Vermont Casting 1655, 1656, 1657, 1658, 1659 Stove User Manual

Vermont Casting 1655, 1656, 1657, 1658, 1659 Stove User Manual
Vermont Castings Madison
The Madison
Woodburning Stove
Models
1655, 1656, 1657, 1658, 1659
Homeowner’s
Installation and
Operating
Manual
For use in the
United States and Canada
SAFETY NOTICE: IF THIS APPLIANCE IS NOT PROPERLY INSTALLED,
OPERATED AND 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.
Do Not Discard This Manual: Retain for Future Use
30001453 10/02 Rev. 1
1
Vermont Castings Madison
Introduction
Thank you for choosing a Vermont Castings Madison to meet your heating needs.
We're confident you will find the Madison to be an effective woodburning heater incorporating
modern, non-catalytic combustion technology with the classic aesthetic appeal of its Vermont
Castings lineage.
The Madison achieves high-efficiency through precisely calibrated delivery of primary and
secondary air into a refractory-insulated firebox. Properly operated and maintained according
to the guidelines in this manual, your Madison will provide safe, dependable, and economical
heating for years to come.
The Madison Model 1655 Series has been tested and is listed by Canadian Standards
Association (CSA). The test standards are ANSI/UL-1482 for the United States and ULC
S627 and CAN/CSA B366.2 for Canada.
The Madison Model 1655 Series is listed for burning wood fuel only. Do not burn other fuels.
C
US
The Madison Model 1655 Series is approved for installation in manufactured (mobile) homes
in the Unties States only, using the optional Mobile Home Kit #1894 in accordance with the
instructions in that kit an any local codes.
The Madison Model 1655 Series complies with the standards set forth by the Federal
Environmental Protection Agency, 40 CFR Part 60.532(b)(2), as stated on the permanent
label attached to each stove. The Madison Model 1655 Series meets Washington State
requirements.
We recommend that you hire a professional, solid-fuel stove technician to install your
Madison, or to advise you on the installation should you attempt to install it yourself. Consult
the authority having local jurisdiction (such as a municipal building department, fire
department, fire prevention bureau, etc.) before installation to determine the need for a
building permit. Also, consult your insurance agent to be sure your installation complies with
specific requirements that may vary locally.
In addition to directions on installation and operation, this manual includes directions on
maintenance and assembly. Please read this entire manual before you install or operate
your new room heater.
Save These Instructions For Future Reference.
Table of Contents
Installation
Accessories
#1891 Outside Air Kit
Specifications ..................................... 3
Installation Requirements .................. 4
Clearances ......................................... 12
Assembly ...........................................15
Operation ...........................................17
Maintenance ......................................20
Draft Management .............................22
Parts List ............................................25
2
#1892 Bottom Heat Shield Kit
#1893 Rear Heat Shield Kit
#1894 Mobile Home Kit
Proposition 65 Warning: Fuels used in gas,
woodburning or oil fired appliances, and the products
of combustion of such fuels, contain chemicals
known to the State of California to cause cancer, birth
defects and other reproductive harm.
California Health & Safety Code Sec. 25249.6
Vermont Castings Madison
Specifications
Madison, Model 1655 Series
Maximum heat output ......................... 39,700 Btu’s/hr.1
Area heated ...................................... Up to 1600 sq. ft.2
Fuel size/type ...................................... 18” (46 cm) logs
Loading ..................................................... Front & Side
Chimney connector .................... 6” (150 mm) diameter
Chimney flue size ...................... 6” (150 mm) minimum
Flue exit position ........................................ Top or Rear
Primary air ... Manually set, thermostatically maintained
Ash handling system ..................... Removable ash pan
Glass panel ........................ High-temperature Infra-red
Weight ............................................................... 420lbs.
Width (Left leg - Right leg) ...................... 29” (59.0 cm)
Depth (Front Plate - Flue Collar) ............. 25” (64.0 cm)
Height ...................................................... 28” (79.5 cm)
1
This value can vary depending on how the stove is
operated, the type and moisture content of the fuel
used, as well as the design, construction and climatic
location of your home. Figures shown are based on
maximum fuel consumption obtained under laboratory
conditions and on average efficiencies.
2
These values are based on operation in building codeconforming homes under typical winter climate conditions in New England. If your home is of nonstandard
construction (e.g., unusually well insulated, not insulated, built under ground, etc.) or if you live in a more
severe or more temperate climate, these figures may
not apply. Since so many variables affect performance,
consult your Vermont Castings Majestic Products
Company authorized dealer to determine realistic
expectations for your home.
Drawings not to scale.
25"
(635mm)
28”
(710mm)
24³⁄₄”
(630mm)
18”
(470mm)
29”
(740mm)
1128
Fig. 1
Madison 1655 dimensions.
3
Vermont Castings Madison
Installation
SAFETY NOTICE: If your stove is not properly
installed, operated and maintained, a house fire
may result. For safety, follow all installation,
operation and maintenance directions. Contact
local building officials about restrictions and
installation inspection requirements in your area.
Before you begin an installation, review your plans to
be certain that:
• Your stove and chimney connector will be far enough
from combustible material to meet all clearance
requirements.
• The floor protector is large enough and is constructed properly to meet all requirements.
• You have all necessary permits from local authorities.
Your local building official is the final authority for
approving your installation as safe and determining
that it meets local and state codes.
The metal label permanently attached to the back
of the stove indicates that the Madison has been
tested to current UL and ULC standards by CSA.
Clearance and installation information is also printed
on the label. Local authorities generally will accept the
label as evidence that, when the stove is installed
according to the information on the label and in this
manual, the installation meets codes and can be
approved. Codes, however, vary in different areas.
Before starting the installation, review your plans with
the local building authority. Your local dealer can
provide any additional information needed.
For any unresolved questions about installation,
refer to the National Fire Protection Association’s
publication ANSI/NFPA 211–1988 Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances. In Canada, the equivalent publication is CSA
CAN-B365, Installation Code for Solid Fuel Burning
Appliances and Equipment. These standards are the
bases for many national codes. They are nationally
recognized and are accepted by most local authorities.
Your local dealer or your local building official may
have a copy of these regulations.
IMPORTANT: FAILURE TO FOLLOW THESE
INSTALLATION INSTRUCTIONS MAY RESULT IN A
DANGEROUS SITUATION, INCLUDING A CHIMNEY
OR HOUSE FIRE. FOLLOW ALL INSTRUCTIONS
EXACTLY AND DO NOT ALLOW MAKESHIFT
COMPROMISES TO ENDANGER PROPERTY AND
PERSONAL SAFETY.
Chimneys
Your stove must be connected either to a sound
masonry chimney that meets local codes, to a relined
masonry chimney that meets local codes, or to an
approved prefabricated metal chimney. Whichever of
those types you use, the chimney and chimney connector must be in good condition and kept clean.
If you use an existing masonry chimney, it must be
inspected to ensure safe condition before the stove is
installed. Your local professional chimney sweep,
building inspector, or fire department official will be
able to make the inspection or direct you to someone
who can.
The chimney should extend at least 3' (900 mm)
above the highest point where it passes through a roof,
and at least 2' (600 mm) higher than any portion of a
building within 10' (3 m).
To assure proper draft and good performance, any
chimney used with this stove should extend at least 16'
(5 m) above the flue collar of the stove.
0 TO 10'
2' Min.
3'
Min.
0 TO 10'
2' Min.
3'
Min.
Reference Point
AC617
Fig. 2 The 2'-3'-10' Chimney Rule.
Masonry Chimneys
An existing masonry chimney must be inspected to
confirm that it has a lining. Do not use an unlined
chimney. The chimney also should be examined for
cracks, loose mortar, other signs of deterioration, and
blockage. Repair any defects before the chimney is
used with your stove.
A prefabricated doublewall insulated chimney
A tile-lined
masonry
chimney
ST241
Fig. 3 Standard Chimney Types
4
Vermont Castings Madison
Masonry Chimneys, cont'd.
• Unused openings in an existing masonry chimney
must be sealed with masonry to the thickness of the
chimney wall, and the chimney liner should be
repaired. Openings sealed with pie plates or
wallpaper are a hazard and should be sealed with
mortar or refractory cement. In the event of a
chimney fire, flames and smoke may be forced out
of these unused thimbles.
• The chimney should be thoroughly cleaned before use.
• A newly-built masonry chimney must conform to the
standards of local building code, or, in the absence
of a local code, to a recognized national code.
Masonry chimneys must be lined, either with codeapproved masonry or precast refractory tiles,
stainless steel pipe, or a code-approved, "poured-inplace" liner. The chimney clean-out door must seal
tightly to ensure a good draft.
Prefabricated Chimneys
A prefabricated metal chimney must be one that is
tested and listed for use with solid-fuel burning appliances to the High-Temperature (H.T.) Chimney Standard UL-103-1985 (2100° F.) for the United States, and
High Temperature (650°C) Standard ULC S-629 for
Canada.
Chimney Size
This Madison is approved for venting into a masonry
chimney with a nominal flue size of 8" x 8" (200 x 200
mm), and into a round flue size of 8" (200 mm) or 6" (150
mm). It may be vented into larger chimneys as well,
however, chimneys with liners larger than 8" x 12" (200
x 300 mm) may experience rapid cooling of smoke and
reduction in draft, especially if they are located outside
the home. Such large chimneys may need to be
insulated or relined for proper stove performance.
