Installation & Operating Manual - Wood Stoves...2 Vermont Castings • Defiant® Model 1975-CAT-C Installation ManualR1 • 07/19 39975 Congratulations on your choice of ®a Vermont

1 8390-975Vermont Castings • Defiant® Model 1975-CAT-C Installation Manual_R1 • 07/19

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

Defiant® Model 1975-CAT-CWood Burning Stove

NOTICE: SAVE THESE INSTRUCTIONS

Installationandserviceofthisapplianceshouldbeperformedbyqualifiedpersonnel.Hearth&HomeTechnologiesrecommendsHHTFactoryTrainedorNFIcertifiedprofessionals.


CongratulationsonyourchoiceofaVermontCastingsDefiant®Model1975-CAT-Cstove.Withthispurchaseyouhavemadeacommitmenttomakethehearthaplaceofwarmth,beautyandcomfortinyourhome.AtVermontCastings,wesharethatjoyandappreciationforthehearth.Weassureyouthatyourcast-ironVermontCastingsstovehasbeenmadewiththeutmost care and will provide 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.Thismanual contains valuable instructionson the installationandoperationof yourVermontCastingsDefiant® Model 1975-CAT-C.Italsocontainsusefulinformationonmaintenance.Pleasereadthemanualthoroughlyandkeepitasareference.Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in property damage,bodilyinjury,orevendeath.

BARCODE LABELHFSerial No.No de série:

8390-976_R1

Date of Manufacture / Date de fabrication:2019 2020 2021 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

Manufactured by / Fabriqué par: Hearth and Home Technologies 352 Mountain House Road, Halifax PA 17032

US ENVIRONMENTAL PROTECTION AGENCYCertified to comply with 2020 US EPA particulate emissions standards at 1.3 g/hr. This wood heater contains a catalytic combustor which needs periodic inspection and replacement for proper operation. Consult the Owner’s Manual for further information. It is against Federal Regulations to operate this wood heater in a manner inconsistent with operating instructions in the Owner’s Manual.

Report #/Rapport #0135WS043S / 0135ES043ETested to / Testé à: ASTM E2515, ASTM E2780, UL 1482-2011, ULC-S627-00, CAN/CSA B415.1NOT APPROVED FOR USE IN MOBILE HOMES IN THE U.S. AND CANADA.Install and use only in accordance with manufacturer’s installation and operation instructions. Contact local building or fire officials about restrictions and installation inspection in your area. Install only with legs provided in accordance with installation instructions.WARNING: Risk of flame and smoke spillage. Do not obstruct the space beneath the heater.Fuel: Use with solid wood fuel only. Do not burn other fuels. Build a fire directly on hearth only. Do not elevate fire. Keep doors fully closed while operating.Chimney: Use a minimum 6” or 8” diameter factory built high temperature (H.T.) chimney which is listed to UL-103 (2100° F) or 8” X 8” nominal or larger approved masonry chimney with flue liner. Inspect and clean chimney frequently - under certain conditions of use, creosote buildup may occur rapidly.DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVICING ANOTHER APPLIANCEChimney Connector: Use a minimum 6” or 8” diameter 24 gauge chimney connector. Install chimney connector at least 30” from ceiling. Refer to local building codes and Vermont Castings Owner’s Guide for special precautions for passing a chimney or chimney connector through a combustible wall or ceiling.Floor Protection: The Defiant does not require R value floor protection. The minimum floor protector material is 20 gauge sheet metal. Other floor protector materials that can be used include: Type I hearth pads, ceramic tile, stone, brick, etc. Protection requirements vary somewhat between the Untied States and Canada.Optional Components: Fan Kit Part No. FK26. 115V 60Hz 1.1 FLA Replace glass only with Vermont Castings 5mm ceramic glass.Do not remove or cover this label. Catalytic Combustor Part No. 30005353CAUTION: Burning of materials other than the specified fuels may make the Catalyst in the combustor inactive. The combustor is fragile, handle carefully.Combustion air cannot be obstructed. Damper must be open before opening doors. Do not overfire. Glowing parts indicate

overfiring.The space heater must be installed with the legs provided, attached as shown in the installation instructions.

MODEL / MODÈLE: “Defiant® Model 1975-CAT-C”LISTED SOLID FUEL ROOM HEATER BURNING FIREPLACE STOVE

HOMOLOGUE POELE A COMBUSTIBLE SOLIDES

MINIMUM CLEARANCES TO COMBUSTIBLE CONSTRUCTION / MINIMUM DE DEGAGEMENT JUSQU’A LA CONSTRUCTION COMBUSTIBLE

Installez et utilisez uniquement conformément aux instructions d’installation et d’utilisation du fabricant. Contactez les responsables locaux de la construction ou les services d’incendie pour connaître les restrictions et l’inspection de l’installation dans votre région. Installez uniquement avec les pieds fournis conformément aux instructions d’installation.Avertissement: Risque de flammes et de fumée. Ne pas obstruer l’espace sous le radiateur.Combustible: Utilisez uniquement du combustible à bois solide. Ne brûlez pas d’autres combustibles. Construire un feu directement sur le foyer seulement. Ne pas élever le feu. Gardez les portes complètement fermées pendant le fonctionnement.Cheminée: Utilisez une cheminée haute température (H.T.) construite en usine et d’un diamètre minimum de 6 ”ou 8”, qui est homologuée UL-103 (2100 ° F) ou une cheminée en maçonnerie nominale ou supérieure approuvée de 8 ”X 8” avec conduit de cheminée. Inspectez et nettoyez fréquemment la cheminée - dans certaines conditions d’utilisation, une accumulation de créosote peut se produire rapidement.Ne connectez pas cet appareil à un conduit de cheminée desservant un autre appareilRaccord de cheminée: Utilisez un raccord de cheminée de calibre 24 minimum de 6 ”ou 8” de diamètre. Installez le raccord de cheminée à au moins 30 po du plafond. Reportez-vous aux codes du bâtiment locaux et au Guide du propriétaire de Vermont Castings pour connaître les précautions particulières à prendre pour faire passer une cheminée ou un connecteur de cheminée à travers un mur ou un plafond inflammable.Protection de sol: Defiant ne nécessite pas de protection de plancher de valeur R. Le matériau de protection de plancher minimum est une tôle de calibre 20. Parmi les autres matériaux de protection de sol pouvant être utilisés, citons: les coussinets de foyer de type I, les carreaux de céramique, la pierre, la brique, etc.Composants facultatifs: kit de ventilateurs (réf. FK26). 115V 60Hz 1.1 FLARemplacez le verre uniquement par du verre en céramique de 5 mm Vermont Castings.Ne pas enlever ni recouvrir cette étiquette. Système de combustion catalytique N ° de pièce 30005353Attention: La combustion de matériaux autres que les carburants spécifiés peut rendre le catalyseur dans la chambre de combustion inactif. La chambre de combustion est fragile, manipulez-la avec précaution.

CAUTION: HOT WHILE IN OPERATION- DO NOT TOUCH- KEEP CHILDRENAND CLOTHING AWAY- CONTACT MAY CAUSE SKIN BURNS- SEE NAMEPLATE AND INSTRUCTIONS. KEEP FURNISHINGS AND OTHER COMBUSTIBLE MATERIALS A CONSIDERABLE DISTANCE AWAY FROM THE APPLIANCE

ATTENTION: CHAUD LORS DU FONCTIONNEMENT- NE TOUCHEZ PAS L’APPAREIL-GARDEZ LES ENFANTS ET LES VÊTEMENTS ÉLOIGNÉS- TOUT CONTACT PEUT ENTRAÎNER DES BRÛLURES DE LA PEAU. RÉFÉREZ-VOUS À LA PLAQUE SIGNALÉTIQUE ET AU MODE D’EMPLOI. GARDEZ LE MOBILIER ET LES AUTRES MATÉRIAUX COMBUSTIBLES BIEN À L’ÉCART DE L’APPAREIL.

