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Specifications - Maine Coast Stove & Chimney

1. ST253b Fireplace and Mantel Trim Clearances Unprotected Protected 28 711mm 15 281 mm 25 635mm 15 281 mm C Side Trim 22 554mm 11 280 mm D Side Wall 22 559 mm Fig 14 Maintain clearances to combustible components of the mantelpiece A Mantel B Top Trim 11 280 mm 11 Encore 2040 Non Catalytic Catalytic Woodburning Stove Encore 2N1 Clearance Chart For use with either 6 or 8 flue collar chimney connection Unprotected Surfaces Protected Surfaces Stove Clearance Stove Installed Stove Stove Installed Stove Parallel to Wall in Corner Parallel to Wall in Corner Top Exit 8 single i To Rear Corners i To Rear Corners wall connector without Shroud Shroud shields vertical flue col B 20 C 18 2 i E 7 F 12 lar heat shield installed 508 mm 470 mm 178 mm 305 mm Top Exit single wall 19 10 I 18 chimney connector heat ne mm oes mm 470 mm shield vertical flue col lar h s installed Rear Exit Q 12 No flue collar heat a te hae 305 mm shield Top Exit double wall chimney connector 18 7 ly 12 J 4 vertical flue collar heat 305 mm 102 mm shield installed Clea
2. 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 approved masonry or pre cast refractory tiles stainless steel pipe or a code approved poured in place liner The chimney s clean out door must seal tightly A loose or leaky clean out door can weaken chimney draft caus ing performance problems 30005295 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 Encore with an 8 203 mm flue collar is approved for venting into a masonry chimney with a nominal flue size of 8 x 8 203 x 203 mm or 8 x 12 203 x 305 mm and into a round
3. Encore Non Catalytic Catalytic Woodburning Stove Model 2040 ZEN i i Homeowner s Installation i 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 Berdana NFI Woodburning Specialists or who are Oregon USA certified in Canada by a Tested amp Listed By Wood Energy Technical Wood Energy CERTIFIED ae echn www nficertified org Training WETT s www c US OMNI Test Laboratories Inc Do Not Discard This Manual Retain for Future Use 30005295 12 11 Rev 9 Encore 2040 Non Catalytic Catalytic Woodburning Soc _ lt _ lt __ _ gt P_ _ _ gt Congratulations on your choice of a Vermont Castings E
4. Please read the manual thoroughly and keep it as a reference Sincerely All of Us at MHSC This manual describes the installation operation and maintenance of the Vermont Castings Encore Model 2040 Non Catalytic Catalytic wood burning heater This heater meets the U S Environmental Protection Agen cy s emission limits for wood heaters sold on or after July 1 1990 Under specific test conditions this heater has been shown to deliver heat at rates ranging from 9 900 to 34 000 Btu hr The Encore Model 2040 has been tested and is listed by OMNI Test Laboratories of Portland Oregon The test standards are ANSI UL 1482 and ANSI UL 737 for the United States and ULC S627 for Canada The Encore is listed for burning wood only Do not burn other fuels We recommend that you hire a professional installer certified by the Wood Heat Education and Research Foundation WHERF or the Wood Energy Technical Training WETT to install your stove or to advise you on the installation should you attempt to install it yourself Please read this entire manual before you install and use your new stove Failure to follow instructions may result in property damage bodily injury or even death The Encore 2N1 is approved for use in mobile homes in the United States and Canada when installed with Ver mont Castings Mobile Home Kit Refer to and follow the instructions provided with the Mobile Home Kit 0336_ to ensure safe installation Propo
5. 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove When the damper is closed smoke travels through the catalytic element which causes ignition of smoke at temperatures of 500 600 F 260 315 C half the temperature normally required for unaided secondary combustion 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 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 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
6. 37 48 months 30 49 60 months 20 61 72 months 10 Any replacement catalyst will be warranted under the terms of the catalyst warranty for the remaining term of the original warranty The purchaser must provide the following information in order to receive a replacement catalyst under the terms of this limited warranty 1 Name address and telephone number 2 Proof of original purchase date 3 Date of failure of catalyst 4 Any relevant information or circumstances regarding determination of failure 5 In addition the owner must return the failed catalyst 30005295 Exclusions amp Limitations 1 This product must be installed or serviced by a qualified installer preferably NFI or WETT Canada certified as prescribed by the lo cal 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 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 identi fied later by warped plates and areas where the paint pigment has burned off Overfiring in enamel fireplaces is identified by bubbling cracking chipping and discoloration of the porcelain enamel finish MHSC offers no warranty on chippi
