburns,butnotaslongashardwood.‘Green’woodcontainsalotofmoisture;itwillburn,butsomeoftheheatpotentialisusedtoboiltheextramoisturefromthe wood. This reduces the amount of heat that reaches your home and can contribute to a creosote problem. There are moisturemetersavailableforfirewood;youcanalsojudgeyourwoodbyitsappearanceandweight.Ifyougetitgreen,liftapieceandgetasenseofitsweight;itcanloseathirdormoreofitsweightasitdries.Alsolookattheendsofalog;as it dries it shrinks and often cracks. The more weathered andcrackedapieceis,thedrieritis.Dry wood burns readily with a good chimney draft. But with modernstoves,woodcanbetoodryandtoovolatile.Smokeand combustible gases can ‘gas out’ from the wood quickly anddenselyenoughtooverloadthecombustionsystem.Ifyouheararumblingorroaringnoise(likeapropanetorch)fromthestove,thatisasignthatthestoveisover-firing.


Keep Your Stove Looking New and Working Its BestLetthefireinthestovegooutandallowthestovetocoolcompletely before beginning any maintenance procedure.Care of the Cast Iron SurfaceAnoccasionaldustingwithadryragwillkeepthepaintedcast iron of your Encore® looking new. Thestove’spaintcanbetouchedupasneeded.First,masktheareas,suchasenameledparts,glass,orhandles,aroundthespot tobepainted.Clean thespotwithawirebrush.Removethegriddleandsetitaside.Itisnormalforthegriddletodarkenafteruse.Youcancleanitwithafine-bristlewirebrush,orsteelwool.Then, touch up the stovewith Vermont Castings’ hightemperaturestovepaint.Applythepaintsparingly;twolightcoats of paint are better than a single heavy one.Care of the Porcelain Enamel SurfaceUse a dry or slightly damp rag or soft brush to remove spills orstains.Fordifficultjobsthatrequireacleaningagent,useonly a kitchen appliance cleaner or polish recommended for use on enamel surfaces.Ifporcelainenamelbecomeschippedorscratchedduringuse,apply“enamelepoxy”tothedamagedareaandallowtodry.Oncetheepoxyhasdried,sandtheareatoblendwithsurroundingareaandapplyappropriatecolortouch-uppaint.Allowtodrycompletelybeforeoperatingstove.Cleaning the GlassMost of the carbon deposits on the glass will burn off during hotfires.However, the ash residue that accumulateson the glasssurface should be removed regularly to prevent etching. To cleantheglass,followthisprocedure:• Be sure the glass is completely cool.• Cleantheglasswithwateroracleanermadeespeciallyfor

this purpose. Do not use abrasive cleaners. Use cleaning agents sparingly and be sure to keep them off the outer surfaces of the stove.

• Rinse the glass thoroughly.• Dry the glass completely.Adjusting Theromstat ControlThethermostatcontrolshouldbeadjustedproperlyfromthefactory,ifaminoradjustmentneedstotakeplace,youwillneedaflatheadscrewdriverandapairofpliers.Locatetheprimarycoveronthelowerbackportionofthestove(Figure42).Withpliers,bendthetabstothestraightpositionanduse the flat head screwdriver to pry the bracket out farenoughtoremovethecover.Oncethecoverisoff,loosenthethumb screw with the primary handle in the closed position. Adjustthesteelcablebyeitherpullingslackoutofthecableor allowing more in. Tighten the thumb screw and test the primary control by turning the handle to the open position andcheckingthepositionoftheflap.Thereshouldnotbeanydelaybetweenthehandleandtheflap.Alwaysensuretheflapwillclosecompletely.

Maintenance

Figure 43-Explodedviewoftheglassassemblyfortherightdoor.

ST854glass xview7/05

Retainer Clips(4)

Glass Panel

Gasket

Right Door

Replace Broken Glass ImmediatelyDo not operate your stove if the glass in the doors is damaged.Ifyouneedtoreplacetheglass,useonlythehightemperature5mmceramicglasssuppliedbyVermontCastings.Donotuse substitutes. Removing the Glass1. Remove the right and left door assemblies by raising the

dooruntilthelowerhingepinclearsitshole;then,anglethe door bottom slightly outward and pull down to release the upper hinge pin. Place the doors face down on a padded work surface. Be especially careful with enameled doors.