DO NOT CONNECT THIS UNIT TO A CHIMNEY
FLUE SERVING ANOTHER APPLIANCE.
NOTE: DO NOT VENT THIS STOVE INTO A
FACTORY-BUILT (ZERO-CLEARANCE) FIREPLACE. THIS STOVE HAS NOT BEEN TESTED
AND LISTED FOR THAT TYPE OF INSTALLATION. FACTORY-BUILT FIREPLACES AND
THEIR CHIMNEYS ARE SPECIFICALLY DESIGNED AS A UNIT FOR USE AS FIREPLACES.
IT MAY VOID THE LISTING OR BE HAZARDOUS
TO ADAPT THEM FOR ANY OTHER USE.
Chimney Connector Guidelines
A chimney connector is the double-wall or singlewall pipe that connects the stove to the chimney. The
chimney itself is a masonry or prefabricated structure
that encloses the flue. Chimney connectors are used
only to make the connection from the stove to the
chimney. They are for interior use only.
Double-wall connectors must be tested and listed
for use with solid-fuel burning appliances. Single-wall
connectors should be made of 24 gauge or heavier
steel, and should be 6" (150 mm) in diameter. Do not
use galvanized chimney connector; it cannot withstand
the high temperatures that can be reached by smoke
and exhaust gases, and may release toxic fumes
under high heat.
If possible, do not pass the chimney connector
through a combustible
wall or ceiling. If
passage through a
Toward
combustible wall is
stove
unavoidable, refer to
the recommendations
in the section following
on Wall Passthroughs. Do not pass
Flue gas
the connector through
direction
an attic, a closet or
any similar concealed
ST242
space. The whole
chimney connector
Fig. 4 Chimney connector.
should be exposed and
accessible for inspection and cleaning.
Install the single wall chimney connector not less
than 23" (585 mm) from the ceiling. Keep it as short
and direct as possible, with no more than two 90
degree turns. If possible, use 45 degree elbows. Slope
horizontal runs of connectors upward 1/4" per foot (20
mm per meter) going from the stove toward the
chimney. The recommended maximum length of a
horizontal run is 3 feet (1 meter), and the total length of
chimney connector should be no longer than 8 feet (2.5
meters).
In cathedral ceiling installations, extend the prefabricated chimney downward to within 8 feet (2.5 meters)
of the stove.
SAFETY NOTE: ALWAYS WEAR GLOVES AND
PROTECTIVE EYEWEAR WHEN DRILLING,
CUTTING OR JOINING CHIMNEY CONNECTOR
SECTIONS .
DO NOT CONNECT THE STOVE TO ANY AIR
DISTRIBUTION DUCT OR SYSTEM.
5
Vermont Castings Madison
Double-wall Chimney Connectors
The Madison is approved for installation in the U.S.
and Canada with double-wall chimney connectors that
have been tested and listed for use with solid-fuel
burning appliances by a recognized testing laboratory.
Follow the instructions for assembling and installing double-wall connectors provided by the manufacturer of the double-wall chimney. To ease assembly
and help assure safety, use chimney components
manufactured by a single source.
NOTE: For installations using double-wall
connectors, minimum clearances must conform to
those listed in the clearance chart on Page 12.
Single-wall Chimney Connectors
• Beginning at the flue collar of the stove, assemble
the chimney connector. Insert the first crimped end
into the stove’s flue collar, and keep each crimped
end pointing toward the stove. Using the holes in
the flue collar as guides, drill 1/8" (3 mm) holes in
the bottom of the first section of chimney connector
and secure it to the flue collar with three #10 x 1/2"
sheet metal screws.
• Secure each joint between sections of chimney
connector, including telescoping joints, with at least
three sheet metal screws. The predrilled holes in
the top of each section of chimney connector serve
as guides when you drill 1/8" (3 mm) holes in the
bottom of the next section.
• Secure the chimney connector to the chimney.
Instructions for various installations follow.
• Be sure the installed stove and chimney connector are
correct distances from nearby combustible material.
Note: Special slip pipes and thimble sleeves that
form telescoping joints between sections of chimney
connector are available to simplify assembly. Slip
pipes eliminate the need to cut individual connector
sections. Consult your local dealer about these special
connector sections.
Thimble Sleeve
Flue
Chimney
Connector
Keep sleeve
end flush with
flue tile
ST243
Fig. 5 The thimble, made of either ceramic or metal, must be
cemented securely in place.
6
Securing the Single-wall Connector to a
Prefabricated Chimney
Follow the installation instructions of the chimney
manufacturer exactly.
Special adaptors are available from your local
dealer to make the connection between the prefabricated chimney and the chimney connector. The top of
such adaptors attach directly to the chimney or to the
chimney’s ceiling support package. The bottom of the
adaptor is secured to the chimney connector.
The adaptor forms a union between the chimney
and chimney connector that ensures any soot or
creosote falling from the inner walls of the chimney will
stay inside the chimney connector.
Securing the Single-wall Connector to a
Masonry Chimney
The Madison may be connected to either a freestanding masonry chimney or to a fireplace masonry
chimney.
Freestanding Installations
If the chimney connector must pass through a combustible wall to reach the chimney, follow the recommendations for Wall Pass-Through construction on
pages 7-8.
The opening through the chimney wall to the flue the "breech" – must be lined with a ceramic or metal
thimble which is securely cemented in place. (Fig. 5)
A metal pipe section called the “thimble sleeve,”
slightly smaller in diameter than standard connector
and the thimbles, will allow the removal of the chimney
connector system for inspection and cleaning. Thimble
sleeves are available from your local dealer.
To install a thimble sleeve, slide it into the breech
until it is flush with the inner flue wall. Be sure that it
does not extend into the flue passage where it could
interfere with the draft.
The thimble sleeve should protrude 1-2" (25-50
mm) into the room. 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.
Vermont Castings Madison
Connection Above the Fireplace
Whenever possible, design the installation so that the
connector does not pass through a combustible wall. If
you must include a wall pass-through in your installation, check with your building inspector before you
begin. Also check with the chimney connector manufacturer for any specific requirements.
Consult with your dealer regarding special connection components available for use as wall passthroughs. Use only parts that have been tested and
listed for use as a wall pass-through.
clearance
*Note
requirement on
pages 12-13
ST244a
Fig. 6 If the clearance between the chimney connector and
either the ceiling or the mantel is inadequate, a protective
heat shield is required.
Fire clay liner
Min. 2" (51mm) Chimney
clearance to brick and
combustibles
Masonry
Chimney
constructed
to NFPA
211
A
Min. 12"
(305 mm)
Chimney
connector
Fire clay
liner
A
A = Minimum 12" (305 mm) brick
construction between liner and
combustible framing materials
ST272
Fig. 7 Masonry Wall Pass-through with single wall
chimney connector.
Min. 9"
230mm
Solid
insulated,
listed factorybuilt chimney
length set flush
with flue
Masonry
Chimney
constructed to
NFPA 211
Alternate methods approved by the NFPA:
• Using a section of double-wall chimney with a 9"
(230 mm) clearance to combustibles. (Fig. 8)
• Placing a chimney connector pipe inside a steel
double-wall ventilated thimble, which is then separated from combustibles by 6" (150 mm) of fiberglass insulating material. (Fig. 9)
*
Mantel
U.S. Requirements:
The National Fire Protection Association (NFPA) has
established guidelines for use in the United States for
passing chimney connectors through combustible
walls. Many building code inspectors follow these
guidelines.
Figure 7 shows one NFPA-approved method. All
combustible material in the wall is cut away to provide
12" (300 mm) clearance to the connector. Brick and
mortar are used to enclose the clearance area.
*
Chimney Flue
Wall Pass-throughs
Chimney Connector
Heat Shield
ST273
Sheet Steel
Supports
Min. 2"
(51mm)
Min. 9"
(230mm)
Chimney Flue
In this installation, the chimney connector enters the
fireplace flue through a thimble located above the
fireplace. (Fig. 6) The liner of the fireplace chimney
should extend at least to the point at which the chimney connector enters the chimney. Follow all the
guidelines for installing a chimney connector into a
freestanding masonry chimney, and pay special
attention to these additional points:
• The stove and chimney connector clearances to
combustible mantel and trim materials are the same
as clearances to combustible walls. If necessary,
use a combination of mantel, trim, and connector
heat shields to provide the required clearances.
Refer to page 12.
• Double-check connector clearance to the ceiling.
• The fireplace damper must be closed and sealed to
prevent room air from being drawn up the flue which
could reduce performance. However, it must be
possible to reopen the damper to inspect or clean
the chimney.
• Floor protection requirements also apply to fireplace
installations.
Non-soluble
refractory cement
Chimney
Connector
Air Space
24 ga.Sheet
Steel
Supports
Fig. 8 Wall Pass-through using factory-built insulated
chimney section.
