Manuals - Fire

Manuals - Fire
Encore® FlexBurn® Non-Catalytic/Catalytic
Wood Burning Stove
Installation and Operating Manual
Model 2040
fire-parts.com
Report No. 227-S-42-2
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.
For use in the
United States and Canada
2425
Encore NC Cover
5/05
The French language version of this manual is available online:www.vermontcastings.com
La version française de ce manuel est disponible en ligne : www.vermontcastings.com
DO NOT DISCARD THIS MANUAL. RETAIN FOR FUTURE USE.
30005295 0515 Rev. 23
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Welcome
Congratulations on your choice of a Vermont Castings Encore® stove. With this purchase you have made a commitment
to make the hearth a place of warmth, beauty and comfort in your home. At Vermont Castings Group, we share that
joy and appreciation for the hearth. We assure you that your cast-iron Vermont Castings stove has been made with the
utmost care and will provide you with many years of service.
As you become acquainted with your new stove, you will find that its appearance is matched by its functionality, due to
cast iron’s unique ability to absorb and radiate heat.
Also, Vermont Castings Group products are among the cleanest-burning wood stoves and fireplaces available today. As
an owner of a Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning
depends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly
operate and maintain your stove.
At Vermont Castings Group, we are equally committed to your satisfaction as a customer. That is why we maintain
an exclusive network of the finest dealers in the industry. Our dealers are chosen for their expertise and dedication to
customer service. They are factory-trained and knowledgeable about every Vermont Castings Group product. Feel free
to contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its
performance.
This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore®. It also
contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
Sincerely,
Vermont Castings Group
This manual describes the installation, operation, and
maintenance of the Vermont Castings Encore® Model 2040
Non-Catalytic / Catalytic wood burning heater. This heater
meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold on or after May 15, 2015.
Under specific test conditions this heater has been shown
to deliver heat at rates ranging from 9,900 to 34,000 Btu/hr.
Table of Contents
Specifications.........................................................3
Installation..............................................................4
Clearance Charts.................................................12
Mobile Home Installation......................................16
Assembly..............................................................17
Smoke Alarm/ Safety Tips....................................20
Operation..............................................................21
Draft Management................................................26
Maintenance.........................................................28
The Catalytic Element..........................................32
Replacement Parts...............................................34
Warranty...............................................................39
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The Encore® Model #2040 has been tested and is listed
by OMNI-Test Laboratories of Portland, Oregon. The test
standards are ANSI/UL-1482-2011 and ANSI/UL-737 for the
United States, and ULC S627-00 for Canada. The Encore®
is listed for burning wood only. Do not burn other fuels.
We recommend that you hire a professional installer certified by the Wood Heat Education and Research Foundation
(WHERF) or the Wood Energy Technical Training (WETT)
to install your stove, or to advise you on the installation
should you attempt to install it yourself.
Please read this entire manual before you install and use
your new stove. Failure to follow instructions may result in
property damage, bodily injury, or even death.
The Encore® Flexburn is approved for use in mobile homes
in the United States and Canada when installed with Vermont Castings Mobile Home Kit. Refer to and follow the
instructions provided with the Mobile Home Kit (#0336_ to
ensure safe installation.
Proposition 65 Warning: Fuels used in gas, wood
burning 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
2
Installation Accessories
Warming Shelf 8" Flue Collar
#0200 Classic Black
#0555 Classic Black
#0205 Biscuit
#0556Biscuit
#0207 Ebony
#0557 Brown Majolica
#0199 Bordeaux
#0560Bordeaux
#0208 Brown Majolica
#0561 Twilight
#0203 Midnight Blue
#0198Twilight
#3265* Outside Air Kit #3185 Outside Air Adapter
#0336* Mobile Home Kit
#0127Firescreen
FK26 Fan Kit
#3190 Connector Pipe Heat Shield
A line of porcelain enamel stove pipe is available in Biscuit,
Bordeaux, Ebony, Brown Majolica colors.
*If you order #3265 or #0336, you must also use #3185.
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Specifications
Encore®, Model 2040
EPA Emissions rating - Non-catalytic
1.6 g/hr*
Range of heat output - Non-catalytic
9,900 - 34,000
EPA Emissions rating - Catalytic 1.1 g/hr*
Efficiency, HHV - Non-catalytic/Catalytic
68/74**
Range of heat output Catalytic
11,800 to 30,000 BTU/hr.*
Peak heat output
65,000 BTU/hr.***
Area heated
Up to 1,800 Square feet****
Fuel length
22"
Fuel capacity
50 pounds, hardwood
Loading
Front and top
Chimney Connector:
for 6" flue collar
6" (152 mm) diameter
for 8" oval flue collar
8" (203 mm) diameter
Chimney Flue Size:
with 8" Chimney Connector 8" (203 mm) minimum
with 6" Chimney Connector 6" (152 mm) minimum
Flue exit position
Top or Rear
Primary Air
Manually Set, Thermostatically Maintained
Secondary Air
Fixed, self-regulating
Ash handling system
Removable ash pan
Glass panels
High-temperature ceramic
Weight
475 lbs. (215 kg.)
Width (leg to leg)
27" (686 mm)
Depth (leg to leg)
15" (381 mm)
Height to top of flue collar
25" (635 mm)
* Under specific conditions during EPA emissions testing.
** Efficiency determined by CSA B415.10
*** 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 rates obtained under laboratory conditions
and on average efficiencies.
**** These values are based on operation in building
code-conforming homes under typical winter climate
conditions in New England. If your home is of nonstandard construction (e.g. unusually well insulated,
not insulated, built underground, 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 Authorized Dealer to determine
realistic expectations for your home.
fire-parts.com
Drawing Not to Scale
22³⁄₄"
(578 mm)
3³⁄₄"
(95 mm)
1³⁄₄"
(44 mm)
27"
(686 mm)
18¹⁄₂"
(470 mm)
22¹⁄₄"
(565 mm)
15¹⁄₂"
(394 mm)
25"
(635 mm)
Top exit
flue collar
height
25³⁄₄"
(654 mm)
5"
(127 mm)
2⁷⁄₈" (73 mm)
23³⁄₄"
(603 mm)
7¹⁄₄"
(184 mm)
27"
(686 mm)
15"
(381 mm)
Fig. 1 Encore® 2040 dimensions.
30005295
5295
Encore 2N1
dimensions
3
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Installation
SAFETY NOTICE: IF YOUR ENCORE® IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. TO
REDUCE THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONTACT LOCAL BUILDING OR
FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.
Before you begin an installation, be sure 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 every
Vermont Castings’ stove indicates that the stove has been
tested to current UL and ULC standards, and gives the
name of the testing laboratory. Clearance and installation
information also is printed on the label. When the stove
is installed according to the information both on the label
and in this manual, local authorities usually will accept the
label as evidence that the installation meets codes and
can be approved.
Outside Air
In some modern, super-insulated homes, there may be
inadequate air supply for combustion because of insufficient air infiltration into the building. Such air enters a
home through unsealed cracks and openings. Exhaust
fans in kitchens or bathrooms can compete with the stove
for available air and compound the problem.
When poor draft is caused by a low infiltration rate, opening
a ground floor window on the windward side of the house
and near the stove will usually alleviate the problem.
A better solution is to install a permanent outside air supply
to the stove and/or room. In fact, bringing air for combustion
from outside the home directly to the air inlet of the stove
is required for new construction in some areas.
Pressure variations within the house do not affect a stove
equipped with an outside air supply, and improved stove
performance often results. An Outside Air Kit for the Encore® is available from your local dealer.
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However, codes 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 installation issues, refer to the National
Fire Protection Association’s publication ANSI/NFPA 211
Standard for Chimneys, Fireplaces, Vents and Solid Fuel
Burning Appliances. For Canada, the equivalent publication is CSA CAN-B365 Installation Code for Solid Fuel
Burning Appliances and Equipment. These standards
are the basis 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.
What Kind of Chimney to Use
You must connect the Encore® to a code-approved masonry
chimney with a flue liner, to a relined masonry chimney that
meets local codes, or to a prefabricated metal chimney that
complies with the requirements for Type HT chimneys in
the Standard for Chimneys, Factory-Built, Residential Type
and Building Heating Appliance, UL 103. Figure 2 illustrates
the two types. The chimney and chimney connector must
be in good condition and kept clean.
A prefabricated doublewall insulated chimney
A tile-lined
masonry
chimney
ST241
Fig. 2 Approved chimney types.
ST241
chimney types
12/13/99 djt
4
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
If you use an existing masonry chimney, it must be inspected to ensure it is in a safe condition before the stove
is installed. Your local professional chimney sweep, building
inspector, or fire department official will be able to inspect
the chimney or provide a referral to someone who can.
The chimney must extend at least 3’ (914 mm) above the
highest point where it passes through or near a roof, and at
least 2’ (610 mm) higher than any part of a building within
10’ (3 m) horizontally. (Fig. 3)
For proper draft and good performance, any chimney used
with a Encore® 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.
Prefabricated Chimneys
A prefabricated metal chimney must be one 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.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
Chimney Size
An Encore® with an 8" (203 mm) flue collar is approved for
venting into a masonry chimney with a nominal flue size
of 8" x 8" (203 x 203 mm) or 8" x 12" (203 x 305 mm), and
into a round flue with nominal flue size of 8" (203 mm). An
Encore® with a 6" (152 mm) flue connector is approved for
venting into a masonry chimney with a nominal flue size of
8" x 8" (203 x 203 mm), and into a round flue with nominal
flue of 6" (152 mm).
NOTE: When installed with a 6" flue collar, the Encore®
may not be operated with the front doors open.
Whatever the flue collar size, an Encore® may be vented
into larger chimneys as well. However, chimneys with
liners larger than 8" x 12" (203 x 305 mm) may experience
rapid cooling of smoke and reduction in draft, especially if
the chimneys are located outside the home. These large
chimneys may need to be insulated or have their flues
relined for proper stove performance.
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Reference
Point
AC617
Fig. 3 The 2’-3’10’ Chimney Rule.
AC617
RLTSKC8
Masonry
Chimneys
2/11/98
An inspection of the chimney must confirm that it has a lining. Do not use an unlined chimney. The chimney should
have no cracks, loose mortar, other signs of deterioration,
and blockage. Repair any defects before the chimney is
used with your stove.
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 your local building code or, in the absence of a
local code, to a recognized national code. Masonry chimneys must be lined, either with code-approved masonry or
pre-cast refractory tiles, stainless steel pipe, or a code-approved, “poured-in-place” liner. The chimney’s clean-out
door must seal tightly. A loose or leaky clean-out door can
weaken chimney draft, causing performance problems.
30005295
Accessories to help make the connection between stainless steel chimney liners and your Encore® are available
through your local dealer.
Chimney Connector Guidelines
A chimney connector is the single-wall pipe that connects the stove to the chimney. The chimney itself is the
masonry or prefabricated structure that encloses the flue.
Chimney connectors are used only to connect the stove
to the chimney.
Single-wall connectors should be made of 24 gauge or
heavier steel. Do not use galvanized connector; it cannot
withstand the high temperatures that can be reached by
smoke and exhaust gases, and may release toxic fumes
under high heat. The connector may be 6" (152 mm) or 8
“ (203 mm) in diameter.
If possible, do not pass the chimney connector through
a combustible wall or ceiling. If passage through a combustible wall is unavoidable, refer to the section on Wall
Pass-Throughs. Do not pass the connector through an
attic, a closet or similar concealed space. The whole connector should be exposed and accessible for inspection
and cleaning.
5
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
In horizontal runs of unshielded chimney connector, maintain a distance of 30" (762 mm) from the ceiling. Keep it
as short and direct as possible, with no more than two
90° turns. Slope horizontal runs of connector upward 1/4"
per foot (6mm per meter) going from the stove toward the
chimney. The recommended maximum length of a horizontal run is 3’ (1 m), and the total length should be no longer
than 8’ (2.4 m). In cathedral ceiling installations, extend the
prefabricated chimney downward to within 8’ (2.4 m) of the
stove. This will help maintain a good draft by keeping the
smoke warm, so that it rises readily.
Chimney
Flue
Elbow
Flue Inner
Slip Pipe
Thimble
Standard
Connector
Oval to
Round Adapter
Flue Collar
Wear gloves and protective eyewear when drilling, cutting
or joining sections of chimney connector.