7. Fig 37 Add larger pieces of wood as the fire begins to burn well 5 Close the damper when the griddle temperature reaches 450 F 230 C 6 Adjust the 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 and how you may need to vary your firing technique if your installation doesn t encour age a good draft Refuel While the Embers Are Still Hot When reloading best results will be achieved if you first de ash the stove by stirring the fuel bed to allow ash to fall through the grate into the ash pan Do not break the charcoal into very small pieces or pound or compress the charcoal bed 24 It is important that air can circulate through the charcoal bed during the burn Larger pieces of charcoal allow more air to circulate under the wood resulting in the fire reviving more quickly Fig 38 Fig 38 Add full size logs after the ember bed is 3 75mm deep For best results when refueling wear long cuffed stove gloves to protect your hands and forearms add fuel while the stove 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
8. a guide to successful refueling 1 Open the damper 2 De ash the stove as described above Open the ashdoor and check the level of ash in the ash pan Empty the pan if necessary and replace it in the stove Close the ash door 3 Open the griddle load the wood smaller pieces first and close the griddle 4 Close the damper 5 When the surface temperature reaches 450 F 230 C adjust the air control for the amount of heat you desire NOTE If the remaining charcoal bed is relatively thick 2 3 51 75 mm and if your fuel is well seasoned it is possible to add fresh fuel smaller pieces first close the door and damper and reset the primary air control for the desired heat output within five minutes WARNING FIREPLACE STOVES EQUIPPED WITH DOORS SHOULD BE OPERATED ONLY WITH DOORS FULLY OPEN OR DOORS FULLY CLOSED IF DOORS ARE LEFT PARTLY OPEN GAS AND FLAME MAY BE DRAWN OUT OF THE FIREPLACE STOVE OPENING CREATING RISKS FROM BOTH FIRE AND SMOKE CAUTION The Encore will be hot while in opera tion Keep children clothing and furniture away Contact may cause skin burns 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove DO NOT OVERFIRE THIS HEATER Overfiring may cause a house fire or can result in permanent dam age to the stove If any part of the Encore glows you are overfiring Ash Disposal Routine ash removal is important for ease of main tenance and is important for the st
9. ceramic components will not be damaged Remove Catalyst Fig 29 Remove catalyst 30005295 19 Encore 2040 Non Catalytic Catalytic Woodburning Stove Operation The Encore Controls Two controls regulate the performance of the Encore a primary air control supplies oxygen for the fire and a damper directs air flow within the stove to activate and deactivate the combustion system Fig 30 Symbols cast into the stove are reminders of the correct directions for using the controls The words Left and right in these directions are facing the stove Griddle Handle Door Handle Air Control y Lever Damper Handle Door Handle Holder Be hind leg Handle Andirons Fig 30 The Encore controls are conveniently located and easy to operate A Single Air Control Regulates Heat Output and Burn Time The primary air control lever on the right side of the stove controls the amount of incoming air for starting maintaining and reviving a fire More air entering the stove makes the fire burn hotter and faster while less air prolongs the burn at a lower heat output level Fig 31 For the greatest air supply and maximum heat output but the shortest burn time move the lever toward the front of the stove For a fire that will last longer with less heat move the lever toward the rear of the st
10. floor protector is required under the stove and must extend at least 16 not including the ash lip from the front of the stove F Fig 11 and at least 6 from the sides and rear D and E Fig 11 In rear venting configurations floor protection must also extend under the chimney connector and 2 to either side C Fig 11 For the 8 203 mm connector the protector must be a minimum of 12 305 mm wide For the 6 152 mm connector the protector must be 10 254 mm wide The protector must be centered under the connector To meet these requirements a floor protector must be at least 39 wide and 45 deep 30005295 In Canada A noncombustible floor protector is required under the stove as well The floor protector must extend 18 457 mm to the front F Fig 11 and 8 203 mm from the sides and rear D and E Fig 11 To meet these requirements a floor protector must be at least 43 1092 mm wide and 49 1245 mm deep Canada 1092 mm 1245 mm 305 mm 8 Connector 250 mm 6 Connector 203 mm 203 mm 460 mm Fig 11 Required floor protection dimensions How to Determine if Alternate Floor Protection Materials are Acceptable All floor protection must be noncombustible i e met als brick stone mineral fiber boards etc Any organic materials i e plastics wo
