Specifications - Maine Coast Stove & Chimney

Specifications - Maine Coast Stove & Chimney
Encore®
Non-Catalytic / Catalytic
Woodburning Stove
Model 2040
Homeowner’s Installation
and Operating Manual
For use in the
United States and Canada
Safety Notice: If this appliance is not properly installed, operated and
2425
maintained, a house fire may result.
Encore
NCto
Cover
To reduce the risk of fire, follow the installation instructions.
Failure
follow instructions may result in property damage, bodily injury
5/05or even
death. Contact local building officials about restrictions and installation
inspection requirements in your area.
Do Not Discard This Manual: Retain for Future Use
30005295 12/11 Rev. 9
Nous recommandons que nos appareils de chauffage
au bois soient installés et entretenus apr des
professionnels qui ont été accrédités aux É.-U. par le
National Fireplace Institute® (NFI) comme étant des
spécialistes du NFI en matière d’appareilsde chauffage
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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 MHSC, 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, MHSC 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 MHSC, 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 MHSC 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,
All of Us at MHSC
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 July
1, 1990. Under specific test conditions this heater has
been shown to deliver heat at rates ranging from 9,900
to 34,000 Btu/hr.
The Encore Model #2040 has been tested and is listed
by OMNI-Test Laboratories of Portland, Oregon. The test
standards are ANSI/UL-1482 and ANSI/UL-737 for the
United States, and ULC S627 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 2N1 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, woodburning or oil fired appliances, and the products of combustion of such fuels, contain chemicals known to the State
of California to cause cancer, birth defects and other
reproductive harm.
California Health & Safety Code Sec. 25249.6
Table of Contents
Specifications.........................................................3
Installation..............................................................4
Clearance Charts.................................................12
Mobile Home Installation......................................16
Assembly..............................................................17
Operation..............................................................20
Draft Management................................................26
Maintenance.........................................................29
The Catalytic Element..........................................33
Replacement Parts...............................................35
Warranty...............................................................39
Installation Accessories
Warming Shelf
#0200 Classic Black
#0205 Biscuit
#0207 Ebony
#0201 Bordeaux
#0208 Brown Majolica
#3265* Outside Air Kit
#3185 Outside Air Adapter
#0336* Mobile Home Kit
#0127 Firescreen
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 need
#3185.
Save These Instructions for Future Reference
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Specifications
Encore, Model 2040
EPA Emissions rating - Noncatalytic................. 1.6 g/hr*
Range of heat output - Noncatalytic........9,900 - 34,000
EPA Emissions rating - Catalytic ..................... 1.1 g/hr*
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.
** 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.
Drawing Not to Scale
226M"
(578 mm)
36M"
(95 mm)
16M"
(44 mm)
27"
(686 mm)
1856O"
(470 mm)
2256M"
(565 mm)
1556O"
(394 mm)
25"
(635 mm)
Top exit
flue collar
height
256M"
(654 mm)
5"
(127 mm)
2(6" (73 mm)
236M"
(603 mm)
756M"
(184 mm)
27"
(686 mm)
15"
(381 mm)
Fig. 1 Encore 2040 dimensions.
30005295
Encore 2N1
dimensions
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
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.
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.
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
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
Reference
Point
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-1031985 (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.
AC617
Fig. 3 The 2’-3’10’ Chimney Rule.
AC617Chimneys
Masonry
RLTSKC8
2/11/98 must confirm that it has
An inspection of the chimney
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
Prefabricated Chimneys
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.
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.
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
In horizontal runs of un shielded 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
Toward
stove. Insert the
Stove
first crimped end
into the stove’s flue
collar, and keep
each crimped end
pointing toward
Flue Gas
the stove. (Fig. 4)
Direction
Using the holes in
the flue collar as
ST242
guides, drill 1/8” (3
mm) holes in the
Fig. 4 Chimney connector.
bottom of the first
ST242
section of chimney connectorChimney
and
secure it to the
connector
12/13/99 djt
flue collar with three #10 x 1/2” sheet metal screws.
Lift off the griddle, and shield 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.
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.
ST492
Fig. 5 An exploded view of the chimney connection in a freestanding masonry installation.
ST492
Defiant
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
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
thimbles, but the fit must be snug and the joint between
the thimble and the chimney wall must be cemented
firmly.
Check These
Clearances
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.
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.