*Less than 3/4” (19mm) protrusion. For additional types of installations and clearabces consult your Owner’s Manual. Por autres modes d’installation et degagement supplementaires, consultz votres manual du proprietaire.Most vertical installations require a ceiling heat shield and a flue collar heat shield to be installed. Consult your Owner’s Manual.

A = Unit to Sidewall 21”B = Unit to Backwall 15”C = Chimney Connector to Sidewall 32”D = Chimney Connector to Backwall 17”E = Unit to Adjacent Wall 5”F = Sides 6”G = Front to Glass 16”H = Rear 6”

A = Entre le mur lateral et l’appareil 533mmB = Entre le mur arriereet l’appareil 381mmC = Entre le tuyau et le mur lateral 813mmD = Entre le tuyau et le mur arriere 432mmE = Entre le mur adjacent et l’appareil 127mmF = Côtés 203mmG = Devant, par rapport au verr 457mmH = Arrière 203mm

LABEL TICKETECO: 89916 LABEL SIZE: 4.25” H x 15.75” W

PART # / REV: 8390-976 ADHESIVE:ORIGINATOR: Spidlet MATERIAL: 24 Gauge Aluminum

DATE: 05/23/19 INK: Black and Red(4) Holes = .156 x .250Corners .062Barcode label must have the serial number on it. The barcode label must be able to read Code 39 Full ASCII.

352 Mountain House RoadHalifax, PA 17032

E

EA

B

C

D

G

F

H

F

MINIMUM FLOOR PROTECTION

Made in U.S.A. of US and imported parts.Fabriqué aux États-Unis-d’Amérique par des pièces d’origine américaine et pièces importées.

Serial No.

S A M P L E

TestLab&ReportNo.

Model Name

Mfg. Date

US ENVIRONMENTAL PROTECTION AGENCYCertifiedtocomplywith2020particulateemissionstandardsusing crib woodPlease read this entire manual before you install and use your new stove. Failure to follow instructions may result in propertydamage,bodilyinjury,orevendeath.


1ProductSpecificandImportantSafetyInformationA.ApplianceCertification. . . . . . . . . . . . . . . . . . . . . . . . 4B.Californiasafetyinformation . . . . . . . . . . . . . . . . . . . 4C.BTU&EfficiencySpecifications . . . . . . . . . . . . . . . . 4D. Stove Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 InstallationA.OutsideAir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B.TypesofChimneytoUse . . . . . . . . . . . . . . . . . . . . . 6C.ChimneySize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D.ChimneyConnectorGuidelines . . . . . . . . . . . . . . . . 6E.FireplaceInstallations . . . . . . . . . . . . . . . . . . . . . . . . 9F. Floor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11G.ClearancestoCombustibles . . . . . . . . . . . . . . . . . . 14

3 AssemblyA.SettingupyourStove . . . . . . . . . . . . . . . . . . . . . . . 19B.InstallBottomHeatShield . . . . . . . . . . . . . . . . . . . . 19C.AdjustLegLevelers. . . . . . . . . . . . . . . . . . . . . . . . . 20D.ReverseFlueCollar . . . . . . . . . . . . . . . . . . . . . . . . 20E.AttachedDamperHandle . . . . . . . . . . . . . . . . . . . . 20F.InstallingCatalystTemperatureProbe . . . . . . . . . . . 20G.AttachPrimaryAirThermostatHandle . . . . . . . . . . 20H.AssembletheRemovableInsertHandle . . . . . . . . . 20I.FanKitInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . 21J.Installing/RemovingCatalyst . . . . . . . . . . . . . . . . . . 21

4 Smoke Alarm / Safety TipsA.SmokeandCODetectors . . . . . . . . . . . . . . . . . . . . 22B. Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5 OperationA.AirControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23B.DamperAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . 23C.ConditioningYourStove . . . . . . . . . . . . . . . . . . . . . 24D.WoodBurningOperation . . . . . . . . . . . . . . . . . . . . 24E.AddingFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25F.AshDisposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27G. Draft Management . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 MaintenanceA.GlassMaintenance . . . . . . . . . . . . . . . . . . . . . . . . 31B.DamperAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . 32C.GasketReplacement . . . . . . . . . . . . . . . . . . . . . . . 32D.TheChimneySystem . . . . . . . . . . . . . . . . . . . . . . . 33E.TheCatalyticElement . . . . . . . . . . . . . . . . . . . . . . . 35

7 Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TABLE OF CONTENTS

Safety Alert Key:• DANGER! Indicatesahazardoussituationwhich,ifnotavoidedwill result in death or serious injury.• WARNING!Indicatesahazardoussituationwhich,ifnotavoidedcould result in death or serious injury.• CAUTION! Indicatesahazardoussituationwhich,ifnotavoided,could result in minor or moderate injury.• NOTICE:Indicatespracticeswhichmaycausedamagetotheapplianceortoproperty.

!

=Containsupdatedinformation


Area Heated..............................1,300to2,800SquarefeetLoading .......................................................... Front and topChimney Connector: ......................................................... for6"fluecollar ...........................6" (152 mm) diameter for8"ovalfluecollar ....................8"(203mm)diameterFlue Exit Position ............................................ToporRearPrimary Air ............Manuallyset,thermostaticallymaintainedSecondary Air ...................................Fixed,self-regulatingAsh Handling System........................ RemovableashpanGlass Panels .............................High-temperatureceramicWeight ......................................................475 lbs. (215 kg.)

B. California Safety Information

MODEL: Defiant®Model1975-CAT-CLABORATORY: OMNITestLaboratories,IncREPORT NO. 0135WS043S/0135WS043E

TYPE: SolidFuelRoomHeater/WoodBurning Type

STANDARD(s): ASTME2515,ASTME2780,UL1482-2011,ULC-S627-00,CAN/CSAB415.1

ELECTRICAL RATING: 115VAC,60Hz

A.ApplianceCertification C.BTU&EfficiencySpecifications

! WARNINGThis product and the fuels used to operate this product (wood),andtheproductsofcombustionofsuchfuels,canexpose you to chemicals including carbon black,whichisknowntotheStateofCaliforniatocausecancer,andcarbonmonoxide,whichisknowtotheStateofCaliforniato cause birth defects or other reproductive harm. For more information go to: www.P65Warnings.ca.gov

Proposition 65 Warning:Fuelsusedingas,woodburningoroilfiredappliances,and theproductsofcombustionof such fuels, contain chemicals known to the StateofCalifornia to cause cancer, birth defects and otherreproductive harm.CaliforniaHealth&SafetyCodeSec.25249.6

1 ProductSpecificandImportantSafetyInformation

EPACertificationNumber:EPACertifiedEmissions: 1.3g/hr*LHVTestedEfficiency: 84.1%**HHVtestedEfficiency: 77.9%***EPA BTU Output: 12,000-24,500****Peak BTU/Hour Output: 56,000Other Important InformationVent Size: 6Inch(152mm)

8Inch(203mm)Firebox Size: 3.2 cu. ft.Max. Wood Length: 25"MaximumIdeal Wood Length: 20"(TopLoad)Fuel SeasonedCordwood

(20%moisture)*Weighted average LHV efficiency using Douglas Firdimensional lumber and data collected during EPAemissions test.**Weighted average HHV efficiency using DouglasFir dimensional lumber and data collected during EPAemissions test.***EfficienciesarebasedontestresultscalculatedusingB415; these calculated efficiencies are then used tocalculate output BTU’s.****ApeakBTUoutoftheappliancecalculatedusingthemaximumfirsthourburnratefromtheHighEPATestandtheBTUcontentofcordwood(8600)timestheefficiency.


