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Defiant woodburning Stove Model 1945

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1. MHSC reserves the right to make changes in design materials specifications prices and discontinue colors and products at any time without notice Defiant Woodburning Stove Model 1945 Item Description Part Number Item Description Part Number 1 Secondary Air Cover Plate 1601492 6 Back 30001581 2 Secondary Air Probe Assy 1601489 7 Left Heat Deflector 1608629 3 Secondary Air Link 1601486 8 Right Heat Deflector 1608630 4 Secondary Air Flap 1601490 9 Refractory Assy Body only 1602512 5 Griddle Gasket 1203668 10 Catalytic Combustor Boxed 30004588 36 30001693 11 12 13 13a 14 14a 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Item Description Refractory Access Panel Thermostat Friction Spring Left Griddle Quad Pre 2010 Left Griddle Quad Right Griddle Quad Pre 2010 Right Griddle Quad Griddle Griddle Handle Griddle Handle Spacer Griddle Handle Bolt Upper Fireback Assy Damper Ramp Upper Firebrick Damper Damper Tab Damper Rod Griddle Handle Bushing Throat Baffle Lower Fireback Upper Fireback Bolt Damper Handle Screw Damper Handle Damper Handle Base Assy Left Side Left Air Plate Inner Side Right Air Plate Inner Side Right Side Thermostat Handle Base Assy Thermostat
2. Defiant Woodburning Stove N Model 1945 Homeowner s Installation and Operating Manual For use in the United States and Canada SAFETY NOTICE IF THIS APPLIANCE IS NOT PROPERLY INSTALLED OPERATED AND MAINTAINED A HOUSE FIRE MAY RESULT TO REDUCE THE RISK OF FIRE FOLLOW THE INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE BODILY INJURY OR EVEN DEATH CONTACT LOCAL BUILDING OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA NATIONAL We recommend that our woodburning FIREPLACE hearth products be installed and serviced by professionals who are certified in the U S by the National Fireplace Institute NFI as NFI Woodburning Specialists or who are certified in Canada by Wood Energy Technical Wood Energy venrtearteiny Training WETT Ge Do Not Discard This Manual Retain for Future Use 30001693 3 10 Rev 29 Defiant Woodburning Stove Congratulations on your choice of a Vermont Castings Defiant stove With this purchase you have made a commit ment to make the hearth a place of warmth beauty and comfort in your home At MHSC we share that joy and appre ciation 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 s
3. Fig 46 Use an inspection mirror to check the reflected view of the secondary probe 31 Defiant Woodburning Stove 6 If the element is in good condition and clean re in stall it in the stove and replace the refractory access cover 7 Replace the fireback the five bricks and their clip the left and right wedges and the throat When you install the lower fireback be sure to align the two slight recesses in its bottom forward edge behind the mating tabs on the firebox floor Fig 43 When you install the wedges be sure to place their rear vertical edges against the outermost left and right edges of the lower fireback to ensure a good seal between the lower fireback and the stove s outer back Tap them downward to seat them snugly but not overly tight 8 Clean the chimney and chimney connector 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 inspec tions 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 abo
4. There are a number of catalytic problems which can cause loss of activity Blockage While the honeycomb pattern ensures good contact it also increases the resistance to flow of the combustion gases and because of the many surfaces provides more places for creosote and fly ash to deposit It is important to follow the operating instructions in order to minimize these deposits and to periodically inspect your catalyst for signs of blockage Masking and Poisoning While the catalyst itself does not enter into the combus tion process certain elements such as lead and sulfur can attach to the active sites on the surface of the hon eycomb Though the catalyst is still there it is covered or masked by the contaminant and cannot function To avoid this situation it is important not to burn any thing in your Defiant that is a source of these contami nants Particularly avoid painted or treated wood coal 34 household trash colored papers metal foils or plastics Chemical chimney cleaners may also contain harmful elements The safest approach is to burn only untreat ed natural wood Flame Impingement The catalytic element is not designed for exposure to direct flame If you continually overfire your Defiant the chemistry of the catalyst coating may be altered inhibit ing the combustion process Do not use your Defiant with the baffle removed or damaged as it shields the catalytic element from direct flame Th
5. combustor How do you know if your draft is excessively high or low Symptoms of too much draft include an uncontrol lable burn or a glowing red stove part Signs of weak draft are smoke leaking into the room through the stove or chimney connector joints low heat and dirty glass In some newer homes that are well insulated and weather tight poor draft may result from insufficient air in the house In such instances an open window near the stove on the windward side of the house will provide the fresh air needed Another option for getting more combustion air to the stove is to duct air directly from the outside to the stove In some areas provisions for outside combustion air are required in all new construction With an optional outside air adapter No 1904 your Defiant will accept a duct to deliver outside air for com bustion 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 30001693 Defiant Woodburning Stove 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
6. 1860 6 x 12 Oval Starter Pipe Specifications Installation Chimney amp Fireplace Hazards Proposition 65 Warning Fuels used in gas wood burning or oil fired appliances and the products of Aline of porcelain enamel stove pipe is also avail combustion of such fuels contain chemicals known to able the State of California to cause cancer birth defects and other reproductive harm California Health amp Safety Code Sec 25249 6 30001693 3 Defiant Woodburning Stove Specifications Defiant Model 1945 EPA Emissions rating s eceeeeeeeeeeeees 8 GPH Range of heat outpult 10 600 to 44 400 Btu s hr Maximum heat output 008 55 000 Btu s hr Area heated ccccceee Up to 2 400 Square feet Fuel Size type assein 22 24 hardwood Fuel capacity nsisonessnirouonri aeneis 50 pounds Loadihg siise soninn ninenin Front or top Chimney Connector for 8 flue collar 0 8 200 mm diameter Chimney Flue Size with 8 Chimney Connector 8 200 mm minimum with 6 Chimney Connector 6 150 mm minimum Flue exit POSItiON cccccccceeeeeeeeeeeeeeees Top or Rear Primary Air Manually set thermostatically maintained Secondary Air scccececeeeeeeeeeeeeeeees Self regulating Ash handling system 005 Removable ash pan Glass panels 00 High temperature ceramic Weight iscrisse i
7. 5 illustrates the general layout of chimney connector parts e Be sure the installed stove and chimney connector are correct distances from nearby combustible mate rials NOTE Special slip pipes and thimble sleeves that form tele scoping joints between sections of chimney connector are avail able to simplify instal lations They often eliminate the need to cut individual connec tor sections Consult your local dealer about these special pieces Fig 5 Chimney connector Securing the Single wall Connector to a Prefabricated Chimney Toward Stove Flue Gas Direction Follow the installation instructions of the chimney manufacturer exactly as you install the chimney The manufacturer of the chimney will supply the acces sories 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 out side 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 frees
8. Outside Air Adapter Kit for the Defiant is available from your local dealer Chimney Height Altitude affects chimney performance When using an 8 oval to 6 flue collar adapter on the Defiant refer to Figure 1 for suggested chimney heights at various altitudes Chimney height should be measured from the flue collar to the top of the chimney The recommended minimum chimney height is 16 feet 5 meters O 2000 4000 6000 8000 10000 12000 Altitude Fig 2 Chimney height requirements with 6 chimney and or chimney connector Defiant Woodburning Stove What Kind of Chimney to Use You must connect the Defiant 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 3 illustrates the two types The chimney and chimney connector must be in good condition and kept clean If you use an existing masonry chimney it must be inspected to ensure 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 refer ral to someone who can See Chimney and Fireplace hazards in the appendix for particulars A prefabri
9. 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 7 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 8 The salt air environment of coastal areas or a high humidity en vironment 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 9 MHSC shall have no obligation to enhance or update any unit once manufactured IN NO EVENT SHALL MHSC BE LIABLE FOR INCIDENTAL AND CON SEQUENTIAL 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 incidential 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 Serv
10. 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 Defiant Control Settings Refer to Figure 27 Page 19 Burn Rate Primary Air Control Low From far right to 1 3 the distance to left Medium From 1 3 to 2 3 the distance to left High From 2 3 the distance to left to far left High Efficiency Wood Burning with Catalytic Combustion A Defiant leaves the factory with the combustor in stalled In the United States it is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual or if the catalytic combustor is deactivated or removed The components of the cata lytic combustion system in your Defiant work together to produce optimum conditions for secondary combustion When the damper is closed smoke travels through the catalytic element which causes ignition of smoke at temperatures of 500 600 F 260 315 C half the temperature normally required for unaided secondary combustion 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 Closing the damper exposes the smoke to the