7
Vermont Castings Madison
• Placing a chimney connector pipe inside a section
of 9" (230 mm) diameter, solid-insulated, factorybuilt chimney, with two inches of air space between
the chimney section and combustibles. (Fig. 10)
Chimney clearance to sheet steel
supports and combustibles
Canadian Requirements:
In Canada, the Canadian Standards Association has
established specific guidelines regarding wall passthough design. Figure 11 shows one approved method
in which all combustible material in the wall is cut away
to provide the required 18" (460 mm) clearance around
the connector. The resulting space must remain
empty. A flush-mounted sheet metal cover may be
used on one side only. If covers must be used on both
sides, each cover must be mounted on noncombustible spacers at least 1" (25 mm) clear of the wall.
Your local dealer or your local building inspector can
provide details of other approved methods of passing a
chimney connector through a combustible wall.
In Canada, this type of installation must conform
to CAN/CSA-B365, Installation Code for Solid Fuel
Burning Appliances and Equipment.
Chimney clearance to sheet
steel supports and combustibles
2" (51mm) Min.
Steel Thimble
with two 1"
(25mm) Ventilated
Channels
Chimney Flue
Masonry Chimney
constructed to NFPA 211
Min. 6"
(152mm)
Chimney Connector
Glass Fiber
Insulation
24 ga.Sheet
Steel Supports
ST274
Fig. 9 Wall Pass-through using single wall chimney
connector with a ventilated steel thimble.
2" (51mm) Min.
air space
Prefab
Chimney
Section
24 ga. Sheet
Steel Supports
ST275
Chimney Flue
Chimney clearance to sheet steel
supports and combustibles
2" (51mm)
Min.
2" (51mm) Min.
Chimney
Connector
Prefab
Chimney
Section
24 ga. Sheet
Steel Supports
Masonry Chimney
constructed to NFPA 211
Fig. 10 Wall Pass-through with ventilated steel thimble.
8
2" (51mm)
Min.
Min. 18"
(460mm)
Chimney Flue
Min. 18"
(460mm)
Chimney
Connector
24 ga.Sheet
Steel Support
24 ga. Sheet
Steel Support
(one side only)
Masonry Chimney
constructed to CAN/CSAB365
ST276
Fig. 11 CSA approved Wall Pass-through.
Floor Protection
A tremendous amount of heat radiates from the
bottom plate of your Madison. The floor area directly
under and around the stove will require protection from
radiant heat as well as from stray sparks or embers
that may escape the firebox.
Heat protection is provided through the use of a
Vermont Castings Bottom Heat Shield #1892. Spark
and ember protection must be provided by a floor
protector constructed with noncombustible material as
specified.
Most installations will require that the bottom heat
shield be attached. Only when the stove is placed on a
completely noncombustible surface such as unpainted
concrete over earth may it be used without the heat shield.
Even when the bottom heat shield is installed, you
must provide special protection to the floor beneath.
For installations with the heat shield attached, use a
noncombustible floor protector such as 1/4” nonasbestos mineral board or equivalent, or 24 gauge
sheet metal. The floor protector may be covered with a
noncombustible decorative material if desired. Do not
obstruct the space under the heater.
Protection requirements vary somewhat between
the United States and Canada as follows:
For U.S. installations the floor protector is required under the stove and must extend at least 18”
from the front of the stove (“D”, Fig. 12), at least 4”
from the right side and rear (“C”, Fig. 12) and 16” from
the left side (“E”, Fig. 12). It must also extend under
the chimney connector and 2” to either side (“F”, Fig.
12).
To meet these requirements, a floor protector must
be at least 48” wide (“A”,Fig. 12) and 48” deep (“B”,Fig.
12)
In Canada, a noncombustible floor protector is
required under the heater also. The floor protector
must extend 18” (460 mm) to the front (D), and 8” (203
mm) from the right side (C) and rear (C) and 18”
(460mm) from left side (E).
Vermont Castings Madison
To meet these requirements, a floor protector must
be at least 54” (1372mm) wide (“A”,Fig. 12) and 52”
(1320mm) deep (“B”, Fig. 12).
Fireplace Hearth Protection
Do not assume that your fireplace hearth is completely
noncombustible. Many fireplace hearths do not satisfy
the “completely noncombustible” requirement because
the brick or concrete in front of the fireplace opening is
supported by heavy wood framing. (Fig. 13) Because
heat is readily conducted by brick or concrete, it can
easily pass through to the wood. As a result, such
fireplace hearths can be a fire hazard and are considered a combustible floor.
For all fireplace installations, follow the floor
protection guidelines described above.
Keep in mind that many raised hearths will extend
less than the required clearance from the front of the
heater when it is installed. In such cases, sufficient
floor protection as described above must be added in
front of the hearth to satisfy the minimum floor protector requirement from the front of the stove: 18" (460
mm) from the front in the United States and 18" (460
mm) from the front in Canada.
Hearth rugs do not satisfy the requirements for
floor protection as they are only fire-retardant, not fire
proof.
Floor Protection Requirements
Rear Vent
F
C
C
B
C
E
C
D
D
A
A
U. S.
A:
B:
C:
D:
E:
F:
48”
48”
4”
18”
16”
10”
ST247a
Fig. 13 Supporting timbers under fireplace hearths are
considered to be combustible.
Clearance to Surrounding
Combustible Materials
When the stove is operating, both the stoveplate and
the chimney connector radiate heat in all directions. A
safe installation requires that adequate clearance be
maintained between the stove and nearby combustible
materials to ensure that those materials do not
overheat.
Clearance is the distance between either your
stove or chimney connector, and nearby walls, floors,
the ceiling, and any other fixed combustible surface.
Keep furnishings and other combustible materials
away from the stove as well. In general, a distance
of 48" (1220 mm) must be maintained between the
stove and moveable combustible items such as drying
clothes, furniture, newspapers, firewood, etc. Keep
this area empty of any combustible material.
Safe Ways To Reduce Clearances
Top Vent
E
Wood framing
requires protection
from radiant heat
Canada
54”
52”
8”
18”
18”
10”
(1372mm)
(1321mm)
(203mm)
(460mm)
(460mm)
(254mm)
The Madison clearance requirements, listed and
diagramed on pages 12-13, have been established
through testing to UL and ULC standards to meet most
installation configurations. These involve four basic
variables:
• When neither the chimney connector nor the wall
has a heat shield installed.
• When only the chimney connector has a heat
shield installed.
• When only the wall has a heat shield mounted on it.
• When a heat shield is installed on both the
chimney connector and wall.
ST500a
Fig. 12 These dimensions are minimum requirements only.
Use greater dimensions whenever possible.
In general, the greatest clearance is required when
the stove will be positioned with no heat shield near a
wall with no heat shield. The least clearance is required when both the stove and the wall have heat
shields. Reducing a stove clearance may require
installation of a listed heat shield on the chimney
connector as well.
Clearances may be reduced only by means
approved by the regulatory authority, or in accordance
with the clearances listed in this manual.
9
Vermont Castings Madison
Wall Shields
Wall shields should be constructed of 24 gauge or
heavier sheet metal, or another noncombustible
material such as 1/2" (13 mm) insulation board (Fig.
14) or common brick "laid on flat," with the 3¹⁄₂" (90
mm) side down.
Shields must be spaced out from the combustible
surface 1" (25 mm) on noncombustible spacers. The
spacers should not be directly behind the stove or
chimney connector.
Air must be able to flow between the wall and the
shield. At least 50% of the bottom 1" (25 mm) of the
shield should be open and the shield must be open at
the top.
C
C
B
A
A
B
C
A = 48” (1219 mm)
B = Max. - C
C = 1” (25 mm)
C
ST550
Fig. 15 Parallel installation, vertical chimney connector, two
wall shields.
Air flow
A = 48” (1219 mm)
B = 48” (1219 mm)
C = 1” (25 mm)
Stud wall
framing
Wall shield
A
A
B
Noncombustible
spacers and
fasteners
B
Shield
C
C
Metal Spacer
ST551
Drywall
Fig. 16 Parallel installation with rear wall pass-through, two
wall shields.
Air flow
ST248a
Fig. 14 Approved Wall shield construction
The following examples of wall shield construction
illustrate common designs used to safely achieve
reduced clearances to combustible wall materials.
Parallel installation, vertical chimney connector,
two wall shields. Fig. 15: Reduced clearances for
both rear and side walls. Wall shields may meet at
corner if desired. Shielding for connector is centered
behind connector.
Parallel installation with rear wall pass-through,
two wall shields. Fig. 16: Reduced clearances for
both rear and side walls. Wall shields may meet at
corner if desired. Shielding for connector is centered
behind connector. Wall pass-through must comply
with codes.
Corner installation, vertical chimney connector,
two wall shields. Fig. 17: Reduced side clearances.
Wall shields MUST meet at corner.
Parallel installation with rear exit, rear wall passthrough, rear wall shield. Fig. 18: Reduced
clearances for rear wall. Shielding for connector is
centered behind connector. Wall pass-through must
comply with codes.
10
C
C
A
B
B
A = 48” (1219 mm)
B = Max. - C
C = 1” (25 mm)
A
C
C
ST552
Fig. 17 Corner installation, vertical chimney connector, two
wall shields.
A = 48” (1219 mm)
B = 48” (1219 mm)
C = 1” (25 mm)
A
B
C
ST564
Fig. 18 Parallel installation, rear wall pass through, rear wall
shield.