*
*
Mantel
Seal
This Off
Thimble Sleeve
Flue
Chimney Connector
Keep
sleeve
end flush
with flue
tile
ST244
Fig. 7 In this installation, the chimney connector attaches to
the chimney above the fireplace opening.
• Check the clearance between the mantel and the
ST243
Fig. 6 The thimble, made of either ceramic or metal, must be
cemented securely in place.
The thimble sleeve should protrude 1-2” (25-50 mm)
into the room. Use furnace cement and thin gasketing
to seal the sleeve in place in the thimble. Secure the
ST243
chimney connector
to the outer end of the sleeve with
thinble connection
sheet metal screws.
12/13/99 djt
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:
30005295
•
•
ST244
chimney connector,
and any combustible trim or the
Plymouth
mantel.
fplc over mantel
12/99between the chimney connecCheck the clearance
tor and the ceiling. The clearance should be at least
30” (762 mm) with unshielded connectors. Consult
the clearance charts 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.
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Flexible
Connector
Mantel Shield
Fireplace Adapter Kit
“Positive Connection”
ST245
Fig. 8 Through the fireplace installation.
Accessories are available for use as wall passthroughs. If using one of these, make sure it has been
tested and listed for use
as a wall pass-through.
ST245
fireplace
In the United States, the
National Fire Protection Asflex connector
sociation (NFPA) has established
guidelines for passing
12/99
chimney connectors through combustible walls. Many
building code inspectors follow these guidelines when
approving installations.
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.
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.
18” (460mm) clearance between pipe and
sides/top/bottom of
opening
T
DE
FI AN
Wall Stud
Chimney
Connector
ST494
Fig. 10 An approved wall pass-through for Canada.
DE
FIA N
12” of
Noncombustible
Material
Floor Protection
ST493
Fig. 9 An approved wall pass-through for the United States.
Your local dealer or your local building inspector can
provide details for other ST494
approved methods of passing
steel a combustible wall in your
a chimney connector through
wall pass thru
area. In Canada, this type
of installation must conform
11/00
to CAN/CSA-B365, Installation Code for Solid Fuel
Burning Appliances and Equipment.
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
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
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)
To meet these requirements, a floor protector must be
at least 43” (1092 mm) wide and 49” (1245 mm) deep.
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.
Even when the bottom heat shield are installed, most
installations require special thermal protection (insulation) for the floor beneath. Use an approved 1” (25 mm)
noncombustible hearth pad with k = 0.84 BTU/in ft2 hr
°F or an equivalent material with an R-value of at least
1.18. (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.
When using a fire screen with doors open, UL737,
Standard for Fireplace Stoves, use an approved 1” (25
mm) noncombustible hearth pad with k = 0.84 Btu/in
ft2 hr °F or an equivalent material with an R-value of
at least 1.18. (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.
30005295
C
D
B
E
E
E
E
F
F
A
A
U.S.Canada
A.
B.
C.
D.
E.
F.
39”
45”
12”
10” 6”
6”
16” 43” (1092 mm)
49” (1245 mm)
12” (305 mm) 8” Connector
ST500
10”
(250 mm) 6” Connector
Defiant
8”
(203 mm)
floor protection
8”
(203
1/31/02
djt mm)
18” (460 mm)
ST500
Fig. 11 Required floor protection dimensions.
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.
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
3. If the overall R-value of the system is greater than
the R-value of the specified floor protector, the alternate is acceptable.
EXAMPLE: The specified floor protector should be 1/2inch 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
R-value: R = 1 x T = 1 x 0.5 = 0.59
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
1
Rmineralboard =
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
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.
10
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.
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 18Z\x”
(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 Page 12 for
approved clearance reduction specifications.
Note: Installation of the Encore is not permitted in
alcoves.
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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
Stud Wall
Framing
Drywall
1" (25mm)
To protect a mantel from the
heat of a stove in a fireplace
installation, use a custommade ventilated mantel shield
that is at least 48” (1220 mm)
long, centered over the stove. ST501
1/4" (6mm)
(Fig. 13) Ventilated shields for
side trim must extend the full Fig. 13 A custom-formed
mantel shield.
length of the trim.
An unprotected mantel (“A”, Fig. 14) cannot be more than
ST501clearance of
9” (230 mm) deep and must have a minimum
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
Noncombustible Spacers
and Fasteners
Noncombustible shields
installed 1” (25 mm) away from
the combustible surface on
noncombustible spacers, called
ventilated shields, may be used
to reduce clearances.