11. be open when starting a fire or when refueling 22 Do not use chemicals or fluids to start the fire Do not burn garbage or flammable fluids such as gaso line naphtha or engine oil 1 Open the stove damper and open the primary air control fully 2 Place several sheets of crumpled newspaper in the stove Do NOT use glossy advertisements or colored paper as they can poison the catalyst Place on the paper six or eight pieces of dry kindling split to a finger width size and on the kindling lay two or three larger sticks of split dry wood approximately 1 2 25 50 mm in diameter Fig 33 Fig 33 Start the fire with newspaper and dry kindling Also never use gasoline type lantern fuel kerosene charcoal lighter fluid or similar liquids to start or fresh en up a fire Keep all such liquids well away from the Defiant while it is in use 3 Light the newspaper and close the door Gradually build up the fire by adding a few 3 5 80 120 mm di ameter splits If this is one of the first few break in fires let the fire burn brightly and then let it die out During the break in fires do not let the stove get hotter than 500 F 260 C as measured on an optional stove top thermometer Adjust the air control lever as neces sary to control the fire Some odor from the stove s hot metal the paint and the cement is normal for the first few fires NOTE Some chimneys must be primed or wa
12. combus tor 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 combus tor close the damper only when a fire is well estab lished 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 clos ing the damper 21 Defiant Woodburning Stove 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 combus tor may stop working or the fire may go out if the
13. connector ero mmj 4533 mm a mm mn mm 430 mm heat shields Stove top exit with rear M 24 N 17 17 14 Q 17 heat Shield and heat rh mm 430 mm re mm he mm 430 mm shields on connector Stove top exit with rear S 24 Va U 17 V 14 W 15 heat shield and double en mm aap mm 430mm 355mm 380 mm wall chimney connector Stove rear exit with rear Y 27 Z 24 AA 17 BB 20 heat shield only ieee mm 610 mm 430 mm ae mm Chimney Connector Clearance Stove in Corner Corners F 18 460 mm X 12 305 mm Unprotected Vertical Surfaces Protected Vertical Surfaces Single wall connector 30 760 mm 25 635 mm Single wall connector rear heat shield on 18 460 mm 14 355 mm stove only Single wall connector with shields and rear heat 14 355 mm 14 355 mm shield on stove Double wall chimney con 14 355 mm 12 305 mm nector Single wall connector Unprotected or Protected Ceiling Surfaces 24 610 mm Clearance to Combustibles in Front of Stove All Installations 48 1220 mm Using a listed double wall oval to round connector 30001693 13 Defiant Woodburning Stove Defiant Clearance Diagrams for use with either a 6 or 8 chimney connection Unprotected Surfaces Protected Surfaces Stove Installed i Stove Installed Parallel Top Exit patiaa no heat shields Top Exit Installa
14. excess ash through the ash slots in the grate down into the ash pan e Close the griddle or doors and unlatch the ash door Fig 36 It will pivot swinging the ash pan out of the stove e Slide the cover onto the pan making sure it is se curely closed Fig 37 Fig 36 Turn the ashdoor handle clockwise to open and coun terclockwise to close 24 Fig 37 Be sure the cover is securely attached before remov ing the ash pan e Remove the ash pan making sure to keep it level e To keep the cover from sliding off and to keep ash from falling on the floor do not tilt the ash pan for ward e Ifthe 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 e Properly dispose of the ash in a metal container with a tight fitting lid Store the container outdoors away from all combustible material e Return the ash pan to its original position in the stove and close and latch the ash door Fig 37 e Do not operate the stove with the ash door open This will result in over firing and could cause dam age 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 Defiant ash will accumulate faster at higher heat outpu
15. 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 30001693 Use the following temperature ranges as a guide e Readings in the 350 500 F 175 260 C range indicate low to medium heat output 500 600 F 260 315 C readings indicate medium heat output e Readings of 600 750 F 315 385 C indicate high heat output Operating your Defiant 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 Too much draft may cause excessive temperatures in the Defiant and could even damage the combustor On the other hand too little draft can cause backpuffing into the room and or the plugging of the chimney or
16. must stop 1 25 mm below the ceiling a Air Flow L Wall Shield Stud Wall Framing Screen Noncombus tible Spacers and Fasteners Ae Shield Metal Spacer 4 Drywall Fig 13 Approved wall shield construction Fe Defiant Woodburning Stove 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 Noncombustible shields installed 1 25 mm away from the combustible surface on noncombustible spacers called ventilated shields may be used to reduce clearances To protect a mantel from the heat of a stove in a fireplace installation use a custom made ventilated mantel shield that is at least 48 1220 mm long centered over the stove Fig 14 Ventilated shields for side trim must extend the full length of the trim 1 4 6mm Fig 14 Acustom formed mantel shield An unprotected mantel A Fig 15 cannot be more than 9 230 mm deep and must have a minimum clearance of 39 991 mm measured from the stove s top plate With a ventilated shield this clearance may be reduced safely to 23 584 mm Unprotected top trim B protruding 9 230 mm or less from the face of the fireplace must be a minimum of 39 991 mm from th
17. 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 Pages 10 13 for approved clearance reduction specifications Use only Vermont Castings Defiant Rear Heat Shield 000 1901 NOTE Alcove installation of the Defiant is not permitted 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 13 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 13 The shield must be a minimum of 48 1220 mm tall and must extend at least 20 520 mm higher than the top of the stove whichever is higher The shield behind the chimney connector must be 30 760 mm wide centered behind the pipe for installations that use an approved prefabricated chimney to pass through the ceiling the shield behind the chimney connector
18. 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 Defiant 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 e With a fire going and the combustor properly activat ed 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 dis sipates 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 Once you have ruled out any other p
19. of 9 230mm diameter solid insulated factory built chimney with 2 50mm 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 11 shows one method in which all combustible material in the wall is cut away to provide the required 18 457mm 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 25mm clear of the wall Defiant Woodburning Stove 18 460mm clear ance between pipe and sides top bottom of opening Fig 11 An approved wall pass through for Canada Your local dealer or your local building inspector can provide details for other approved methods of passing a chimney connector through a combustible wall in your area In Canada this type of installation must conform to CAN CSA B365 Installation Code for Solid Fuel Burning Appliances and Equipment NOTE Do not vent your Defiant into a factory built zero clea
20. perform a thorough cleaning inspection and repair e Thoroughly clean the chimney and chimney connec tor e Inspect the chimney for damage and deterioration Replace weak sections of prefabricated chimney Have a mason make repairs to a masonry chimney e Inspect the chimney connector and replace any damaged sections e Check gasketing for wear or compression and re place if necessary e Inspect and clean the catalytic element Lightly clean the refractory assembly that houses the element but be careful not to damage the refractory material which is very fragile e Clean the glass Ash left on the glass can etch it resulting in a chalky appearance Also check for cracking replace if needed e Check door and damper handles for tightness Ad just if needed e Check heat shield screws Tighten as necessary e Clean dust from the inner sides of bottom rear and connector heat shields e Use a clean dry fine bristle wire brush to remove any built up accumulation on the top of the griddle It is normal for the griddle to darken with use and this is not treatable e Remove ashes from the ash pan and replace with moisture absorbing material such as cat litter to keep the stove interior dry e Touch up the paint on black stoves 33 Defiant Woodburning Stove Appendix Catalytic Combustor In any chemical reaction including the combustion process there are certain conditions which must be met before the reacti
21. 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 in cluding a chimney or house fire Follow all instruc tions exactly and do not allow makeshift compro mises to endanger property and personal safety 30001693 Outside Air In some modern super insulated homes there is inad equate air supply for combustion because of insufficient air infiltration into the building Such air enters a home through unsealed cracks and openings Exhaust fans for kitchen or bath can compete with the stove for avail able 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 im proved stove performance often results An
22. sparks and embers leaving the stove Use only the Defiant spark screen Item 1907 with your Defiant Defiant spark screens are available from your Ver mont Castings Dealer Infra Red Reflective Glass Panels for Clear Fire Viewing The outer surfaces of the ceramic glass panels have an infrared reflective coating which keeps the inner surfaces warm This design along with a pre heated airwash makes clear fire viewing possible at most fir ing levels Andirons Help Protect the Glass Your stove has andirons to keep logs away from the glass panels The andirons are essential to maintain clear fireviewing and should be left permanently in place Since the andirons may slightly hinder refueling through the front doors most stove owners will prefer the convenience of top loading through the griddle Do not place fuel between the andirons and the doors Burn Only High Quality Wood The Defiant 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 22 24 559 610 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 catalytic combustor or pollute the air Do not burn ocean drift wood when it burns the salt it absorbs will attack the cast iron T