D. Stove Dimensions

Figure 1.1

Drawing Not to Scale

32-3/8”(822mm)

28-7/8”(733mm)

31-1/2”(800mm)

5-1/8”(130mm)

19”(483mm)

1693Defiant dimensions1/02

29-7/8” (759mm)

23-5/8”(600mm)

19”(483mm)

26”(660mm)

CL

28-7/8”(733mm)

Rear Venting

44-5/8”(1133mm)

23-3/4”(603mm)


SAFETY NOTICE: IF YOUR APPLIANCE 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:• Yourstoveandchimneyconnectorwillbefarenoughfrom

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

properly to meet all requirements.• Youhaveallnecessarypermitsfromlocalauthorities.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 informationneeded.Foranyunresolvedinstallationissues,refertotheNationalFireProtectionAssociation’s publicationANSI/NFPA211Standard forChimneys,Fireplaces,Vents andSolidFuelBurningAppliances.ForCanada,theequivalentpublicationisCSACAN-B365InstallationCodeforSolidFuelBurningAppliancesandEquipment.Thesestandardsarethebasisformanynationalcodes.Theyarenationallyrecognizedandareacceptedbymostlocalauthorities.Yourlocaldealeroryourlocalbuildingofficialmayhaveacopyoftheseregulations.IMPORTANT: Failure to follow these installation instructions may result in a dangerous situation, including achimneyorhousefire.Followallinstructionsexactly,and do not allow makeshift compromises to endanger property and personal safety.

A. Outside AirAsourceofair(oxygen)isnecessaryinorderforcombustionto take place. Whatever combustion air is consumed by the firemustbereplaced.Airisreplacedviaairleakagearoundwindowsandunderdoors.Inhomesthathavetightlysealeddoorsandwindows,anoutsideairsourceisneeded.Items Needed for Installation (not supplied)

• Outside air adapter (available at your authorizedVermontCastingsdealer)

• Phillips head screw driver • Silicone sealant• 3”FlexorRigidDuct• 3”OutsideAirTerminationCapwithScreen• HoseClamps• Drills and saws necessary for cutting holes through

thewallorflooringinyourhome.1. Usinga#2Phillipsscrewdriverattachtheflexadapterto

theapplianceusing4screws,Figure2.7.2. Floor&RearInstallation:Cuta3”(76mm)holeinoutside

wallorfloortoaccommodateoutsideairpiping.Use3”(76mm)aluminummetalflexor rigidpiping todirectlyconnect outside air to appliance intake. Use the supplied termination cap with a rodent screen. Seal between the wall(orfloor)andthepipewithsiliconetopreventmoisturepenetration.

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.

B. Types of Chimney to UseYoumustconnectthisappliancetoacode-approvedmasonrychimneywithaflueliner,toarelinedmasonrychimneythatmeetslocalcodes,ortoaprefabricatedmetalchimneythatcomplieswiththerequirementsforTypeHTchimneysintheStandardforChimneys,Factory-Built,ResidentialTypeandBuildingHeatingAppliance,UL103.Figure2illustratesthetwo types. The chimney and chimney connector must be in good condition and kept clean.

2 Important Safety Information


2' Min.

2' Min.

3'Min.

0 To 10'

3'Min.

0 To 10'

AC617RLTSKC8

2/11/98

ReferencePoint

Figure 2.2-The2’-3’10’ChimneyRule.

Masonry ChimneysAninspectionofthechimneymustconfirmthatithasalining.Do not use an unlined chimney. The chimney should have nocracks, loosemortar, other signsof deterioration, andblockage.Repairanydefectsbefore thechimney isusedwith 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.

C. Chimney SizeThisappliancewithan8"(203mm)fluecollarisapprovedforventingintoamasonrychimneywithanominalfluesizeof8"x8"(203x203mm)or8"x12"(203x305mm),andintoaroundfluewithnominalfluesizeof8"(203mm).Thisappliancewitha6"(152mm)flueconnectorisapprovedforventingintoamasonrychimneywithanominalfluesizeof8"x8"(203x203mm),andintoaroundfluewithnominalflueof6"(152mm).Whateverthefluecollarsize,thisappliancemaybeventedinto larger chimneys as well. However, chimneyswithlinerslargerthan8"x12"(203x305mm)mayexperiencerapidcoolingofsmokeandreductionindraft,especiallyifthe chimneys are located outside the home. These large chimneysmayneedtobeinsulatedorhavetheirfluesrelinedfor proper stove performance. Accessoriestohelpmaketheconnectionbetweenstainlesssteel chimney liners and your appliance are available through your local dealer.

D. 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.

ST241chimney types12/13/99 djt

Aprefabricateddouble-wallinsulated chimney

Atile-linedmasonry chimney

Figure 2.1-Approvedchimneytypes.

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.(Figure2.2)Forproperdraftandgoodperformance,anychimneyusedshouldextendatleast16’(5m)abovethefluecollarofthestove.


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

first crimpedend into thestove’sfluecollar,andkeepeach crimped end pointing toward the stove, Figure2.3. Using the holes in the flue collar as guides, drill1/8" (3mm) holes in thebottomof thefirstsectionof chimney 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 2.4 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 joints between sections of chimney connector are available to simplify installations. They often eliminate theneedtocutindividualconnectorsections.Consultyourlocal dealer about these special pieces.

Figure 2.4 -An exploded viewof the chimney connection in afreestanding masonry installation.

ST242Chimney connector

12/13/99 djt

Flue Gas Direction

Toward Stove

Figure 2.3

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”) must belinedwitheitheraceramicormetalcylinder,calledthe“thimble,”whichiscementedsecurelyinplace.Mostchimneybreechesincorporatethimbles,butthefitmustbesnugandthe joint between the thimble and the chimney wall must be cementedfirmly.

ST492Defiantfreestanding installation11/00

Chimney

Elbow

Slip Pipe

Standard Connector

OvaltoRoundAdapter

FlueCollar

Thimble

Flue Inner

Flue


Figure 2.6-Inthisinstallation,thechimneyconnectorattachestothechimneyabovethefireplaceopening.ST243

thinble connection12/13/99 djt

Thimble Sleeve

ChimneyConnector

Flue

Keepsleeveendflushwithfluetile

Figure 2.5-Thethimble,madeofeitherceramicormetal,mustbe cemented securely in place.

• Thefireplacedampermustbesealedtopreventroomairfromescapinguptheflue.However,itmustbepossibletore-openthedampertoinspectorcleanthechimney.

Through the FireplaceIf your fireplaceopeningheight is at least 29" (737mm),you may install your appliance through the opening using a“positiveconnection”kit,availablefromyourlocaldealer.Positiveconnectionkitsensureatightfitbetweenthestovefluecollarandthechimneyflue,Figure2.7.Fireplaceinstallations,whetherconnectedtotheflueaboveor through the fireplace opening, have special clearancerequirementstoadjacenttrimandthemantel.You’llfindtherequiredsafeclearancesforfireplaceinstallationsonPage12. Floor protection requirements also apply to fireplace installations.Refertothe"FloorProtection"sectioninthismanual.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.