11. new construction The Encore is equipped to deliver outside air for com bustion and outside air kit 3265 is available When first using the stove keep track of the air control settings You will quickly find that a specific setting will give you a fixed amount of heat It may take a week or two to determine the amount of heat and the length of burn you should expect from various settings Most installations do not require a large amount of combustion air especially if adequate draft is available Do not for any reason attempt to increase the firing of your heater by altering the air control adjustment range outlined in these directions Use the following air control settings as a starting point to help determine the best settings for your installation Each is described as a fraction of the total distance the lever may be moved from right to left Encore Control Settings Refer to Page 20 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 DO NOT OPERATE THE STOVE WITH THE ASH DOOR OPEN OPERATION WITH THE ASH DOOR OPEN CAN CAUSE AN OVERFIRING CONDITION TO OCCUR OVERFIRING THE STOVE IS DANGER OUS AND CAN RESULT IN PROPERTY DAMAGE INJURY OR LOSS OF LIFE 30005295 Conditioning Your Stove Cast iron is extremely strong but it can be broken with a sharp blow from a hammer or from the thermal shoc
12. 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 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Too much draft may cause excessive temperatures in the Encore and could even damage the stove On the other hand too little draft can cause backpuffing into the room and or the plugging of the chimney How do you know if your draft is excessively high or low Symptoms of too much draft include an 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 or low heat output In some newer homes that are well insulated and weather tight poor draft may result from an insufficient air supply in the house In such instances an open window near the stove on the windward side of the house can provide the combustion air supply needed Another option for getting more combustion air to the stove is to duct air directly from outside to the stove In some areas provisions for outside combustion air are required in all
13. or insert operation depends on natural unforced draft Natural draft occurs when the exhaust is hotter and therefore lighter than the outdoor air at the top of the chimney The bigger the temperature difference the stronger the draft As the hot gases rise through the chimney they provide suction or draw that pulls air into the stove for combustion A slow lazy fire with the stove s air inlets fully open indicates a weak draft A brisk fire supported only by air entering the stove through the normal inlets indicates a good draft The stove s air inlets are passive they regulate how much air can enter the stove but they don t move air into it Depending on the features of your installation steel or masonry chimney inside or outside the house matched to the stove s outlet or oversized your system may warm up quickly or it may take a while to warm up and operate well With an airtight stove one which restricts the amount of air getting into the firebox the chimney must keep the stove s exhaust warm all the way to the outdoors in order for the stove to work well Some chimneys do this better than others Here s a list of features and their effects Masonry Chimney Masonry is a traditional material for chimneys but it can perform poorly when it serves an airtight stove Masonry is a very effective heat sink it absorbs a lot of heat It can cool the chimney gases enough to dimin ish draft
14. rather than a science Once the stove and chimney system are in place you can only vary your technique mostly your timing to achieve good results If you keep track of your burning habits and relate them to their effects on the stove s operation you ll be rewarded with good performance and year of reliable heating 28 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Maintenance Keep Your Stove Looking New If you need to replace the glass use only the high and Working Its Best temperature 5 mm ceramic glass supplied by Vermont Castings Do not use substitutes Let the fire in the stove go out and allow the stove to z cool completely before beginning any maintenance Removing the Glass procedure 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 An occasional dusting with a dry rag will keep the down to release the upper hinge pin Place the doors painted cast iron of your Encore looking new face down on a padded work surface Be especially The stove s paint can be touched up as needed First careful with enamelled doors mask the areas such as enamelled parts glass or 2 Remove the screws that hold the glass retainer clips handles around the spot to be painted Clean the spot in place and remove the clips with a wire brush Remove the griddle and set it aside 3 Carefully lift
15. 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 2 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 33 Encore 2040 Non Catalytic Catalytic Woodburning Stove 3 If the element is in good condition and clean re in stall it in the stove and replace the refractory inner fireback and access door Operate the stove in your usual manner for two weeks inspecting the chimney and the chimney connector frequently during this period If creosote does not build up as fast it is likely that the performance change was caused by fly ash deposits on the catalytic element However continue the 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