2. Remove the screws that hold the glass retainer clips in place,andremovetheclips.

3.Carefullyliftthebrokenglasspanelfromthedoor.Installing the GlassCheckthegasketaroundthewindow;itshouldbesoftandresilient so that the glass will seal properly against the door. Replace the gasket if it has hardened or if it is compressed.1. Centertheglassonthegasket.2. Secure the glass on both doors with the retainer clips.

Tightenallscrews.(Figure43)3. Replace the doors on the stove. 4.Openandclosethedoorstocheckthattheyfitandwork

properly.Adjustasnecessary.

Figure 42-PrimarycoverandBracket.

Bracket

PrimaryCover

TabTab


PressureAdjustingScrew

AllenWrenchLock Nut

Damper

Figure 44-AdjustthedamperwiththeAllenwrench.

Figure 45-Rotatepawland/orremoveflatwashertoadjustlatch.

ST1154door pawl

Roller

Lock Nut

Set Screw

Shoulder Screw

HandleStubFlat Washer

Replace the Stove Gaskets as NeededYour Encore®usesfiberglassropegasketstomakeatightsealbetweensomeparts.Withuse,particularlyonmovingparts,gasketscanbecomebrittleandcompressedandcanbegin to lose their effectiveness. These will need periodic replacement.Thesizesofreplaceablegasketarelistedbelow,alongwiththeir applications.Gasket Diameter......And the Parts it Seals5/16"Thegriddletothestovetop(wirereinforcedgasket)5/16"Thedampertotheupperfireback3/8" The frontdoors to thestove front;and thedoors to

each other.3/8" Theashdoortothefrontofthebottompanel3/16"TheouterglasspanestothedoorIfyouneedtochangeagasket,firstobtainanappropriatereplacementfromyourVermontCastings’AuthorizedDealer.Waituntilthefireisoutandthestovehascooled.Besuretofollow the standard safety procedure for working with dusty materials: wear safety goggles and a dust mask. Theprocedureforreplacinggasketsisthesame,regardlessof the gasket location. Follow these steps:1. Removetheexistinggasketbygraspinganendandpulling

firmly.(Figure46)

Tighten the Damper Handle as NeededAhandleontheleftsideofthestovecontrolsthedamper.The handle attaches to the damper rod with a set screw. Periodically check the set screw and tighten as necessary.How to Adjust the Door LatchesThe front door of the stove should close securely to prevent accidental opening and should close tightly to prevent air fromleakingintothefirechamber.Thedoorhandlewillbepositioned vertically when the door is closed.Over a period of time, the gasket around the doorwillcompressandthelatchmayneedadjustment.Toadjustthehandle,followthisprocedure:1. Remove and retain the lock nutwith a 9/16"wrench.

(Figure45)2. Loosenthesetscrewwitha1/8"Allenwrench.3. Rotatethepawl180°.Replacethelocknut.Tightenthe

set screw.4. Additionaladjustmentcanbemadebyremovingtheflat

washer.Oranycombinationofwasher removaland/orpawl rotation.

Testthedoorseal.Closethedooronadollarbillandattemptto pull it free. If the bill is freedwith little resistance, thegasket isn’t snug enough at that spot. Continue tomakesmalladjustmentsuntilthesettingisright.Ifadditionaladjustingofthelatchdoesnotenablethedoortosealsufficientlyinonearea,tryadjustingthegasketinthatarea. Pack more cement or a smaller diameter gasket into the channel beneath the gasket so the main gasket is raised and makescontactwiththedoorframe.Ifthisproceduredoesn’tsolvetheproblem,replacethegasket.Instructionsforgasketreplacement are given later in this section.

Adjust the Damper as NeededThe tension on the Encore®’s damper is adjustable tocompensate for compression of the gasket that seals the dampertotheupperfireback.Toadjustthedamper:1. Remove the griddle. Loosen the lock nut at the center of

thedamper.(Figure44)2. Turn the pressure screw approximately one half turn

clockwisewithanAllenwrenchprovidedwithyourstove.3. Tighten the lock nut. Prevent the pressure screw from

turningasyoutightenthenut.Re-testthedamper.


ST559Removegasket11/30/00 djt

Figure 46-Removegasketthencleanchannelwithwirebrush.

ST559Removegasket11/30/00 djt

CementStove Gasket

Figure 47-Layabeadofgasketsiliconeorcementthenpressgasket in place.