Vermont Castings Madison
Alcove Installations
Because of their restricted air flow and heat retention
characteristics, specific construction requirements and
special clearances apply to installations into alcoves.
No stove or chimney connector heat shields are used in
alcove installations.
ALCOVE INSTALLATION OF THE MADISON IS NOT
PERMITTED IN CANADA.
Construction Requirements
The following illustrations show non-combustible ceiling
framing and maximum and minimum permitted dimensions for alcove construction.
ST504
Fig. 21 Cutaway perspective of alcove installation.
36"
Max.
7/16” Durock®
(or equivalent)
spaced 1” off
wood studs on
noncombustible
spacers
Use recommended
floor protection
48" Min.
ST502
Fig. 19 Alcove floor plan. Sheetrock on front face butts to
Durock® (or equivalent) alcove lining.
Existing Combustible
Framing
24"
11"
Min.
Metal studs
support 7/16”
Durock® (or
equivalent)
ceiling
36"
Min.
14¹⁄₄"
Joist Shield
(Supplied by
Chimney
Manufacturer)
48" Min.
ST505
Fig. 22 Reflected ceiling plan.
Metal
Stud
Combustible
facing may
overlap metal
studs by only
1”
1” air gap top
and bottom,
on both
sides and
back wall
7/16” Durock® (or
equivalent)
Ceiling support
package
extends 2”
below Durock®
(or equivalent)
ceiling
1” air gap,
top, bottom,
on both
sides and
back wall
65"
62" Min.
to Alcove
Ceiling
INTREPID II
ST503
Fig. 20 Alcove side section.
NOTE:
From 62” to
65” must be
covered by
a noncombustible
material.
ST506
Fig. 23 Front view: 65” minimum clearance form hearth to
combustibles on front face. Combustible facing may overlap
metal studs by only 1”. It should not extend below the height of
the noncombustible ceiling.
11
Vermont Castings Madison
Madison 1655 Series Clearance Chart
Use the chart below together with the diagrams on the next page to determine the minimum clearance required for
your particular installation. In any case, it is always advisable to locate the stove as far away from walls as possible in order to take full advantage of the radiant properties of cast iron.
Stove clearances are measured between the cast iron Top Plate of the stove and the combustible surface. Note
that the cast iron back on the Madison protrudes 5” (130 mm) out from the stovetop, and will therefore be closer to
the wall than the top of the stove.
Chimney Connector clearances are measured between the connector surface and the combustible surface. For
Douible-wall Chimney Connector, use the manufacturer’s listed clearance specification.
Use NFPA 211 default clearance or manufacturer’s installation specifications for those configurations not tested.
UNPROTECTED SURFACES
Parallel Installation
STOVE CLEARANCE
Side
Rear
PROTECTED SURFACES
Corner
Installation
Corner
Parallel Installation
Side
Rear
A 21”
(533 mm)
B 24”
(610 mm)
C 21”
(533 mm)
Top exit, heat shields on stove,
no shields on single wall
connector
Top exit, heat shield on stove,
heat shield on single wall
connector
Top exit, heat shield on stove,
double wall chimney connector
G 21”
(533mm)
H 24”
(610 mm)
I 21”
(533 mm)
M 21”
(533mm)
N 22”
(559 mm)
O 18”
(457 mm)
P 12”
(305 mm)
Q 14”
(356 mm)
R 8”
(203 mm)
S 16”
(406 mm)
T 12”
(305 mm)
U 18”
(457 mm)
V 12”
(305 mm)
W 11”
(279 mm)
X 8”
(203 mm)
Rear exit, no heat shields
Y 18”
(457 mm)
Z 20”
(508 mm)
N/A
AA 12”
(305 mm)
BB 15”
(381 mm)
N/A
Rear exit, heat shields
CC 16”
(406 mm)
DD 18”
(457 mm)
N/A
EE 12”
(305 mm)
FF 12”
(305 mm)
N/A
Without Connector Heat Shields
UNPROTECTED SURFACE / Vertical
E 14”
(356 mm)
Corner
Top exit, no heat shields
CHIMNEY CONNECTOR
CLEARANCE
D 12”
(305 mm)
Corner
Installation
J 12”
(305 mm)
K 14”
(356 mm)
F 10”
(250 mm)
L 10”
(250 mm)
PROTECTED SURFACE / Vertical
19” (483 mm)
13” (330 mm)
With Connector Heat Shields
UNPROTECTED SURFACE / Horizontal
Single-wall Connector
FRONT CLEARANCE
TO COMBUSTIBLES*
PROTECTED SURFACE / Horizontal
23” (584 mm)
23” (584 mm)
ALL INSTALLATIONS
48" (1220mm)
* A distance of 48" must be maintained between the stove and moveable combustible items such as drying
clothes, furniture, firewood, etc.
12
Vermont Castings Madison
Madison 1655 Series Clearance Diagram
Top Exit, Bottom Heat Shield always used, floor
protection, minimum 18” (457mm) in front.
UNPROTECTED SURFACES
Stove Installed
Parallel to Wall
PROTECTED
SURFACES
Stove Installed
Parallel to Wall
Stove in Corner
Stove in Corner
Top Exit Installations, no heat shields
C
B
A
F
E
C
D
F
Top Exit Installations, heat shield on stove, no shields on single-wall connector
I
H
G
L
K
J
I
L
Top Exit Installations, heat shield on stove, heat shields on single-wall connector
O
N
M
R
Q
P
O
R
Top Exit Installations, heat shield on stove, double-wall chimney connector
U
T
S
X
W
U
V
X
ST553
13
Vermont Castings Madison
Madison 1655 Series Clearance Diagram
Rear Exit Installations, Bottom Heat Shield, floor
protection, minimum 18” (457mm) in front.
UNPROTECTED SURFACES
Stove Installed
Parallel to Wall
PROTECTED
Stove Installed
Parallel to Wall
Stove in Corner
SURFACES
Stove in Corner
Rear Exit Installations, no heat shields
Z
BB
N/A
N/A
Y
AA
Rear Exit Installations, heat shields
DD
FF
CC
EE
ST563
14
Vermont Castings Madison
Assembly
You will need the following tools to assemble the Madison:
• 9/16" open end wrench • safety glasses & gloves
• flat head screwdriver
• power drill w/ 1/8" (3mm) bit
• stub handle phillips screwdriver
2. Mount the bottom heat shield to the stove bottom
using the same phillips head screw previously removed. The corners of the shield will butt against the
cast leg locators at each corner of the stove bottom.
Unpack the Stove
1. Remove the shipping straps and plastic wrap.
2. Inspect the stove and contents for shipping damage
or missing parts. Immediately notify your dealer of
any damage. Do not install this stove if any damage
is evident or any parts are missing.
Hardware Bag contents:
• Stove Legs, 4
• 3/8-16 x 1¹⁄₄” hex head Leg Bolts with washers, 4
• Owner's Registration Card
• Touch-up Paint (Porcelain enamel stoves only)
Install Stove Legs
ST465
1/4-20 x 1/2” Pan Head Screw
Fig. 25 Attach the Bottom Heat Shield to the boss in the
center of the stove bottom.
Storing the Handle
Remove and discard the four large slot-head screws
from the stove bottom. Install the stove legs using the
hex head bolts from the parts bag. Use 3/8” washers
with all four legs; the door handle holder installs on the
right front leg. Position the holder so the hole to accept
the handle hub faces out from the right side of the
stove. Tighten the bolts firmly. CAUTION: Overtightening can strip tapped threads.
Use the removable handle to open or close the doors.
After using it, remove the handle so it will not get hot.
Store the handle in the handle holder installed behind
the right front leg. (Fig. 25a)
Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer
ST564
Leg Bolt and
Washer
Fig. 25a Handle holder and heat shield positions.
Leg Leveller
ST466
Fig. 24 Attach the stove legs with leg levellers.
Install the Bottom Heat Shield
The #1892 Bottom Heat Shield must be used in the
U.S. and Canada in any installation on a floor that is
not comprised of unpainted cement on earth.
1. Remove the 1/4-20x 1/2" phillips screw from the
central mounting boss in the stove bottom. (Fig. 25)
When Installing Rear Heat Shield
Models 1655, 1656, 1567, 1658, 1659 only.
Remove and retain the factory installed flue collar heat
shield. Loosen two phillips screws, on either side of the
flue collar, approximately one turn each.Slide heat
shield away from the flue collar, then push flue collar
forward and retighten phillips screws.
15
Vermont Castings Madison
Install the Outside Air Adaptor
The optional #1891 Outside Air Adaptor provides a
collar to which a 3 inch diameter air duct may be
attached directly to the air inlet area at the back of the
stove. This option can be installed in two different
configurations, with Rear Heat Shield #1893 and
without the heat shield.
Without Rear Heat
Shield
Stove Back
Outside Air
Standoff
With Rear Heat Shield
Outside Air
Adaptor
1. Engage the Adaptor against the Air inlet opening in
the Rear Heat Shield. Align clearance holes in the
adaptor with pilot holes in the Rear Heat Shield as
shown at the bottom of Figure 26.
2. Use two sheet metal screws provided in the kit to
attach the Adaptor to the Rear Heat Shield at the
aligned holes.