23. 533 mm 28 710 mm 29 749 mm 17 432 mm 8 chimney 8 chimney Defiant With Rear Heat Shield and Shielded Connector Side A Rear B Corner C Sid 3912 1003mm 6 chimney 17 432 mm 8 chimney 18 457 mm 294 749 mm Rear E Corner F 6 chimney 17 432 mm 8 chimney 18 457 mm Defiant With Rear Heat Shield and Double wall Connector 391 1003mm 6 chimney 17 432 mm 8 chimney 18 457 mm 29 749 mm 6 chimney 23 584 mm 15 381 mm 8 chimney 16 406 mm 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 34 865 mm in the United States and 36 914 mm in Canada 16 30001693 Defiant Woodburning Stove Assembly Set Up Your Stove Cast iron stoves are heavy and it will take two to four people to move your Defiant into position Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel Install the handle on the griddle Slip the bolt through a washer a nylon bushing then through the handle and the other bushing then through the steel spacer and into the griddle tab Fig 20 Tighten securely D o Spacer Bushings VE Kasb gt S Washer ox Bolt Fig 20 Attach the griddle handle Install Sto
24. Assy Grate Primary Air Cover Plate Top Ashdoor Hinge Support Door Handle Holder Bottom Ashlip Left Side Wedge Right Side Wedge Firebrick 1 x 4 x 9 Firebrick Retainer Andiron Andiron Shelf Leg Leveller Ashdoor Handle Shaft Door Latch Assy Ashdoor Ashdoor Handle Wood Ashdoor Hinge Rod Cotter Pin Ashdoor Ashdoor Bottom Hinge Support Ashpan Bracket Primary Air Valve Assy Primary Air Frame 30001693 Part Number 1602511 1201846 1301807 30005118 1301832 30005119 1300641 1600657 1600070 1200907 5000030 1300643 1300633 1300634 1601488 1600065 1201895 1300635 1300638 1201374 1201310 1600664 30002720 See Chart Pg 38 1300637 1300636 See Chart Pg 38 30002716 5005470 1300639 1300622 30001689 1600600 30001577 See Chart Pg 38 1300628 1300644 1601103 1600066 1300646 1300640 1201745 1600622 30002362 1300619 1600663 30004028 30001749 1300642 30001908 5000024 1307411 61 62 63 64 65 66 67 68 69 70 71 T2 73 74 75 76 TT 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 Defiant Woodburning Stove Defiant Woodburning Stove Model 1945 continued Item Description Primary Air Rod Primary Air Valve Thermostat Handle Wood Airwash Manifold Front Thermostat Cable Left Door Door Hinge Strip Top Glass Clip Glass Clip Right Door only Front Door Handle amp Shaft R
25. OFFICIALS ABOUT RESTRIC TIONS AND INSTALLATION INSPECTION REQUIRE MENTS IN YOUR AREA Before you begin an installation be sure that e Your stove and chimney connector will be far enough from combustible material to meet all clear ance requirements e The floor protector is large enough and is construct ed properly to meet all requirements e You have all necessary permits from local authori ties Your local building official is the final authority for ap proving 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 instal lation 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
26. Partially insert a bolt into each spacer Do not tighten 3 Align the bottom heat shield against the bolted spacers with the stepped side toward the rear of the stove 4 Pass all four bolts through the large end of the key holes Pull the shield forward to engage the smaller ends of the keyhole slots Fig 23 5 Attach the heat shield sides by passing the slots over the bolt heads Tighten the hex bolts Fig 23 Fig 23 Attach the optional bottom heat shield 17 Defiant Woodburning Stove Install the Optional Ash Door Heat Shield 1 Remove the two Phillips pan head screws from the ash door 2 Insert the screws through the ash door heat shield from the painted side place the 5 16 spacers over the screws and carefully thread them back into the original holes Fig 24 The curved lip should be upward under the ashlip of the stove 3 Tighten securely Spacers ST540 Fig 24 Install the ashdoor heat shield Fig 26 Assemble the front door handle Adjust the Leg Levellers Lift the stove slightly so there is no weight on the leg Ope ration while making the adjustment The Defiant Controls Reverse the Flue Collar If Necessary Reverse the flue collar by removing the two screws that Two controls regulate the performance of the Defiant a attach it to the back of the stove Be sure the gasket primary air control supplies oxygen for the fire and a a
27. ance requirement nor the clearance requirement in corner installations may be reduced Flue Collar Heat Shield Rear Heat Shield c Spacers Truss Head Phillips Screws Fig 19 Defiant rear heat shield with flue collar heat shield for top exit configuration 15 Defiant Woodburning Stove Distance from the Center of the Flue Collar to the Wall The information on this page is helpful in planning stove placement particularly in those installations with chimneys that pass through the ceiling However this is not a clearance chart Final stove clearances must adhere to the guidelines in the clearance chart on Page 12 Note that rear dimensions differ for installations with 6 or 8 chimney connectors Defiant with No Stove or Connector Heat Shields Unprotected Surfaces Protected Surfaces Parallel Installations orner Parallel Installations Corner Installations Installations Side A Rear B Corner C Side D Rear E Corner F 6 chimney 6 chimney 39 1003 mm 33 838 mm 34 864 mm 2912 749 mm 28 711 mm 29 737 mm 8 chimney 8 chimney 34 864 mm 29 737 mm Defiant with Rear Heat Shield Only Unprotected Surfaces Protected Surfaces Parallel Installations Corner Parallel Installations Corner Installations Installations Side A Rear B Corner C Side D Rear E Corner F 6 chimney 6 chimney 39 1003 mm 21
28. asket that seals the damper to the upper fireback To adjust the damper 1 Remove the griddle Loosen the lock nut at the cen ter of the damper Fig 40 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 30001693 Defiant Woodburning Stove Pressure Ad justing Screw Lock Nut Allen Damper Wrench Fig 40 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 Defiant s doors should close securely to prevent accidental opening and to keep air from leaking into the stove On adequately adjusted doors the handles should resist slightly as they are turned to the closed position and the doors themselves should be drawn slightly toward the stove Over time the gasket around the doors will compress and the latches may need adjustment To adjust the latches loosen the small lock nut rotate the striker screw a half turn and re tighten the small lock nut Fig 41 Your stove kit includes an Allen wrench for latch adjustments Hold the striker screw to keep it from turning as you tighten the lock nut Make re
29. cated double wall insulated chimney A tile lined masonry chimney Fig 3 Approved chimney types The chimney must extend at least 3 194 mm above the highest pint where it passes through or past a roof and at least 3 610 mm higher than any part of a build ing within 10 3 m horizontally Fig 4 For proper draft and good performance any chimney used with a Defiant should extend at least 16 5 m above the flue collar of the stove Reference Point AC617 Fig 4 The 2 3 10 Chimney Rule Masonry Chimneys An inspection of the chimney must confirm that it has a lining Do not use an unlined chimney The chimney should have no cracks loose mortar other signs of deterioration and blockage Repair any defects before the chimney is used with your stove Unused openings in an existing masonry chimney must be sealed with masonry to the thickness of the chimney wall and the chimney liner should be repaired Open ings 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 a
30. connector to the outer end of the sleeve with sheet metal screws Thimble Sleeve Chimney Connector Keep sleeve end flush with flue tile Fig 7 The thimble made of either ceramic or metal must be cemented securely in place Without a thimble a suitable length of chimney con nector 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 Defiant may be connected to a chimney above a fireplace opening Fig 8 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 M Check These Clearances S O aca mE DEP m Ac CO a S This Off Fig 8 In this installation the chimney connector attaches to the chimney above the fireplace opening If the chimney connector in your installation enters the chimney above a fireplace follow all the guidelines men
31. d by the local jurisdiction It must be installed and operated at all times in ac cordance 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 is transferable however proof of original retail pur chase is required 3 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 bub bling 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 4 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 burn ing salt saturated wood chemically treated wood or any fuel not recommended in the Owner s Guide 5 This warranty does not cover a stove repaired by someone other than a Vermont Castings Authorized Dealer 6 Damage to the unit while in transit is not covered by this warranty but is subject to
32. d how you may need to vary your firing technique if your installation doesn t encour age a good draft ST264a Fig 35 Add full size logs after the ember bed is 3 75mm deep 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 30001693 Defiant Woodburning Stove Do not break the charcoal into very small pieces or pound or compress the charcoal bed It is important that air can circulate through the charcoal bed during the burn Larger pieces of charcoal allow more air to circulate under the wood resulting in the fire reviving more quickly Fig 35 For best results when refueling wear long cuffed stove gloves to protect your hands and forearms add fuel while the stove still has plenty of glowing embers to re kindle the fire and include some smaller pieces of wood in the new fuel load to help the stove regain its operating temperature quickly Use this sequence as a guide to successful refueling 1 Open the damper 2 De ash the stove as described above Open the ashdoor and check the level of ash in the ash pan Empty the pan if necessary and replace it in the stove Close the ash door 3 Open the griddle load the wood smaller pieces first and close the griddle 4 Close the damper 5 When the surface temperature reaches 450 F 230 C adjust t