16. 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 freestanding 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 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove thimbles but the fit must be snug and the joint between the thi
17. to vent vertically into a completely straight and vertical chimney If you are starting from scratch use this layout if possible If the stovepipe must elbow to enter a chimney locate the thimble about midway between the stove top and the ceiling This achieves several goals it allows the gases to speed up before they must turn it leaves some pipe in the room for heat 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove transfer and it gives you long term flexibility for install ing a different stove without relocating the thimble There should be no more than eight feet of single wall stove pipe between the stove and a chimney longer runs can cool the exhaust enough to cause draft and creosote problems With prefabricated chimney bring it down to six to eight feet from the stove With a masonry chimney arrange the pipe so that it turns into the 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 and performance of the stove suffers Imagine a vacuum cleaner with a hole in the hose to understand the effect here In some cases the other appliance can even cause a negative draft through the stove and result in a dangerous draft reversal Creosote Creosote is a by product of slow wood burn
18. you when to ad just the air control and when to refuel Fig 35 ST523 Fig 35 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 the stove is hot enough and it may be time to close the damper Note that the stove will warm up much sooner than the chimney though a warm chimney is the key to easy ef fective stove operation Please review the draft man agement information on Page 27 to see how the size type and location of your chimney will affect your stove operation When thermometer readings drop below 350 F 175 C it s time to adjust the air control for a higher burn rate or to reload the stove A temperature reading over 750 F 385 C is a sign to cut back on the air supply to slow the burn rate Use the following temperature ranges as a guide 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 Readings of 600 750 F 315 385 C indicate high heat output Operating your Encore continuously at griddle temperatures of 750 F 385 C or higher may damage the cast iron or enamel finish Use the Air Control Settings that Work Best for You No single air control setting will fit every situation Each installation will differ depending on the quality of the fuel the amount
19. 8 K mm 1220 mm Fig 15 Parallel installation vertical chimney connector two Fig 17 Corner installation vertical chimney connector two wall shields Reduced clearances for both rear and side walls wall shields Reduced side clearances Wall shield MUST Wall shields may meet at corner if desired Shielding for con meet at corner nector is centered behind connector gz 1220 mm Fig 16 Parallel installation with rear wall pass through two wall shields Reduced clearances to both rear and side walls Wall shields may meet at corner if desired Wall pass through must comply with codes Refer to Special Installations 30005295 15 Encore 2040 Non Catalytic Catalytic Woodburning Stove Mobile Home Installation 11 If unit burns poorly while exhaust blower is on in home i e kitchen range hood increase combus You must use an MHSC Vermont Castings Kit 0336 for installation into a mobile home 1 An outside air inlet must be provided for combus tion and must remain clear of leaves debris ice and or snow It must be unrestricted while stove is in use to prevent room air starvation which can cause smoke spillage and an inability to maintain a fire Smoke spillage can also set off smoke alarms 2 Stove must be secured to the mobile home struc ture using the fasteners provided in the Mobile Home Kit 3 Stove must be grounded with 8 solid copper gro
20. 877 Flue Collar 1305050 2325050 30004873 Front 30004878 Ashlip 30002402 30003051 30002610 30003071 30004875 Subassy 30003974 30003984 30003976 30003988 30004882 Left Door 30003938 30003958 30003950 30003962 30004884 Subassy 30003975 30003985 30003977 30003989 30004881 Right Door 30003939 30003959 30003951 30003963 30004883 Single Leg 30002396 30003050 30002611 30003070 30004874 Does not contain glass or glass gasket NOTES In the diagram and throughout this manual left and right mean as you face the stove When ordering parts be sure to mention the stove s model number When ordering external parts be sure to specify color The hardware in the Encore is in standard sizes most bolts are 1 4 diameter by 20 threads per inch Most hardware stores can supply re placement hardware if you specify bolt diameter number of threads per inch and length Fasteners inside the firebox should be replaced with stainless steel for ease of future disassembly 30005295 37 Encore 2040 Non Catalytic Catalytic Woodburning Stove 38 30005295 LIMITED LIFETIME WARRANTY Limited Lifetime Warrant MHSC warrants that all refractory brick and material used in this product will be warranted against deterioration not resulting from physical dam age or overloading of the woodstove for the lifetime of this product This coverage includes the components of the 2N1 System engine in