Primary Air Flap
With Rear Heat Shield
Rear Heat Shield
Without Rear Heat Shield
1. Facing the rear of the stove, loosen the pan head
screw located a the upper left hand corner of the
primary air inlet two revolutions. Position the
Adaptor over the air inlet opening in the rear of the
stove with the pan head screw passing through the
slotted tab in the Standoff. Make certain that the
damper tab is located between the stove and the
standoff and is oriented as it was before the screw
was loosened. Tighten the pan head screw using
the access hole in the standoff. The Thermostat and
Primary Air Flap should operate freely.
2. Engage the Adaptor against the air inlet opening in
the Outside Air Standoff. Align clearance holes in
the adaptor with pilot holes in the Standoff as
shown at the top of Figure 26.
3. Use two sheet metal screws provided in the kit to
attach the Adaptor to the Outside Air Standoff at the
aligned holes.
16
ST462
Oustide Air Adpator
Fig. 26 Outside Air Adaptor options.
Attach the Chimney Connector
Insert the crimped end of the first section of chimney
connector into the flue collar. Using the holes in the
collar as guides, drill 1/8" (3mm) holes through the
connector pipe. Use the three #10 x 1/2" sheet metal
screws provided to secure the chimney connection to
the flue collar.
If applicable, attach Chimney Connector Heat Shields
following the instructions included with those parts.
Vermont Castings Madison
Operation
How the Madison Works
Combustion control is achieved in the Madison through
two separate air delivery systems.
The primary air control lever, located at the left
rear corner of the stove, controls the amount of
incoming primary air for starting, maintaining, and
reviving the fire. More air entering the stove makes the
fire burn hotter and faster, while less air prolongs the
burn at a lower heat level.
For the greatest air supply and maximum heat
output (but the shortest burn time), move the lever to
the left most position. For a fire that will last longer
with less heat, move the lever to the right. You can set
the lever anywhere in between the upper and lower
extremes.
DO NOT USE CHEMICALS OR FLUIDS TO
START THE FIRE. DO NOT BURN GARBAGE
OR FLAMMABLE FLUIDS SUCH AS GASOLINE, NAPTHA, OR ENGINE OIL. ALSO,
NEVER USE GASOLINE-TYPE LANTERN
FUEL, KEROSENE, CHARCOAL LIGHTER
FLUID, OR SIMILAR LIQUIDS TO START OR
"FRESHEN UP" A FIRE. KEEP ALL SUCH
LIQUIDS WELL AWAY FROM THE MADISON
WHILE IT IS IN USE.
CAUTION: THE MADISON WILL BE HOT
WHILE IN OPERATION. KEEP CHILDREN,
CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN BURNS.
DO NOT OVERFIRE THIS HEATER.
OVERFIRING MAY CAUSE A HOUSE FIRE,
OR CAN RESULT IN PERMANENT DAMAGE
TO THE STOVE. IF ANY PART OF THE
STOVE GLOWS, YOU ARE OVERFIRING.
The Madison features an automatic thermostat to
ensure an even heat output at any manual setting you
select. As the fuel burns, the thermostat reacts to the
heat radiating from the stove surface and,
consequently, adjusts the air shutter attached to it. As
the fire intensity (and heat output) builds, the
thermostat slowly closes the air shutter, thereby
restricting incoming combustion air. As the fire intensity
then wanes (and heat output lessens), the thermostat
responds and gradually opens the air shutter which
allows more combustion air to again enliven the fire.
This ebb and flow action functions continuously to
prolong the burn cycle until the fuelbed is exhausted.
Another separate supply of oxygen is delivered to
the upper area of the firebox to support combustion of
gases released from the main fuel bed. This Secondary Air enters the stove through two, unrestricted inlets
and is heated while passing through separate channels
before being delivered through three stainless steel
multi-ported tubes located at the top of the firebox.
Burn Only High-Quality Wood
THE MADISON IS DESIGNED TO BURN NATURAL
WOOD ONLY; DO NOT BURN ANY OTHER FUELS.
You will enjoy the best results when burning wood
that has been adequately air-dried. Avoid burning
“green” wood that has not been properly seasoned.
The wood should be no longer than 18" (460 mm) in
length, however, you will find that shorter wood lengths
ease refueling and promote the most efficient combustion.
The best hardwood fuels include oak, maple,
beech, ash, and hickory that has been split, stacked,
and air-dried outside under cover for at least one year.
For areas that do not have a supply of hardwood,
commonly burned softwoods include tamarack, yellow
pine, white pine, Eastern red cedar, fir, and redwood.
These too should be properly dried.
Keep wood a safe distance from the heater and
keep it out of the areas around the heater used for
refueling and ash removal.
Use the Air Control Setting that Works
Best for You
No single air control setting will be appropriate for
every situation. Settings will differ depending on the
quality of the fuel, the amount of heat desired, and how
long you wish the fire to burn.
The control setting also depends on your particular
installation’s “draft,” or the force that moves air from
the stove up through the chimney. Draft is affected by
such things as the length, type, and location of the
chimney, local geography, nearby obstructions, and
other factors.
Too much draft may cause excessive temperatures
in the Madison, and could even damage it. On the
other hand, too little draft can cause backpuffing into
the room and/or the “plugging” of the chimney.
How do you know if your draft is excessively high
or low? Symptoms of too much draft include an
uncontrollable burn or a glowing-red stove part. A sign
of inadequate draft is smoke leaking into the room
through the stove or chimney connector joints, low
heat, and dirty glass.
In newer homes that are well-insulated and
weather-tight, poor draft may result from insufficient air
in the house. In such cases, a slightly opened window
near the stove on the windward side of the house will
provide the fresh air needed.
17
Vermont Castings Madison
A more effective option for delivering ample
combustion air to the stove is to duct air directly from
outdoors to the stove. In fact, in some areas,
provisions for outside combustion air are required in all
new construction. The optional Madison Outside Air
Adaptor is available from your dealer.
When you first begin using the stove, pay attention
to the air control settings. You will quickly find that a
specific setting will give you a fixed amount of heat. It
may take some time to determine the amount of heat
and the length of burn you should expect from various
settings.
Do not for any reason attempt to increase the
firing of your heater by altering the air control
adjustment range outlined in these directions.
Use the following air control settings as a starting
point to help determine the best settings for your
installation.
Step 1. Open the primary air control fully. (Lever at left
most position)
Step 2. Place several sheets of crumpled newspaper
in the stove. Avoid using glossy or colored paper,
as these burn poorly. At the front of the firebox,
place on the paper six or eight pieces of dry kindling
split to a finger-width size, and on the kindling lay
two or three larger sticks of split dry wood approximately 1-2" (25-50 mm) in diameter. (Fig. 27)
Madison Control Settings
Burn Rate
Primary Air Control
Shutter Position
High
Medium
Left most position
Fully Open
Half Open
Low
Right most position
Fully Closed
Before you begin using the stove, please read the
Appendix on Draft Management, starting on page 22,
to learn how the characteristics of your particular
installation will affect your stove's performance. You
and the stove are parts of a system; other parts of the
system have a strong effect on performance. You may
need to vary your firing technique to get the results you
desire.
Starting and Maintaining a Fire
Conditioning Your Stove
Cast iron is extremely strong, but it can be broken
with a sharp blow from a hammer or from the thermal
shock of rapid and extreme temperature change.
The cast plates expand and contract with changes
in temperature. When you first begin using your
Madison, minimize thermal stress by allowing the
plates to adjust gradually during three or four initial
break-in fires following Steps 1- 3.
ST263
Fig. 27 Start a fire with small, dry kindling.
Step 3. Light the newspaper and close the doors.
Gradually build up the fire by adding a few 3-5" (80120 mm) diameter splits. (Fig. 28) If this is one of
the first few "break-in" fires, let the fire burn brightly,
and then let it die out.
• During the break-in fires, don't let the stove get
hotter than 500°F. (260°C) as measured on an
optional stove-top thermometer. Adjust the air
control lever as necessary to control the fire.
• Some odor from the stove’s hot metal, the paint,
and the cement is normal for the first few fires.
BURN SOLID WOOD FUEL ONLY, AND BURN IT
DIRECTLY ON THE GRATE. DO NOT ELEVATE
THE FUEL. DO NOT BURN COAL OR OTHER
FUELS.
WARNING: OPERATE THIS STOVE ONLY WITH
THE DOORS FULLY CLOSED.
The Primary Air Inlet must be open when starting a
fire or when refueling.
18
ST264
Fig. 28 Gradually add larger pieces of wood until all the wood
is burning well.
Vermont Castings Madison
NOTE: Some chimneys need to be “primed,” or
warmed up, before they will draw sufficiently to
sustain a fire. To correct this situation, roll up a
couple pieces of newspaper, place them on top of
the kindling and toward the back of the stove, light
them, and close the doors. This should heat the
chimney enough to initiate strong draft.
Once the draft is established, open the front doors
and light the rest of the fuel bed at the bottom. Do
not light the main bed of fuel until the chimney
begins drawing.
Step 4. After the stove has been broken-in using Steps
1-3, continue to build the fire gradually. Add larger
wood with a diameter of 3-4" (75-100 mm).