Single-wall Chimney Connectors
• Begin assembly at the flue collar of the stove. Insert
the first crimped
end into the stove’s
Toward
flue collar, and keep
Stove
each crimped end
pointing toward the
stove. (Fig. 4) Using
the holes in the flue
collar as guides, drill
Flue Gas
1/8" (3 mm) holes
Direction
in the bottom of the
first section of chimST242
ney connector and
secure it to the flue Fig. 4 Chimney connector.
collar with three #10
x
ST242
1/2" sheet metal screws. Lift off
the
griddle, and shield
Chimney
connector
12/13/99 djt
the stove’s surface between the griddle opening and
the front of the flue collar to protect the finish when you
drill the front hole.
Fasten each joint between sections of chimney connector, including telescoping joints, with at least three
(3) sheet metal screws. The pre-drilled 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.
Fasten the chimney connector to the chimney. Instructions for various installations follow. Figure 5 illustrates
the general layout of chimney connector parts.
Be sure the installed stove and chimney connector are
correct distances from nearby combustible materials.
ST492
Fig. 5 An exploded view of the chimney connection in a freestanding masonry installation.
ST492
Defiant
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•
•
•
NOTE: Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney connector
are available to simplify installations. They often eliminate
the need to cut individual connector sections. Consult your
local dealer about these special pieces.
6
freestanding Connector to a
Securing the Single-wall
installation
Prefabricated
Chimney
11/00
Follow the installation instructions of the chimney manufacturer exactly as you install the chimney. The manufacturer
of the chimney will supply the accessories to support the
chimney, either from the roof of the house, at the ceiling of
the room where the stove is installed, or from an exterior
wall.
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, while the bottom of the adapter is
screwed to the chimney connector.
These adapters are designed so the top end will fit outside
the inner wall of the chimney, and the bottom end will fit
inside the first section of chimney connector.
Securing the Single-wall Connector to a
Masonry Chimney
Both freestanding masonry chimneys and fireplace masonry chimneys may be used for your installation.
Freestanding Installations
If the chimney connector must pass through a combustible
wall to reach the chimney, follow the recommendations in
the Wall Pass-Through section that follows. The opening
through the chimney wall to the flue (the “breech”) must
be lined with either a ceramic or metal cylinder, called
the “thimble,” which is cemented securely in place. Most
chimney breeches incorporate thimbles, but the fit must be
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
snug and the joint between the thimble and the chimney
wall must be cemented firmly.
A special piece called the “thimble sleeve,” slightly smaller
in diameter than standard connectors and most thimbles,
will facilitate the removal of the chimney connector system
for inspection and cleaning. (Fig. 6) Thimble sleeves are
available from your local dealer.
Check These
Clearances
Thimble Sleeve
*
*
Flue
Chimney Connector
Mantel
Keep
sleeve
end flush
with flue
tile
Seal
This Off
ST243
Fig. 6 The thimble, made of either ceramic or metal, must be
cemented securely in place.
To install a thimble sleeve, slide it into the breech until it is
flush with the inner flue wall. Do not extend it into the actual
flue passage, as this could interfere with the draft.
ST244
Fig. 7 In this installation, the chimney connector attaches to
the chimney above the fireplace opening.
• Check the clearance between the chimney connector
fire-parts.com
ST243
The thimble
sleeve
should protrude 1-2" (25-50 mm) into
thinble connection
the room. Use
furnace
and thin gasketing to seal
12/13/99 cement
djt
the sleeve in place in the thimble. Secure the chimney
connector to the outer end of the sleeve with sheet metal
screws.
Without a thimble, a suitable length of chimney connector
can be extended through the breech to the inner face of
the flue liner, and cemented securely in place. Additional
pieces of connector are then attached with sheet metal
screws.
Fireplace Installations
The chimney connector may be connected to the chimney above the fireplace opening or through the fireplace.
Above the Fireplace
The Encore may be connected to a chimney above a
fireplace opening. (Fig. 7) In such installations, the stove
is positioned on the hearth in front of the fireplace and the
chimney connector rises from the stove top and then angles
ninety degrees back into the chimney. The chimney liner
should extend to the point at which the chimney connector
enters the chimney.
®
If the chimney connector in your installation enters the
chimney above a fireplace, follow all the guidelines mentioned above for freestanding installations. In addition, give
special consideration to the following points:
• Check the clearance between the mantel and the
chimney connector, and any combustible trim or the
mantel.
30005295
•
ST244
and the ceiling. The
clearance should be at least 30"
Plymouth
(762 mm) with unshielded
connectors. Consult the
fplc over mantel
clearance charts 12/99
for other installation options.
The fireplace damper must be sealed to prevent room
air from escaping up the flue. However, it must be
possible to re-open the damper to inspect or clean the
chimney.
Through the Fireplace
If your fireplace opening height is at least 29" (737 mm),
you may install a Encore® through the opening using a
“positive connection” kit, available from your local dealer.
Positive connection kits ensure a tight fit between the stove
flue collar and the chimney flue. (Fig. 8)
Fireplace installations, whether connected to the flue above
or through the fireplace opening, have special clearance
requirements to adjacent trim and the mantel. You’ll find
the required safe clearances for Encore® fireplace installations on Page 12.
Floor protection requirements also apply to fireplace installations. This information is on Page 9.
Wall Pass-Throughs
Whenever possible, design your installation so the connector does not pass through a combustible wall. If you are
considering 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.
Accessories are available for use as wall pass-throughs.
If using one of these, make sure it has been tested and
listed for use as a wall pass-through.
7
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Flexible
Connector
Mantel Shield
Fireplace Adapter Kit
“Positive Connection”
ST245
Fig. 8 Through the fireplace installation.
In the United States, the National Fire Protection Association (NFPA) has established guidelines for passing chimney
ST245
connectors through combustible
walls. Many building
code inspectors follow fireplace
these guidelines when approving
flex connector
installations.
Three other methods are also approved by the NFPA:
• Placing a section of chimney connector inside a ventilated thimble, which in turn is separated from combustibles by 6" (152 mm) of fiberglass insulating material.
• Placing a section of chimney connector inside a section
of 9" (230 mm) diameter, solid-insulated, factory-built
chimney, with 2" (51 mm) of air space between the
chimney section and combustibles.
• Using a section of solid-insulated double-wall high
temperature chimney, with an inside diameter the same
as the chimney connector, at least one inch of solid
insulation, 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 has established different guidelines for wall pass-throughs. Figure
10 shows one method, in which all combustible material in
the wall is cut away to provide the required 18" (457 mm)
clearance for 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.
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12/99
Figure 9 shows one NFPA-recommended method. All
combustible material in the wall is cut away from the single-wall connector to provide the required 12" (305 mm)
clearance. Any material used to close up the opening must
be noncombustible.
18" (460mm) clearance
between pipe and
sides/top/bottom of
opening
T
Wall Stud
ST494
Chimney
Connector
Fig. 10 An approved wall pass-through for Canada.
Your local dealer or your local building inspector can
ST494
provide details for othersteel
approved methods of passing
a chimney connector through
a thru
combustible wall in your
wall pass
11/00
area. In Canada, this type
of installation must conform to
CAN/CSA-B365, Installation Code for Solid Fuel Burning
Appliances and Equipment.
T
12" of
Noncombustible
Material
Floor Protection
ST493
Fig. 9 An approved wall pass-through for the United States.
NOTE: Do not vent your Encore® into a factory-built
(zero-clearance) fireplace. These appliances 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.
DO NOT CONNECT THE Encore® TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
30005295
8
ST493
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Floor Protection
A tremendous amount of heat radiates from the bottom
plate of your stove. 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 with the use of the Bottom Heat
Shield supplied with the stove.
Most installations will require the bottom heat shield to 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.
With the bottom heat shield installed the Encore® 2040
was tested using a 1⁄2" (13mm) non-combustible hearth
material with a thermal conductivity, (k) = 0.47 BTU - in/
hr - ft2 -°F, resulting in the requirement of providing a total
thermal resistance (R) of 1.06. (Refer to “How to Determine
if Alternate Floor Protection Materials are Acceptable” section.) The floor protector may be covered with a decorative
noncombustible material if desired. Do not obstruct the
space under the heater.
To meet these requirements, a floor protector must be at
least 43" (1092 mm) wide and 49" (1245 mm) deep.
C
D
B
E
E
E
F
F
A
U.S.Canada
A.
B.
C.
D.
E.
F.
E
39"
45"
12"
10" 6"
6"
16" A
43" (1092 mm)
49" (1245 mm)
12" (305 mm) 8" Connector
10"
(250 mm) 6" Connector
ST500
Defiant
8"
(203 mm)
floor protection
8"
(203 mm)
1/31/02 djt
18" (460 mm)
ST500
Fig. 11 Required floor protection dimensions.
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When using a fire screen with doors open, UL737, Standard
for Fireplace Stoves, this unit was tested using a 1" (25mm)
non-combustible hearth pad with a thermal conductivity, (k)
= 0.47 BTU - in/hr - ft2 -°F, resulting in the requirement of
providing a total thermal resistance (R) of 2.12. (Refer to
“How to Determine if alternate Floor Protection Materials
are Acceptable” section.) The floor protector may be covered with a decorative noncombustible material if desired.
Do not obstruct the space under the heater. An 8" chimney
and chimney connector is required an the bypass damper
must be in the fully open position.
Important: All installations on a combustible floor require the use of the supplied bottom heat shield.
Protection requirements vary somewhat between the Untied States and Canada as follows:
In U. S. installations the floor protector is required under
the stove and must extend at least 16" (not including the
ash lip) from the front of the stove (“F,” Fig. 11), and at least
6" from the sides and rear. (“D” and “E,” Fig. 11)
In rear venting configurations, floor protection must also
extend under the chimney connector and 2" to either side.
(“C,” Fig. 11) For the 8" (203 mm) connector, the protector
must be a minimum of 12" (305 mm) wide. For the 6" (152
mm) connector, the protector must be 10" (254 mm) wide.
The protector must be centered under the connector.
To meet these requirements, a floor protector must be at
least 39" wide and 45" deep.
In Canada: A noncombustible floor protector is required
under the stove as well. The floor protector must extend
18" (457 mm) to the front (“F,” Fig. 11), and 8" (203 mm)
from the sides and rear. (“D” and “E,” Fig. 11)
30005295
How to Determine if Alternate Floor
Protection Materials are Acceptable
All floor protection must be noncombustible (i.e. metals,
brick, stone, mineral fiber boards, etc.). Any organic materials (i.e. plastics, wood paper products, etc.) are combustible and must not be used. The floor protection specified
includes some form of thermal designation such as R-value
(thermal resistance) or k-factor (thermal conductivity).
Procedure:
1. Convert specifications to R-value:
i. R-value given - no conversion needed.
ii. k-factor is given with a required thickness (T) in
inches: R = 1 x T
k
iii. K-factor is given with a required thickness (T) in
inches: R = 1
xT
K x 12
iv. r-factor is given with a required thickness (T) in
inches: R = r x T
2. Determine the R-value of the proposed alternate floor
protector:
i. Use the formula in Step 1 to convert values not expressed as R.
ii. For multiple layers, add R-values of each layer to
determine overall R-value.
3. If the overall R-value of the system is greater than the
R-value of the specified floor protector, the alternate
is acceptable.
9
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
EXAMPLE: The specified floor protector should be 1/2-inch
thick material with k-factor of 0.84. The proposed alternate
is 4" brick with an r-factor of 0.2 over 1/8" mineral board
with a k-factor of 0.29
Step a: Use formula above to convert specification to R1
1
value:
R= xT =
x 1.00 = 1.18
k
0.84
Step b: Calculate R of proposed system.
4" brick of r = 0.2, therefore:
Rbrick = 0.2 x 4 = 0.8
1/8" mineral board of k = 0.29, therefore
Rmineralboard = 1 x 0.125 = 0.431
0.29
Rtotal = Rbrick + Rmineralboard = 0.8 + 0.431 = 1.231
Step c: Compare proposed system Rtotal of 1.231 to specified R of 0.59. Since proposed system Rtotal is greater
than required, the system is acceptable.
Definitions
(ft2)(hr)(°F)
Btu
R=
K = (Btu)(ft)
(ft2)(hr)(°F)
k=
r=
(Btu)(in)
= K x 12
(ft2)(hr)(°F)
(ft2)(hr)(°F) 1
=
(Btu)(in)
k
Keep the Stove a Safe Distance
From Surrounding Materials
Both a stove and its chimney connector radiate heat in all
directions when operating, and nearby combustible materials can overheat dangerously if they are too close to the
heat source. A safe installation requires that adequate
clearance be maintained between the hot stove and its
connector and nearby combustibles.