E. Fireplace InstallationsThe chimney connector may be connected to the chimney abovethefireplaceopeningorthroughthefireplace.Above the FireplaceYour appliancemaybe connected to a chimneyaboveafireplaceopening,Figure2.6.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,Figure2.5.Thimblesleevesareavailable from your local dealer.

ST244Plymouthfplc over mantel12/99

*

*

CheckTheseClearances

Mantel

Seal ThisOff


Figure 2.7-Throughthefireplaceinstallation.

Figure 2.8-Anapprovedwallpass-throughfortheUnitedStates.

Figure 2.9-Anapprovedwallpass-throughforCanada.

Yourlocaldealeroryourlocalbuildinginspectorcanprovidedetails 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:Donotventyourapplianceintoafactory-built(zero-clearance)fireplace.Theseappliancesandtheirchimneysarespecificallydesignedasaunitforuseasfireplaces.Itmayvoidthelistingorbehazardoustoadaptthemforanyother use.DO NOT CONNECT THIS APPLIANCE 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,and a minimum of 9" (229 mm) air space between the outer wall of the chimney section and combustibles.

In Canada, The Canadian Standards Association hasestablisheddifferentguidelinesforwallpass-throughs.Figure2.9showsonemethod,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" (25 mm) clear of the wall.IntheUnitedStates,theNationalFireProtectionAssociation

(NFPA) has established guidelines for passing chimneyconnectors through combustible walls. Many building code inspectors follow these guidelines when approving installations. Figure 2.8 shows oneNFPA recommendedmethod.Allcombustible material in the wall is cut away from the single-wallconnectortoprovidetherequired12"(305mm)clearance.Anymaterialusedtocloseuptheopeningmustbe noncombustible.

ST245fireplace flex connector12/99

FlexibleConnector

Mantel Shield

FireplaceAdapterKit"PositiveConnection"

ST493Brick pass thru11/00

Wall Stud

ChimneyConnector

Floor Protection

12" of Noncombustible Material

T

ST494steelwall pass thru11/00

18"(460mm)clearancebetweenpipeandsides/top/bottom of opening


U.S. CanadaA 44" 48"(1219mm)B 46" 50"(1270mm)

C 12"10"

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

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

F. 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 this appliance was tested with spark and ember protection only. There is no required"R"value,andthefloorprotectoronlyneedstobeanon-combustiblematerial,e.g.ceramictileorsheetmetal.Important:Allinstallationsonacombustiblefloorrequirethe use of the supplied bottom heat shield.TheDefiantdoesnotrequireRvaluefloorprotection.Theminimumfloorprotectormaterialis20gaugesheetmetal.OtherfloorprotectormaterialsthatcanbeusedincludeTypeIhearthpads,ceramictile,stone,brick,etc.Protection requirements vary somewhat between the Untied StatesandCanadaasfollows:In U. S. installationsthefloorprotectorisrequiredunderthestoveandmustextendatleast16"(notincludingtheashlip)fromthefrontofthestove(“F,”Figure2.10),andatleast6"fromthesidesandrear.(“D”and“E,”Figure2.10)In rear venting configurations, floor protectionmust alsoextendunderthechimneyconnectorand2"toeitherside.(“C,” Figure 2.10) For the 8" (203mm) connector, theprotectormustbeaminimumof12"(305mm)wide.Forthe6"(152mm)connector,theprotectormustbe10"(254mm)wide. The protector must be centered under the connector.Tomeettheserequirements,afloorprotectormustbeatleast39" wide and 45" deep.In Canada:A noncombustible floor protector is requiredunderthestoveaswell.Thefloorprotectormustextend18"(457mm)tothefront(“F,”Figure2.10),and8"(203mm)fromthesidesandrear.(“D”and“E,”Figure2.10)Tomeettheserequirements,afloorprotectormustbeatleast43"(1092mm)wideand49"(1245mm)deep.

Figure 2.10-Requiredfloorprotectiondimensions.

D

E

A

B

A

E

C

ST500Defiantfloor protection1/31/02 djt

E

F

E

F


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 orchimney connector, and nearbywalls, floors, the ceiling,andanyotherfixedcombustiblesurface.Thisappliancehasspecificclearancerequirementsthathavebeenestablishedafter careful research and testing. These clearance requirements must be strictly observed.Inaddition,keepfurnishingsandothercombustiblematerialsaway from thestove. Ingeneral, adistanceof 48" (1219mm) must be maintained between the stove and movable combustible items such as drying clothes, furniture,newspapers,firewood,etc.Keepingthoseclearanceareasempty assures that nearby surfaces and objects will not overheat. 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. For example, when this appliance is installed using 6"connector pipe parallel to the rear wall and no connector shield isused, itmustbeat least15" (381mm) from thewallbehinditandatleast19"(483mm)fromwallsoneitherside. These dimensions are measured from the back of the rear shroud and the side edge of the cast iron top to the combustible wall.Ifthisapplianceisinstalledinacornerandnoshieldisused,thecornersofthestovetopmustbeatleast18-1/2"(470mm) from nearby walls.Clearancesmaybereducedonlybymeansapprovedbytheregulatoryauthority,andinaccordancewiththeclearanceslistedinthismanual.Refertotheclearancechartforapprovedclearancereductionspecifications.NOTE: Installation of this appliance is not permitted in alcoves.

ST248wall shield construction12/14/99 djt

Stud Wall Framing

Wall Shield

Noncombustible Spacers and Fasteners

Drywall

AirFlow

AirFlow

Screen

Shield

Metal Spacer

Figure 2.11-Approvedwallshieldconstruction.

Theshieldmustbeaminimumof48"(1219mm)tall,andmustextendatleast19"(483mm)higherthanthetopofthestove,whicheverishigher.Theshieldbehindthechimneyconnectormustbe30"(760mm)wide,centeredbehindthepipe; for installations that use an approved prefabricated chimneytopassthroughtheceiling,theshieldbehindthechimney connector must stop 1" (25 mm) below the ceiling. With8"connectionsandchimneys,becauseofpotentiallyhigher pipe temperatures, the shieldmust extend the fullheight of the wall (up to 9’ (2.7 m)) and stop 1" (25 mm) 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,asinFigure2.11.Thespacers should not be directly behind the stove or chimney connector.Airmustbeabletoflowbetweenthewallandtheshield.Atleast50%ofthebottom1"(25mm)oftheshieldmustbeopen,andtheshieldmustbeopenatthetop.Metalscreeningacross the top will keep small stray objects from being trapped behindtheshield,Figure2.11.


N o n c o m b u s t i b l e s h i e l d s installed 1" (25 mm) away from the 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,centered over the stove. (Figure 13) Ventilated shields for sidetrimmust extend the full lengthof the trim.Anunprotectedmantel (“A,”Figure2.13)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 this appliance.

1" (25mm)

1/4" (6mm)

ST501mantel andtrim shield11/10/00 djt

Figure 2.12 -A custom-formed mantel shield.

Figure 2.15-Parallelinstallationwithrearwallpass-through,twowallshields.Reducedclearancestobothrearandsidewalls.Wallshieldsmaymeet at corner if desired.Wall pass-throughmustcomply with codes.

Figure 2.14-Parallelinstallation,verticalchimneyconnector,twowallshields.Reducedclearancesforbothrearandsidewalls.Wallshields may meet at corner if desired. Shielding for connector is centered behind connector.

Figure 2.16-Cornerinstallation,verticalchimneyconnector,twowallshields.Reducedsideclearances.WallshieldMUSTmeetatcorner.