Continue adding split logs of this size to the brisklyburning fire until there is a glowing ember bed at
least 2" (50 mm) deep. A good ember bed is
necessary for proper functioning and may take up
to an hour to establish.
Step 5. Adjust the thermostatic air control for the
desired heat output.
Refuel While the Embers Are Still Hot
Reload the Madison while it is still hot and there are
plenty of glowing embers to re-kindle the fire. Include
some smaller pieces of wood in the new load of fuel to
help the stove return to its operating temperature
quickly. Wear stove gloves, and follow this procedure
when you reload your stove:
Step 1. Open the thermostat lever.
Step 2. Open the doors and check the ash level in the
ash pan. If necessary, dispose of the ashes and
replace the pan.
Step 3. Use a fireplace tool to break up the charcoal
and direct ash through the grate. Pull the charcoal
from the back to the front.
Step 4. Load wood — smaller, split pieces first. Close
the doors. Ideal performance will be achieved by
operating with the air control set in the maximum
(HIGH) positon for several minutes after refueling.
Reset the primary air control for the desired heat
output after the fire is re-established.
Ash Disposal
Remove ash before it reaches the top of the ash pan.
Check the level at least once a day, and before each
re-fueling. Using stove gloves, pull the ash pan out of
the stove by its handle. Remove the ash pan and
properly dispose of the ashes. Be sure to keep the pan
level during disposal.
Empty the ash pan regularly, typically every one
to three days. The frequency will vary depending on
how you operate your Madison; if you burn more wood
at higher heat output settings, ash will accumulate
rapidly.
Dispose of ashes into a metal container with a
tight-fitting lid, kept outdoors. Put the closed container
of ash on a noncombustible floor or on the ground, well
away from all combustible materials, pending final
disposal. If the ash is disposed of by burial in soil or
otherwise locally dispersed, keep it in the closed
container until all cinders have thoroughly cooled. You
can use wood ash as a garden fertilizer.
CAUTION: Never use your household or shop
vacuum cleaner to remove ash from the stove;
always remove and dispose of the ash properly.
CAUTION: AVOID SLAMMING THE STOVE
DOOR OR STRIKING THE GLASS PANEL. DO
NOT OPERATE THE STOVE WITH THE GLASS
PANEL MISSING, DAMAGED, OR BROKEN. DO
NOT INSTALL SUBSTITUTE MATERIALS. SEE
MAINTENANCE SECTION FOR REPLACEMENT
INSTRUCTIONS.
Smoke Detectors
The use of smoke detectors throughout the home is
strongly advised, if not required by building codes or
insurance regulations. It is a good idea to install a
smoke detector in the living areas and each bedroom.
You may not, however, wish to install a detector in
the immediate vicinity of the stove. Depending on the
sensitivity of the unit, the alarm can be set off while you
are tending the fire or emptying the ashes. If you install
a detector in the same room, locate it as far away from
the stove as possible.
19
Vermont Castings Madison
Maintenance
Let the fire in the stove go out and allow the stove to
cool completely before beginning any maintenance
procedure.
Care of the Cast Iron Surface
An occasional dusting with a dry rag will keep the
painted cast iron of your Madison looking new.
The stove’s paint can be touched up as needed.
First, clean the areas to be painted with a wire brush.
Then, touch up the stove with Vermont Castings high
temperature stove paint. Apply the paint sparingly,
and keep in mind that two light coats of paint are better
than a single heavy one.
Care of Porcelain Enamel Finish
Use a dry or slightly damp rag or a soft brush to
remove spills or stains. For difficult jobs that require a
cleaning agent, use only a kitchen appliance cleaner or
polish recommended for use on enamel surfaces.
Cleaning the Glass
Most of the carbon deposits on the glass will burn off
during hot fires. However, the ash residue that
accumulates on the glass surface should be removed
regularly to prevent etching. Follow this procedure to
clean the glass:
• Be sure the glass is completely cool.
• Clean the glass with water or a cleaner made
especially for this purpose. Do not use abrasive
cleaners.
• Rinse the glass thoroughly.
• Dry the glass completely.
Glass Replacement
Replace glass only with Vermont Castings glass
panels. The glass panel rests on a cushion provided by
a gasket, and is held in place by two clips. The glass
is coated on one side which is slightly colored.
Remove the door from the stove and place it on a
sturdy, level work surface. Use a towel to protect the
porcelain enamel finish.
1. Remove the Retainer Clips. (Two phillips head
screws on each clip).
2. Inspect the Gasket. If the window gasket is in good
condition, you can leave it in place. If you replace it,
use only Vermont Castings gasket 1203556. Be sure
the channel around the window opening is clean,
and free of dust.
Place the gasket into the panel inset.
20
3. Install the Glass. Lay the glass on the inner gasket
with the coated side down, marked “This Side Out”
(toward the outside of the door). Tighten the screws
snugly, but loose enough to allow for a little movement of the glass when the stove is in operation.
Overtightening can crack the glass immediately or
cause it to crack if it is unable to expand when hot.
Gasket Replacement
Your Madison uses rope-type fiberglass gaskets to
make a tight seal between some parts. With use,
particularly on those parts that move, gaskets can
become brittle and compressed and can begin to lose
their effectiveness. These will need periodic
replacement.
The sizes of replaceable gasket are listed below,
along with their applications.
Gasket Size
3/8” Fiberglass
Door Gasket - 1203589
Wait until the fire is out and the stove has cooled.
Be sure to follow the standard safety procedure for
working with dusty materials: Wear safety goggles and
a dust mask.
Step 1. Remove the existing gasket by grasping an
end and pulling firmly.
Step 2. Use a wire brush or a screwdriver to clean the
channel of any remaining cement or bits of gasket.
Remove stubborn deposits of cement with a cold chisel
if necessary.
Step 3. Determine the correct length of the appropriate-sized gasket by laying it out in the channel. Allow
an extra 1-2" (25-50 mm), and mark the spot to be cut.
Step 4. Remove the gasket from the channel, place it
on a wood cutting surface, and cut it at the marked
spot with a utility knife.
Twist the ends slightly to discourage the gasket from
unraveling.
Step 5. Lay an unbroken 1/8" (3 mm) bead of gasket
cement in the newly-cleaned channel.
Step 6. Starting at one end, press the gasket into the
channel.
Ensure a good joint where the gasket meets before
trimming any excess. Do not overlap the gasket ends
or leave ends with ragged edges.
Step 7. Press the gasketed part firmly against its
normal mating surface to seat the gasket evenly in its
channel. Close and latch the door to do this; close the
door on a piece of waxed paper to keep the cement
from migrating onto the non-gasketed part, or mask
other parts
Step 8. Clean excess cement from around the channel. Let the cement that holds the new gasket dry
thoroughly.
Vermont Castings Madison
The Chimney System
Annual Maintenance
Creosote
Perform a thorough cleaning, inspection and repair
each Spring, at the end of the heating season.
• Thoroughly clean the chimney and chimney connector.
• Inspect the chimney for damage and deterioration.
Replace weak sections of prefabricated chimney.
Have a mason make repairs to a masonry chimney.
• Inspect the chimney connector and replace any
damaged sections.
• Clean ash debris from under the primary air plate.
See procedure below.
• Check gasketing for wear or compression, and
replace if necessary. A 'paper test' will guide you on
this. Close and lock the door on a slip of paper and
then try to pull the paper out. If the paper pulls out
with little or no resistance, the gasket isn't snug
enough at that spot. If adjusting the latch doesn't
result in a seal that makes it hard to pull the paper
out, replace the gasketing.
• Check door handle for tightness. Adjust if needed.
• Check heat shield screws. Tighten as necessary.
• Clean dust from the inner sides of bottom, rear and
connector heat shields.
• Remove ashes from the ash pan and replace with
moisture absorbing material (such as cat litter) to
keep the stove interior dry. Close the stove door to
keep cats from using the litter.
• Touch up the paint on black stoves.
Your Madison is designed to reduce creosote buildup
significantly. However, regular chimney inspection and
maintenance must still be performed. For safety, good
stove performance, and to protect your chimney and
chimney connector, inspect your chimney and chimney
connector on a regular schedule. Clean the system if
necessary. Failure to keep the chimney and connector
system clean can result in a serious chimney fire.
When wood is burned slowly, it produces tar,
organic vapors and moisture that combine to form
creosote. The creosote vapors condense in the
relatively cool chimney flue. As a result, creosote
residue accumulates on the flue lining. When
ignited, this creosote makes an extremely hot fire
within the flue system that can damage the chimney and overheat adjacent combustible material.
If you do have a chimney fire, promptly:
• Close the thermostat lever.
• Get everyone out of the house.
• Call the Fire Department.
You should inspect the system every two weeks
during the heating season as part of a regular
maintenance schedule. To inspect the chimney, let the
stove cool completely. Then, using a mirror and a
strong light, sight up through the flue collar into the
chimney flue. If it is not possible to inspect the flue
system in this fashion, the stove must be disconnected
to provide better viewing access.
If a significant layer of creosote has accumulated
—1/8" (3 mm) or more — remove it to reduce the risk
of a chimney fire.