Clearance is the distance between either your stove or
chimney connector, and nearby walls, floors, the ceiling,
and any other fixed combustible surface. The Encore® has
specific clearance requirements that have been established after careful research and testing. These clearance
requirements must be strictly observed.
In addition, keep furnishings and other combustible materials away from the stove. In general, a distance of 48"
(1219 mm) must be maintained between the stove and
moveable combustible items such as drying clothes, furniture, newspapers, firewood, etc. Keeping those clearance
areas empty assures that nearby surfaces and objects will
not overheat.
fire-parts.com
Floor Protection for Fireplace Installation
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. Because heat passes readily through
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, including the need for a bottom
shield. Keep in mind that many raised hearths will extend
less than the required clearance from the front of the heater. 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: 16" (410 mm) in the United States and 18" (460 mm)
in Canada. Hearth rugs do not satisfy the requirement for
floor protection as they are not fire proof.
Fireplace installations also have special clearance requirements to the side walls, side decorative trim and fireplace
mantel. Refer to the information on fireplace and mantel
trim shields in this section.
Safe Ways to Reduce Clearances
Clearance requirements are established to meet every
installation possibility, and they involve the combination
of these 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.
In general, the greatest clearance is required when you
place a stove and its connector near a wall with no heat
shield.
For example, when the Encore® is installed using 6" connector pipe parallel to the rear wall and no connector shield
is used, it must be at least 15" (381 mm) from the wall
behind it and at least 19" (483 mm) from walls on either
side. These dimensions are measured from the back of
the rear shroud and the side edge of the cast iron top to
the combustible wall.
If the Encore® is installed in a corner and no shield is used,
the corners of the stove top must be at least 181⁄2" (470
mm) from nearby walls.
Clearances may be reduced only by means approved by
the regulatory authority, and in accordance with the clearances listed in this manual. Refer to the clearance chart
for approved clearance reduction specifications.
NOTE: Installation of the Encore® is not permitted in
alcoves.
10
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Wall Shields
One way to reduce clearances is with a wall shield constructed of 24 gauge or heavier sheet metal, or of another
noncombustible material such as 1/2" (13 mm) insulation
board such as Durock® or Wonderboard®, 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, as in Figure 12.
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 must
be open, and the shield must be open at the top. Metal
screening across the top will keep small stray objects from
being trapped behind the shield. (Fig. 12)
Air Flow
Screen
Noncombustible shields
installed 1" (25 mm) away from
the combustible surface on
noncombustible spacers, called
ventilated shields, may be used
to reduce clearances.
1" (25mm)
To protect a mantel from the
heat of a stove in a fireplace
installation, use a custom-made
ventilated mantel shield that is
at least 48" (1220 mm) long,
centered over the stove. (Fig. ST501
1/4" (6mm)
13) Ventilated shields for side
trim must extend the full length Fig. 13 A custom-formed
mantel shield.
of the trim.
An unprotected mantel (“A,” Fig. 14) cannot be more than
9" (230 mm) deep and must have a minimum
clearance of
ST501
mantel
and With
28" (711 mm), measured from the stove’s
top plate.
trim
shield
a ventilated shield, this clearance may be reduced safely
11/10/00 djt
to 15" (381 mm).
Unprotected top trim (B) protruding 3/4" (19 mm) or less
from the face of the fireplace must be a minimum of 25"
(635 mm) from the stove’s top surface. With a ventilated
trim shield, this clearance may not be reduced safely.
Wall Shield
fire-parts.com
Stud Wall
Framing
Noncombustible
Spacers and
Fasteners
Drywall
Unprotected side trim (C) that protrudes 3/4" (19 mm) or
less from the face of a fireplace must have a minimum
clearance of 22" (554 mm), measured from the stove’s top
side edge. If the trim extends more than 3/4" (19 mm), it is
subject to the requirements for wall clearance.
Shield
Metal
Spacer
Air Flow
ST248
The charts and sample installations that follow list all
the clearances required for the various installation
configurations of the Encore®.
Fig. 12 Approved wall shield construction.
The shield mustST248
be a minimum of 48" (1219 mm) tall, and
shield
must extend at wall
least
19"construction
(483 mm) higher than the top
12/14/99 djt
of the stove, whichever
is higher. The shield behind the
chimney connector must be 30" (760 mm) wide, centered
behind the pipe; for installations that use an approved
prefabricated chimney to pass through the ceiling, the
shield behind the chimney connector must stop 1" (25 mm)
below the ceiling.
A
C
Side
Wall
B
C
D
With 8" connections and chimneys, because of potentially
higher pipe temperatures, the shield must extend the full
height of the wall (up to 9’ (2.7 m)) and stop 1" (25 mm)
below the ceiling.
Fireplace and Mantel Trim Shields
A fireplace installation requires special clearance between
the side of the stove and the right and left walls, between
the side of the stove and the decorative side trim on the
fireplace face, and between the top of the stove and the
mantel.
30005295
ST253b
Fireplace and Mantel Trim Clearances
A. Mantel
B. Top Trim
C. Side Trim
D. Side Wall
UnprotectedProtected
28" (711
mm)
15" (281 mm)
ST253b
Encore
25" (635
mm)
15" (281 mm)
trim clearances
22" (554
mm)
11" (280 mm)
02/01 djt
22" (559
mm)
11" (280 mm)
Fig. 14 Maintain clearances to combustible components of
the mantelpiece.
11
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Clearance Chart
For use with either 6” or 8” flue collar/chimney connection
Unprotected Surfaces
Protected Surfaces
Stove Clearance
Top Exit, 8” single
wall connector without
shields, vertical flue collar heat shield installed
Stove Installed
Parallel to Wall
Side
(A) 19"
(483 mm)
Top Exit, single-wall
(G) 19"
chimney connector heat (483 mm)
shield2, vertical flue collar h.s. installed
Rear Exit
No flue collar heat
shield
(M) 22"
(559 mm)
Stove
in Corner
Stove Installed
Parallel to Wall
Stove
in Corner1
To Rear
Corners
Side
Shroud
(B) 20"
(C) 181⁄2"
(D) 5"
(508 mm)
(470 mm)
(127 mm)
To Rear
Shroud
(E) 7"
(178 mm)
(H) 10"
(254 mm)
(152 mm)
(152 mm)
(305 mm)
(P) 11”
(279 mm)
(Q) 12"
(305 mm)
n/a
(I) 181⁄2"
(470 mm)
(N) 12"
(305 mm)
n/a
(J) 6"
(K) 6"
Corners
(F) 12"
(305 mm)
(L) 12"
fire-parts.com
Top Exit, double-wall
chimney connector3,
vertical flue collar heat
shield installed
(G) 18"
(457 mm)
(H) 7"
(178 mm)
(I) 12"
(305 mm)
(J) 4"
(102 mm)
(K) 5"
(127 mm)
(L) 5"
(127 mm)
Clearance to Combustible in Front of Stove
All Installations (S) 48" (1219 mm)
The provided rear shroud must be used in all installations. The flue collar heat shield must be used in all vertical
installations.
1. A ceiling heat shield 24" (610 mm) in diameter and suspended 1" (25 mm) from the ceiling must surround the
pipe in installations where chimney penetrates the ceiling.
2. The connector pipe heat shield must extend 36" (914 mm) above flue collar.
3. Using listed double wall oval to round adapter when installing optional 8" oval flue collar.
6" Chimney Connector ONLY
Top Exit, single wall
6" connector without
shields, vertical flue collar heat shield installed
12
(A) 19"
(483 mm)
(B) 15"
(381 mm)
(C) 181⁄2"
(470 mm)
(D) 5"
(127 mm)
(E) 7"
(178 mm)
(F) 12"
(305 mm)
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Clearance Diagrams
For use with either 6" or 8" flue collar/chimney connector
Unprotected Surfaces
Stove Installed
Parallel to Wall
Protected Surfaces
Stove Installed
Parallel to Wall
Stove in Corner
Stove in Corner
Top Exit Installations, No Stove Heat Shields, collar heat shield installed.
B
A
C
C
E
D
F
F
Top Exit Installations, vertical collar heat shield, and chimney connector heat shields or double-wall connector.
fire-parts.com
H
G
I
K
J
I
L
L
Rear Exit Installations.
N
Q
N/A
M
N/A
P
ST628
Encore Clearance
Diagrams
02/01
30005295
13
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Distance from the Center of the Flue Collar to the Wall in Top-Exit Installations
The information on this page is helpful in planning stove placement for top-exiting installations, particularly those installations with chimneys that pass through the ceiling. However, this is not a clearance chart. Final stove clearances
must adhere to the guidelines stated in the clearance chart on Page 13.
Dimensions indicated are valid for installations with either 6" or 8" flue collars.
Encore®: WITHOUT Chimney Connector Heat Shields
Unprotected Surfaces
Parallel Installations
Side (A)
Protected Surfaces
Corner Installations**
Parallel Installations
Rear (B)
Side (A)
Side (D)
Corner
Installations**
Rear (E)
Corner (F)
321⁄2"231⁄4"221⁄2"181⁄2"101⁄4"181⁄2"
(826 mm)
(591 mm)
(572 mm)
(470 mm)
(260 mm)
(470 mm)
A
B
D
C
E
F
*
*
fire-parts.com
ST632
* This distance, from the center of the flue collar to the front edge of the hearth, is the same for all installations on this page:
351⁄4" in the United States and 371⁄4" (946 mm) in Canada.
Encore®: WITH
Unprotected Surfaces
Parallel Installations
Side (A)
ST632
Encore
flue centerline
Chimney
Connector
Diagrams
2/01
Heat Shields
Protected Surfaces
Corner Installations**
Parallel Installations
Rear (B)
Corner (C)
Side (D)
Corner
Installations**
Rear (E)
Corner (F)
321⁄2"131⁄4"221⁄2"191⁄2"91⁄4"181⁄2"
(826 mm)
(337 mm)
(572 mm)
(495 mm)
(235 mm)
(470 mm)
A
B
D
C
E
F
ST632a
**To locate center of flue collar for corner installation, add 61⁄2" (165 mm) to the clearance distance from stove corner to wall.
Mark off the resulting distance from the corner along both walls. Next, measure the same distance from these two points out
from the walls. These last two measurements will meet at a point representing the center of the flue collar. Refer to the diagrams above.
14
ST632a
Encore
flue centerline
Diagrams
02/01
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
48"
(1220 mm)
48"
(1220 mm)
48"
(1220 mm)
48"
(1220 mm)
ST499
ST497
Fig. 15 Parallel installation, vertical chimney connector, two wall
shields. Reduced clearances for both rear and side walls. Wall
shields may meet at corner if desired. Shielding for connector is
centered behind connector.
Fig. 17 Corner installation, vertical chimney connector, two wall
shields. Reduced side clearances. Wall shield MUST meet at
corner.
fire-parts.com
ST499
Defiant
Wall Shield C
11/00
ST497
Defiant
wall shield A
11/00
48" (1220 mm) ST498
Fig. 16 Parallel installation with rear wall pass-through, two wall
shields. Reduced clearances to both rear and side walls. Wall
shields may meet at corner if desired. Wall pass-through must
ST498 comply with codes.
Defiant Wall shield B Refer to “Special Installations.”
11/00 30005295
15
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Mobile Home Installation
You must use an Vermont Castings Group Vermont Castings Kit #0336 for installation into a mobile home.
1. An outside air inlet must be provided for combustion
and must remain clear of leaves, debris, ice and/or
snow. It must be unrestricted while stove is in use to
prevent room air starvation which can cause smoke
spillage and an inability to maintain a fire. Smoke
spillage can also set off smoke alarms.
2. Stove must be secured to the mobile home structure
using the fasteners provided in the Mobile Home Kit.
3. Stove must be grounded with #8 solid copper grounding wire or equivalent and terminated at each end with
N.E.C. approved grounding device.
4. Stove must be installed with an approved UL103 HT
ventilated chimney connector, UL103 HT chimney and
terminal cap with spark arrestor. Never use a single
wall connector (stove pipe) in a mobile home installation. Use only double-wall connector pipe, Dura-Vent
DVL, Selkirk metalbestos DS, Security DL double wall
connector or any listed double wall pipe connector.