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST498Defiant

Wall shield B 11/00

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST497Defiantwall shield A11/00

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)


Fireplace and Mantel Trim ClearancesUnprotected Protected

A Mantel Trim 41"(1041mm) 29" (737 mm)B Top Trim 28"(711mm) 21" (533 mm)C Side Trim 14" (356 mm) 14" (356 mm)D Side Wall 21" (533 mm) 11"(280mm)

Figure 2.13-Maintainclearancestocombustiblecomponentsofthe mantel piece.

ST253bEncoretrim clearances02/01 djt

A B

D

C C

Side Wall


G. Clearance to CombustiblesForusewitheither6”or8”fluecollar/chimneyconnection

Theattachedrearshroudmustbeusedinallinstallations.Thefluecollarheatshieldmustbeusedinallverticalinstallations.1. Theconnectorpipeheatshieldmustextend36"(914mm)abovethefluecollar.2. Using a listed double wall oval to round connector.3. Aminimumof67”(170cm)fromthetopofthestovetotheceilingisrequiredforallinstallationsoftheDefiant®.

Stove ClearanceUnprotected Surface

No Connector Heat ShieldProtected Surfaces1

with Connector Heat Shield

Stove Installed Parallel to Wall Stove in Corner Stove Installed Parallel to Wall Stove in

CornerSide Rear2 Corners Side Rear2 Corners

(to rear shroud)

(to back edge of

cast)

(to rear shroud)

(to back edge of

cast)Topexitwithsinglewall connector pipe

(A)21"(521 mm)

(B) 15"(381mm)

(C)21"(521 mm)

(D) 5"(127 mm)

(E)5"(127 mm

(F) 3"(76 mm)

(G) 9"(229 mm)

(D) 5"(127 mm)

TopExitwithDoublewall3 connector pipe

(H)21"(521 mm)

(I)15"(381mm)

(J) 21"(521 mm)

(K)5"(127 mm)

(L) 5"(127 mm)

(M) 3"(76 mm)

(N) 9"(229 mm)

(O)2"(51 mm)

RearExit(P) 21"

(521 mm)(Q)10"

(254 mm)(R)16"(407mm)

N/A N/A N/A N/A N/A


Unprotected Surfaces Protected SurfacesStove InstalledParallel to Wall Stove in Corner

Stove Installed Parallel to Wall

Stove Installed Parallel to Wall

Forusewitheither6"or8"fluecollar/chimneyconnector

E

F

D

D

D

ST855aDefiant 2n1ClearanceDiagrams

D

A

B

L

M

O

O

KH

KI

PN/A N/A

Q

C G

JN

N/A

R

TopExitInstallations,double-wallchimneyconnector,fluecollarshieldinstalled

Top Exit Installations, single-wall connector

Rear Exit Installations


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 14.Dimensionsindicatedarevalidforinstallationswitheither6"or8"fluecollars.

Double Wall ConnectorSide (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)

36-1/2"(927mm) 21" (533 mm) 16"(406mm) 20-1/2"(521mm) 9" (229 mm) 16"(406mm)

ST511Defiant

Flue CenterlineDiagrams

04/19

*

A B C

*

D E F

*Thisdistance,fromthecenterofthefluecollartothefrontedgeofthehearth,isthesameforallinstallationsonthispage:34"(865mm)intheUnitedStatesand36"(914mm)inCanada.

Single Wall - No Connector Heat ShieldsUnprotected Surface Protected Surface

Parallel Installations Corner Installations Parallel Installations Corner

InstallationsSide (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)

36-1/2"(927mm) 21" (533 mm) 16"(406mm) 20-1/2"(521mm) 9" (229 mm) 16"(406mm)

Doors Open - 8" ConnectorUnprotected Surfaces

Parallel Installations Corner Installations

Side (A) Rear (B) Corner (C)37-1/2(953mm) 18"(457mm)


Figure 2.15-Parallelinstallationwithrearwallpass-through,twowallshields.Reducedclearancestobothrearandsidewalls.Wallshieldsmaymeet at corner if desired.Wall pass-throughmustcomply with codes.

Figure 2.14-Parallelinstallation,verticalchimneyconnector,twowallshields.Reducedclearancesforbothrearandsidewalls.Wallshields may meet at corner if desired. Shielding for connector is centered behind connector.

Figure 2.16-Cornerinstallation,verticalchimneyconnector,twowallshields.Reducedsideclearances.WallshieldMUSTmeetatcorner.

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST498Defiant

Wall shield B 11/00

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

ST497Defiantwall shield A11/00

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)

48"(1220 mm)


Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel. Install the handle onthegriddle.First,placethe griddle upside down at the edge of a flat surface and assemble thehandle,Figure3.2.With the handle pointing 45°fromitsfinalposition,tighten the nut as far as possible with the pliers. Move the handle to its finalpositionwhilestillholdingthenutwiththepliers.

ST857abottom heat shield12/051/10

Figure 3.4-Attachthebottomheatshield.

BottomHeatShield

ST516Attach griddle handle11/17/00 djt

Figure 3.2-Attachthegriddlehandle.

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

bagintothefourholeslocatedunderthestove,Figure3.4.

2. Alignthebottomheatshieldkeyholestothefourhexboltspreviouslyinstalledintobase,Figure3.4.Theoutsideaircutout hole should be toward the rear of the stove.

3. Attachtheheatshieldsidesbypassingtheslotsovertheboltheads.Tightenthehexheadbolts,Figure3.4.

Storing the HandleUsetheremovablehandletoopenorclosethedoors.Afterusingit,removethehandlesoitwillnotgethot.Storethehandle in the handle holder installed behind the right front leg,Figure3.3.

CAUTION!Overtighteningcanstriptappedthreads.

Figure 3.1-Removeunitfromshippingbrackets.

1/4-20 Bolt

3 Assembly

A. Setting up your StoveRemovetheunitfromtheshippingbracketsbyremoving(2)1/4-20hexheadboltsfromeachshippingbracket,leavingbracketsattachedtotheskid,Figure3.1.(Savethe1/4-20hexheadboltsastheywillbeneededlater to installheatshield.)NOTE:Whenmovingthestove,liftthestovetotakeweightoffthelegswheneverpossible.Draggingorslidingthestove,especially across rough surfaces can cause the legs to loosen or even break.

Figure 3.3-Handleholderandheatshieldpositions.

ST564handle holder12/13/00

ST564handle holder12/13/00

BottomHeatShield

DoorHandleHolder

Leg Bolt and Washer

20 8390-975Vermont Castings • Defiant® Model 1975-CAT-C Installation Manual_R1 • 07/19ST540Assemblyhandle11/00

Figure 3.8-Assemblethefrontdoorhandle.

ST635EncoreInstall thermostathandle2/01

Figure 3.7-Attachthethermostathandle.E. Attach Damper Handle Usethe1/4"-20x3"screwtoattachthedamperhandletothe damper stub on the left side.

F. Install Catalyst Temperature ProbeToinstallthecatalysttemperatureprobe,removetheholeplugfromthecastironwallbehindtherearshield,Figure3.6.Usetwo#10sheetmetalscrewsandbracketsupplied,securethebracketandprobetothebackofyourstove,Figure3.6.

H. 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,Figure3.8.Tightencarefullyuntilsnug.

G. Attach 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,Figure 3.7.

WARNING!Thefluecollarheatshieldmustbeinstalledinallverticalinstallations.Thefluecollarheatshieldisnotusedwhenthefluecollarisintherearexitposition.