All Gasketed Construction GasketsOthergasketsformsealsbetweenallothernon-movingparts,butthesearenotsubjecttothesamewearanddeteriorationasgasketsonmovingparts.Itisunlikelythatyouwilleverneed to replace these gaskets unless the involved parts are disassembledandthenputbacktogether.Ifthisisthecase,thejobshouldbedoneonlybyaqualifiedservicetechnician.5/16"diametergasketsealsthefollowingparts:• Thelowerfirebacktothebackpanel• Theleftandrightairplates(innersides)• Allconnectionsbetweenthestoveplates.

The Chimney SystemCreosote Your Encore® is designed to reduce creosote build-upsignificantly. However, regular chimney inspection andmaintenancemuststillbeperformed.Forsafety,goodstoveperformance, and to protect your chimney and chimneyconnector,inspectyourchimneyandchimneyconnectoronaregularschedule.Cleanthesystemifnecessary.Failureto keep the chimney and connector system clean can result inaseriouschimneyfire.Whenwoodisburnedslowly,itproducestar,organicvaporsand moisture that combine to form creosote. The creosote vaporscondenseintherelativelycoolchimneyflueofaslow-burningfire.Asaresult,creosoteresidueaccumulatesonthefluelining.Whenignited,thiscreosotemakesanextremelyhotfirewithinthefluesystemthatcandamagethechimneyandoverheatadjacentcombustiblematerial.Ifasignificantlayerofcreosotehasaccumulated—1/8"(3mm)ormore—itshouldberemovedtoreducetheriskofachimneyfire.Youcanneverbetoosafe.Contactyourlocalfireauthorityforinformationonwhattodointheeventofachimneyfire,and have a clearly understood plan on how to handle one.Ifyoudoexperienceachimneyfire,actpromptlyto:

• Closethedamperandaircontrollever.• Get everyone out of the house.• CalltheFireDepartment.

Inspect the system every twoweeks during the heatingseason as part of a regular maintenance schedule. To inspect thechimney, let thestovecool completely.Then,usingamirrorandastronglight,sightupthroughthefluecollarintothechimneyflue.Ifyoucannotinspectthefluesysteminthisfashion, thestovemustbedisconnectedtoprovidebetterviewing access.

6.Startingatoneend,press thegasket into thechannel.(Figure47)Ensureagoodjointwherethegasketmeetsbeforetrimminganyexcess.Donotoverlapthegasketends or leave ends with ragged edges.

7.Pressthegasketedpartfirmlyagainstitsnormalmatingsurfacetoseat thegasketevenly in itschannel.Closeandlatchthedoortodothis,ortapotherpartswiththerubbermallet(orhammer/blockofwood).

8.Cleananyexcesscementfromaroundthechannel,thenlet the cement that holds the new gasket dry thoroughly.

9.Thestove’sdoorsmayneedadjustmentafteryouhaveregasketed them. Initially, itmay require loosening thelatchtoaccommodatethenewgasket;afterafewweeks,it may need tightening to compensate for compression of thenewgasket.Thedirectionsforadjustingthelatchesare on Page 30.

2. Use a wire brush or the tip of a screwdriver to clean the channel of any remaining cement or bits of gasket. Remove stubborn deposits of cement with a cold chisel ifnecessary.(Figure46)

3.Determine the correct length of the appropriate-sizedgasketbylayingitoutinthechannel.Allowanextra1-2"(25-50mm),andmarkthespottobecut.

4.Removethegasketfromthechannel,placeitonawoodcuttingsurface,andcutitatthemarkedspotwithautilityknife.

Twist the ends slightly to keep the gasket from unraveling.5.Layanunbroken1/8"(3mm)beadofsiliconeorcement

inthenewly-cleanedchannel.(Figure47)


The Chimney ConnectorTwo Weeks • Inspect the chimney connector and chimney.Clean if

necessary.Two Months:• Inspectthechimneyandchimneyconnector.Payparticular

attentiontothehorizontalrunsofchimneyconnector,andtheelbows.Cleanthesystemifnecessary.

Annual Spring Cleaning:• Disassemble the chimney connector and take it outdoors

for inspection and cleaning. Replace weak sections of connector.

• Inspectthechimneyforsignsofdeterioration.Repairstoa masonry chimney should be made by a professional mason. Replace damaged sections of prefabricated chimney. Your local Vermont Castings dealer or achimney sweep can help determine when replacement is necessary.

• Thoroughly clean the chimney.