33. 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 re placement catalyst and the cost of labor necessary for its installation at the time of replacement For stove purchases made after June 30 1990 a third year 25 36 months of no charge replacement will be made when combus tor 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 determina tion of failure 5 In addition the owner must return the failed catalyst 30001693 Exclusions amp Limitations 1 This product must be installed or serviced by a qualified installer preferably NFI or WETT Canada certified as prescribe
34. der specific test conditions this heater has been shown to deliver heat at rates ranging from 10 600 to 55 000 Btu hr The Defiant Model 1945 has been tested and is listed by Canadian Standards Association CSA The test standards are ANSI UL 1482 and ANSI UL 737 for the United States and ULC S627 and CAN CSA B366 2 for Canada The Defiant is listed for burning wood only Do not burn other fuels The Defiant is approved for use in manufactured mo bile homes only in the United States and only when installed with Vermont Castings Mobile Home Kit No 1900 Installation or service of this woodburning stove should only be completed by a qualified installer preferably NFI or WETT Canada certified 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 Save These Instructions for Future Reference 2 30001693 Defiant Woodburning Stove The Story of the Defiant No wood burning appliance save for Ben Franklin s Pennsylvania Fireplace has a stronger heritage than the Ver mont Castings Defiant Named for a 19th century steamship the original Vermont Castings Defiant Wood Stove came to epitomize America s resolve and independence during the Energy Crisis of the 1970s The year was 1975 With energy prices going through the roof and not an attractive or efficient wood stove to be found anywhere two entrepreneurs set out to crea
35. dle or doors are opened 30001693 Defiant Woodburning Stove The damper is closed when the handle points forward Smoke travels through the catalytic combustion system where it can be further burned before passing up the chimney Fig 29 The damper is either fully open or fully closed There are no intermediate positions When closing the damper be sure to pull firmly enough to snap the handle into the locked position Damper Positions ras DEFIANT Gn DEFIANT 7 Open E a p Updraft Mode Catalytic Mode p gt o Fig 29 The Defiant s damper operating positions Two Ways to Add Fuel The Defiant s griddle lifts for convenient top loading of logs and is the easiest way to add fuel Fig 30 SOS ESOS ISS lt gt lt gt oS SL SoS So fs bs ar Sy Sp NS re i Fig 30 Top loading is the best way to add fuel during regular use Front loading is useful for kindling a fire However the front doors open as well for adding an occasional log to a fire If the stove is equipped with 8 203 mm stove pipe the front doors may be opened or even removed and the optional Defiant spark screen placed in the opening for open fire viewing The Defiant is not approved for operation with the fro
36. e home These large chimneys may need to be insulated or have their flues relined for proper stove performance 30001693 Accessories to help make the connection between stainless steel chimney liners and your Defiant are available through your local dealer Chimney Connector Guidelines Achimney connector is the single wall pipe that con nects 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 re lease 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 com bustible 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 in spection and cleaning In horizontal runs of chimney connector maintain a dis tance of 24 610 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 towa
37. e 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 smoke 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 smoke 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 smoke warm The insulation is less dense than ma sonry 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
38. e stove s top surface With a ventilated trim shield this clearance may be reduced safely to 23 584 mm Unprotected side trim C that protrudes 2 51 mm or less from the face of a fireplace must have a minimum clearance of 14 356 mm measured from the stove s top side edge With a ventilated trim shield the clearance may be reduced safely to 6 152 mm If the trim extends more than 2 51 mm it is subject to the requirements for wall clearance The charts and sample installations that follow list all the clearances required for the various installation configurations of the Defiant 12 ST253b Fireplace and Mantel Trim Clearances Protected 23 584 mm 23 584 mm 6 152 mm Unprotected 39 991 mm 39 991 mm 14 356 mm A Mantel B Top Trim C Side Trim Fig 15 Maintain clearances to combustible components of the mantelpiece 30001693 Defiant Woodburning Stove Defiant Clearance Chart for use with either a 6 or 8 chimney connection Stove Clearance Unprotected Surfaces Protected Surfaces Stove Stove Installed in Stove Installed Parallel to Wall Corner Parallel to Wall sn mew comme se rer No stove A 24 B 33 C 23 D 14 E 28 heat shields 610 mm 840 mm 585 mm 355mm 710 mm Stove top exit with rear G 24 H 21 17 14 K 17 heat shield na
39. eaner 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 e Rinse the glass thoroughly e Dry the glass completely Replace Broken Glass Immediately Do not operate your stove if the glass in the doors is damaged If you need to replace the glass use only the high temperature ceramic glass supplied by Vermont Cast ings Do not use substitutes Be sure to specify left or right glass the panels are not interchangeable due toa heat reflective coating on the side toward the room Removing the Glass 1 Remove the right and left door assemblies by rais ing 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 Be sure to place the glass so that the infrared reflective coating is on the exterior side facing toward the room 2 Secure the glass on both door
40. er 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 Any woodburning stove or part thereof that is repaired or replaced dur ing the limited warranty period will be warranted under the terms of the limited warranty for a period not to exceed the remaining term of the original limited warranty or six 6 months whichever is longer Limited 1 Year Warranty The following parts of the woodburning stove are warranted to be free of defects in material and workmanship for a period of one year from the date you receive it The thermostat assembly handles glass door panels cement and gasketing Any of these items found to be defec tive will be repaired or replaced at no charge upon the return of the part with postage prepaid to a Vermont Castings Authorized Dealer Any part 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
41. ermal degradation of the ceramic base may also oc cur causing the element to disintegrate Stay within the recommended guidelines of the Operation section Overfiring At low firing rates especially with a large load of fuel the catalytic element can become overloaded with gases which do not burn in the firebox This puts increased strain on the catalytic element causing it to operate near or even beyond the high end of its nor mal temperature range An immediate sign of this is a low rumbling sound or a sound like a small gas torch coming from the stove s rear chamber If you frequently hear such a sound or continually see a bright glow through the baffle open up the stove s primary air valve to make the fire burn more cleanly in the firebox and cut back on the size of your firewood load Essentially the catalyst is an afterburner and will last longer under lighter loads Mechanical Damage If the element is mishandled damage may occur Always treat the element carefully Remember the catalyst is made of a ceramic material treat it as you would fine china Hairline cracks will not affect the performance of the catalyst as long as the steel sleeve holds the element in the proper position Peeling The surface coat may peel if the catalytic element is frequently subjected to excessive temperatures Follow the operating instructions carefully to avoid this type of damage Every Vermont Castings Defiant is equipped w
42. fire dies down immediately as a result of the damper being closed Once the combustor starts working heat gener ated by burning the smoke will keep it working To determine whether the combustor is operating ob serve the amount of smoke leaving the chimney when the damper is activated and when it is not This proce dure is described on Page 30 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 un der cover for more than 18 months may be considered very dry If you must burn extra dry wood mix it with greener wood for a longer fire and less stress on the combustor Also do not use a full load of dry slab wood or scrap wood For long burns use a mix of dry and moderately dry wood 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 Defiant minimize thermal stress by letting the plates adjust gradually during three or four initial break in fires follow ing Steps 1 3 below Starting and Maintaining a Wood Fire Burn only solid wood in the Defiant and burn it directly on the grate Do not elevate the fuel Do not burn coal or other fuels The damper must
43. g liner to serve any stove or insert vented through a fireplace chimney in the US the National Fire Protection Association recommends one 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 Even the best stove installation will not perform well with poor fuel The best fuel is hardwood that has air dried 12 18 months Softwood burns but not as long as hardwood Fairly green wood has a lot of moisture in it it will burn but some of the heat potential is used to drive the remaining moisture off the wood This reduces the amount of heat that reaches your home and can contribute to a creosote problem There are moisture meters available for firewood you can also judge your wood by its appearance and weight If you get it green lift a piece and get a sense of its weight it can lose a third or more of its weight as it dries Also look at the ends of a log as it dries it shrinks and often cracks The more weathered and cracked a piece is the drier it is Dry wood burns readily with a good chimney draft But with modern stoves especially catalytic ones the wood can be too dry While extra dry wood has little creosote in it the remainder can gas out from the wood quickly and densely enough to overload the catalytic burner If you hear a rumbling or roaring noise like a propane torch from the stove t