5. Refer to the clearance charts in this manual or the
serial number label on the back of the stove for clearances to combustibles.
6. Floor protection requirements on Page 9 must be followed precisely.
7. In Canada, this appliance must be connected to a 6
inch (152 mm) factory-built chimney conforming to
CAN/ULC 629M, STANDARD FOR FACTORY BUILT
CHIMNEYS. Floor protection referenced on Page 10
must be followed.
8. Use silicone to create an effective vapor barrier at the
location where the chimney or other component penetrates to the exterior of the structure.
9. Follow the chimney and chimney connector manufacturer’s instructions when installing the flue system for
use in a mobile home.
NOTE: Offsets from the vertical, not exceeding 45°, are
allowed per Section 905(a) of the Uniform Mechanical
Code (UMC). Offsets greater than 45° are considered
horizontal and are also allowed, providing the horizontal run does not exceed 75% of the vertical height
of the vent. Construction, clearance and termination
must be in compliance with the UMC Table 9C. This
installation also complies with NFPA 211.
NOTE: Top sections of the chimney must be removable
to allow maximum clearance of 13.5 ft. (411 cm) from
ground level for transportation purposes.
10.Burn wood only. Other types of fuels may generate
poisonous gases (e.g. carbon monoxide).
11. If unit burns poorly while exhaust blower is on in home,
(i.e. kitchen range hood) increase combustion air.
WARNING: NEVER DRAW COMBUSTIBLE AIR
FROM A WALL, FLOOR OR CEILING CAVITY OR
FORM ANY ENCLOSED SPACE SUCH AS AN ATTIC
OR GARAGE.
CAUTION: THE STRUCTURAL INTEGRITY OF
THE MOBILE HOME FLOOR, WALL AND CEILING/
ROOF MUST BE MAINTAINED. (i.e., DO NOT CUT
THROUGH FLOOR JOIST, WALL STUD, CEILING
TRUSS, etc.).
WARNING:
DO NOT INSTALL IN SLEEPING ROOM
Spark
Arrestor
Cap
Storm Collar
Roof
Flashing
fire-parts.com
Joint
Shield/
Firestop
Listed Chimney
Connector
Floor
Protection
Outside Air Kit
Connector
Outside Air Floor Vent
KT1190
Fig. 18 Mobile home installation.
ST1190
mobile home install
16
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Assembly
Set Up Your Stove
Storing the Handle
Cast iron stoves are heavy, and it will take two to four people
to move your Encore® into position.
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. 21)
Wipe the protective coating of oil from the griddle with a
clean dry rag or a paper towel.
Install the handle on the griddle. First, place the griddle
upside down at the edge of a flat surface and assemble
the handle as shown.
With the handle pointing 45° from its final position, tighten
the nut as far as possible with the pliers.
Move the handle to its
final position while still
holding the nut with
the pliers.
Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer
ST564
Fig. 21 Handle holder and heat shield positions.
Install Stove
Install the Bottom Heat Shield
ST516
Fig. 19 Attach the griddle handle.
NOTE: The Bottom Heat Shield is required in most installations. Refer to Floor Protection, Page 9, for further
details.
1. Loosen the four 1/4-20 hex head bolts from the corners
of the ash drop on the stove bottom.
2. Align the bottom heat shield holes with the four bolts.
The outside air cutout hole should be toward the rear
of the stove. The unpainted side must face up towards
the stove.
3. Pass all four bolts through the large end of the keyholes
and then pulling the shield forward to engage the smaller
ends of the keyhole slots. (Fig. 22)
4. Attach the heat shield sides by passing the slots over
the bolt heads. Tighten the hex head bolts.
fire-parts.com
ST516
Legs
Attach
The stove is shipped with the legs attached.
some ingriddleIn
handle
stances, the legs may have been removed.
Follow
11/17/00 djt these
instructions to reattach the legs. Install the stove legs (Fig.
20) 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.
NOTE: When moving the stove, lift the stove to take weight
off the legs whenever possible. Dragging or sliding the
stove, especially across rough surfaces can cause the legs
to loosen or even break.
ST564
handle holder
12/13/00
Leg Bolt and
Washer
Bottom Heat Shield
ST857a
ST858
Fig. 22 Attach the bottom heat shield.
Fig. 20 Attach the stove legs.
30005295
ST858
attach legs
12/05
ST857
abottom heat shield
12/05
1/10
17
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Adjust the Leg Levellers
Bracket mounting screw
hole location
Lift the stove slightly so there is no weight on the leg while
making the adjustment.
Reverse the Flue Collar (If necessary)
Reverse the flue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket around
the flue collar opening is in position when you screw the
collar back onto the stove.
Attach Flue Collar Heat Shield
WARNING: The flue collar heat shield must be attached
to the Encore® stove. Use four #10 sheet metal screws
supplied to secure the flue collar heat shield to the rear of
the stove. (Fig. 23)
1.8"
1.4"
Insert catalyst
probe bracket with
self-drilling screw.
Fold bracket strap
over catalyst probe
shaft and secure with
screw.
Insert catalyst probe
through sheet metal
into cast iron back.
Remove hold plug
from cast iron back.
ST1180
Fig. 24 Install the Catalyst Temperature Probe
Sheet
Metal
Screws
Attach the Primary Air Thermostat Handle
The primary air thermostat handle is the smaller of the
two black handles. Secure the handle to the stub on the
right side of the stove with an 8-32 x 2" slot head machine
screw. (Fig. 25)
fire-parts.com
Flue Collar
Heat Shield
Sheet
Metal
Screws
Fig. 23 Install flue collar heat shield.
WARNING: The flue collar heat shield must be installed
in all vertical installations. The flue collar heat shield is not
used when the flue collar is in the rear exit position.
Attach the Damper Handle
Use the 1/4"-20 x 3" screw to attach the damper handle to
the damper stub on the left side.
Attach the Catalyst Temperature Probe
ST1180
To install the catalyst temperature
the
flueprobe,
collarremove
heat shield
hole plug from the cast iron wall behind the rear shield
as shown (Fig. 24) use two #10 sheetmetal screws and
bracket supplied, secure the bracket and probe to the
back of your stove. Fig. (24)
ST635
Fig. 25 Attach the thermostat handle.
Assemble the Removable Insert Handle
ST635handle opens and closes the
The ceramic removable insert
front doors. Remove afterEncore
each use, and store it in the handle
holder behind the right front
leg.thermostat
Assemble the handle by
Install
passing the 33⁄8" screw through
handle the ceramic shaft and into
the bright metal nub. (Fig.
26) Tighten carefully until snug.
2/01
ST540
Fig. 26 Assemble the front door handle.
18
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Fan Kit Installation
1. Attach the fan assembly at the bottom edge of the inner back with two (2) 1/4-20 x 3/4" hex head screws.
2. Attach snapstat to the mounting holes on the underside
of the bottom with two (2) 1/4-20 pan head screws.
3.Attach the rheostat holder (provided with the stove)
under the right front wing of the bottom heat shield with
two (2) #10 sheet metal screws.
4. Attach the rheostat to its holder by inserting the rheostat control shaft through the holder hole. Install the
retaining ring 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. Fan will not operate until stove reaches approximately
109°F.
7.Plug blower cord into a grounded outlet. Do not remove ground prong from plug. Route power cord to
avoid heat from the stove or other damage. Do not
route cord under or in front of appliance.
Access
Cover
ST1187
Fig. 28 Remove access cover.
Inner Cover
fire-parts.com
ST1187
remove access cover
Hole for Wire
Tie to Secure
Cable
Rheostat
Knob
ST1188
Fig. 29 Remove inner cover.
Rheostat
Holder
Rheostat
Snapstat
Screws
ST848
Fig. 27 Fan installation (Kit # 2767).
ST1188
remove inner cover
ST848
Installing or Removing
Catalyst
fanby
install
1. Remove the access cover
gently lifting up and pull6/05
ing out from the bottom edge. (Fig. 28)
2. Remove the inner cover by pulling it straight out. (Fig.
29)
3. Remove the catalyst by gently pulling it straight out.
(Fig. 30) Place the catalyst where the catalyst’s ceramic components will not be damaged.
Remove Catalyst
ST1189
Fig. 30 Remove catalyst.
30005295
ST1189
remove catalyst
19
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Smoke and CO Detectors
The use of smoke and carbon monoxide (CO) detectors
throughout the home is strongly advised, even 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. Follow the smoke/CO detector
manufacture's placement and installation instructions and
maintain regularly.
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.
Safety Tips
Conveniently locate a "Class A" fire extinguisher to contend with small fires. Be sure the fire extinguisher works
and is clearly visible. All occupants of the house should
know where it is, and how it operates. Have heavy stove
gloves available near the stove. Have special safety accessories (e.g., Child Guard Screen) available for use if
small children will be in the home.
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In the event of a stove pipe or chimney fire….
• Evacuate the house immediately
• Notify the fire department
• If the fire isn't too threatening, closing down the stove
tight, (damper, primary air, all doors) will help to smother the fire.
• Inspect your stove, stove pipe and chimney for any
damage caused by the fire and correct any damage
before using your stove again.
20
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Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Operation
The Encore® Controls
Low Heat
Two controls regulate the performance of the Encore®: a
primary air control supplies oxygen for the fire, and a
damper directs air flow within the stove to activate and
deactivate the combustion system. (Fig. 31)
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.
Damper Handle
High Heat
Griddle Handle
Door Handle
Air Control
Lever
Door Handle
Holder (Behind leg)
ST637
Fig. 32 The handle may be positioned anywhere between the
two extremes for different heat levels.
A Damper Directs Air Flow
Within the Stove
ST637
encore
The damper is open when
the handle points to the rear,
enabling smoke to pass directly into the chimney. The
Airstarting
control
damper must be open when
or reviving a fire, and
whenever the griddle or doors are opened.
The damper is closed2/01
when the handle points forward.
The damper handle on the left side of the stove operates
the damper to direct air flow within the stove.
fire-parts.com
Ashdoor
Handle
Andirons
ST636
Fig. 31 The Encore® controls are conveniently located and easy
to operate.
ST633
A Single Air
Control Regulates
Encore
Heat Output and Burn Time
controls
The primary air control lever, on the right side of the
2/01 of incoming air for starting,
stove, controls the amount
maintaining, and reviving a fire.
More air entering the stove makes the fire burn hotter and
faster, while less air prolongs the burn at a lower heat
output level. (Fig. 32)
For the greatest air supply and maximum heat output (but
the shortest burn time), move the lever toward the front
of the stove. For a fire that will last longer with less heat,
move the lever toward the rear of the stove.
WARNING
This wood heater has a manufactured-set minimum low
burn rate that must not be altered. It is against federal
regulations to alter this setting or otherwise operate this
wood heater in a manner inconsistent with operating
instructions in this manual.
30005295
Smoke travels through the non-catalytic combustion system where it can be further burned, before passing up the
chimney. (Fig. 33)
The damper should always be either fully open or fully
closed. There are no intermediate positions. When
closing the damper, be sure to pull firmly enough to
snap the handle into the locked position.
Damper Positions
Open
(Updraft Mode)
Closed
(High Efficiency
Mode)
ST638
Fig. 33 The damper is either open or closed. There are no
intermediate positions.
ST638
Encore
21
damper control
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
High-Efficiency Wood Burning
with Catalytic Combustion
A Encore® leaves the factory with the combustor packaged
separately.
In the United States, it is against the law to operate this
wood heater in a manner inconsistent with operating
instructions in this manual. The components of the catalytic combustion system in your Encore® work together to
produce optimum conditions for secondary combustion.
When the damper is closed, smoke travels through the catalytic element, which causes ignition of smoke at temperatures of 500°-600° F (260°-315°C), half the temperature
normally required for unaided secondary combustion.
Avoid using a full load of very dry wood in the firebox. This
may result in continuous very high temperatures in the
secondary combustion area and damage the combustor.
Wood which has been split, and stored under cover for
more than 18 months may be considered very dry. If you
must burn extra-dry wood, mix it with greener wood for a
longer fire and less stress on the combustor. Also, do not
use a full load of dry slab wood or scrap wood. For long
burns, use a mix of dry and moderately dry wood.