Clean the chimney using a brush the same size
and shape as the flue liner. Flexible fiberglass rods
are used to run the brush up and down the liner,
causing any deposits to fall to the bottom of the
chimney where they can be removed through the
clean-out door.
The chimney connector should be cleaned by
disconnecting the sections, taking them outside, and
removing any deposits with a stiff wire brush. Reinstall
the connector sections after cleaning, being sure to
secure the individual sections with sheet metal screws.
If you cannot inspect or clean the chimney
yourself, contact your local Vermont Castings’
Authorized Dealer or hire a professional chimney
sweep.
Clean the Primary Air Outlet
1. Remove the phillips head screws that retain the
Primary Air Plate.
2. Use a screwdriver to pry the plate out of the cemented seams.
3. Remove ash debris from the cavity.
4. Use high-temperature furnace cement to reseal the
front seam and side seams and replace the plate.
Secure with the phillips head screws.
21
Vermont Castings Madison
Draft Management
Your stove is only one part of a system that includes
the chimney, the operator, the fuel and the home. The
other parts of the system will affect how well the stove
works. When there is a good match between all the
parts, the stove works well.
Wood stove operation depends on natural
(unforced) draft. Natural draft occurs when exhaust gas
is hotter (and therefore lighter) than the outdoor air at
the top of the chimney. The greater the temperature
difference, the stronger the draft. As the hot exhaust
gas rises out of the chimney it generates suction that
draws air into the stove for combustion. A slow, lazy
fire with the stove’s air inlets fully open indicates a
weak draft. A brisk fire, supported only by air entering
the stove through the normal inlets, indicates a good
draft. The inlets are passive; they regulate how much
air can enter the stove, but they do not move air into it.
The efficiency of a modern woodburning appliance, (in which the amount of air available for combustion is regulated), depends on the chimney to keep
exhaust gases warm all the way outdoors. The characteristics of your chimney - whether it is steel or masonry, interior or exterior, matched or mismatched to
the stove collar - determine how quickly it will warm up
and how well it will sustain the optimum temperatures
necessary to maintain strong draft and efficient combustion. Here follows a description of various flue
system characteristics and related effects on stove
performance.
Masonry Chimney
Although masonry is the traditional material used for
chimney construction, it can have distinct performance
disadvantages when used to vent a controlled-combustion woodstove. Masonry forms an effective ‘heat sink’
- that is, it absorbs and holds heat for long periods of
time. The large mass, however, may take a long time
to become hot enough to sustain a strong draft. The
larger the chimney (in total mass), the longer it will take
to warm up. Cold masonry will actually cool exhaust
gases enough to diminish draft strength. This problem
is compounded if the chimney is located outside the
home or if the chimney flue has a cross-sectional size
larger than the stove outlet.
Steel Chimney
Most factory-made ‘Class A’ steel chimneys have a
layer of insulation around the inner flue. This insulation
keeps the smoke warm and protects the surrounding
structure from the high flue temperatures. Because the
insulation is less dense than masonry, the inner steel
liner warms up more quickly than a masonry chimney.
22
Although steel chimneys are not as attractive as their
masonry counterparts, they are very durable and
generally outperform masonry.
Inside/Outside Location
Because the chimney’s function is to keep the smoke
warm, it is best to locate it inside the house. This
location uses the house as insulation for the flue and
allows some radiant heat release from the flue into the
home. Since an interior chimney does not continuously
lose its heat to the outdoors, it takes less heat from the
stove to get it warm and keep it warm.
Flue Sizing
The flue size for a controlled-combustion appliance
should be based on the cross-sectional volume of the
stove flue outlet. In this case, more is definitely not
better. Hot gases lose heat through expansion; if a
stove with a six-inch flue collar (28 square inch area) is
vented into a 10” x 10” flue, the gases will expand to
over three times their original volume. As gases cool
with expansion, draft strength decreases. If an oversized flue is also outside the house, the heat it absorbs
will be conducted to the outdoor air and the flue will
remain relatively cool.
It is common for a masonry flue to be oversized for
the stove. Such a chimney can take quite a while to
warm up and the stove performance will likely be
disappointing. The best solution to an oversize flue
problem is the installation of an insulated steel chimney
liner of the same diameter as the appliance flue outlet.
The liner keeps the exhaust gas warm and the result is
a stronger draft. An uninsulated liner is a second choice
- although the liner will keep the exhaust restricted to its
original volume, the air around the liner will require time
and heat energy to warm up.
Check your local codes. You may be required to
install a flue liner in any oversize or masonry flue.
Pipe & Chimney Layout
Every bend in the flue will act as a brake on the
exhaust as it flows from the firebox to the chimney cap.
The ideal pipe and chimney layout is straight up from
the stove through a completely straight chimney. Use
this layout if at all possible as it will promote optimum
stove performance and simplify maintenance.
If the stovepipe must elbow to enter a chimney,
locate the elbow about midway between the stove top
and the chimney thimble. This configuration lets the
smoke speed up before it must turn, keeps some pipe
in the room for heat transfer, and allows long-term
flexibility for installing a different appliance without
relocating the thimble.
Vermont Castings Madison
There should be no more than eight feet of
single-wall stove pipe between the stove and a chimney. Longer runs can cool the smoke enough to cause
draft and creosote problems. Use double-wall stove
pipe for longer runs.
Single Venting
Your stove requires a dedicated flue. Do not connect
the stove to a flue used by any other appliance.
Chimney draft is a natural form of energy and follows
the path of least resistance. If the stove is vented to a
flue that also serves an open fireplace or another
appliance, the draft will also pull air in through those
avenues. The additional air flow will lower flue temperatures, reduce draft strength and promote creosote
development; overall stove performance will suffer.
The effect is similar to that of a vacuum cleaner with a
hole in the hose. In some extreme instances, the other
appliance can even impose a negative draft and result
in a dangerous draft reversal.
Fuel
Even the best stove installation will not perform
well if poor fuel is used. If available, always use
hardwood that has been air-dried (‘seasoned’) 12-18
months. Softwood burns more rapidly than hardwood
and has a high resin content conducive to creosote
production. Decayed wood of any type has little heat
value and should not be used.
All unseasoned (‘green’) wood has a high moisture content. Much of its heat value will be used to
evaporate moisture before the wood can burn. This
significantly reduces not only the amount of energy
available to warm your home, but also the intensity of
the fire and temperature of the exhaust gas. Incomplete combustion and cool flue temperatures promote
creosote formation and weak draft.
You can judge the moisture content of wood by its
appearance and weight or use a commercially available moisture meter for an exact measurement.
Unseasoned wood will be a third heavier than dry
wood. Also, look for cracks (‘checking’) in the ends of
the log that result from contraction as the wood dries.
The longer and wider the cracks, the dryer the wood is.
Purchase your fuel from a reputable dealer.
Creosote
Creosote is a by-product of low-temperature stove
operations, weak draft or both. It is a tar that results
when unburned gases condense inside the flue system
at temperatures below 290°F. Creosote is volatile and
can generate chimney fire. All of the installation
characteristics that adversely affect chimney draft also
promote creosote condensation. Consequently, you
can minimize creosote accumulation with an effective
chimney design and the use of operational techniques
that encourage good draft and complete combustion.
Backpuffing
Backpuffing is a condition that results when the draft is
too weak to pull flue gases out of the chimney system
as fast as the fire is generating more. Volatile gases
build up within the firebox until reaching a density and
temperature at which they ignite. With this ignition, you
may hear a muffled popping sound and see a bit of
smoke forced out of the air inlets.
This condition is most likely to occur in the spring
or fall when moderate outdoor temperatures and low
intensity fires combine to inhibit draft strength. If your
stove backpuffs, open the air inlets to induce a livelier
fire and speed airflow through the stove. Avoid large
loads of firewood at one time. You should always see
lively, dancing flames in the firebox; a lazy, smoky fire
is inefficient and will promote draft problems.
Negative Pressure
Good draft also depends on a sufficient supply of air to
the stove. The chimney cannot pull more air than is
available. Sluggish draft can be caused by a house
that is tight enough to prevent the ready flow of air to
the stove, or by competition between the stove and
other appliances that vent indoor air to the outside; i.e.,
exhaust fans for range hoods, clothes dryers, bathroom, etc. If the chimney draws well when all such
equipment is turned off (or sealed, in the case of the
fireplaces and/or other stoves), you simply need to be
attentive in timing the use of the other appliances. If
you need to crack a nearby window or door to enable
the chimney to pull well, you should install an outsideair intake to bring combustion air directly to the stove.
Consult your Vermont Castings Majestic Products
dealer regarding an adapter to attach to the stove to
connect an air duct for outdoor combustion air.
Conclusion
Woodburning is more an art than a science. Art includes technique and since installations, homes and
fuel vary, the stove operator must also vary technique,
(mostly timing), to achieve satisfying results. Over
time, you will become familiar with the intricacies and
nuances of your particular installation and you will be
able to identify cause and effect in a variety of seasonal circumstances.
23
Vermont Castings Madison
15
42
30
16
31
6
39
2
23
8
44
12
36
24
37
43
25
26
27
20
35
4
19
33
45
34
11
22
3
13
9
10
7
18
14 41
40
1
5
38
17
21
29
32
28
1453
The Vermont Castings Majestic Products Company reserves the right to make changes in design, materials, specifications, prices and discontinue
colors and products at any time, without notice.