Cleanthechimneyusingabrushthesamesizeandshapeastheflueliner.Flexiblefiberglassrodsareusedtorunthebrushupanddown the liner, causinganydeposits to fallto the bottom of the chimney where they can be removed throughtheclean-outdoor.Cleanthechimneyconnectorbydisconnectingthesections,takingthemoutside,andremovinganydepositswithastiffwirebrush.Reinstalltheconnectorsectionsaftercleaning,beingsuretosecurethejointsbetweenindividualsectionswith sheet metal screws.Ifyoucannotinspectorcleanthechimneyyourself,contactyourlocalVermontCastingsdealeroraprofessionalchimneysweep.

Maintenance Schedule-The StoveDaily:• Clear any ash build-up fromaround the air holes and

combustionflowpathinthelowerfireback.• Ashesshouldberemovedbeforetheyreachthetopof

theashpan.Checkaccumulationatleastonceaday.• Keeptheareaaroundthestoveclearofanycombustible

materialssuchaswood,furnitureorclothing.Two Months: • Check door handle to be sure it is working properly.

Gasketing becomes compressed after a period of time. Adjusthandletightnessifnecessary.

• Check leg bolts and heat shield screws; tighten ifnecessary.

Annual Spring Cleaning:• Checkgasketingforwear,andreplaceifnecessary.• Remove ashes from the ash pan and replace with a

moistureabsorbingmaterial(suchaskittylitter)tokeepthe interior of the stove dry.

• Cleanthedustfromtheinnersidesofbottom,rearorpipeheatshieldsifyourstoveisequippedwiththem.Cleansurfacesarebetterheatreflectorsthandirtysurfaces.

• Touch up the black paint.• Inspectforandremoveashbuild-upbehindthecombustion

package.Thisshouldbedoneinconjunctionwithannualcleaningofthechimneyconnector.Inspectthepassagebehindthecombustionpackage(amirrorwillbehelpful)and vacuumaway ash using a flexible vacuumhoseinsertedinthepassage.(Figure48)

Cleanoutanyash build up

Remove these components

Figure 48 - Inspectandcleanoutashaccumulationbehind thecombustion system.


The Catalytic ElementThiswoodheatercontainsacatalyticcombustor,whichneedsperiodicinspectionandreplacementforproperoperation.Inthe United States it is against the law to operate this wood heater in a manner inconsistent with the operating instructions in this manual. Undernormaloperatingconditions,thecatalyticcombustorshouldremainactivefortwotosixyears(dependingontheamountofwoodburned).However,itisimportanttomonitorthe combustor periodically to ensure that it is functioning properly,aswellastodeterminewhenitneedstobereplaced.Anon-functioningcombustorwillresultinalossofheatingefficiency,andanincreaseincreosoteandemissions.Inspection and CleaningInspectthecombustorforflyashaccumulationandphysicaldamagetwotothreetimesperyear.Cleanthecombustoras needed.The refractory package that houses the catalytic combustor shouldbe inspected for a buildupof fly ashand cleanedif necessary. Thismay be donewhen you examine thecombustor.When to Suspect a Combustor ProblemThe best way to evaluate the performance of your Encore®’s combustor is to observe the amount of smoke leaving the chimney—bothwhenthecombustorhas“lighted-off”andwhen it has not. Follow these steps: • Withafiregoingandthecombustorproperlyactivated,with

the damper closed to route smoke through it as described in the Operation Section, go outside and observe thesmoke leaving the chimney.

• Then,openthestovedamperandonceagaincheckthesmoke leaving the chimney.

Youshould seesignificantlymore smokewhen thestovedamper is open and exhaust does not pass through thecombustor.However,becarefulnottoconfusesmokewithsteamfromwetwood.Steamdissipatesintheairquickly;smoke does not. Ifthistestindicatesaproblem,considerotherpossiblefactorsaswell,suchastheweatherorachangeinthequalityofyourfuel.Inwarmweather,draftisweakerthanitisincolderwinterweather,andfirescanburnsluggishly.Small,hotfiresare a good solution under these conditions.Burning“green”(insufficientlyseasoned)woodwillresultinpoorer performance than burning properly seasoned fuel. Reloading with green wood can also thermal shock the catalyst,resultingincracking,ortheeventualfallout,oftheceramic honeycomb substrate. You may have to run your stovehotter(moreair)toachieveacceptableperformanceusing green or wet wood.Also,consideranychangesinyouroperatingroutine.Onceyouhaveruledoutanyotherpossiblecauses foradeclineinperformance,inspectandcleanthecombustorifnecessary. Be sure to protect any surface you use for setting the stove parts aside.