Two Ways to Add Fuel
The Encore ’s griddle lifts for convenient top-loading of
logs, and is the easiest way to add fuel. (Fig. 34)
®
The catalytic element is a ceramic “honeycomb” coated
with the catalytic material. The element is located in the
secondary combustion chamber, molded from a special
high-temperature insulating refractory material. The
chamber provides the correct environment necessary for
secondary combustion of the fuel (smoke).
Def
iant
Closing the damper exposes the smoke to the combustor.
If the combustor is at least 600°F (315°C), it will begin to
burn the smoke.
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Closing the stove damper may also reduce the draft, so
to avoid putting out the fire or deactivating the combustor,
close the damper only when a fire is well-established and
the chimney is thoroughly warmed. When starting a fire,
wait until the fire is well established and there is an ember
bed of at least 3-4 inches before closing the damper.
Never kindle a fire with colored paper or paper that has
colored ink or a glossy surface, and never burn treated
wood, garbage, solvents, or trash. All of these may poison
the catalyst and prevent it from operating properly. Never
burn cardboard or loose paper except for kindling purposes.
Never burn coal; doing so can produce soot or large flakes
of char or fly ash that can coat the combustor and cause
smoke to spill into the room. Coal smoke also can poison
the catalyst so that it won’t operate properly.
In general, the fire must be sufficiently well-established to
ensure that catalytic activity is initiated. When first starting a
fire, a medium- to high- firing rate must be maintained until
the stove, catalyst, and fuel are all stabilized at the proper
operating temperatures, and the chimney is warmed.
Even though it is possible for the fire to get quite hot within
a few minutes after a fire is started, the combustor may
stop working or the fire may go out if the fire dies down
immediately as a result of the damper being closed. Once
the combustor starts working, heat generated by burning
the smoke will keep it working.
ST521
Fig. 34 Top loading is the best way to add fuel during regular
use. Front loading
is useful for kindling a fire.
ST521
Intrepid
However, the front
doors open as well for adding an occasional log to loading
a fire. If the stove is equipped with 8" (203
11/00
mm) stove pipe, the front doors may be opened (or even
removed) and the optional Encore® spark screen placed
in the opening for open-fire viewing. The Encore® is not
approved for operation with the front doors open if
equipped with a 6" (152 mm) chimney connector or
chimney.
To open the front doors, insert the handle into the door latch
stub and turn it to the left and up. (Fig. 35)
Clockwise to
Open
Counterclockwise
to Close
ST544
Fig. 35 To open the front doors, turn the handle clockwise.
To determine whether the combustor is operating, observe
the amount of smoke leaving the chimney when the damper
is activated and when it is not. This procedure is described
on Page 33.
22
ST544
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
To close them, always close the left door first. Turn the
handle in the right door to the left and up (to the open position) and close it. Finally, push on the door as you turn
the handle to the right and down. The doors will draw in
slightly, and the handle should offer some resistance as
you turn it to the closed position.
To reduce the risk of breaking the glass, avoid striking the
glass or slamming the doors.
When you are not using the door handle, store it in the
holder behind the right front leg of the stove. Be careful to
not drop the handle, since it is breakable.
WARNING: Fireplace stoves equipped with doors
should be operated only with doors fully open or doors
fully closed. If doors are left partly open, gas and flame
may be drawn out of the fireplace stove opening, creating risks from both fire and smoke.
WARNING: For safety and greatest efficiency, operate
your stove only with all doors/griddles fully closed.
The test standard for your stove when it is operated
in this mode is UL 1482.
The Encore® may be used as a fireplace with the front
doors open or removed, BUT only when it is equipped
with 8" (203 mm) stove pipe and only when the optional
spark screen is secured correctly in the opening to
protect against the possibility of sparks and embers
leaving the stove. The test standard for your stove
when it is operated in this mode is UL 737. 1" floor
protection is also required. Refer to “Floor Protection”
section on Pages 9 - 10.
Andirons Help Protect the Glass
Your stove has andirons to keep logs away from the glass
panels. The andirons are essential to maintain clear fire
viewing, and should be left permanently in place. Since
the andirons may slightly hinder refueling through the front
doors, most stove owners will prefer the convenience of
top loading through the griddle. Do not place fuel between
the andirons and the doors.
Burn Only High-Quality Wood
The Encore® 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 or synthetic materials such as fire starter logs (containing
wax) in this appliance. Never burn liquid-based fuels
such as kerosene, gasoline or alcohol.
Burning any materials not allowed in these instructions,
or over-firing the stove, may void the warranty.
You’ll enjoy the best results when burning wood that has
been adequately air-dried. The wood should be 18"-20"
(457-508 mm) in length. Avoid burning “green” wood that
has 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. Do not burn ocean driftwood; when it burns,
the salt it contains will attack the cast iron.
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Use only the Encore® spark screen, Item #1907, with
your Encore®.
Encore® spark screens are available from your Vermont
Castings Dealer.
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.
If hardwood is not available, you can burn softwoods that
include tamarack, yellow pine, white pine, Eastern red cedar, fir, and redwood. These should also be properly dried.
Store wood under cover to keep it dry. The longer it is
stored, the better heating and fire-viewing performance
you will enjoy. Even for short-term storage, be sure to
keep wood a safe distance from the heater and keep it
out of the areas around the heater used for refueling and
ash removal.
AS
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23
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Surface Thermometer is a
Valuable Guide to Operation
Use the Air Control Settings
that Work Best for You
An optional surface thermometer tells you when to adjust
the air control, and when to refuel. (Fig. 36)
No single air control setting will fit every situation. Each
installation will differ depending on the quality of the fuel, the
amount of heat desired, and how long you wish the fire to
burn; outdoor air temperature and pressure also affect draft.
ST523
Fig. 36 Take temperature readings with a thermometer located
in the middle of the griddle.
For example, when the thermometer registers at least
450°F. (230°C) after start-up you know the stove is hot
enough and it may be time to close the damper. Note that
the stove will warm up much sooner than the chimney,
though; a warm chimney is the key to easy, effective stove
operation. Please review the draft management information
on Page 27 to see how the size, type, and location of your
chimney will affect your stove operation. When thermometer readings drop below 350°F. (175°C) it’s time to adjust
the air control for a higher burn rate or to reload the stove.
A temperature reading over 650°F. (340°C) is a sign to
reduce the air supply to slow the burn rate.
•
ST523
Readings in the 350°-500°F.
(175°-260°C) range indiIntrepid
cate low to medium heat output.
temp
readings
500°-600°F. (260°-315°C)
readings
indicate medium
heat output.
11/00
• Readings of 600°-650°F. (315-340°C) indicate high heat
output. Operating your Encore® continuously at griddle
temperatures higher than 650° F (340°C) may damage
the cast iron or enamel finish.
Temperature Probe
Your stove is equipped with a 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. If the probe indicator is below the operate
catalyst range, add fuel or open the bypass damper too
allow the fire to build. Closing the bypass damper should
then result in an increase in catalyst temperature to within
the operate catalyst range.
If the probe indicator is above the operate catalyst range,
the catalytic combustor is running to hot and may be damaged. In many cases, increasing the primary air can reduce the catalyst temperature and adding less wood with
each loading can also help if overheating is persistent.
Overly dry wood can also cause overheating of the catalyst element. Do not add wood to the stove if the probe
reads above the operate catalyst range.
24
Too much draft may cause excessive temperatures in the
Encore®, and could even damage the stove. 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. Signs of weak draft are
smoke leaking into the room through the stove or chimney
connector joints or low heat output.
fire-parts.com
Use the following temperature ranges as a guide:
•
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. See Page
26 for details on how the installation affects performance.
In some newer homes that are well-insulated and weather-tight, poor draft may result from an insufficient air supply
in the house. In such instances, an open window near the
stove on the windward side of the house can provide the
combustion air supply needed.
Another option for getting more combustion air to the stove
is to duct air directly from outside to the stove. In some
areas provisions for outside combustion air are required
in all new construction.
The Encore® is equipped to deliver outside air for combustion and outside air kit #3265 is available.
When first using the stove, keep track of the air control
settings. You will quickly find that a specific setting will give
you a fixed amount of heat. It may take a week or two to
determine the amount of heat and the length of burn you
should expect from various settings.
Most installations do not require a large amount of combustion air, especially if adequate draft is available. 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. Each
is described as a fraction of the total distance the lever may
be moved from right to left.
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Encore® Control Settings
(Refer to the first page of the Operation section.)
Burn Rate
Primary Air Control
Low
From far right to 1/3
the distance to left
From 1/3 to 2/3
Medium
the distance to left
High
From 2/3 the distance
to left, to far left
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.
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.
ST263
Fig. 37 Start the fire with newspaper and dry kindling.
3. Light the newspaper and close the door. Gradually build
up the fire by adding a few 3-5" (80-120 mm) diameter
pieces of split firewood. If this is one of the first few
“break-in” fires,ST263
let the fire burn brightly, and then let
starting a fire
it die out.
12/99
During the break-in
fires, do not 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.
fire-parts.com
The cast plates expand and contract with changes in
temperature. When you first begin using your Encore®,
minimize thermal stress by letting the plates adjust gradually during three or four initial break-in fires following Steps
1-3 below.
Non-Catalytic Wood Burning
Burn only solid wood in the Encore®, and burn it directly
on the grate. Do not elevate the fuel. Do not burn coal or
other fuels.
The bypass damper must be open when starting a fire
or when refueling.
Do not use chemicals or fluids to start the fire. Do
not burn garbage. Never use flammable fluids such as
gasoline, gasoline type lantern fuel, kerosene, charcoal
lighter fluid, naptha, engine oil or similar liquids to
start or “freshen up” a fire in this heater. Keep all such
liquids well away from the heater while it is in use.
1. Open the stove bypass damper, and open the primary
air control fully.
2. Place several sheets of crumpled newspaper in the
stove. Place six or eight pieces of dry kindling split to a
finger-width size on the paper. On the kindling, lay two
or three larger sticks of split dry wood approximately 1-2"
(25-51 mm) in diameter. (Fig. 37)
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Some odor from the stove’s hot metal and the paint is
normal for the first few fires.
NOTE: Some chimneys must be “primed,” or warmed up,
before they will draw sufficiently to start 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 will encourage
the smoke to rise rapidly, making it easier to establish a
good draft.
Once the draft is established, open the front door and light
the rest of the fuel from the bottom. Do not light the main
bed of fuel until the chimney begins drawing, and repeat
the procedure as often as necessary if the initial attempt
is unsuccessful.
NOTE: Effectiveness of a "top-down" method to start a
fire. Smoke emissions when starting a fire can be difficult
to control because the stove is not yet heated to its optimum
temperature. One method of reducing emissions during a
cold start-up is the use of a "top-down" kindling procedure.
In this, place larger pieces of kindling on the bottom of the
kindling pile followed by smaller and smaller pieces as the
pile is added to. Very finely split pieces should be on the
top. 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 size without
creating an air-starved condition.
4. If your Encore® has been broken-in previously 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 briskly-burning fire until there
25
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
is a glowing ember bed 2-3" (51-75 mm) deep. (Fig. 38)
A good ember bed is necessary for proper functioning of
the non-catalytic system and may take an hour or more
to establish.
ST264
Fig. 38 Add larger pieces of wood as the fire begins to burn
well.
5. Close the damper when the griddle temperature reaches
450°F (230°C).
6. Adjust the airST264
control for your desired heat output.
For best results when refueling, wear long-cuffed stove
gloves to protect your hands and forearms, add fuel while
the stove still has plenty of glowing embers to re-kindle the
fire, and include some smaller pieces of wood in the new
fuel load to help the stove regain its operating temperature quickly. Use this sequence as a guide to successful
refueling:
1. Open the damper.
2. De-ash the stove as described above. Open the ashdoor and check the level of ash in the ash pan. Empty
the pan if necessary and replace it in the stove. Close
the ash door.
3. Open the griddle, load the wood (smaller pieces first),
and close the griddle.
4. Close the damper.
5. When the surface temperature reaches 450°F. (230°C),
adjust the air control for the amount of heat you desire.
NOTE: If the remaining charcoal bed is relatively thick
(2-3"/51-75 mm) and if your fuel is well seasoned, it is
possible to add fresh fuel (smaller pieces first), close the
door and damper, and reset the primary air control for the
desired heat output within five minutes.
fire-parts.com
good firevary widely, and the operating
NOTE: Stove installations
guidance given here
is only a starting point . The draft man12/99
agement information on Page 26 will explain in detail how
the features of your installation may help or hinder good
draft, and how you may need to vary your firing technique
if your installation doesn’t encourage a good draft.