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 is
djthigher. The shield behind the
of the stove, whichever
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” ST253b
(711 mm)
15” (281 mm)
25” Encore
(635 mm)
15” (281 mm)
22” trim
(554clearances
mm)
11” (280 mm)
djt
22” 02/01
(559 mm)
11” (280 mm)
Fig. 14 Maintain clearances to combustible components of
the mantelpiece.
11
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Encore 2N1 Clearance Chart
For use with either 6” or 8” flue collar/chimney connection
Unprotected SurfacesProtected Surfaces
Stove Clearance
Stove Installed
Parallel to Wall
Top Exit, 8” single
wall connector without
shields, vertical flue collar heat shield installed
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
Top Exit, double-wall
chimney connector3,
vertical flue collar heat
shield installed
Stove
Stove Installed
in CornerParallel to Wall
Stove
in Corner1
To RearCorners
Side
Shroud
(B) 20”
(C) 18Z\x”
(D) 5”
(508 mm)
(470 mm)
(127 mm)
To RearCorners
Shroud
(E) 7”
(F) 12”
(178 mm)
(305 mm)
(H) 10”
(254 mm)
(152 mm)
(152 mm)
(305 mm)
(I) 18Z\x”
(470 mm)
(J) 6”
(K) 6”
(L) 12”
(M) 22”
(559 mm)
(N) 12”
(305 mm)
n/a
(P) 11”
(279 mm)
(Q) 12”
(305 mm)
n/a
(G) 18”
(457 mm)
(H) 7”
(178 mm)
(J) 4”
(102 mm)
(K) 5”
(127 mm)
(L) 5”
(127 mm)
(I) 12”
(305 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) 18Z\x”
(470 mm)
(D) 5”
(127 mm)
(E) 7”
(178 mm)
(F) 12”
(305 mm)
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Encore 2N1 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.
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® 2040 Non-Catalytic / Catalytic Woodburning 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
Protected Surfaces
Corner Corner
Parallel InstallationsInstallations**Parallel InstallationsInstallations**
Side (A)
Rear (B)
Side (A)
Side (D)
Rear (E)
Corner (F)
32¹⁄₂”
(826 mm)
23Z\v”
(591 mm)
22Z\x”
(572 mm)
18¹⁄₂”
(470 mm)
10Z⁄₄”
(260 mm)
18Z\x”
(470 mm)
A
B
D
C
E
F
*
*
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:
35Z\v” in the United States and 37Z\v” (946 mm) in Canada.
ST632
Encore
flue centerline
Encore: WITH Chimney
Connector Heat Shields
Diagrams
Unprotected Surfaces
Protected Surfaces
2/01
Corner Corner
Parallel InstallationsInstallations**Parallel InstallationsInstallations**
Side (A)
Rear (B)
Corner (C)
Side (D)
Rear (E)
Corner (F)
32¹⁄₂”
(826 mm)
13Z⁄₄”
(337 mm)
22Z\x”
(572 mm)
19¹⁄₂”
(495 mm)
9Z⁄₄”
(235 mm)
18Z\x”
(470 mm)
A
B
D
C
E
F
ST632a
**To locate center of flue collar for corner installation, add 6Z\x” (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® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
48"
(1220 mm)
Fig. 17 Corner installation, vertical chimney connector, two
wall shields. Reduced side clearances. Wall shield MUST
meet at corner.
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
ST498 must comply with codes. Defiant Wall shield B Refer to “Special Installations.”
11/00 30005295
15
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Mobile Home Installation
You must use an MHSC 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 Pages 12, 13 and 14 of 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
Joint
Shield/
Firestop
Listed Chimney
Connector
Floor
Protection
Outside Air Kit
Connector
Outside Air Floor Vent
KT1190
Fig. 18 Mobile home installation.
16
30005295
ST1190
mobile home install
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Assembly
Storing the Handle
Set Up Your Stove
Cast iron stoves are heavy, and it will take two to four
people to move your Encore into position.
Wipe the protective coating of oil from the griddle with a
clean dry rag or a paper towel.
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)
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
Fig. 21 Handle holder and heat shield positions.
Install the Bottom Heat Shield
ST516
Fig. 19 Attach the griddle handle.
ST516
Install Stove Legs
Attach
The stove is shipped with the legs attached.
some
griddle In
handle
instances, the legs may have been removed.