ST1180catalyst access

Catalyst

AccessDoorInnerFireback

Figure 49-Inspectthecatalyticcombustor.

Toassurealonglifeforthecombustor,itisrecommendedto service the combustor on a regular basis based on the amountofuse.Thisproceduretakesaboutfive(5)minutesand requires no tools except for a vacuum if cleaning isnecessary. Cleaning the Combustor1. Check the combustors honeycomb-like element for a

buildupofflyash.Ifanyisevident,takethecombustoroutside and clean it by blowing air gently through it. Do notpushanything through thehoneycomb;donotusecompressed air to clear the passages. Such abrasion can scrapethethincoatingofplatinum(thecatalyst)offtheceramicbase,shorteningthecatalyst’slifeandreducingits effectiveness.

2.Inspecttheelementfordamageordegradation.Althoughsmall hairline crackswill not affect performance, theelement should be essentially intact. If the element isbroken inpiecesorhassectionsmissing, it shouldbereplaced.Call your localVermontCastingsAuthorizedDealer for a replacement element.

3.Iftheelementisingoodconditionandclean,re-installitinthestoveandreplacetherefractoryinnerfirebackandaccess door.

Inspecting the CombustorRemoveaccessdoorandinnerfireback.Removethecatalyticcombustorbyliftingandslidingittowardsyou.(Figure49)


Operate the stove in your usual manner for two weeks,inspecting the chimney and the chimney connector frequently during this period. If creosote does not build up as fast, it is likely that theperformance changewas caused by fly ash deposits onthecatalyticelement.However,continuetheinspectionsofthe chimney system for a few weeks to ensure that proper performance continues.If you continue to finda significant creosotebuildupor ifyou continue to see excessive smoke from the chimney,thecatalyticelementwillneedtobereplaced.ContactyournearestVermontCastings’AuthorizedDealerforinformationabout a replacement element.NOTE: Use only the replacement catalyst supplied by a VermontCastingsdealer.


Service Parts

Beginning Manufacturing Date: N/A Ending Manufacturing Date: Active

Encore Flexburn

Part number list on following page. 05/18

0002040 (Classic Black) 0002043 (Ebony) (End Manufacturing Date: 2013)0002041 (Biscuit) 0002045 (Midnight Blue) (End Manufacturing Date: Dec 2014)0002042 (Majolica Brown) 0002041T (Biscuit w/Transition Doors (End Manufacturing Date: March 2017)0002044 (Bordeaux) 0002042T (Majolica Brown w/Transition Doors)(End Manufacturing Date:March 2017)0002046 (Twilight) 0002044T (Bordeaux w/Transition Doors) (End Manufacturing Date: March 2017)0002040T (Classic Black w/TransitionDoors) 0002046T (Twilight w/Transition Doors) (End Manufacturing Date: March 2017)

56

783

21

17 20

19

16

18

58

12

2263

57

32

38

3136

39

45

87 27 2669

70

66

65a

7040

49

37

79

4759

3029

2628 71

5

68

67

62

61b

77

55

82

54

5253

51

49

16

50

27

2

77

10

11

73

48

80

80

14

24

75

7485

72

23

23 8

25

15

35

41

44

42

6

7

46

43

84

64

64

13

9

33

76

83

81

86

34

60

1

4

89

90

91

92

93

61a

65b

88

Service Parts List


Service Parts


Encore Flexburn

IMPORTANT: THIS IS DATED INFORMATION. Parts must be ordered from a dealer or distributor. Hearth and Home Technologies does not sell directly to consumers. Provide model number and serial number when requesting service parts from your dealer or distributor.

Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER1 Brick Support Bracket 300052792 Griddle Gasket, 10’ 1-00-1203668 Y3 Back 30005289A4 Refractory Right End 300054975 Refractory Left End 300054986 Refractory Support 300052337 Gasket, Refractory Support 300052378 Back Insulation Board 300052699 Outer Back 30005261

10 Left Griddle Quadrant 3000239911 Right Griddle Quadrant 30002401A12 Griddle 30002386A13 HS Flue Collar 3000526614 Bracket Upper Side 3000526715 Catalyst, Ceramic 3000662316 Damper Gasket, 15’ 1-00-1203588 Y