44. hat is a sign that the catalyst is seriously overfiring The catalyst is a platinum film on a ceramic base the metal can get to higher temperatures than the ceramic can take and overfiring the catalyst can break it Dry wood can also burn out faster than you want If your dry wood burns out too quickly or overloads the catalyst you can mix in greener wood to slow the fire down 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 till they re dense enough and hot enough to ignite If your stove back puffs you should open up the damper to let the smoke rise to the flue more quickly let more air into the firebox and avoid big loads of firewood You should always see lively dancing flames in the firebox a lazy smoky fire is inefficient and can contribute to creosote buildup in the chimney 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 Re sults 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 a while longer and manage the fire with t
45. he air control for the amount of heat you desire NOTE If the remaining charcoal bed is relatively thick 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 thermostat for the desired heat output WARNING Operate your Defiant only with the doors either fully open or fully closed CAUTION The Defiant will be hot while in opera tion Keep children clothing and furniture away Contact may cause skin burns DO NOT OVERFIRE THIS HEATER Overfiring may cause a house fire or can result in permanent dam age to the stove and to the catalytic combustor If any part of the Defiant other than the baffle and or catalytic combustor glows you are overfiring The throat is made of a special cast iron which can withstand higher temperatures than most other parts of your stove It protects the catalytic element from direct flame impingement which can shorten the catalyst s life Since the throat is in the direct path of flame between the firebox and the catalyst it reaches higher temperatures than other firebox parts and it may glow at times If it does glow you will see this directly through the front doors The glow is normal and does not indicate a problem At times you may see a glow from the catalyst shining through the ports of the throat This is also normal and does not indicate a problem The catalytic element 23 Defiant Woodburni
46. he 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 30001693 Negative Pressure Good draft also depends on a supply of air to the stove a chimney can t pull in more air than is avail able 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 gear If you need to crack a nearby window or door to enable the chimney to pull well that s a sign that you should install an outside air intake to bring combustion air directly to the stove An outside air adapter will attach to the stove to connect an air duct for outdoor combustion air Conclusion Wood burning is an art rather than a science Once the stove and chimney system are in place you can only vary your technique mostly your timing to achieve good results If you keep track of your burning habits and relate them to their effects on the stove s operation you ll be rewarded with good performance and a safe system 30001693 Def
47. he best hardwood fuels include oak maple beech ash and hickory that has been split stacked and air dried outside under cover for at least one year If hardwood is not available you can burn softwoods that include tamarack yellow pine white pine East ern red cedar fir and redwood These should also be properly dried Store wood under cover to keep it dry The longer it is stored the better heating and fire viewing performance you will enjoy Even for short term storage however 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 ad just the air control and when to refuel Fig 32 ST523 Fig 32 Take temperature readings with a thermometer lo cated in the middle of the griddle For example when the thermometer registers at least 450 F 230 C after start up you know that the stove is hot enough to begin catalytic combustion and that 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 opera tion Please review the draft management information on Page 26 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
48. 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 com bustible floor 6 Connector 30001693 For all fireplace installations follow the floor protec tion guidelines described above 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 Keep the Stove a Safe Distance from Sur rounding 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
49. iant Woodburning Stove 27 Defiant 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 Defiant 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 Cleaning the Glass Most of the carbon deposits on the glass will burn off during hot fires However the ash residue that accumulates on the glass surface should be removed regularly to prevent etching To clean the glass follow this procedure e Be sure the glass is completely cool e Clean the glass with water or a cl
50. ice 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 Name address and telephone number of the purchaser Date of purchase Serial number from the label on the back Nature of the defect or damage 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 Cie Oo 39 MHSC 149 Cleveland Drive Paris Kentucky 40361 www mhsc com
51. ight Door Door Gasket Gasket Fiberglas 3 16 4nd Blk Left Door Glass Right Door Glass Lower Door Hinge Pin Spacer for Damper Rod Upper Door Hinge Pin Handle Base Stub Wood Handle Handle Bolt Thermostat Handle Bolt Ash Pan Assy Flat Washer Flue Collar Leg Finish Bag Washer 1 4 Flat Hex Head Jam Nut Bottom Heat Shield Base Right BHS Wing Left BHS Wing Ashdoor Heat Shield not shown HS Spacer 1 25 not shown Control Spacer not shown Part Number 1600058 1307412 1600660 1300627 See Chart Pg 38 5005471 See Chart Pg 38 1300645 See Chart Pg 38 30001715 30001716 30002717 See Chart Pg 38 1203588 1203556 1600064 1600062 30002727 1201779 30002727 30002714 1600664 1201310 1201243 30001690 1202475 See Chart Pg 38 See Chart Pg 38 30001695 1202471 1203290 30005033 30005034 30005035 1401911 1601755 1201781 37 Defiant Woodburning Stove Defiant Woodburning Stove Model 1945 continued Shell Enamel Parts Defiant Enamel Color Top Left Side Right Side Front Ashlip Leg Classic 30001583 Biscuit 30002968 Bordeaux 30002958 Brown Majolica 30004816 Chestnut Brown 30002978 Ebon 30002988 Forest Green 30001628 Midnight Blue 30001622 Sand 30001616 Suede Brown 30002580 Vermont Classic Green 30002997 30002993 30002992 30002994 30002991 30002998 Shell Enamel Parts Defiant eee e Left Door Left Door Right Door Right Door Color Flue Collar Subassembly Only Subassembly On
52. it s best to locate it inside the house This uses the house as insulation for the flue and allows some heat release into the home An indoor chimney won t lose its heat to the outdoors so it takes less heat from the stove to heat it up and keep it warm 30001693 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 the smoke must warm up at the far end from the heat source the stove Don t make a chimney taller unless you must to meet the safety rules or un less there s some nearby feature causing a downdraft Even then there are downdraft preventing chimney caps available which are probably the smarter choice 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 through expansion if we vent a stove with a six inch flue collar 28 square inch area into a 10 x 10 flue the gases expand to over three times their original size This cools the gases which weakens draft strength If an oversized flue is also outside the house the heat it absorbs get
53. ith either a Corning Long Life or an Applied Ceramics combus tor The products are equivalent If you must ship your catalytic element for any reason remember its fragile nature Place the element in a plastic bag and package it with a generous amount of shock absorbing material 30001693 Defiant Woodburning Stove Appendix Chimney and Fireplace Hazards A Improper chimney height The top of the chimney must be at least 3 feet higher than the spot where it passes through or past the roof or two feet higher than everything else within ten feet horizontally whichever is higher Deteriorated chimney cap Structural defects indicated by creosote stains on outside of chimney Blockage within chimney Improper clearance between chimney and nearby combustibles less than 2 check local codes K Loose or leaky cleanout door For a fireplace F Improper clearance between smoke chamber and framing materials less than 2 check local codes Creosote buildup on smoke shelf Structural deterioration Loose or broken bricks or mortar Insufficient hearth depth The hearth must extend 16 18 460mm in Canada beyond the fireplace opening With a fireplace insert or a free standing stove vented through a fireplace the hearth must extend 16 18 460mm in Canada beyond the front door opening of the stove or insert QW mO iQ 30001693 35 Defiant Woodburning Stove
54. ly Vermont NOTES NOTE Does not contain glass or glass gasket In this 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 pars be sure to specify color 1 Included in Item 19 5000030 Upper Fireback Assy 2 Not interchangeable due to a heat reflective coating on the room side of the glass 3 Included in Item 59 50000024 Primary Air Assy The hardware in the Defiant is in standard sizes most bolts are 1 4 diameter by 20 threads per inch Any hardware store can supply replacement hardware if you specify bolt diameter number of threads per inch and length 38 30001693 Warranty Limited 3 Year Warranty MHSC warrants that this woodburning stove will be free of defects in material and workmanship for a period of three years from the date you receive it except that the catalyst thermostat assembly handles glass door panels cement and gasketing shall be war ranted as described below MHSC will repair or replace at its option any part found to be defective upon inspection by a Vermont Castings Authorized Dealer The cus tomer 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 custom