Refuel While the Embers Are Still Hot
When reloading, best results will be achieved if you first
de-ash the stove by stirring the fuel bed to allow ash to fall
through the grate into the ash pan.
Do not break the charcoal into very small pieces or pound
or compress the charcoal bed.
It is important that air can circulate through the charcoal
bed during the burn. Larger pieces of charcoal allow more
air to circulate under the wood, resulting in the fire reviving
more quickly. (Fig. 39)
WARNING: FIREPLACE STOVES EQUIPPED WITH
DOORS SHOULD BE OPERATED ONLY WITH DOORS
FULLY OPEN OR DOORS FULLY CLOSED. IF DOORS
ARE LEFT PARTLY OPEN, GAS AND FLAME MAY BE
DRAWN OUT OF THE FIREPLACE STOVE OPENING
CREATING RISKS FROM BOTH FIRE AND SMOKE.
CAUTION: The Encore® will be hot while in operation.
Keep children, clothing and furniture away. Contact
may cause skin burns.
DO NOT OVERFIRE THIS HEATER. Over-firing may cause
a house fire, or can result in permanent damage to the
stove. If any part of the Encore® glows, you are over-firing.
Ash Disposal
Routine ash removal is important for ease of maintenance,
and is important for the stove’s durability. Remove ash before
it reaches the top of the ash pan. Check the level at least
once a day. Every few days, clear any ash from the outer
edges of the firebox. Most of the ash will fall through the
grate. Slice or stir the ash with a shovel or poker so that
it falls through the grate slots.
IMPORTANT: Check the level of ash in the ash pan before
reloading the stove. If the ash level is close to the top edge
of the pan, empty the pan according to this procedure:
ST264a
Fig. 39 Add full size logs after the ember bed is 3" (75mm)
deep.
26
ST264a
add wood fire
• Open the damper.
• Open the griddle or front doors, and use a shovel or
poker to stir excess ash through the ash slots in the
grate down into the ash pan.
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
• Close the griddle or doors, and unlatch the ash door.
•
•
(Fig. 40) It will pivot, swinging the ash pan out of the
stove.
Slide the cover onto the pan, making sure it is securely
closed. (Fig. 41)
Remove the ash pan, making sure to keep it level.
• Do not operate the stove with the ash door open. This
will result in over-firing, and could cause damage to the
stove, void the warranty, or even lead to a house fire.
Empty the ash pan regularly, typically every one to three
days. The frequency will vary depending on how you operate your Encore®: ash will accumulate faster at higher
heat outputs.
Remove ash frequently and place it outdoors in a metal
container with a tight-fitting lid. Place 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, it should be kept in the closed container until
all cinders have thoroughly cooled.
You can use wood ash as a garden fertilizer.
Open
CAUTION: Never use your household or shop vacuum
cleaner to remove ash from the stove; always remove and
dispose of the ash properly.
Close
ST545
Fig. 40 Turn the ashdoor handle clockwise to open and counterclockwise to close.
fire-parts.com
ST545
ashdoor
11/00
ST566
Fig. 41 Be sure the cover is securely attached before removing the ash pan.
ST566
• To keep the cover from remove
sliding offashpan
and to keep ash from
•
•
•
falling on the floor, do not
tilt the ash pan forward.
7/05
If the stove is in operation, close the ash door while
disposing of the ash. You may need to lift the latch end
of the door slightly to align the latch with the mating part
on the stove bottom.
Properly dispose of the ash in a metal container with a
tight-fitting lid. Store the container outdoors away from
all combustible material.
Return the ash pan to its original position in the stove,
and close and latch the ash door. (Fig. 41)
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27
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Draft Management
A stove is part of a system, which 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 system
works well.
Wood stove or insert operation depends on natural (unforced) draft. Natural draft occurs when the exhaust is
hotter (and therefore lighter) than the outdoor air at the
top of the chimney. The bigger the temperature difference,
the stronger the draft. As the hot gases rise through the
chimney they provide suction or ‘draw’ that pulls 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 stove’s air inlets are
passive; they regulate how much air can enter the stove,
but they don’t move air into it.
Depending on the features of your installation - steel or
masonry chimney, inside or outside the house, matched
to the stove’s outlet or oversized - your system may warm
up quickly, or it may take a while to warm up and operate
well. With an ‘airtight’ stove, one which restricts the amount
of air getting into the firebox, the chimney must keep the
stove’s exhaust warm all the way to the outdoors in order
for the stove to work well. Some chimneys do this better
than others. Here’s a list of features and their effects.
Chimney Height
The common wisdom tells us that a taller flue draws better
than a short one. This isn’t necessarily so. If a chimney is
tall enough to meet the safety requirements of the 2/3/10
foot rule, then adding more height isn’t the right answer to
a draft problem. In fact it could make the problem worse by
adding more mass to the chimney system, which must be
warmed up, a distance from the heat source (the stove).
Don’t make a chimney taller unless you must in order to
meet the safety rules, or unless there’s some nearby feature
causing a downdraft. Even then, there are downdraft-preventing chimney caps available, which are probably the
smarter choice.
Flue Sizing
The inside size of a chimney for an ‘airtight’ stove should
match the size of the stove’s flue outlet. When a chimney
serves an airtight stove, more is not better; in fact, it can
be a disadvantage. Hot gases lose heat faster as they
travel slower through a chimney; if we vent a stove with
a six-inch flue collar (28 square inch area) into a 10 x 10"
flue, the gases slow to one third their original speed. This
allows the gases to cool more rapids, which weakens draft
strength. If an oversized flue is also outside the house, the
heat it absorbs gets transferred to the outdoor air and the
flue usually stays cool.
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Masonry Chimney
Masonry is a traditional material for chimneys, but it can
perform poorly when it serves an ‘airtight’ stove. Masonry
is a very effective ‘heat sink’ - it absorbs a lot of heat. It
can cool the chimney gases enough to diminish draft. The
bigger the chimney, the longer it takes to warm up. It’s often very difficult to warm up an outdoor masonry chimney,
especially an oversized one, and keep it warm enough to
maintain an adequate draft.
Steel Chimney
Most factory-made steel chimneys have a layer of insulation
around the inner flue. This insulation keeps the chimney
warm. The insulation is less dense than masonry, so a
steel chimney warms up more quickly than a masonry
chimney. Steel doesn’t have the good looks of masonry,
but it performs much better.
Indoor/Outdoor Location
Because the chimney must keep the smoke warm, it’s
best to locate it inside the house. This uses the house as
insulation for the flue and allows some heat release into
the home. An indoor chimney won’t lose its heat to the
outdoors, so it takes less heat from the stove to heat it up
and keep it warm.
28
It is common for a masonry flue, especially one serving a
fireplace, to be oversized for the stove. It can take quite
a while to warm up such a flue, and the results can be
disappointing. The best solution to an oversized flue is an
insulated steel chimney liner, the same diameter as the
stove or insert’s flue outlet; the liner keeps the exhaust
warm, and the result is a stronger draft. An non-insulated
liner is a second choice - the liner keeps the exhaust
restricted to its original size, but the hot gases still must
warm up the air around the liner. This makes the warm-up
process take longer.
Pipe & Chimney Layout
Every turn the exhaust must take as it travels to the chimney
top will slow it down. The ideal pipe and chimney layout
is to vent vertically into a completely straight and vertical
chimney. If you are starting from scratch, use this layout if
possible. If the stovepipe must elbow to enter a chimney,
locate the thimble about midway between the stove top
and the ceiling. This achieves several goals: it allows the
gases to speed up before they must turn, it leaves some
pipe in the room for heat transfer, and it gives you long-term
flexibility for installing a different stove without relocating
the thimble.
There should be no more than eight feet of single-wall
stove pipe between the stove and a chimney; longer runs
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Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
can cool the exhaust enough to cause draft and creosote
problems. With prefabricated chimney, bring it down to
six to eight feet from the stove. With a masonry chimney,
arrange the pipe so that it turns into the chimney within
eight feet of the stove.
Single Venting
Each ‘airtight’ stove requires its own flue. If an airtight stove
is vented to a flue that also serves an open fireplace, or
a leakier stove, it’s easier for the chimney draft to pull air
in through those channels and performance of the stove
suffers. Imagine a vacuum cleaner with a hole in the hose
to understand the effect here. In some cases the other appliance can even cause a negative draft through the stove,
and result in a dangerous draft reversal.
Creosote
Creosote is a by-product of slow wood-burning. It’s an
organic tar that can condense in the flue if it is present in
the exhaust, slow-moving, and cools to less than 290°F
(130°C). Condensed creosote is volatile, and can generate chimney fires if it gets hot enough. All the features that
affect chimney draft also affect creosote condensation - so
use whatever combination of installation features and operational steps that will encourage good draft and minimize
creosote production.
quickly and densely enough to overload the combustion
system. If you hear a rumbling or roaring noise (like a
propane torch) from the stove, that is a sign that the stove
is over-firing.
Back-puffing
Back-puffing results when the fire produces volatile gases
faster than the chimney draft pulls them out of the firebox.
The gases back up in the firebox until they are concentrated
enough and hot enough to ignite. If your stove back-puffs,
the stove needs to cool down. You should open the damper
to let the smoke rise to the flue more quickly, allow more
air into the firebox, avoid big loads of firewood and check
that the wood moisture is not too low.
Draft Testing
An easy way to test your chimney draft is to close the stove’s
damper, wait a few minutes to let the airflow stabilize,
then see whether you can vary the strength of the fire by
swinging the air control open and closed. Results are not
always instant; you may need to wait a few minutes for a
change in the air control setting to have an effect on the
fire. If there’s no change, then the draft isn’t strong enough
yet to let you close the damper, and you’ll need to open
it for awhile longer and manage the fire with the air inlet
until the draft strengthens. If you keep track of your burning habits and relate them to their effects on the stove’s
operation, you’ll be rewarded with good performance and
a safe system.
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Because letting the exhaust cool off and slow down is one
of the keys to creosote accumulation, it makes sense to
line a chimney to match the stove’s outlet size, for safety
reasons as well as performance. Canadian law requires a
matching liner to serve any stove or insert vented through
a fireplace chimney; in the US, the National Fire Protection
Association (NFPA) recommends a chimney liner if the flue
is more than three times bigger (in square area) than the
outlet on the stove or insert. Some localities enforce the
NFPA guidelines as part of their building codes.
Fuel
Even the best stove installation will not perform well with
poor fuel. The best fuel is hardwood that has air-dried 1218 months. Softwood burns, but not as long as hardwood.
‘Green’ wood has a lot of moisture in it; it will burn, but some
of the heat potential is used to boil the extra moisture from
the wood. This reduces the amount of heat that reaches
your home and can contribute to a creosote problem. There
are moisture meters available for firewood; you can also
judge your wood by its appearance and weight. If you get it
green, lift a piece and get a sense of its weight; it can lose a
third or more of its weight as it dries. Also look at the ends
of a log; as it dries it shrinks and often cracks. The more
weathered and cracked a piece is, the drier it is.
Dry wood burns readily with a good chimney draft. But
with modern stoves, wood can be too dry and too volatile.
Smoke and combustible gases can ‘gas out’ from the wood
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Negative Pressure
Good 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
ready flow of air to the stove, or by competition between
the stove and other equipment that sends indoor air outside
- especially power-driven equipment like range hoods,
clothes dryers, etc. If the chimney draws well with all other
equipment turned off (or sealed, in the case of fireplaces
and/or other stoves), then you simply need to be careful
with timing the use of the other air consuming equipment.
If you need to crack a nearby window or door to enable
the chimney to flow well, it may be a good idea to install
an outside-air intake to bring combustion air directly to the
stove. An outside air kit is available to connect the stove
directly to a source of outdoor combustion air.
Conclusion
Wood-burning is an art rather than a science. Once the
stove and chimney system are in place, you can only vary
your technique, mostly your timing, to achieve good results.
If you keep track of your burning habits and relate them to
their effects on the stove’s operation, you’ll be rewarded
with good performance and year of reliable heating.
29
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Maintenance
Keep Your Stove Looking New
and Working Its Best
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 Encore® looking new.
The stove’s paint can be touched up as needed. First, mask
the areas, such as enamelled parts, glass, or handles,
around the spot to be painted. Clean the spot with a wire
brush. Remove the griddle and set it aside. It is normal
for the griddle to darken after use. You can clean it with a
fine-bristle wire brush, or steel wool.