C. Adjust the Leg Levelers Lift the stove slightly so there is no weight on the leg while making the adjustment.

D. Reverse Flue Collar (If necessary)Reversethefluecollarbyremovingthetwoscrewsthatattachit to the back of the stove. Be sure the gasket around the fluecollaropeningisinpositionwhenyouscrewthecollarback onto the stove.

Figure 3.6-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.

Removeholdplugfrom cast iron back.

Insertcatalystprobebracketwithself-drillingscrew.

Figure 3.5-Installfluecollarheatshield.

ST1180flue collar heat shield

Sheet Metal Screws

Sheet Metal Screws

FlueCollarHeatShield


ST1187remove access cover

I. Fan Kit Installation1. Attachthefanassemblyatthebottomedgeoftheinner

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

ofthebottomwithtwo(2)1/4-20panheadscrews.3. Attach the rheostat holder under the right front wing

of thebottomheatshieldwith 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 groundprongfromplug.Routepowercordtoavoidheatfrom the stove or other damage. Do not route cord under or in front of appliance.

Figure 3.9-Faninstallation

J. Installing/Removing Catalyst1. Removetheaccesscoverbygentlyliftingupandpulling

outfromthebottomedge,Figure3.10.2. Removetheinnercoverbypullingitstraightout,Figure

3.11.3. Remove the catalyst by gently pulling it straight out,

Figure 3.12 Place the catalyst where the catalyst’s ceramic components will not be damaged.

AccessCover

Figure 3.10-Removeaccesscover.

ST1188remove inner cover

InnerCover

Figure 3.11-Removeinnercover.

ST1189remove catalyst

RemoveCatalyst

Figure 3.12-Removecatalyst.

ST848fan install6/05

RheostatKnob

Rheostat Snapstat Screws

HoleforWireTie to Secure Cable

RheostatHolder


A. 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.

B. 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….• Evacuatethehouseimmediately• 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.

4 Smoke Alarm / Safety Tips


TheDefiant® Model 1975-CAT-C Controls Two controls regulate the performance of your appliance: a primary air control suppliesoxygenforthefire,andadamper directsairflowwithinthestovetoactivateanddeactivatethecombustionsystem,Figure5.1.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 5.1 -The controls are conveniently located andeasy tooperate.

ST637encoreAir control2/01

Low Heat

High Heat

Figure 5.2 - The handle may be positioned anywhere between the twoextremesfordifferentheatlevels.

Damper Positions

Figure 5.3 -Thedamper iseitheropenorclosed.Therearenointermediate positions.

B. Damper AdjustmentThe 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,Figure5.3.The damper should always be either fully open or fully closed. There are no intermediate positions. When closingthedamper,besuretopullfirmlyenoughtosnapthe 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. Primary Air ControlThe 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,Figure5.2.Forthegreatestairsupplyandmaximumheatoutput(buttheshortestburntime),movethelevertowardthefrontofthestove.Forafirethatwilllastlongerwithlessheat,movethe lever toward the rear of the stove.

5 Operation

ST541Defiantfront viewcontrols11/00

GriddleHandleDoorHandle

AirControlLever

AshDoorHandle

DoorHandleHolder

(Behind Leg)

Andiron

Damper Handle

DEFIANT DEFIANT

Open(UpdraftMode) Closed(EfficientMode)


C. 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 appliance,minimizethermalstressbylettingtheplatesadjustgraduallyduringthreeorfourinitialbreak-infiresfollowingSteps1-3below.

D. Wood Burning OperationBurnonlysolidwoodinthisappliance,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.Thebypassdampermustbeopenwhenstartingafireor when refueling. Donotusechemicalsorfluidstostartthefire.Donotburn garbage. Never use flammable fluids such asgasoline, gasoline type lantern fuel, kerosene, charcoal lighter fluid, naptha, engine oil or similar liquids tostart or “freshen up” afireinthisheater.Keepallsuchliquids 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,Figure5.4.

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 appliance 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-EfficiencyWoodBurningwiththeCatalyticCombustorYour Defiant stove was shipped from the factory with aseparately packaged catalytic combustor.

ST263starting a fire12/99

Figure 5.4-Startthefirewithnewspaperanddrykindling.

3. Light the newspaper and close the door. Gradually build upthefirebyaddingafew3-5"(80-120mm)diameterpiecesofsplitfirewood. If this isoneof thefirst few“break-in”fires, let thefireburnbrightly,and thenlet 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.


The catalytic combustor creates optimum conditions for secondary combustion. Refer back to the "Installing or Removing Catalyst" section of this manual.The catalytic element is a ceramic “honeycomb” coated with 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,suchasdryslabwoodorwoodwithbelow14%moisturecontent.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 can occur 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.

E. Adding FuelThegriddle lifts forconvenient top-loadingof logs,and istheeasiestwaytoaddfuel,Figure5.5.However, the front doors open as well for adding anoccasionallogtoafire.

ST521Intrepidloading11/00

Figure 5.5-Toploadingisthebestwaytoaddfuelduringregularuse.Frontloadingisusefulforkindlingafire.

Toopenthefrontdoors,insertthehandleintothedoorlatchstubandturnittotheleftandup,Figure5.6.To close them, always close the left door first. Turn thehandle in the right door to the left and up (to the open position)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 5.6-Toopenthefrontdoors,turnthehandleclockwise.


WARNING!Forsafetyandgreatestefficiency,operateyourstoveonly with all doors/griddles fully closed. The test standard for your stove when it is operated in this mode is UL 1482.

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 GlassYourstovehasandironstokeeplogsawayfromtheglasspanels. The andirons are essential to maintain clear fireviewing,andshouldbeleftinplaceduringoperation.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 WoodThis appliance is designed to burn natural wood only; do not burn fuels other than that for which it was designed. IMPORTANT: Do not burn any type of artificial orsyntheticmaterialssuchasfirestarterlogs(containingwax) 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; they often contain chemicals and metals that can damage 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,Figure5.7.

Figure 5.7-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°-700°F.(315-371°C)indicatehighheat

output.Operatingyourappliancecontinuouslyatgriddletemperatureshigherthan650°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,andhowlongyouwishthefireto burn; outdoor air temperature and pressure also affect draft.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 theappliance,andcouldevendamagethestove.Ontheotherhand, too little draft can causebackpuffing into the roomand/orthe“plugging”ofthechimney.

ST523Intrepidtemp readings11/00


Howdoyouknowifyourdraft isexcessivelyhighorlow?Symptoms of too much draft include an uncontrollable burnoraglowing-redstovepart.Signsofweakdraftaresmoke leaking into the room through the stove or chimney connector joints or low heat output.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.This appliance is equipped to deliver outside air for combustion. An outside air adapter (available at yourauthorized Vermont Castings dealer) is required forinstallation and any 3" non combustible duct will need to supplied by the installer.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.Donotforanyreasonattempttoincreasethefiringofyourheater by altering the air control adjustment range outlined in these directions.Use the following air control settings as a starting point to helpdeterminethebestsettingsforyourinstallation.Eachis described as a fraction of the total distance the lever may be moved from right to left.

F. Ash Disposal

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,Figure5.8.Itwillpivot,swingingtheashpanoutofthestove.

Figure 5.8- Turn the ashdoor handle clockwise to open andcounterclockwise to close.

ST545ashdoor11/00

Open

Close

• Slidethecoverontothepan,makingsureitissecurelyclosed,Figure5.9.

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.

Routineashremovalisimportantforeaseofmaintenance,and is important for the stove’s durability. Remove ashbeforeitreachesthetopoftheashpan.Checkthelevelatleastonceaday.Every fewdays,clearanyashfromtheouteredgesofthefirebox.Mostoftheashwillfallthroughthe grate. Stir the ash with a shovel or poker so that it falls through the grate slots.