55. ng Stove located below and behind the throat can glow at high temperatures This is also normal However the ele ment can be active and operate properly without glow ing The lack of a glow does not indicate that the cata lyst isn t working Note that the catalyst is most likely to glow at its higher temperatures which it reaches when the firebox is in its lower range the catalyst is an after burner and the more waste fuel there is in the smoke the hotter the catalyst gets We strongly advise the use of a stove top thermometer as a guide to stove performance Normal operating temperatures are between 450 F 220 C and 700 F 370 C Lower temperatures can indicate incomplete combustion and weak draft higher temperatures can shorten the life of the castings Ash Disposal Routine ash removal is important for ease of main tenance 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 e Open the damper e Open the griddle or front doors and use a shovel or poker to stir
56. nstallation Wall Pass Throughs Whenever possible design your installation so the con nector does not pass through a combustible wall If you are considering a wall pass through in your installation check with your building inspector before you begin Also check with the chimney connector manufacturer for any specific requirements Accessories are available for use as wall pass throughs If using one of these make sure it has been tested and listed for use as a wall pass through In the United States the National Fire Protection As sociation NFPA has established guidelines for passing chimney connectors through combustible walls Many building code inspectors follow these guidelines when approving installations 30001693 Defiant Woodburning Stove Figure 10 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 open ing must be noncombustible Wall Stud Chimney Connector Noncombustible Material Floor Protec tion Fig 10 An approved wall pass through for the United States Three other methods are also approved by the NFPA e Placing a section of chimney connector inside a ventilated thimble which in turn is separated from combustibles by 6 152mm of fiberglass insulating material Placing a section of chimney connector inside a section
57. nstallations 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 12 and at least 6 from the sides and rear D and E Fig 12 It must also extend under the chimney connector and 2 to either side C Fig 12 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 42 wide and 43 deep In Canada A noncombustible floor protector is required under the stove as well The floor protector must extend 18 457 mm to the front F Fig 12 and 8 203 mm from the sides and rear D and E Fig 12 To meet these requirements a floor protector must be at least 46 1168 mm wide and 47 1194 mm deep Canada 1168 mm 1194 mm 305 mm 8 Connector 254 mm 203 mm 203 mm 460 mm Fig 12 Required floor protection dimensions 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
58. nt doors open if equipped with a 6 152 mm chimney connector To open the front doors insert the handle into the door latch stub and turn it to the left and up Fig 31 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 resis tance as you turn it to the closed position 19 Defiant Woodburning Stove Clockwise to Counter clockwise to Close Fig 31 To open the front doors turn the handle clockwise To reduce the risk of breaking the glass avoid striking the glass or slamming the doors When you re not using the door handle store it in the holder behind the left front leg of the stove Be careful to not drop the handle since it is breakable WARNING Fireplace stoves equipped with doors should be operated only with doors fully open or doors fully closed If doors are left partly open gas and flame may be drawn out of the fireplace stove opening creating risks from both fire and smoke The Defiant may be used as a fireplace with the front doors open or removed BUT only when it is equipped with 8 203mm stove pipe and only when the optional spark screen is placed correctly in the opening to protect against the possibility of
59. odat 480 Ibs 220 kg Width leg to leg sssesesiinesrrenrerirennn 33 826 mm Depth leg to leg sicccccvtisseacieeaicen 19 362 mm Height to top of flue collar 30 775 mm Drawing Not to Scale 191 i E j S 489mm 489mm Fig 1 Defiant dimensions Under specific conditions during EPA emissions test ing This value can vary depending on how the stove is operated the type and moisture content of the fuel used as well as the design construction and climatic location of your home Figures shown are based on maximum fuel consumption obtained under laboratory conditions and on average efficiencies These values are based on operation in building code conforming homes under typical winter climate conditions in New England If your home is of nonstan dard construction e g unusually well insulated not in sulated 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 U S and foreign design and mechanical patents pend ing HS aa 31 788mm 30001693 Defiant Woodburning Stove Installation SAFETY NOTICE IF YOUR DEFIANT IS NOT PROP ERLY INSTALLED A HOUSE FIRE MAY RESULT TO REDUCE THE RISK OF FIRE FOLLOW THE INSTALLATION INSTRUCTIONS CONTACT LOCAL BUILDING OR FIRE
60. ols 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 28 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 The Defiant s air control system includes an automatic thermostat to ensure an even heat output at whatever manual setting you select The thermostat senses the heating and cooling of the stove surface and adjusts the air valve accordingly Air Control Positions 2 X DEFIANT B Range m m Range Sern Low Heat Range High Heat Range DEFIANT Fig 28 The handle also may be positioned anywhere be tween the two extremes for different heat levels A Damper Directs Air Flow Within the Stove The damper handle on the left side of the stove oper ates 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 grid
61. on can take place For example a reaction may require a certain temperature or a certain concentration of the reactants the combustion gases and oxygen or a certain amount of time Catalysts act at a molecular level to change these requirements though they are not changed themselves during the re action In the Defiant s secondary combustion chamber the catalyst reduces the temperature at which second ary combustion can start from the 1000 1200 F 540 650 C range to the 500 600 F 260 315 C range increasing efficiency and reducing creosote and emissions The catalytic reaction does have some limitations of its own Primary among these is that the reactants the gases come into close physical contact with the catalyst itself To ensure the necessary contact the catalytic element in your Defiant is a ceramic base in the shape of a honeycomb Each of the honeycomb s many surfaces carries a coating of the catalyst usually a noble metal such as platinum or palladium The large surface area exposed in this way ensures that the combustion gases have the greatest opportunity to come in contact with the catalyst Loss of catalytic activity will be apparent in several ways First you may notice an increase in fuel con sumption Second there will be a visible increase in the rate at which creosote builds up in your chim ney connector system You may also notice a heavy discharge of smoke from the chimney
62. ossible causes for a decline in performance inspect and clean the com bustor if necessary Be sure to protect any surface you use for setting the stove parts aside Inspecting the Combustor 1 Lift the throat off its support brackets and then remove it from the stove and place it on a protected surface Fig 42 2 Use a flashlight and a mirror if necessary to exam ine the combustor If no fly ash or damage is visible the inspection is complete and you may replace the baffle If closer examination or cleaning is needed go to the next section Baffle Support Brackets Catalytic Element ST555 Fig 42 Lift the baffle off its supports to inspect the catlyst Removing and Cleaning the Combustor 1 Remove the firebricks Lift off the steel clip and remove the bricks individually Fig 43 2 Tap the left and right wedges upward and remove the lower fireback by pulling it forward You can either let it lie face down on the firebox floor or re move it from the stove through the front door open ing Fig 44 30001693 Alignment Notches Left Wedge Right Wedge Brick Guide Brick Clip Bricks Fig 43 Remove the bricks and the brick retainer Lower Fireback Fig 44 Remove the lower fireback 3 Carefully remove the catalytic combustor s refrac tory access cover then remove the combustor The refrac
63. peated small adjustments until the setting is right Pawl Small Lock ing Nut co Striker Screw Set Screw Handle Stub Fig 41 Turn the door latch striker screw in or out to tighten or loosen the screw 29 Defiant 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 or if the cata lytic element is deactivated or removed Under normal operating conditions the catalytic com bustor should remain active for two to six years de pending 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 de termine 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 Inspection and Cleaning Inspect the combustor in place for fly ash accumula tion and physical damage three times per year Clean the combustor as needed Do not remove the com bustor unless a more detailed inspection is warranted because of diminished performance as outlined in the next section The refractory package that houses the catalytic com bustor should be inspected annually for a buildup of fly ash and cleaned if
64. pproved 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 to the stove causing performance problems Prefabricated Chimneys A prefabricated metal chimney must be one tested and listed for use with solid fuel burning appliances to the High Temperature H T Chimney Standard UL 103 1985 2100 F for the United States and High Temper ature 650 C Standard ULC S 629 for Canada DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE Chimney Size An Defiant 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 Defiant with a 6 152 mm flue collar 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 Defi ant may not be operated with the front doors open Whatever the flue collar size an Defiant 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 th