11/17/00Foldjt
low 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
NOTE: The Bottom Heat Shield is required in most inhandle holder
stallations. Refer to Floor Protection, Page 9, for further
12/13/00
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.
Leg Bolt and
Washer
Bottom Heat Shield
ST857a
ST858
ST564
Fig. 22 Attach the bottom heat shield.
Fig. 20 Attach the stove legs.
30005295
34
ATTACHLEGS
ST857
abottom heat shield
12/05
1/10
17
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Adjust the Leg Levellers
Attach the Damper Handle
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.
Use the 1/4” -20 x 3” screw to attach the damper handle
to the damper stub on the left side.
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. 24)
Adjust Air Deflector
Assemble the Removable Insert Handle
If you have the optional fan kit, you may decide to
adjust the air deflector to blow heat across the top of
your stove. (Fig. 23) Loosen the two (2) screws on each
side and raise or lower the deflector. After adjustment,
tighten the screws.
The ceramic removable insert handle opens and closes
the front doors. Remove after each use, and store it in
the handle holder behind the right front leg. Assemble
the handle by passing the 3³⁄₈" screw through the
ceramic shaft and into the bright metal nub. (Fig. 25)
Tighten carefully until snug.
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)
Air Deflector
Air Deflector
Sheet
Metal
Screws
ST635
Fig. 24 Attach the thermostat handle.
Flue Collar
Heat Shield
Sheet
Metal
Screws
ST635
Encore
Install thermostat
handle
2/01
ST540
Fig. 25 Assemble the front door handle.
ST1180
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 isST1180
in the rear exit position.
flue collar heat shield
18
ST540
Assembly
handle
11/00
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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. 27 Remove access cover.
Inner Cover
ST1187
remove access cover
Hole for Wire
Tie to Secure
Cable
Rheostat
Knob
ST1188
Fig. 28 Remove inner cover.
Rheostat
Holder
Rheostat
Snapstat
Screws
ST848
ST1188
remove inner cover
Fig. 26 Fan installation (Kit # 2767).
Installing or Removing Catalyst
34
1. Remove the access cover by gently lifting up and
FANINSTALL
pulling out from the bottom
edge. (Fig. 27)
2. Remove the inner cover
by pulling it straight out.
(Fig. 28)
3. Remove the catalyst by gently pulling it straight out.
(Fig. 29) Place the catalyst where the catalyst’s
ceramic components will not be damaged.
Remove Catalyst
ST1189
Fig. 29 Remove catalyst.
30005295
ST1189
remove catalyst
19
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Operation
The Encore Controls
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. 30)
Low Heat
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
Griddle Handle
Door Handle
High Heat
Air Control
Lever
ST637
Fig. 31 The handle may be positioned anywhere between the
two extremes for different heat levels.
Door Handle
Holder (Behind leg)
Ashdoor
Handle
Andirons
ST636
Fig. 30 The Encore controls are conveniently located and
easy to operate.
ST633
A Single Air Control Regulates
Encore
Heat Output and Burn Time
controls
The damper is closed when the handle points forward.
Smoke travels through the non-catalytic combustion
system where it can be further burned, before passing
up the chimney. (Fig. 32)
ST637
encore
Damper Positions Air control
2/01
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.
Open
(Updraft Mode)
The primary air control
lever, on the right side of the
2/01
stove, controls the amount of incoming air for starting,
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. 31)
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.
A Damper Directs Air Flow
Within the Stove
The damper handle on the left side of the stove operates the damper to direct air flow within the stove.
The damper is open when the handle points to the
rear, enabling smoke to pass directly into the chimney.
The damper must be open when starting or reviving a
fire, and whenever the griddle or doors are opened.
20
Closed
(High Efficiency
Mode)
ST638
Fig. 32 The damper is either open or closed. There are no
intermediate positions.
High-Efficiency Wood Burning
with Catalytic Combustion
ST638
A Encore leaves the factory
with the combustor packEncore
aged separately.
In the United States, it is against
the law tocontrol
operate this
damper
wood heater in a manner inconsistent with operating
instructions in this manual.
The components of the cata2/01
lytic combustion system in your Encore work together to
produce optimum conditions for secondary combustion.
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
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.
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).
The Encore’s griddle lifts for convenient top-loading of
logs, and is the easiest way to add fuel. (Fig. 33)
Two Ways to Add Fuel
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.
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.
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.