17 Damper RampPre 0081347991 1301811A YPost 0081347991 2-00-1301811S Y

18 Damper Housing 30005293A19 Damper 3000646720 Damper Tab Pkg of 10 1601488-1021 Damper Rod 160085122 Griddle Handle Assembly 30002775 Y23 Gasket, Back Refractory, 10’ 1-00-3000527024 Rheostat Bracket 3000286325 Refractory, Engine - E/D 3000520226 Damper Handle Screw (Qty 2 req) Pkg of 10 1201310-1027 Damper Handle Qty 2 req 1600664 Y28 Damper Handle w/Screw 30002720A Y

29 Left Side

Classic Black 30002388Biscuit 30003052Bordeaux 30006679Ebony 30003072Majolica Brown 30004876Twilight 30007027

30 Left Air Manifold 3000240831 Right Air Manifold 30005290

Additional service part numbers appear on following page.


Service Parts


Encore Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER

32 Right Side


33 Thermostat Handle Base 30002716 Y34 Washer Damper Rod Pkg of 10 30007257-1035 Fireback Plate, S/S 3000521736 Inner Bottom 30005291

37 Ashdoor Hinge UpperPre 0081347991 30002403Post 0081347991 1-00-30002403

38 Door Handle Bracket 3000290939 Bottom Outer 30005292A

40 Ashlip

Classic Black 30002402ABiscuit 30003051Bordeaux 30006678Ebony 30003071Majolica Brown 30004862Twilight 30007026

41 Gasket, Fireback 3000520942 Refractory, Fireback 3000530243 Retainer, Fireback Refractory 3000524844 Refractory, Inner Cover 30005205 Y45 Andiron 30002397A Y46 Refractory, Access Cover 3000725147 Leg Leveler Pkg of 10 1201745-1048 Ashdoor Handle Shaft 160062249 Pawl Assembly Qty 2 req 30005157 Y50 Ashdoor 30002392A51 Ashdoor Handle (Wood) 1600663 Y

52Ashdoor Hinge Rod Pre 0081347991 30007285Hinge Hardware Post 0081347991 1-00-2473

53 Cotter Pin, Ashdoor Pre 0081347991 30001749

54 Ashdoor Hinge LowerPre 0081347991 30002404APost 0081347991 1-00-30002404

55 Ashpan Bracket 1601039Additional service part numbers appear on following page.


Service Parts


Encore Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER56 Lower Side Bracket 30005268

57 Thermostat Handle 1600660 Y58 Front Manifold 30002407

59 Front

Classic Black 30002393A

Biscuit 30003054

Bordeaux 30006681

Ebony 30003074

Majolica Brown 30004878

Twilight 30007029

60 Flue Collar Gasket 15 Ft 1-00-30002422

61A

Left Door (Shell Enamel Parts)


Biscuit 30003958

Bordeaux 30006685

Ebony 30003962


Twilight 30007033

Left Door Sub Assembly (Shell Enamel Parts) (Does not contain glass or glass gasket)

Classic Black 30003974

Biscuit 30003984

Bordeaux 30006687

Ebony 30003988


Twilight 30007072

61B

Left Door (Transition Door Enamel)


Biscuit 30007083

Bordeaux 30007087


Twilight 30007107

Left Door Sub Assembly (Transition Door Enamel)

Classic Black 30007165

Biscuit 30007167

Bordeaux 30007169


Twilight 30007173

62 Door Hinge Strip 1308634A

63 Top


Biscuit 30003055

Bordeaux 30006682

Ebony 30003075


Twilight 30007030



Service Parts


Encore Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER64 Glass Clip Qty 8 req 1601394 Y

65A

Right Door (Shell Enamel Parts)


Right Door Sub Assembly (Shell Enamel Parts) (Does not contain glass or glass gasket)


65B

Right Door (Transition Door Enamel)

Classic Black 30007080ABiscuit 30007082Bordeaux 30007086Majolica Brown 30007084Twilight 30007106

Right Door Sub Assembly (Transition Door Enamel)

Classic Black 30007166Biscuit 30007168Bordeaux 30007170Majolica Brown 30007172Twilight 30007174

66 Door Gasket, 15’ 1-00-1203588 Y67 Glass Gasket, 10’ 1-00-1186258229 Y68 Left Door Glass 3000530069 Right Door Glass 3000529970 Door Hinge Pin Qty 2 req 30002727 Y71 Spacer (for Damper Rod) Pkg of 10 1201779-1072 Primary Air Valve Assembly 30005324