65. r com pression of the new gasket The directions for adjusting the latches are on page 28 Permanent Defiant Gaskets Other gaskets form seals between non moving parts but these are not subject to the same wear and dete rioration 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 e The lower fireback to the back panel e The left and right air plates inner sides The Chimney System Your Defiant 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 ee 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 creo sote residue accumulates on the flue lining When ignit ed this creosote makes an extremely hot fire within the flue system that can damage the chimney and overheat adjacent combu
66. raft and creosote problems With prefabricated chimney bring it down to six to eight feet from the stove With a masonry chimney arrange the pipe layout to elbow into the chim ney 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 fire place or a leakier stove it s easier for the chimney draft to pull air in through those channels than it is to pull air through the airtight and performance suffers Imagine a vacuum cleaner with a hole in the hose to see the ef fect here In some cases the other appliance can even cause a negative draft through the airtight 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 s dense in the smoke and slow moving and cools off 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 installa tion features and operational steps will encourage good draft and minimize creosote production Because letting the smoke cool off and slow down is one of the keys to creosote production 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 matchin
67. rance 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 DEFIANT TO ANY AIR DIS TRIBUTION DUCT OR SYSTEM Floor Protection A tremendous amount of heat radiates from the bottom plate of your stove The floor area directly under and around the stove will require protection from radiant heat as well as from stray sparks or embers that may escape the firebox Heat protection is provided through the use of a Ver mont Castings Bottom Heat Shield 1905 Spark and ember protection must be provided by a floor protector constructed with noncombustible material as specified Most installations will require the bottom heat shield be attached Only when the stove is placed on a complete ly noncombustible surface such as unpainted concrete over earth may it be used without the heat shield Even when the bottom heat shield is installed you must provide special protection to the floor beneath For installations with the heat shield attached use a non combustible floor protector such as 1 4 nonasbestos mineral board or equivalent or 24 gauge sheet metal The floor protector may be covered with a noncombus tible decorative material if desired Do not obstruct the space under the heater 10 Protection requirements vary somewhat between the Untied States and Canada as follows In U S i
68. rd the chim ney 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 Wear gloves and protective eyewear when drilling cut ting or joining sections of chimney connector Single wall Chimney Connectors e Begin assembly at the flue collar of the stove Insert the first crimped end into the stove s flue collar and keep each crimped end pointing toward the stove Fig 5 Using the holes in the flue collar as guides drill 1 8 8mm holes in the bottom of the first sec tion of chimney connector and secure it to the 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 e 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 8mm holes in the bot tom of the next section 30001693 Defiant Woodburning Stove e Fasten the chimney connector to the chimney Instructions for various installations follow Figure
69. rmed up before they will draw sufficiently to start a fire To correct this situation roll up a couple pieces of news paper place them on top of the kindling and toward the back of the stove light them and close the doors This will encourage the smoke to rise rapidly making it easier to establish a good draft Once the draft is established open the front door and light the rest of the fuel from the bottom Do not light the main bed of fuel until the chimney begins drawing and repeat the procedure as often as necessary if the initial attempt is unsuccessful 30001693 4 If your Defiant has been broken in previously us ing Steps 1 3 continue to build the fire gradually Add larger wood with a diameter of 3 4 75 100 mm Con tinue adding split logs of this size to the briskly burning fire until there is a glowing ember bed at least 3 75 mm deep Fig 34 A good ember bed is necessary for proper functioning of the catalytic system and may take an hour or more to establish Fig 34 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 air control for your desired heat output NOTE Stove installations vary widely and the operat ing guidance given here is only a starting point The draft management information on Page 26 will explain in detail how the features of your installation may help or hinder good draft an
70. round the flue collar opening is in position when you damper directs air flow within the stove to activate and screw the collar back onto the stove deactivate the catalytic combustor Fig 27 Attach the Damper Handle Symbols cast into the stove are reminders of the cor i rect directions for using the controls Left and right in Use the 1 4 20 x 3 screw to attach the damper these directions mean as you face the stove handle to the damper stub on the left side Attach the Primary Air Thermostat Handle Damper erie Door Handle The primary air thermostat handle is the smaller of the two black handles Secure the handle to the stub on the right side of the stove with an 8 32 x 2 slot head machine screw Fig 25 Assemble the Removable Insert Handle Lever Door Handle The ceramic removable insert handle opens and closes Holder the front doors Remove after each use and store it in Benino the handle holder behind the right front leg Assemble the handle by passing the 3 screw through the ceramic shaft and into the bright metal nub Fig 26 Tighten carefully until snug Fig 27 The Defiant s controls are conveniently located and easy to operate 18 30001693 A Single Air Control Regulates Heat Output and Burn Time The primary air control lever on the right side of the stove contr
71. s transferred to the outdoor air and the flue usually stays cool It s 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 diam eter as the stove or insert s flue outlet the liner keeps the smoke warm and the result is a stronger draft An uninsulated liner is a second choice the liner keeps the smoke restricted to its original size but the smoke still must warm up the air around the liner This makes the warm up process take longer Pipe amp Chimney Layout Every turn the smoke must take as it travels to the chimney top will slow it down The ideal pipe and chim ney layout is straight up from the stove to a completely straight chimney If you re 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 lets the smoke speed up before it must turn it leaves some pipe in the room for heat transfer and it gives you long term flexibility for installing a different stove without relocating the thimble Defiant Woodburning Stove There should be no more than eight feet of single wall stove pipe between the stove and a chimney longer runs can cool the smoke enough to cause d
72. s with the retainer clips Tighten all screws Fig 38 3 Replace the doors on the stove 4 Open and close the doors to check that they fit and work properly Adjust as necessary Left Door Glass Gasket iw Glass Panel Retainer Clip Retainer Clip Fig 38 An exploded view of the glass assembly 30001693 Check the Operation of the Primary Air Shutter The primary air shutter is at the back of the ash drop and is visible from the back of the stove Fig 39 The shutter must open and close freely when you move the thermostat lever If it doesn t remove any obstruction If you need assistance consult your local Vermont Cast ings Authorized Dealer Do not change the adjustment of the cable in an at tempt to gain increased firing The air shutter controls how much air can enter the stove but chimney draft is the force that pulls air into the stove If changing the thermostat handle position does not lead to changes in the fire s intensity within four or five minutes it s prob ably due to weak chimney draft in the case of a weak fire you can t increase or an air leak in the stove in the case of a fire you can t decrease mi Primary Air Shutter Fig 39 The primary air shutter must move freely Adjust the Damper as Needed The tension on the Defiant s damper is adjustable to compensate for compression of the g
73. ssary Fig 47 Fig 47 Remove gasket then clean channel with wire brush 3 Determine the correct length of the appropriate sized gasket by laying it out in the channel Allow an extra 1 2 25 50 mm and mark the spot to be cut 4 Remove the gasket from the channel place it on a wood cutting surface and cut it at the marked spot with a utility knife Twist the ends slightly to keep the gasket from un raveling 5 Lay an unbroken 1 8 3 mm bead of gasket cement in the newly cleaned channel Fig 48 6 Starting at one end press the gasket into the chan nel Fig 48 Ensure a good joint where the gasket meets before trimming any excess Do not overlap the gasket ends or leave ends with ragged edges Fig 48 Lay a bead of gasket cement then press gasket in place 30001693 N Press the gasketed part firmly against its normal mating surface to seat the gasket evenly in its chan nel Close and latch the door to do this or tap other parts with the rubber mallet or hammer block of wood Clean any excess cement from around the channel then let the cement that holds the new gasket dry thoroughly Adjust the Door Latch If Necessary The stove s doors may need adjustment after you have regasketed them Initially it may require loosening the latch to accommodate the new gasket after a few weeks it may need tightening to compensate fo