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
30005295
Def
iant
ST521
Fig. 33 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 logloading
to a fire. If the stove is equipped with 8”
11/00
(203 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. 34)
Clockwise to
Open
Counterclockwise
to Close
ST544
Fig. 34 To open the front doors, turn the handle clockwise.
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
ST544
holder behind the right front leg of the stove. Be careful
open
to not drop the handle, since itdoor
is breakable.
11/00
21
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
Use only the Encore spark screen, Item #1907, with
your Encore.
Encore spark screens are available from your Vermont Castings Dealer.
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.
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.
A Surface Thermometer is a Valuable
Guide to Operation
An optional surface thermometer tells you when to adjust the air control, and when to refuel. (Fig. 35)
ST523
Fig. 35 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 750°F. (385°C) is a sign to cut back on the
air supply to slow the burn rate.
ST523
Intrepid
Readings in the 350°-500°F. (175°-260°C) range
indicate low to medium
heat output.
temp
readings
500°-600°F. (260°-315°C) readings indicate medium
11/00
heat output.
Use the following temperature ranges as a guide:
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.
•
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.
• Readings of 600°-750°F. (315-385°C) indicate high
The best hardwood fuels include oak, maple, beech,
ash, and hickory that has been split, stacked, and airdried 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
22
heat output. Operating your Encore continuously
at griddle temperatures of 750° F. (385°C) or higher
may damage the cast iron or enamel finish.
Use the Air Control Settings
that Work Best for You
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.
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.
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Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
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.
Conditioning Your Stove
Cast iron is extremely strong, but it can be broken with
a sharp blow from a hammer or from the thermal shock
of rapid and extreme temperature change.
The cast plates expand and contract with changes in
temperature. When you first begin using your 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. 36)
Encore Control Settings
(Refer to Page 20)
Burn Rate
Low
Medium
High
Primary Air Control From far right to 1/3 the distance to left
From 1/3 to 2/3 the distance to left
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 OVERFIRING CONDITION
TO OCCUR. OVERFIRING THE STOVE IS DANGEROUS AND CAN RESULT IN PROPERTY DAMAGE,
INJURY OR LOSS OF LIFE.
30005295
ST263
Fig. 36 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, let the fire burn brightly,
ST263
and then let it die out.
starting a fire
During the break-in
fires, do not let the stove get hotter
12/99
than 500°F. (260°C) as measured on an optional stovetop thermometer. Adjust the air control lever as necessary to control the fire.
23
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
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. 38)
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.
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 is a glowing ember bed 2-3” (51-75
mm) deep. (Fig. 37) 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. 37 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.
NOTE: Stove installations
good fire vary widely, and the operating guidance given
here is only a starting point . The
12/99
draft management 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.
24
ST264a
Fig. 38 Add full size logs after the ember bed is 3” (75mm)
deep.
For best results when refueling, wear long-cuffed stove
gloves to protect your hands and forearms, add fuel
while the stove stillST264a
has plenty of glowing embers to
re-kindle the fire, and include some smaller pieces of
add wood fire
wood in the new fuel load to help the stove regain its
11/00
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.
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.
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Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
DO NOT OVERFIRE THIS HEATER. Overfiring may
cause a house fire, or can result in permanent damage to the stove. If any part of the Encore glows, you
are overfiring.
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:
• 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.
Close the griddle or doors, and unlatch the ash door.
(Fig. 39) It will pivot, swinging the ash pan out of the
stove.
ST566
Fig. 40 Be sure the cover is securely attached before removing the ash pan.
34
• Properly dispose of theREMOVEASHPAN
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. 40)
• 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.
Open
Close
ST545
Fig. 39 Turn the ashdoor handle clockwise to open and counterclockwise to close.
• Slide the cover onto the pan, making sure it is se-
You can use wood ash as a garden fertilizer.
CAUTION: Never use your household or shop vacuum
cleaner to remove ash from the stove; always remove
and dispose of the ash properly.
ST545
curely closed. (Fig. 40)
• Remove the ash pan, making sure to keep it level.
ashdoor
• To keep the cover from sliding off and to keep ash
11/00
•
from falling on the floor, do not tilt the ash pan forward.
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.
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25
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
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
26
to the outdoors, so it takes less heat from the stove to
heat it up and keep it warm.
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.
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
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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 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.
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 airdried 12-18 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
30005295
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 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 overfiring.
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.
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.
27
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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.
28
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
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.
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.
1. Center the glass on the gasket.
2. Secure the glass on both doors with the retainer
clips. Tighten all screws. (Fig. 41)
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
Cleaning the Glass
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 espe-
•
•
cially 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.