Primary Air Frame 1307411Primary Air Rod 30005260

73 Front Door Handle and Shaft 30002717 Y74 Thermostat Friction Spring Pkg of 10 1201846-1075 Thermostat Cable 5005471 Y76 Thermostat Handle Bolt Pkg of 10 1201243-10



Service Parts


Encore Flexburn


Stocked at Depot

ITEM DESCRIPTION COMMENTS PART NUMBER77 Ash Pan Assembly 5005746

78

Flue Collar, 6” Round


Flue Collar, 8” Oval


79 Single Leg


80 Hex Head Jam Nut (Qty 2 req) Pkg of 10 1203290-1081 Bottom Heat Shield 3000247082 Bottom Heat Shield Right Wing 3000503083 Bottom Heat Shield Left Wing 3000503184 Grate Bottom 3000529485 Thermostat Assembly 500547086 Washer Pkg of 10 1202471-1087 Handle Base Sub 3000271488 Fallaway Handle Complete 30004175K89 Thermostat Handle Assembly 3000706790 Primary Air Cover 3000706991 Primary Air Base 3000707192 Temperature Probe 3000727493 Bracket, Temperature Probe 30007278

Tempertature Probe Assembly 30007283A


4021-645J • 08-03-171

Hearth & Home TechnologiesLIMITED LIFETIME WARRANTY

Hearth & Home Technologies, on behalf of its hearth brands (“HHT”), extends the following warranty for HHT gas, wood, pellet and electric hearth appliances that are purchased from an HHT authorized dealer.

WARRANTY COVERAGE:HHT warrants to the original owner of the HHT appliance at the site of installation, and to any transferee taking ownership of the appliance at the site of installation within two years following the date of original purchase, that the HHT appliance will be free from defects in materials and workmanship at the time of manufacture. After installation, if covered components manufactured by HHT are found to be defective in materials or workmanship during the applicable warranty period, HHT will, at its option, repair or replace the covered components. HHT, at its own discretion, may fully discharge all of its obligations under such warranties by replacing the product itself or refunding the verified purchase price of the product itself. The maximum amount recoverable under this warranty is limited to the purchase price of the product. This warranty is subject to conditions, exclusions and limitations as described below.

WARRANTY PERIOD:Warranty coverage for consumers begins at the date of installation. In the case of new home construction, warranty coverage begins on the date of first occupancy of the dwelling or six months after the sale of the product by an independent, authorized HHT dealer/distributor, whichever occurs earlier. However, the warranty shall commence no later than 24 months following the date of product shipment from HHT, regardless of the installation or occupancy date. The warranty period for parts and labor for covered components is produced in the following table.The term “Limited Lifetime” in the table below is defined as: 20 years from the beginning date of warranty coverage for gas appliances, and 10 years from the beginning date of warranty coverage for wood and pellet appliances. These time periods reflect the minimum expected useful lives of the designated components under normal operating conditions.

Parts Labor Gas Pellet Wood Electric Venting Components Covered

X X Igniters, auger motors, electronic components, and glass

X X X Factory-installed blowers

X Molded refractory panels

X Ignition Modules

X Firepots, burnpots, mechanical feeders/auger assemblies

X Vent Free burners, Vent Free ceramic fiber logs, Aluminized Burners

X X Castings and Baffles

6 years 3 years X Catalyst - limitations listed

7 years 3 years X X Manifold tubes, HHT chimney and termination

10 years 1 year X Burners, logs and refractory

Limited Lifetime 3 years X X X

Firebox and heat exchanger, Grate and Stainless Steel Burners, FlexBurn® System (engine, inner

cover,access cover and fireback)

X X X X X All replacement parts beyond warranty period

Warranty Period HHT Manufactured Appliances and Venting

All parts and material except as covered by Conditions, Exclusions, and Limitations listedX X X

2 years

3 years

1 Year

90 Days

5 years 1 year

xX

4021-645J • 08-03-172

WARRANTY CONDITIONS:• This warranty only covers HHT appliances that are purchased through an HHT authorized dealer or distributor. A list of HHT

authorized dealers is available on the HHT branded websites.

• This warranty is only valid while the HHT appliance remains at the site of original installation.

• This warranty is only valid in the country in which the HHT authorized dealer or distributor that sold the appliance resides.

• Contact your installing dealer for warranty service. If the installing dealer or distributor is unable to provide necessary parts, contact the nearest HHT authorized dealer or supplier. Additional service fees may apply if you are seeking warranty service from a dealer other than the dealer from whom you originally purchased the product.