ST566remove ashpan7/05

Figure 5.9-Besurethecoverissecurelyattachedbeforeremovingthe ash pan.

• 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

disposingoftheash.Youmayneedtoliftthelatchendof 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,and close and latch the ash door.


CAUTION!Never use your household or shop vacuum cleaner to remove ash from the stove; always remove and dispose of the ash properly.

• Do not operate the stove with the ash door open. This willresultinover-firing,andcouldcausedamagetothe 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 appliance: ash will accumulate faster at higher heat outputs.Removed ash should be placed outdoors in a metalcontainerwithatight-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.


G. Draft ManagementA 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 (and therefore lighter) than the outdoor air at the top ofthechimney.Thebiggerthetemperaturedifference,thestrongerthedraft.Asthehotgasesrisethroughthechimneythey provide suction or ‘draw’ that pulls air into the stove for combustion.Aslow,lazyfirewiththestove’sairinletsfullyopenindicatesaweakdraft.Abriskfire,supportedonlybyairenteringthestovethroughthenormalinlets,indicatesagooddraft. The stove’s air inlets are passive; they regulate how muchaircanenterthestove,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-wallstovepipe between the stove and a chimney; longer runs can cool theexhaustenoughtocausedraftandcreosoteproblems.Withprefabricatedchimney,bringitdowntosixtoeightfeetfromthestove.Withamasonrychimney,arrangethepipeso that it turns into the chimney within eight feet of the stove.


Back-puffingBack-puffingresultswhenthefireproducesvolatilegasesfasterthanthechimneydraftpullsthemoutofthefirebox.Thegasesbackupinthefireboxuntiltheyareconcentratedenoughandhotenoughtoignite.Ifyourstoveback-puffs,thestoveneedstocooldown.Youshouldopenthedampertoletthesmokerisetothefluemorequickly,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 PressureGood draft also depends on a supply of air to the stove; a chimney 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 times bigger (in square area) than the outlet on the stoveorinsert.SomelocalitiesenforcetheNFPAguidelinesas part of their building codes.FuelEven thebest stove installationwill not performwellwithpoorfuel.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,lift a piece and get a sense of its weight; it can lose a third or moreofitsweightasitdries.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.Ifyou hear a rumbling or roaring noise (like a propane torch) 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 appliance 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.

A. Glass MaintenanceCleaning 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.

• Rinsetheglassthoroughly.• Dry the glass completely.Replace Broken Glass ImmediatelyDo not operate your stove if the glass in the doors is damaged.Ifyouneedtoreplacetheglass,useonlythehightemperature5mmceramicglasssuppliedbyVermontCastings.Donotuse substitutes.

Removing the Glass1.Removetherightandleftdoorassembliesbyraisingthe

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.Removethescrewsthatholdtheglassretainerclipsinplace,andremovetheclips.

3.Carefullyliftthebrokenglasspanelfromthedoor.Installing the GlassCheckthegasketaroundthewindow;itshouldbesoftandresilient so that the glass will seal properly against the door. Replacethegasketifithashardenedorifitiscompressed.1. Centertheglassonthegasket.2. Secure the glass on both doors with the retainer clips.

Tightenallscrews,Figure6.1.3. Replacethedoorsonthestove.4.Openandclosethedoorstocheckthattheyfitandwork

properly.Adjustasnecessary.

6 Maintenance

Figure 6.1-Explodedviewoftheglassassemblyfortherightdoor.

ST547door install11/00

RetainerClip

Glass Panel

Glass Gasket

Door Gasket

RetainerClip

Left Door

Right Door (Back Side)


Figure 6.3-Rotatepawland/orremoveflatwashertoadjustlatch.

ST1154door pawl

Roller

Lock Nut

Set Screw

Shoulder Screw

HandleStubFlat Washer

C. Gasket ReplacementReplace the Stove Gaskets as NeededYourapplianceusesfiberglassropegasketstomakeatightsealbetweensomeparts.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"TheouterglasspanestothedoorWaituntilthefireisoutandthestovehascooled.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,Figure6.4.2. Use a wire brush or the tip of a screwdriver to clean

the channel of any remaining cement or bits of gasket. Removestubborndepositsofcementwithacoldchiselifnecessary,Figure6.4.

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 doorwillcompress and the latch may need adjustment. To adjust the handle,followthisprocedure:1. Removeandretainthelocknutwitha9/16"wrench,Figure

6.3.2. 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 tomakesmall adjustments until the setting is right.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.

B. Damper AdjustmentAdjust the Damper as NeededThe tension on this appliance’s damper is adjustable to compensate for compression of the gasket that seals the dampertotheupperfireback.Toadjustthedamper:1. Removethegriddle.Loosenthelocknutatthecenterof

thedamper,Figure6.2.2. Turn the pressure screw approximately one half turn

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

turningasyoutightenthenut.Re-testthedamper.

Figure 6.2-AdjustthedamperwiththeAllenwrench.

ST554Damper adjustment11/00

PressureAdjustingScrew

AllenWrench

Lock Nut

Damper


ST559Removegasket11/30/00 djt

Figure 6.4-Removegasketthencleanchannelwithwirebrush.

ST559Removegasket11/30/00 djt

CementStove Gasket

Figure 6.5-Layabeadofgasketsiliconeorcementthenpressgasket in place.

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. The stove’s doors may need adjustment after you have regasketed them. Initially, itmay require loosening thelatchtoaccommodatethenewgasket;afterafewweeks,it may need tightening to compensate for compression of the new gasket. See Figure 6.3 for directions on adjusting the latches.

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)

All Gasketed Construction GasketsOthergasketsformsealsbetweenallothernon-movingparts,but these are not subject to the same wear and deterioration asgasketsonmovingparts.Itisunlikelythatyouwilleverneed to replace these gaskets unless the involved parts are disassembledandthenputbacktogether.Ifthisisthecase,thejobshouldbedoneonlybyaqualifiedservicetechnician.5/16"diametergasketsealsthefollowingparts:• Thelowerfirebacktothebackpanel• The left and right air plates (inner sides)• Allconnectionsbetweenthestoveplates.

D. The Chimney SystemCreosote Your appliance 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.


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 inspectionand cleaning.Replaceweak sectionsofconnector.

• Inspectthechimneyforsignsofdeterioration.Repairstoa masonry chimney should be made by a professional mason. Replace damaged sections of prefabricatedchimney. 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,being sure to secure the joints between individual sections with 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 replacewith a

moisture absorbing material (such as kitty litter) to keep the interior of the stove dry.

• Cleanthedustfromtheinnersidesofbottom,rearorpipeheatshieldsifyourstoveisequippedwiththem.Cleansurfacesarebetterheatreflectorsthandirtysurfaces.

• Touch up the black paint.• Inspectforandremoveashbuild-upbehindthecombustion

package. This should be done in conjunction with annual cleaningofthechimneyconnector.Inspectthepassagebehind the combustion package (a mirror will be helpful) and vacuumaway ash using a flexible vacuumhoseinsertedinthepassage,Figure6.6.

Figure 6.6 - Inspectandcleanoutashaccumulationbehindthecombustion system. ST1162

ash clean out

Cleanoutanyash build up

Removethesecomponents


. 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 appliance’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,becarefulnottoconfusesmokewithsteam from wet wood. Steam dissipates in the air quickly; 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. Reloadingwith greenwood can also thermal shock thecatalyst,resultingincracking,ortheeventualfallout,oftheceramichoneycombsubstrate.Youmayhave to runyourstove hotter (more air) to achieve acceptable performance using green or wet wood.Also,consideranychangesinyouroperatingroutine.Onceyouhaveruledoutanyotherpossiblecauses foradeclineinperformance,inspectandcleanthecombustorifnecessary. Be sure to protect any surface you use for setting the stove parts aside.