30005295
ST854
Fig. 41 Exploded view of the glass assembly for the right
door.
ST854
glass xview
7/05
29
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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. 42)
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
Lock Nut
Set Screw
Flat Washer
Pressure Adjusting Screw
Allen
Wrench
Lock Nut
Damper
ST554
Fig. 42 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
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.
Over a period of time, the gasket around the door will
compress and the latch may need adjustment. To adST554
just the handle, follow this
procedure:
Damper
adjustment
1. Remove and retain the
lock nut with
a 9/16” wrench.
(Fig. 43)
11/00
2. Loosen the set screw with a 1/8” Allen wrench.
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.
30
Handle Stub
ST1154
Fig. 43 Rotate pawl and/or remove flat washer to adjust
latch.
If additional adjusting of the latch does not enable the
ST1154
door to seal sufficiently
in one area, try “adjusting” the
doormore
pawlcement or a smaller
gasket in that area. Pack
diameter gasket into the channel beneath the gasket so
the main gasket is raised and makes contact with the
door frame. If this procedure doesn’t solve the problem,
replace the gasket. Instructions for gasket replacement
are given later in this section.
Replace the Stove Gaskets as Needed
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.
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
3/8”
the front doors to the stove front; and the doors to each other.
3/8”
The ash door to the front of the bottom panel
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:
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
1. Remove the existing gasket by grasping an end and
pulling firmly. (Fig. 44)
2. Use a wire brush or the tip of a screwdriver to clean
the channel of any remaining cement or bits of gasket.
Remove stubborn deposits of cement with a cold chisel
if necessary. (Fig. 44)
ST560
Fig. 44 Remove gasket then clean channel with wire brush.
ST559
3. Determine the correctRemove
length of the appropriate-sized
gasket by laying it out ingasket
the channel. Allow an extra
11/30/00 djt
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. 45)
et
ask
ve G ent
Sto Cem
ST561
Fig. 45 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. (Fig. 45) Ensure a Remove
good joint where the gasket
meets before trimming gasket
any excess. Do not overlap the
gasket ends or leave ends
with djt
ragged edges.
11/30/00
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
30005295
the latch to accommodate the new gasket; after a few
weeks, 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
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.
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.
31
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
The Chimney Connector
TWO WEEKS:
• Inspect the chimney connector and chimney. Clean if
necessary.
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.
TWO MONTHS:
If you cannot inspect or clean the chimney yourself,
contact your local Vermont Castings dealer or a professional chimney sweep.
Annual Spring Cleaning:
Maintenance Schedule
The Stove
• Inspect the chimney and chimney connector. Pay
particular attention to the horizontal runs of chimney
connector, and the elbows. Clean the system if necessary.
• Disassemble the chimney connector and take it
•
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. 46)
32
•
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.
Clean
out any
ash build
up
Remove these components
ST1162
Fig. 46 Inspect and clean out ash accumulation behind the
combustion system.
ST1162
ash clean out
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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. 47)
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.
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.
30005295
Inner Fireback
Access Door
ST1180
Fig. 47 Inspect the catalytic combustor.
To assure a long life for the combustor, it is recomST1180
mended to service the
combustor on a regular basis
based on the amountcatalyst
of use.access
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.
33
Encore® 2040 Non-Catalytic / Catalytic Woodburning 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.
34
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
9a
9b
14
17
9
12
20
11
2
21
22
56
63
19
33
80
3
16
57
1
10
78
58
18
60
32
41
23
35
8
13
23
25
44
84
46
43
15
42
6
43
38
4
86
31
36
85
7
76
71
87 27 26
39
65
72
24
77
45
68
40
82
49
74
26
30
29
37
67
34
28 73
75
47
5
72
81
70
59
79
61
27
16
55
49
79
65
82
48
83
69
62
83b
83a
53
52
50
51
54
MHSC reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time, without
notice.
Encore Noncatalytic/Catalytic Woodburning Stove
30005295
35
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Encore Noncatalytic/Catalytic Woodburning Stove
Model 2040 (continued)
Item DescriptionPart Number
Item DescriptionPart Number
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
65.
66.
67.
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.
1.
2.
3.
4.
5.
6.
7.
8.
9.
9a.
9b.
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.