Madison Woodburning Stove
Model 1655
Item Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
24
Bottom, Outer
End, Left
Back
Secondary Manifold, Left
Front
Load Door
Ashlip
Door End Inner Shield
Firebrick (4)
Bottom, Inner
Primary Air Flap
Part Number
30000795
See Chart Pg. 25
30000798
30000802
See Chart Pg. 25
See Chart Pg. 25
See Chart Pg. 25
30000812
1601103
30000799
30000778
Item Description
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Fireback
End, Right
Primary Air Manifold
Top
Exhaust Flue
Leg
Door Assy.
Damper Tab
Pan Hd, PH 1/4-20 x 3/8”
Grate
Secondary Manifold, Right
Part Number
30000813
See Chart Pg. 25
30001491
See Chart Pg. 25
See Chart Pg. 25
See Chart Pg. 25
See Page 25
1601488
1200993
30001445
30000801
Vermont Castings Madison
Madison Woodburning Stove
15
14
Model 1655 (continued)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Item Description
Brick Support
Secondary Air Tube (Rear)
Secondary Air Tube (Middle)
Secondary Air Tube (Front)
Friction Spring
Leveller Blt, Hx Hd 1/4-20 x 1” Z
Washer, 1/4 pl 7/8 o.d.
Pan Hd, PH 10-24 x 1” blk
Nut, Square, 1/4-20 Pln
Insert Door Handle, Holder
Latch, Door
Pan Hd, 10-24 x 1/4” Z
Fl Hd, PH 1/4-20 x 1³⁄₄” Blk
Front Handle w/ Shift
Pawl Assy., Ash Door
CS, Hex Hd 1/4-20 x 5/8” Blk
Fl Hd. Allen 1/4-20 x 3/4” Blk
Ashpan Assy.
Cover Plate, Primary Air
Heat Shield, Flue Collar
Thermostat Sub Assy.
Thermostat Cover
Fl Hd, PH 1/4-20 x 2.50 - Blk
Part Number
30000804
30001493
30001494
30001495
1201846
1201745
1202470
1200907
1203329
1600600
1408628
1200996
1200830
5004245
5004025
1201372
30001166
30001167
30001393
30001456
30001390
30001414
30001444
Maintenance Kits Available from your Dealer
1884
1876
3427
Gasket Kit
Thermostat Kit
Gasket Kit for Glass
Madison Doors Exploded View
1.
2.
3.
4.
Item Description
Door, Right
Door. Left
Gasket, Fiberglas 3/16 4nd, Blk
Glass, Door, Right
Part Number
See Chart Pg. 25
See Chart Pg. 25
1203556
1408629
Shell Enamel Parts - Madison Model 1655
Part Name
Classic
Green
Top
30000817
30001213
Left Side
30000797
30001211
Right Side
30000796
30001210
Flue Collar
7000969
2310969
Front
30000808
30001212
Ashlip
30000815
30001214
Left Door
Subassembly
30001173
30001241
Left Door Only
30000810
30001216
Right Door
Subassembly
30001172
30001240
Right Door Only 30000809
30001215
Single Leg
30000816
30001218
Load Door
30000811
30001217
16
2
17
18
9
1
3
10
5
11
7
8
12
4
6
Madison Doors Exploded View
Item Description
Part Number
5. Glass, Door, Left
1408630
6. Glass Retainer
30000474
7. Pan hd, PH 10-24 x 3/8-Z
1200983
8. Hinge Strap, Door -Right Hand
30001222
9. Hinge Strap, Door - Left Hand
30001223
10. Pin, Long, Door
1600547
11. CS, Hex Hd 1/4-20 x 3/8 Gr. 5 Blk
1201337
12. Washer, Flat 1/4-Z
1202474
Fallaway Handle Complete
0004342
14. Handle, Ceramic
1600620
15. Oval Head Slotted Screw 1/4-20 x 3/375 1201294
16. Griddle Opener/Insert Door Handle
1600650
17. Door Handle Assy w/set screw
30001759
18. SS, Soc 7/16-20X1 Cup Pt.-Blk.
1200334
Moonlight
3001203
30001201
30001200
30001258
30001202
30001204
Sand
30001193
30001191
30001190
7020969
30001192
30001194
Red
30001183
30001181
30001180
2320969
30001182
30001184
30001237
30001206
30001233
30001196
30001229
30001186
30001236
30001205
30001208
30001207
30001232
30001195
30001198
30001197
30001228
30001185
30001188
30001187
25
Vermont Castings Madison
26
Vermont Castings Madison
Warranty
Limited 3 Year Warranty
The Vermont Castings Majestic Products Company warrants
that your Madison® will be free of defects in material and
workmanship for a period of three years from the date you
receive it, except that the handles, glass door panel, fireback
arch inserts, cement, and gasketing shall be warranted as
described below.
The Vermont Castings Majestic Products Company will
repair or replace, at its option, any part found to be defective
when the Madison is returned with shipping charges prepaid
to an Authorized Dealer. The customer must pay for any
Authorized Dealer in-home travel fees, service charges, or
transportation costs for returning the stove to the Authorized
Dealer. It is the dealer's option whether the repair will be
done in the dealer's shop or in the customer's home. If upon
inspection, the damage is found to be the fault of the
manufacturer, repairs will be authorized at no charge to the
customer for parts and/or labor.
Any Madison or part thereof that is repaired or replaced
during the limited warranty period will be warranted under the
terms of the limited warranty for a period not to exceed the
remaining term of the original limited warranty or six (6)
months, whichever is longer.
Limited 1 Year Warranty
®
The following parts of the Madison are warranted to be free
of defects in material and workmanship for a period of one
year from the date you receive it. These parts are the
handles, glass door panel, all firebricks, cement and
gasketing. Any of these items found to be defective will be
repaired or replaced at no charge, upon the return of said
part to an Authorized Dealer with postage prepaid.
Exclusions & Limitations
1. This warranty is transferable; however, proof of original
retail purchase is required.
2. This warranty does not cover misuse of the stove. Misuse
includes overfiring which will result if the stove is used in
such a manner as to cause one or more of the stove plates
to glow red. Overfiring can later be identified by warped
plates and areas where the paint pigment has burned off.
Overfiring in enamel stoves is identified by bubbling,
cracking, chipping and discoloration of the porcelain enamel
finish.
The Vermont Castings Majestic Products Company offers no
warranty on chipping of enamel surfaces. Inspect your stove
for any damage to the enamel prior to accepting it.
3. This warranty does not cover misuse of the Madison as
described in the Owner's Guide, nor does it cover a Madison
which has been modified unless authorized by a Vermont
Castings Majestic Products Company representative in
writing. This warranty does not cover damage caused by
burning treated wood, saltwater driftwood, or any fuel not
recommended in the Owner's Guide.
4. This warranty does not cover a stove repaired by
someone other than a Vermont Castings Majestic
Products Company Authorized Dealer.
5. Damage to the unit while in transit is not covered by this
warranty but is subject to claim against the common
carrier. Contact the Authorized Dealer from whom you
purchased your Madison. (Do not operate the Madison as
this may negate the ability to process the claim with the
carrier.)
6. Claims are not valid where the installation does not
conform to local building and fire codes or, in their
absence, to the recommendations in the Owner's Guide.
7. The salt air environment of coastal areas, or a high
humidity environment can be corrosive to the porcelain
enamel finish. These conditions can cause rusting of the
cast iron beneath the porcelain enamel, which will cause
the porcelain enamel finish to flake off. This warranty does
not cover damage caused by a salt air or high-humidity
environment.
8. The Vermont Castings Majestic Products Company
shall have no legal obligation to enhance or update any
unit once manufactured.
IN NO EVENT SHALL THE VERMONT CASTINGS
MAJESTIC PRODUCTS COMPANY BE LIABLE FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES. ALL
IMPLIED WARRANTIES INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS,
ARE LIMITED TO THE DURATION OF THIS WRITTEN
WARRANTY. THIS WARRANTY SUPERSEDES ALL
OTHER ORAL OR WRITTEN WARRANTIES.
Some states do not allow the exclusion or limitations of
incidental and consequential damages or limitations on
how long an implied warranty lasts, so the above
limitations may not apply to you. This warranty gives you
specific rights and you may have other rights which vary
from state to state.
How To Obtain Service
If a defect is noted within the warranty period, the
customer should contact a Vermont Castings Authorized
Dealer with the following information:
1. Name, address, and telephone number of the
purchaser.
2. Date of purchase.
3. Serial number from the label on the back of the stove.
4. Nature of the defect or damage.
5. Any relevant information or circumstances, i.e.,
installation, mode of operation when defect was noted.
A warranty claim will then start in process. The Vermont
Castings Majestic Products Company reserves the right to
withhold final approval of a warranty claim pending a
visual inspection of the defect by authorized
representatives.
27
Vermont Castings Madison
Vermont Castings, Majestic Products
410 Admiral Blvd. • Mississauga, Ontario, Canada L5T 2N6 • 905-670-7885
www.vermontcastings.com
© Vermont Castings, Majestic Products
28
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