Then, touch up the stove with Vermont Castings’ high
temperature stove paint. Apply the paint sparingly; two light
coats of paint are better than a single heavy one.
If you need to replace the glass, use only the high temperature 5 mm ceramic glass supplied by Vermont Castings.
Do not use substitutes.
Removing the Glass
1. Remove the right and left door assemblies by raising
the door until the lower hinge pin clears its hole; then,
angle the 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
enamelled doors.
2. Remove the screws that hold the glass retainer clips in
place, and remove the clips.
3. Carefully lift the broken glass panel from the door.
Installing the Glass
Check the gasket around the window; it should be soft
and resilient so that the glass will seal properly against
the door. Replace the gasket if it has hardened or if it is
compressed.
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Care of the Porcelain Enamel Surface
Use a dry or slightly damp rag or 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.
If porcelain enamel becomes chipped or scratched during
use, apply “enamel epoxy” to the damaged area and allow
to dry. Once the epoxy has dried, sand the area to blend
with surrounding area and apply appropriate color touch-up
paint. Allow to dry completely before operating stove.
Cleaning the Glass
1. Center the glass on the gasket.
2. Secure the glass on both doors with the retainer clips.
Tighten all screws. (Fig. 42)
3. Replace the doors on the stove.
4. Open and close the doors to check that they fit and work
properly. Adjust as necessary.
Right Door
Gasket
Glass Panel
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.
To clean the glass, follow this procedure:
Retainer
Clips (4)
• 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. Use
cleaning agents sparingly and be sure to keep them off
the outer surfaces of the stove.
Rinse the glass thoroughly.
Dry the glass completely.
Replace Broken Glass Immediately
Do not operate your stove if the glass in the doors is damaged.
30
ST854
Fig. 42 Exploded view of the glass assembly for the right door.
ST854
glass xview
7/05
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Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Adjust the Damper as Needed
Roller
The tension on the Encore ’s damper is adjustable to
compensate for compression of the gasket that seals the
damper to the upper fireback. To adjust the damper:
1. Remove the griddle. Loosen the lock nut at the center
of the damper. (Fig. 43)
2. Turn the pressure screw approximately one half turn
clockwise with an Allen wrench provided with your
stove.
3. Tighten the lock nut. Prevent the pressure screw from
turning as you tighten the nut. Re-test the damper.
Shoulder Screw
®
Pressure Adjusting Screw
Lock Nut
Set Screw
Flat Washer
Lock Nut
Allen
Wrench
Damper
ST554
Handle Stub
ST1154
Fig. 44 Rotate pawl and/or remove flat washer to adjust latch.
into the channel beneath the gasket so the main gasket
is raised and makes contact with the door frame. If this
ST1154
procedure doesn’t solve the problem, replace the gasket.
pawl are given later in this
Instructions for gasketdoor
replacement
section.
Replace the Stove Gaskets as Needed
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Fig. 43 Adjust the damper with the Allen wrench.
Tighten the Damper Handle as Needed
A handle on the left side of the stove controls the damper.
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 Latches
Your Encore® uses fiberglass rope gaskets to make a tight
seal between some parts. With use, particularly on moving
parts, 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.
The front door of the stove should close securely to prevent
accidental opening and should close tightly to prevent air
from leaking into the fire chamber. The door handle will be
positioned vertically when the door is closed.
Gasket Diameter......And the Parts it Seals
5/16" The griddle to the stove top (wire reinforced gasket)
5/16" The damper to the upper fireback
Over a period of time, the gasket around the door will
compress and the latch may need adjustment. To adjust
the handle, follow this procedure:
3/8"
the front doors to the stove front; and the doors to each other.
ST554
1. Remove and retain the
lock nut with a 9/16" wrench.
(Fig. 44)
Damper adjustment
2. Loosen the set screw with a 1/8" Allen wrench.
11/00
3. Rotate the pawl 180°. Replace the lock nut. Tighten the
set screw.
4. Additional adjustment can be made by removing the flat
washer. Or any combination of washer removal and/or
pawl rotation.
Test the door seal. Close the door on a dollar bill and attempt to pull it free. If the bill is freed with little resistance,
the gasket isn’t snug enough at that spot. Continue to make
small adjustments until the setting is right.
If additional adjusting of the latch does not enable the door
to seal sufficiently in one area, try “adjusting” the gasket in
that area. Pack more cement or a smaller diameter gasket
30005295
3/8"
panel
The ash door to the front of the bottom The outer glass panes to the door
3/16"
If you need to change a gasket, first obtain an appropriate replacement from your Vermont Castings’ Authorized
Dealer.
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.
The procedure for replacing gaskets is the same, regardless of the gasket location. Follow these steps:
1. Remove the existing gasket by grasping an end and
pulling firmly. (Fig. 45)
31
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
it may need tightening to compensate for compression of
the new gasket. The directions for adjusting the latches
are on Page 30.
All Gasketed Construction Gaskets
ST560
Fig. 45 Remove gasket then clean channel with wire brush.
ST559
2. Use a wire brush or Remove
the tip of a screwdriver to clean
gasket
the channel of any remaining
cement or bits of gasket.
11/30/00 djt
Remove stubborn deposits of cement with a cold chisel
if necessary. (Fig. 45)
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.
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 keep the gasket from unraveling.
5. Lay an unbroken 1/8" (3 mm) bead of silicone or cement
in the newly-cleaned channel. (Fig. 46)
Other gaskets form seals between all other non-moving
parts, but these are not subject to the same wear and
deterioration as gaskets on moving parts. It is unlikely
that you will ever need to replace these gaskets unless
the involved parts are disassembled and then put back
together. If this is the case, the job should be done only
by a qualified service technician.
5/16" diameter gasket seals the following parts:
• The lower fireback to the back panel
• The left and right air plates (inner sides)
• All connections between the stove plates.
The Chimney System
Creosote
Your Encore is designed to reduce creosote build-up
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.
®
fire-parts.com
sket
e Ga nt
Stov Ceme
ST561
Fig. 46 Lay a bead of gasket silicone or cement then press
gasket in place.
6. Starting at one end, ST559
press the gasket into the channel.
Remove
(Fig. 46) Ensure a good
joint where the gasket meets
before trimming any gasket
excess. Do not overlap the gasket
11/30/00 djt
ends or leave ends with
ragged edges.
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, or tap other parts with the
rubber mallet (or hammer/block of wood).
8. Clean any excess cement from around the channel,
then let the cement that holds the new gasket dry
thoroughly.
9. The stove’s doors may need adjustment after you have
regasketed them. Initially, it may require loosening the
latch to accommodate the new gasket; after a few weeks,
32
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 of a
slow-burning fire. 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 a significant layer of creosote has accumulated —1/8"
(3 mm) or more — it should be removed to reduce the risk
of a chimney fire.
You can never be too safe. Contact your local fire authority for information on what to do in the event of a chimney
fire, and have a clearly understood plan on how to handle
one.
If you do experience a chimney fire, act promptly to:
• Close the damper and air control lever.
• Get everyone out of the house.
• Call the Fire Department.
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 you cannot inspect the flue
system in this fashion, the stove must be disconnected to
provide better viewing access.
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Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
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.
Clean
out any
ash build
up
Clean the chimney connector 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 joints between individual
sections with sheet metal screws.
If you cannot inspect or clean the chimney yourself, contact your local Vermont Castings dealer or a professional
chimney sweep.
Maintenance Schedule
The Stove
Remove these components
DAILY:
• Clear any ash build-up from around the air holes and
combustion flow path in the lower fireback.
• Ashes should be removed before they reach the top of
the ash pan. Check accumulation at least once a day.
• Keep the area around the stove clear of any combustible
materials such as wood, furniture or clothing.
TWO MONTHS:
• Check door handle to be sure it is working properly.
Gasketing becomes compressed after a period of time.
Adjust handle tightness if necessary.
• Check leg bolts and heat shield screws; tighten if necessary.
ANNUAL SPRING CLEANING:
• Check gasketing for wear, and replace if necessary.
• Remove ashes from the ash pan and replace with a
moisture absorbing material (such as kitty litter) to keep
the interior of the stove dry.
• Clean the dust from the inner sides of bottom, rear or
pipe heat shields if your stove is equipped with them.
Clean surfaces are better heat reflectors than dirty surfaces.
• Touch up the black paint.
• Inspect for and remove ash build-up behind the combustion package. This should be done in conjunction
with annual cleaning of the chimney connector. Inspect
the passage behind the combustion package (a mirror
will be helpful) and vacuum away ash using a flexible
vacuum hose inserted in the passage. (Fig. 47)
ST1162
Fig. 47 Inspect and clean out ash accumulation behind the
combustion system.
ST1162
The Chimney
Connector
ash clean out
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30005295
TWO WEEKS:
• Inspect the chimney connector and chimney. Clean if
necessary.
TWO MONTHS:
• Inspect the chimney and chimney connector. Pay
particular attention to the horizontal runs of chimney
connector, and the elbows. Clean the system if necessary.
ANNUAL SPRING CLEANING:
• Disassemble the chimney connector and take it outdoors
•
•
for inspection and cleaning. Replace weak sections of
connector.
Inspect the chimney for signs of deterioration. Repairs to
a masonry chimney should be made by a professional
mason. Replace damaged sections of prefabricated
chimney. Your local Vermont Castings dealer or a chimney sweep can help determine when replacement is
necessary.
Thoroughly clean the chimney.
33
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
The
Catalytic Element
This wood heater contains a catalytic combustor, which
needs periodic inspection and replacement for proper
operation. In the United States it is against the law to operate this wood heater in a manner inconsistent with the
operating instructions in this manual.
Under normal operating conditions, the catalytic combustor should remain active for two to six years (depending
on the amount of wood burned). However, it is important
to monitor the combustor periodically to ensure that it is
functioning properly, as well as to determine when it needs
to be replaced. A non-functioning combustor will result in
a loss of heating efficiency, and an increase in creosote
and emissions.
Once you have ruled out any other possible causes for a
decline in performance, inspect and clean the combustor
if necessary. Be sure to protect any surface you use for
setting the stove parts aside.
Inspecting the Combustor
Remove access door and inner fireback. Remove the catalytic combustor by lifting and sliding it towards you. (Fig. 48)
Catalyst
Inspection and Cleaning
Inspect the combustor for fly ash accumulation and physical damage three times per year. Clean the combustor as
needed.
The refractory package that houses the catalytic combustor
should be inspected for a buildup of fly ash and cleaned
if necessary. This may be done when you examine the
combustor.
fire-parts.com
When to Suspect a Combustor Problem
The best way to evaluate the performance of your Encore®’s
combustor is to observe the amount of smoke leaving the
chimney — both when the combustor has “lighted-off” and
when it has not. Follow these steps:
• With a fire going and the combustor properly activated,
with the damper closed to route smoke through it as
described in the Operation Section, go outside and
observe the smoke leaving the chimney.
• Then, open the stove damper and once again check
the smoke leaving the chimney.
You should see significantly more smoke when the stove
damper is open and exhaust does not pass through the
combustor. However, be careful not to confuse smoke with
steam from wet wood. Steam dissipates in the air quickly;
smoke does not.
If this test indicates a problem, consider other possible factors as well, such as the weather or a change in the quality
of your fuel. In warm weather, draft is weaker than it is in
colder winter weather, and fires can burn sluggishly. Small,
hot fires are a good solution under these conditions.
Burning “green” (insufficiently seasoned) wood will result in
poorer performance than burning properly seasoned fuel.
You may have to run your stove hotter (more air) to achieve
acceptable performance using green or wet wood.
Also, consider any changes in your operating routine.
34
Inner Fireback
Access Door
ST1180
Fig. 48 Inspect the catalytic combustor.
To assure a long life for the combustor, it is recommended
ST1180
to service the combustor
on a regular basis based on the
catalyst access
amount of use. This procedure
takes about five (5) minutes
and requires no tools except for a vacuum if cleaning is
necessary.
Cleaning the Combustor
1. Check the combustor’s honeycomb-like element for a
buildup of fly ash. If any is evident, take the combustor
outside 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 ceramic base, shortening the catalyst’s life and
reducing its effectiveness.
2. Inspect the element for damage or degradation. Although small hairline cracks will not affect performance,
the element should be essentially intact. If the element
is broken in pieces or has sections missing, it should be
replaced. Call your local Vermont Castings Authorized
Dealer for a replacement element.