36
Brick Support Bracket
Griddle Gasket
Back
Refractory Rt End
Refractory Lt End
Refractory Support
Gasket, Fiber, Refractory Support
Back Insulation Board
Outer Back
Right Air Deflector
Left Air Deflector
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 Assy
Washer Damper Rod
Fireback Plate, S/S
Inner Bottom
Ashdoor Hinge Upper
Door Handle Bracket
Bottom Outer
Ashlip
Gasket, Fireback
Refractory, Fireback
Retainer, Inner Cover Refractory
Refractory, Inner Cover
Andiron
Refractory, Access Cover
Leg Leveller
Ashdoor Handle Shaft
Pawl Assy Ashdoor
30005279
1203668
30005289
30005497
30005498
30005233
30005237
30005269
30005261
30005314
30005315
30002399
30002401
30002386
30005266
30005267
30005353
1203588
1301811
30005293
30002389
1601488
1600851
30002775
30005270
30002863
30005202
1201310
1600664
30002720
See Chart Pg. 37
30002408
30005290
See Chart Pg. 37
30002716
1202560
30005217
30005291
30002403
30002909
30005292
See Chart Pg. 37
30005209
30005302
30005248
30005205
30002397
30005303
1201745
1600622
30005157
30002392
Ashdoor Handle (Wood)
Ashdoor Hinge Rod
Cotter Pin, Ashdoor
Ashdoor Hinge Lower
Ashpan Bracket
Lower Side Bracket
Thermostat Handle
Front Manifold
Front
Flue Collar Gasket
Left Door
Door Hinge Strip
Top
Glass Clip Long
Front Door Handle & Shaft
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
includes #’s 26, 27, 87
1600663
30002473
30001749
30002404
1601039
30005268
1600660
30002407
See Chart Pg. 37
30002422
See Chart Pg. 37
1308634
See Chart Pg. 37
1601396
30002717
See Chart Pg. 37
1203588
1203556
30005300
30005299
30002727
1201779
30005324
1307411
30005260
30002717
1201846
5005471
1201243
5005746
See Chart Pg. 37
See Chart Pg. 37
1203290
30002470
30005030
30005031
30005294
5005470
1202471
30002714
30004175
30005295
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
Encore Noncatalytic/Catalytic Woodburning Stove
Model 2040 (continued)
Shell Enamel Parts - Encore Model 2040
Brown
Part NameClassicBiscuitBordeauxEbony Majolica
Top
30002387 30003055 30002615
30003075 30004879
Left Side
30002388 30003052 30002613
30003072 30004876
Right Side
30002405 30003053 30002612
30003073 30004877
Flue Collar
1305050
30003160
2325050
30003162 30004873
Front
30002393 30003054 30002614
30003074 30004878
Ashlip
30002402 30003051 30002610
30003071 30004875
Left Door
Subassy*
30003974 30003984 30003976
30003988 30004882
Left Door
30003938 30003958 30003950
30003962 30004884
Right Door
Subassy*
30003975 30003985 30003977
30003989 30004881
Right Door
30003939 30003959 30003951
30003963 30004883
Single Leg
30002396 30003050
30002611
30003070 30004874
*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.
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Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
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30005295
Encore 2040
Non-Catalytic / Catalytic Woodburning Stove
LIMITED LIFETIME
WARRANTY
®
Limited Lifetime Warranty
MHSC 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 2N1 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. MHSC 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 overfiring.
Limited 1 Year Warranty
The following parts of the woodburning 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, MHSC 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 MHSC’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.
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.
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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
overfiring which will result if the stove is used in such a manner as to
cause one or more of the plates to glow red. Overfiring can be identified later by warped plates and areas where the paint pigment has
burned off. Overfiring in enamel fireplaces is identified by bubbling,
cracking, chipping and discoloration of the porcelain enamel finish.
MHSC offers no warranty on chipping of enamel surfaces. Inspect
your woodburning 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 MHSC 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
MHSC 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. MHSC shall have no obligation to enhance or update any unit once
manufactured.
IN NO EVENT SHALL MHSC 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.
How to Obtain Service
If a defect is noted within the warranty period, the customer should contact a Vermont Castings Authorized Dealer or MHSC 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. MHSC reserves the right to
withhold final approval of a warranty claim pending a visual inspection of
the defect by authorized representatives.
39
Encore® 2040 Non-Catalytic / Catalytic Woodburning Stove
MHSC
149 Cleveland Drive • Paris, Kentucky 40361
www.mhsc.com
40
30005295
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