• Check with your dealer in advance for any costs to you when arranging a warranty call. Travel and shipping charges for parts are not covered by this warranty.

• Limited Catalyst Warranty

o For wood burning products containing a catalyst, the catalyst will be warranted for a six-year period as follows: if the original catalyst or a replacement catalyst proves defective or ceases to maintain 70% of its particulate emission reduction activity (as measured by an approved testing procedure) within 36 months from the purchase date, the catalyst will be replaced for free.

o From 37 to 72 months a pro-rated credit will be allowed against a replacement catalyst and labor credit necessary to install the replacement catalyst. The proration rate is as follows:

Amount of Time Since Purchase Credit Towards Replacement Cost0 - 36 Months 100%

37 - 48 Months 30%49 - 60 Months 20%61 - 72 Months 10%

o Any replacement catalyst will be warranted under the terms of the catalyst warranty for the remaining term of the original warranty. The purchaser must provide the name, address, and telephone number of the location where the product is installed, proof of original purchase date, date of failure, and any relevant information regarding the failure of the catalyst.

WARRANTY EXCLUSIONS:This warranty does not cover the following:

• Changes in surface finishes as a result of normal use. As a heating appliance, some changes in color of interior and exterior surface finishes may occur. This is not a flaw and is not covered under warranty.

• Damage to printed, plated, or enameled surfaces caused by fingerprints, accidents, misuse, scratches, melted items, or other external sources and residues left on the plated surfaces from the use of abrasive cleaners or polishes.

• Repair or replacement of parts that are subject to normal wear and tear during the warranty period are not covered. These parts include: paint, wood and pellet gaskets, firebricks, grates, flame guides, batteries and the discoloration of glass.

• Minor expansion, contraction, or movement of certain parts causing noise. These conditions are normal and complaints related to this noise are not covered by this warranty.

• Damages resulting from: (1) failure to install, operate, or maintain the appliance in accordance with the installation instructions, operating instructions, and listing agent identification label furnished with the appliance; (2) failure to install the appliance in accordance with local building codes; (3) shipping or improper handling; (4) improper operation, abuse, misuse, continued operation with damaged, corroded or failed components, accident, or improperly/incorrectly performed repairs (5) environmental conditions, inadequate ventilation, negative pressure, or drafting caused by tightly sealed constructions, insufficient make-up air supply, or handling devices such as exhaust fans or forced air furnaces or other such causes; (6) use of fuels other than those specified in the operation instructions; (7) installation or use of components not supplied with the appliance or any other components not expressly authorized and approved by HHT; (8) modification of the appliance not expressly authorized and approved by HHT in writing; and/or (9) interruptions or fluctuations of electrical power supply to the appliance.

• Non-HHT venting components, hearth connections or other accessories used in conjunction with the appliance.

• Any part of a pre-existing fireplace system in which an insert or a decorative gas appliance is installed.

• HHT’s obligation under this warranty does not extend to the appliance’s capability to heat the desired space. Information is provided to assist the consumer and the dealer in selecting the proper appliance for the application. Consideration must be given to the appliance location and configuration, environmental conditions, insulation and air tightness of the structure.

4021-645J • 08-03-173

This warranty is void if:• The appliance has been over-fired, operated in atmospheres contaminated by chlorine, fluorine, or other damaging chemicals.

Over-firing can be identified by, but not limited to, warped plates or tubes, deformation/warping of interior cast iron structure or components, rust colored cast iron, bubbling, cracking and discoloration of steel or enamel finishes.

• The appliance is subjected to prolonged periods of dampness or condensation.

• There is any damage to the appliance or other components due to water or weather damage which is the result of, but not limited to, improper chimney or venting installation.

LIMITATIONS OF LIABILITY• The owner’s exclusive remedy and HHT’s sole obligation under this warranty, under any other warranty, express or implied, or in

contract, tort or otherwise, shall be limited to replacement, repair, or refund, as specified above. In no event will HHT be liable for any incidental or consequential damages caused by defects in the appliance. Some states do not allow exclusions or limitation of incidental or consequential damages, so these limitations may not apply to you. This warranty gives you specific rights; you may also have other rights, which vary from state to state. EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY SPECIFIED HEREIN. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF THE EXPRESSED WARRANTY SPECIFIED ABOVE.



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Installation & Operating Manual - Hearth N Homedownloads.hearthnhome.com/installManuals/30005295... · 2 Vermont astings • Encore® Fleburn nstallation ManualR3 • 0518 303000525