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Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
3. If the element is in good condition and clean, re-install
it in the stove and replace the refractory inner fireback
and access door.
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 the
performance change was caused by fly ash deposits on
the catalytic element. However, continue the inspections of
the chimney system for a few weeks to ensure that proper
performance continues.
If you continue to find a significant creosote buildup or if
you continue to see excessive smoke from the chimney,
the catalytic element will need to be replaced. Contact your
nearest Vermont Castings’ Authorized Dealer for information about a replacement element.
NOTE: Use only the replacement catalyst supplied by a
Vermont Castings dealer.
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30005295
35
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Encore® Non-catalytic/Catalytic Wood Burning Stove
Model 2040 Replacement Parts
14
17
9
92
12
20
11
2
21
22
56
63
89
19
93
33
80
3
16
57
1
10
78
58
18
60
32
41
23
35
8
13
23
25
fire-parts.com
44
84
46
15
42
6
43
38
4
86
31
36
85
24
76
7
71
87 27 26
39
65
72
77
45
90
68
40
82
72
49
74
26
29
30
34
28 73
67b
37
75
91
81
70
5
27
47
59
79
61a
16
67a
55
49
79
65
61b
83
83a
53
52
69
62
82
48
83b
50
51
54
Vermont Castings Group reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time, without notice.
36
30005295
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Encore® Non-catalytic/Catalytic Wood Burning Stove
Model 2040 Replacement Parts (continued)
Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
Description
Brick Support Bracket
Griddle Gasket
Back
Refractory Rt End
Refractory Lt End
Refractory Support
Gasket, Fiber, Refractory Support
Back Insulation Board
Outer Back
Left Griddle Quadrant
Right Griddle Quadrant
Griddle
HS Flue Collar
Bracket Upper Side
Catalyst, Ceramic
Damper Ashdoor Gasket
Damper Ramp
Damper Housing
Damper1
Damper Tab1
Damper Rod1
Griddle Handle Assy
Gasket, Fiber Back Refractory
Rheostat Bracket
Refractory, Engine - E/D
Damper Handle Screw
Damper Handle
Damper Handle w/Screw Assy
Left Side
Left Air Manifold
Right Air Manifold
Right Side
Thermostat Handle Base
Washer Damper Rod
Fireback Plate, S/S
Inner Bottom
Ashdoor Hinge Upper
Door Handle Bracket
Bottom Outer
Ashlip
Gasket, Fireback
Refractory, Fireback
Retainer, Fireback Refractory
Refractory, Inner Cover
Andiron
Refractory, Access Cover
Leg Leveller
Ashdoor Handle Shaft
Pawl Assy
Ashdoor
Ashdoor Handle (Wood)
Ashdoor Hinge Rod
Cotter Pin, Ashdoor
Ashdoor Hinge Lower
Ashpan Bracket
Lower Side Bracket
Part Number
Item
30005279
1203668
30005289
30005497
30005498
30005233
30005237
30005269
30005261
30002399
30002401
30002386
30005266
30005267
30005353
1203588
1301811
30005293
30006467
1601488
1600851
30002775
30005270
30002863
30005202
1201310
1600664
30002720
See Chart Pg. 36
30002408
30005290
See Chart Pg. 36
30002716
1202560
30005217
30005291
30002403
30002909
30005292
See Chart Pg. 36
30005209
30005302
30005248
30005205
30002397
30007251
1201745
1600622
30005157
30002392
1600663
30002473
30001749
30002404
1601039
30005268
57.
58.
59.
60.
61a.
61b.
62.
63.
65.
66.
67a.
67b.
68.
69.
70.
71.
72.
73.
74.
74a.
74b.
75.
76.
77.
78.
79.
80.
81.
82.
83.
83a.
83b.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
Description
Thermostat Handle
Front Manifold
Front
Flue Collar Gasket
Left Door
Left Door
Door Hinge Strip
Top
Glass Clip Long
Front Door Handle & Shaft
Right Door
Right Door
Door Gasket
Glass Gasket
Left Door Glass
Right Door Glass
Door Hinge Pin
Spacer (for Damper rod)
Primary Air Valve Assy.
Primary Air Frame
Primary Air Rod
Front Door Handle and Shaft
Thermostat Friction Spring
Thermostat Cable
Thermostat Handle Bolt
Ash Pan Assy
Flue Collar
Leg
Hex Head Jam Nut
Bottom Heat Shield
Bottom Heat Shield Rt Wing
Bottom Heat Shield Lt Wing
Grate Bottom
Thermostat Assy.
Washer
Handle Base Stub
Fallaway Handle Complete
Thermostat Handle Assembly
Primary Air Cover
Primary Air Base
Temperature Probe
Bracket, Temperature Probe
Part Number
1600660
30002407
See Chart Pg. 36
30002422
See Chart Pg. 36
See Chart Pg. 36
1308634
See Chart Pg. 36
1601396
30002717
See Chart Pg. 36
See Chart Pg. 36
1203588
1203556
30005300
30005299
30002727
1201779
30005324
1307411
30005260
30002717
1201846
5005471
1201243
5005746
See Chart Pg. 36
See Char t Pg. 36
1203290
30002470
30005030
30005031
30005294
5005470
1202471
30002714
30004175
30007067
30007069
30007071
30007274
30007278
fire-parts.com
30005295
37
Encore® FlexBurn® 2040 Non-Catalytic / Catalytic Wood Burning Stove
Encore® Non-catalytic/Catalytic Wood Burning Stove
Model 2040 Replacement Parts (continued)
SHELL ENAMEL PARTS: ENCORE® MODEL 2040
Classic
Black
Biscuit
Bordeaux
Ebony
Majolica
Brown
Midnight
Blue
Twilight
Top
30002387
30003055
30006682
30003075
30004879
30002635
30007030
Left Side
30002388
30003052
30006679
30003072
30004876
30002633
30007027
Right Side
30002405
30003053
30006680
30003073
30004877
30002632
30007028
Flue Collar
1305050
30003160
30006683
30003162
30004873
2375050
30007031
Front
30002393
30003054
30006681
30003074
30004878
30002634
30007029
Ashlip
30002402
30003051
30006678
30003071
30004875
30002630
30007026
Left Door Sub
Assembly*
30003974
30003984
30006687
30003988
30004882
30003980
30007072
Left Door (61a)
30003938
30003958
30006685
30003962
30004884
30003954
30007033
Right Door Sub
Assembly*
30003975
30003985
30006686
30003989
30004881
30003981
30007073
Right Door (67a)
30003939
30003959
30006684
30003963
30004883
30003955
30007032
Single Leg
30002396
30003050
30006677
30003070
30004874
30002631
30007025
Part Name
fire-parts.com
TRANSITION DOOR ENAMEL PARTS: ENCORE® MODEL 2040
Classic
Black
Biscuit
Bordeaux
Majolica
Brown
Twilight
Left Door Assembly
30007165
30007167
30007169
30007171
30007173
Left Door (61b)
30007081
30007083
30007087
30007085
30007107
Right Door Assembly
30007166
30007168
30007170
30007172
30007174
Right Door (67b)
30007080
30007082
30007086
30007084
30007106
Part Name
*Does not contain glass or glass gasket.
NOTES:
In the diagram and throughout this manual, ‘left’ and ‘right’ mean as you face the stove.
When ordering parts, be sure to mention the stove’s model number. When ordering external parts, be sure to specify color.
The hardware in the Encore® is in standard sizes; most bolts are 1/4" diameter by 20 threads per inch. Most hardware stores can supply replacement hardware if you specify bolt diameter, number of threads per inch and length. Fasteners inside the firebox should be replaced with stainless
steel for ease of future disassembly.
38
30005295
Limited Lifetime Warranty
LIMITED LIFETIME WARRANTY
Vermont Castings Group warrants that all refractory brick and material
used in this product will be warranted against deterioration not resulting
from physical damage or overloading of the woodstove for the lifetime of
this product. This coverage includes the components of the FlexBurn®
System: “engine, inner cover, access cover and fireback.” In addition all
cast iron parts are warranted against breakage, cracking or burn-through
and glass door panels against thermal breakage. Coverage is provided
only to the original purchaser. Vermont Castings Group will also pay labor
associated with repairing or replacing the component described above
for up to five years.
Limited 5 Year Warranty
The porcelain finish is warranted to be free of defects in material and
workmanship for a period of five years from the date you purchase the
stove. Warranty excludes chipping, scratching or other surface damage
to the porcelain that might result from normal wear and tear and also
excludes failure of porcelain coating due to misuse or over-firing.
Limited 1 Year Warranty
The following parts of the wood burning stove are warranted to be free
of defects in material and workmanship for a period of one year from the
date you purchase the stove: handles, gasketing and thermostat assembly
As designated in the descriptions above, Vermont Castings Group will repair or replace, at its option, any part found to be defective upon inspection by a Vermont Castings, Authorized Dealer. The customer must return
the defective part or the stove, with shipping prepaid, to the Authorized
Dealer or pay for any Authorized Dealer in-home travel fees or service
charges for in-home repair work. It is the dealer’s option whether the repair work will be done in the customer’s home or in the dealer’s shop. 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. Labor rates will be determined by Vermont Castings Group’s published labor rates in effect at the time labor is performed.
Any parts 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.
Exclusions & Limitations
1. This product must be installed or serviced by a qualified installer,
preferably NFI or WETT (Canada) certified, as prescribed by the local jurisdiction. It must be installed and operated at all times in accordance with the Installation and Operating instructions furnished
with the product any alterion, willful abuse, accident or misuse of this
product shall nullify this warranty.
2. This warranty does not cover misuse of the stove. Misuse includes
over-firing which will result if the stove is used in such a manner as to
cause one or more of the plates to glow red. Over-firing can be identified later by warped plates and areas where the paint pigment has
burned off. Over-firing in enamel fireplaces is identified by bubbling,
cracking, chipping and discoloration of the porcelain enamel finish.
Vermont Castings Group offers no warranty on chipping of enamel
surfaces. Inspect your wood burning stove prior to accepting it for any
damage to the enamel.
3. This warranty does not cover misuse of the stove as described in the
Owner’s Guide, nor does it cover an stove which has been modified
unless authorized by a Vermont Castings Group representative in
writing. This warranty does not cover damage to the stove caused by
burning salt saturated wood, chemically treated wood, 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 Authorized Dealer.
5. Damage to the unit while in transit is not covered by this warranty but
is subject to a claim against the common carrier. Contact Vermont
Castings Authorized Dealer from whom you purchased your stove or
Vermont Castings Group if the purchase was direct. (Do not operate
the stove 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 our 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
finish, 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. Vermont Castings Group shall have no obligation to enhance or update any unit once manufactured.
IN NO EVENT SHALL Vermont Castings Group 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 SUPERCEDES 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.
fire-parts.com
Limited Catalyst Warranty
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 24 months from the date the
stove is received, the catalyst itself will be replaced free.
From 25 - 72 months a pro-rated credit will be allowed against a replacement catalyst and the cost of labor necessary for its installation at the
time of replacement.
A third year (25 - 36 months) of no charge replacement will be made
when combustor failure is due to thermal degradation of the substrate
(crumbling of ceramic material). The customer must pay for any in-home
travel fees, service charges, or transportation costs for returning the
stove to the Authorized Dealer.
Amount of Time Credit Towards
Since Purchase Replacement Cost
0 - 24 months 100%
25 - 36 months 50%
37 - 48 months 30%
49 - 60 months 20%
61 - 72 months 10%
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 following information in order to receive a replacement catalyst under the terms of this limited warranty:
1. Name, address and telephone number.
2. Proof of original purchase date.
3. Date of failure of catalyst.
4. Any relevant information or circumstances regarding determination of
failure.
5. In addition, the owner must return the failed catalyst.
How to Obtain Service
If a defect is noted within the warranty period, the customer should contact a Vermont Castings Authorized Dealer or Vermont Castings Group if
the purchase was direct 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.
4. Nature of the defect or damage.
5. Any relevant information or circumstances, e.g., installation, mode of
operation when defect was noted.
A warranty claim will then start in process. Vermont Castings Group reserves the right to withhold final approval of a warranty claim pending a
visual inspection of the defect by authorized representatives.
fire-parts.com
149 Cleveland Drive • Paris, Kentucky 40361
www.vermontcastingsgroup.com
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