74. stible 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 If you do experience a chimney fire act promptly to e Close the damper and thermostat lever e Get everyone out of the house e Call the Fire Department 30001693 Defiant Woodburning Stove Inspect the system every two weeks during the heat ing 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 in spect the flue system in this fashion the stove must be disconnected to provide better viewing access Clean the chimney using a brush the same size and shape as the flue liner Flexible fiberglass rods are used to run the brush up and down the liner causing any deposits to fall to the bottom of the chimney where they can be removed through the clean out door Clean the chimney connector by disconnecting the sec tions taking them outside and removing any deposits with a stiff wire brush Reinstall the connector sections after cleaning being sure to secure the joints between individual sections with sheet metal screws If you cannot inspect or clean the chimney yourself contact your local Vermont Castings dealer or a profes sional chimney sweep Annual Maintenance Every Spring at the end of the heating season
75. tanding masonry chimneys and fireplace ma sonry chimneys may be used for your installation Freestanding Installations If the chimney connector must pass through a combus tible wall to reach the chimney follow the recommen dations in the Wall Pass Through section that follows The opening through the chimney wall to the flue the breech must be lined with either a ceramic or metal cylinder called the thimble which is cemented securely in place Most chimney breeches incorporate thimbles but the fit must be snug and the joint between the thimble and the chimney wall must be cemented firmly N Defiant Woodburning Stove Chimney Elbow Slip Pipe Standard Connector Oval to Round Adapter Fig 6 An exploded view of the chimney connection in a free standing masonry installation 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 7 Thimble sleeves should be 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 The thimble sleeve should protrude 1 2 25 50 mm into the room Use furnace cement and thin gasketing to seal the sleeve in place in the thimble Secure the chimney
76. te a stove that was a thing of beauty as well as utility Finely crafted from cast iron the Defiant was the first wood stove to combine an artistically designed exterior with a methodically engineered interior using new technologies for efficient combustion Americans purchased over a quarter million Defiants as they rediscovered the common sense of heating with wood a home grown fuel with none of the political and economic entanglements of foreign oil Thirteen years later in 1988 Vermont Castings retired the Defiant replacing it with modern wood burners such as the Encore With its 1998 return the new Defiant incorporates all the finest aesthetic convenience and performance features to be found on any wood stove In a sense the new Defiant has been 23 years in the making Due to its significant role in American history the original model Defiant is in the permanent collection of the Smithso nian Institution Each new purchase of the Defiant stove continues that history Table of Contents Installation Accessories Warming Shelf 1560 Classic 1562 Sand 1553 Brown Majolica 1565 Bordeaux Clearance Charts 1555 Biscuit 1566 Forest Green Assembly 1556 Chestnut Brown 1567 Midnight Blue Operation 1557 Ebony Maintenance 1558 Vt Classic Green Appendix Catalytic Combustor 1900 Mobile Home Kit Appendix 1904 Outside Air Adapter 1905 Bottom Heat Shield Kit 1901 Rear Heat Shield Kit Parts Diagram 1907 Firescreen
77. tioned above for freestanding installations In addi tion give special consideration to the following points e Check the clearance between the stove and the chimney connector and any combustible trim or the mantel e Check the clearance between the chimney con nector and the ceiling The clearance should be at least 24 610 mm e 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 30001693 Through the Fireplace If your fireplace opening height is at least 29 737 mm you may install a Defiant through the opening using a positive connection kit available from your local deal er Positive connection kits ensure a tight fit between the stove flue collar and the chimney flue Fig 9 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 Defiant fire place installations on Page 12 Floor protection requirements also apply to fireplace installations This information is on Page 10 Flexible Connector Mantel Shield Fireplace Adapter Kit Positive Connection Fig 9 Through the fireplace i
78. tions heat shield on stove double wall chimney connector ja li a T y Be 4 7N P LP Rear Exit Installations rear heat shields m N ST486a 14 30001693 Fig 16 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 con nector is centered behind connector 45 1220mm Fig 17 Parallel installation with rear wall pass through two wall shields Reduced clearances to both rear and side walls Wall shields may meet at corner if desired Wall pass through must comply with codes Refer to Special Installations 30001693 Defiant Woodburning Stove 48 i 48 1220mm 1220 48 48 1220mm 1220mm Fig 18 Corner installation vertical chimney connector two wall shields Reduced side clearances Wall shield MUST meet at corner Stove Heat Shields The Vermont Castings Defiant Rear Heat Shield shown below is one way to reduce the clearance to the rear wall The rear heat shield can be installed in any set ting However since the chimney connector also radi ates heat toward the wall you must use a chimney con nector shield whenever you use the rear heat shield Clearance reductions with the rear heat shield apply only to the wall to the rear in parallel installations Nei ther the side clear
79. tory material is brittle handle it carefully Fig 45 4 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 honey comb do not use compressed air to clear the pas sages Such abrasion can scrape the thin coating of platinum the catalyst off the ceramic base shorten ing the catalyst s life and reducing its effectiveness 30001693 Defiant Woodburning Stove Catalytic Ele ment Catalytic Access Panel Fig 45 Remove and inspect the catalytic element 5 Inspect the element for damage or degradation Although small hairline cracks will not affect per formance the element should be essentially intact If the element is broken in pieces or has sections missing it should be replaced Call your local Ver mont Castings Authorized Dealer for a replacement element While the catalytic element is removed check the condition of the secondary air probe Use an inspec tion mirror to locate the probe within the combustion chamber Fig 46 The probe should extend 1 to 1 into the chamber and show no signs of excessive de terioration such as warping corrosion or short length A damaged secondary air probe can affect catalytic performance If the probe needs replacement contact your local dealer
80. tove 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 Defiant 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 Defiant Model 1945 cata lytic equipped 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 Un
81. ts 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 pend ing final disposal If the ash is disposed of by burial in soil or otherwise locally dispersed it should be kept in the closed container until all cinders have thoroughly cooled You can use wood ash as a garden fertilizer CAUTION Never use your household or shop vacuum cleaner to remove ash from the stove always remove and dispose of the ash properly 30001693 Defiant Woodburning Stove DEURMVEUEC a 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 smoke 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 smoke rises from the chimney it provides 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 passiv
82. ut a replacement element NOTE Use only the replacement catalyst supplied by a Vermont Castings dealer Replace the Stove Gaskets as Needed Your Defiant uses fiberglass rope gaskets to make a tight seal between some parts With use particu larly 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 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 3 16 The outer glass panes to the door If you need to change a gasket first obtain an appropri ate replacement from your Vermont Castings Autho rized Dealer 32 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 eight steps 1 Remove the existing gasket by grasping an end and pulling firmly Fig 47 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 nece
83. ve Legs The stove is shipped with the legs attached In some instances the legs may have been removed Fol low these instructions to reattach the legs Install the stove legs Fig 21 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 a Fig 21 Attach the stove legs 30001693 Storing the Handle 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 22 Bottom Heat Shield Door Handle Holder Leg Bolt and Washer Fig 22 Handle holder and heat shield positions Install the Optional Bottom Heat Shield NOTE The Bottom Heat Shield is required in most installations Refer to Floor Protection Page 10 for further details 1 Remove the four 10 24 x 1 2 hex head bolts from the corners of the ash drop on the stove bottom 2 Screw the four 11 4 spacers into the holes from which you removed the bolts finger tight
84. walls floors the ceiling and any other fixed combustible surface The Defiant 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 1220 mm must be maintained between the stove and moveable combustible items such as drying clothes furniture newspapers firewood etc Keep ing 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 e When the stove has no listed heat shield mount ed on it e When the wall has no heat shield mounted on it e When the wall has a heat shield mounted on it e When the wall and stove 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 Defiant is installed parallel to the rear wall and no shield is used it must be at least 33 815 mm from the wall behind it and at least 24 610 mm from walls on either side 30001693 Defiant Woodburning Stove If the Defiant is installed in a corner and no shield is used the corners of the stove must be at least 23 585 mm from

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