Figure 6.7-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 not push anything through the honeycomb; do not use compressed air to clear the passages. Such abrasion can scrape the thin coating of platinum (the catalyst) off the ceramicbase,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,Figure6.7.

ST1180catalyst access

Catalyst

AccessDoorInnerFireback


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 PartsBeginning Manufacturing Date: Oct 2019

Ending Manufacturing Date: Active

Defiant CAT-C

Part number list on following page. 06/19

1975-CAT-C (Classic Black)1976-CAT-C (Biscuit)1977-CAT-C (Majolica Brown)1979-CAT-C (Bordeaux)1980-CAT-C (Twilight)1975T-CAT-C (Classic Black w/Transition Doors)

9

80

21

20

17

19 16

18

10 11

2

13a1415

13b

63

58

32

59

3

36

29

81

39

40

47

38

12

45

37

31

50

51

52

5570

69

64

68

62

74

72

61a

71 69

65

67a

74

7262

30

60

56

34

5656

20

2053

1

57

78

33

81

4783

24

79

8249

48

53

77

76

75a82

49

66

68

64

64

26

27

28

73

54

1

20

83a

83b

23

23

8

25

4

3541

5

44

42

6

7 46

84

8687

85

88

89

90

13c

13

43

91

93

92

61b

67b

94

95

75

96

7 Service Parts List




Defiant CAT-C

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 Ft 1-00-1203668 Y3 Back 30005242A4 Refractory, Right End 300052065 Refractory, Left End 300052076 Refractory Support 300052337 Gasket, Cast Base SRV8344-0008 Back Insulation Board 300052699 Outer Back 30005249

10 Griddle Quadrant, Left 30002399A11 Griddle Quadrant, Right 30002401A12 Griddle 30005257A13 Complete Griddle Handle Assembly 30002775 Y

13a Griddle Handle, Wood 1600661 Y13b Griddle Handle, CRS-BN1 3000271513c Nut, Hex 1/4-20 Pkg of 10 1203210-1014 Griddle Handle Bushing Pkg of 10 1201900-1015 Griddle Handle Bolt Pkg of 10 1201308-1016 Damper Gasket 15 Ft 1-00-1203588 Y17 Damper Ramp 130064318 Damper Housing 30002821A19 Damper 3000281620 Damper Tab Pkg of 10 1601488-1021 Damper Rod 160006523 Gasket, Back Refractory 10 Ft 1-00-3000527024 Rheostat Bracket 3000286325 Refractory, Engine - E/D 3000520226 Damper Handle Screw Pkg of 10 1201310-1027 Damper Handle 1600664 Y28 Damper Handle w/Screw Assembly 30002720A Y

29 Left Side

Classic Black 30002832ABiscuit SRV30002872Bordeaux SRV30006697Majolica Brown SRV30004834Twilight SRV30007126

30 Left Air Manifold 3000281831 Right Air Manifold 30005243

Additional service part numbers appear on following page.




Defiant CAT-C


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 Refractory Gasket Plate, S/S SRV8000-00836 Inner Bottom 3000524137 Top Ashdoor Hinge 1-00-3000283638 Door Handle Bracket 3000284439 Bottom 30005240A

40 Ashlip


41 Gasket, Fireback 3000520942 Refractory, Fireback 3000520343 Retainer, Fireback Refractory 3000524844 Refractory, Inner Cover 30005205 Y45 Andiron 30002827A Y46 Refractory, Access Cover 3000725247 Leg Leveler Pkg of 10 1201745-1048 Ashdoor Handle Shaft 3000530149 Pawl Assembly, 3/4 Short Adj. 30005157 Y49a Spring Washer Pkg of 10 63D0069-1050 Ashdoor 30002810A

50a Ashdoor Gasket 15 Ft 1-00-120358951 Ashdoor Handle, Wood 1600663 Y52 Hinge Hardware 1-00-282653 Gasket, Ceramic Fiber SRV3000751354 Ashdoor Bottom Hinge Support 1-00-130064255 Ashpan Bracket 3000190856 Rear Side Bracket 3000284557 Thermostat Handle 1600660 Y58 Airwash Manifold, Front 30005244





Defiant CAT-C


Stocked at Depot


59 Front


60 Flue Collar Gasket 1-00-30002422

61a

Left Door (Shell Enamel Parts)


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

Classic Black 30002854Biscuit 30002879Bordeaux 30006773Majolica Brown 30004840Twilight 30007133

61b

Left Door (Transition Door Enamel)


Left Door Sub Assembly (Transition Door Enamel)


62 Door Hinge Strip 1300645A

63 Top


64 Glass Clip 3000171565 Glass Clip ( Right Door Only ) 3000171666 Front Door Handle and Shaft 30002717 Y





Defiant CAT-C


Stocked at Depot


67a

Right Door (Shell Enamel Parts)


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


67b

Right Door (Transition Door Enamel)


Right Door Sub Assembly (Transition Door Enamel)


68 Door Gasket 15 Ft 1-00-7000910 Y69 Glass Gasket 10 Ft 1-00-1186258229 Y70 Left Door Glass 3000524771 Right Door Glass 3000524772 Lower Door Hinge Pin 30002727 Y73 Spacer ( For Damper Rod ) Pkg of 10 1201779-1074 Upper Door Hinge Pin 30002727 Y75 Complete Handle Assembly 30004175K Y75a Handle Base Stub 30002714 Y76 Wood Handle 1600664 Y77 Handle Bolt Pkg of 10 1201310-1078 Thermostat Handle Botl Pkg of 10 1201243-1079 Ash Pan Assembly 30001690

80 Flue Collar






Defiant CAT-C


Stocked at Depot


81 Leg

Classic Black 30002835ABiscuit SRV30002877Bordeaux 30006695AMajolica Brown 30004843ATwilight 30007124

82 Jam Nut, Hex Head Pkg of 10 1203290-1083 Bottom Heat Shield 30005037

83a Bottom Heat Shield, Right Wing 3000503883b Bottom Heat Shield, Left Wing 3000503984 Grate Bottom 30005234A85 Thermostat Assembly 5005470 Y86 Thermostat Cable 5005471 Y87 Thermostat Friction Spring Pkg of 10 1201846-1088 Primary Air Valve Assembly 3000527589 Heat Plate Vertical Flue 3000526590 Catalyst, Ceramic 3000662391 Thermostat Handle Assembly 3000706792 Primary Air Cover 3000706993 Primary Air Base 3000707194 Temperature Probe 3000727495 Braket, Temperature Probe 3000727896 Gasket, Slotted Refractory SRV8344-001

Finish Bag SRV8000-007

Warming Shelf Kit


Shelf


Dragon Bracket

Classic Black 1302220ABiscuit SRV30002948Bordeaux 30006690AMajolica Brown SRV30004818Twilight SRV30007075

Bracket, Left 30002478ABracket, Right 30002479A

43 8390-975Vermont Castings • Defiant® Model 1975-CAT-C Installation Manual_R1 • 07/19 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

8 Warranty


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.


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 - Wood Stoves...2 Vermont Castings • Defiant® Model 1975-CAT-C Installation ManualR1 • 07/19 39975 Congratulations on your choice of ®a Vermont