21. Ashdoor Hinge Lower Ashpan Bracket Lower Side Bracket Thermostat Handle Front Manifold Front Flue Collar Gasket Left Door Door Hinge Strip Top Glass Clip Long Front Door Handle amp Shaft Right Door Door Gasket Glass Gasket Left Door Glass Right Door Glass Door Hinge Pin Spacer for Damper rod Primary Air Valve Assy Primary Air Frame Primary Air Rod Front Door Handle and Shaft Thermostat Friction Spring Thermostat Cable Thermostat Handle Bolt Ash Pan Assy Flue Collar Leg Hex Head Jam Nut Bottom Heat Shield Bottom Heat Shield Rt Wing Bottom Heat Shield Lt Wing Grate Bottom Thermostat Assy Washer Handle Base Stub Fallaway Handle Complete includes s 26 27 87 Part Number 1600663 30002473 30001749 30002404 1601039 30005268 1600660 30002407 See Chart Pg 37 30002422 See Chart Pg 37 1308634 See Chart Pg 37 1601396 30002717 See Chart Pg 37 1203588 1203556 30005300 30005299 30002727 1201779 30005324 1307411 30005260 30002717 1201846 5005471 1201243 5005746 See Chart Pg 37 See Chart Pg 37 1203290 30002470 30005030 30005031 30005294 5005470 1202471 30002714 30004175 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Encore Noncatalytic Catalytic Woodburning Stove Model 2040 continued Shell Enamel Parts Encore Model 2040 Part Name Classic Biscuit Bordeaux Majolica Top 30004879 Left Side 30003052 30003072 30004876 Right Side 30004
22. The bigger the chimney the longer it takes to warm up It s often very difficult to warm up an outdoor masonry chimney especially an oversized one and keep it warm enough to maintain an adequate draft Steel Chimney Most factory made steel chimneys have a layer of insulation around the inner flue This insulation keeps the chimney warm The insulation is less dense than masonry so a steel chimney warms up more quickly than a masonry chimney Steel doesn t have the good looks of masonry but it performs much better Indoor Outdoor Location Because the chimney must keep the smoke warm it s best to locate it inside the house This uses the house as insulation for the flue and allows some heat release into the home An indoor chimney won t lose its heat 26 to the outdoors so it takes less heat from the stove to heat it up and keep it warm Chimney Height The common wisdom tells us that a taller flue draws better than a short one This isn t necessarily so If a chimney is tall enough to meet the safety requirements of the 2 3 10 foot rule then adding more height isn t the right answer to a draft problem In fact it could make the problem worse by adding more mass to the chimney system which must be warmed up a distance from the heat source the stove Don t make a chimney taller unless you must in order to meet the safety rules or un less there s some nearby feature causing a downdraft Even then there are d
23. all has a heat shield mounted on it e When the wall and stove pipe have heat shields In general the greatest clearance is required when you place a stove and its connector near a wall with no heat shield For example when the Encore is installed using 6 con nector pipe parallel to the rear wall and no connector shield is used it must be at least 15 381 mm from the wall behind it and at least 19 483 mm from walls on either side These dimensions are measured from the back of the rear shroud and the side edge of the cast iron top to the combustible wall If the Encore is installed in a corner and no shield is used the corners of the stove top must be at least 18 470 mm from nearby walls Clearances may be reduced only by means approved by the regulatory authority and in accordance with the clearances listed in this manual Refer to Page 12 for approved clearance reduction specifications NOTE Installation of the Encore is not permitted in alcoves 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove One way to reduce clearances is with a wall shield con structed 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 3 90 mm side down Shields must be spaced out from the combustible surface 1 25 mm on noncombustible spacers as in Figure 12 The
24. antel 30005295 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 13 Ventilated shields for side trim must extend the full Fig 13 A custom formed length of the trim mantel shield NX 1 4 6mm ST501 An unprotected mantel A Fig 14 cannot be more than 9 230 mm deep and must have a minimum clearance of 28 711 mm measured from the stove s top plate With a ventilated shield this clearance may be reduced safely to 15 381 mm Unprotected top trim B protruding 3 4 19 mm or less from the face of the fireplace must be a minimum of 25 635 mm from the stove s top surface With a ventilated trim shield this clearance may not be reduced safely Unprotected side trim C that protrudes 3 4 19 mm or less from the face of a fireplace must have a minimum clearance of 22 554 mm measured from the stove s top side edge If the trim extends more than 3 4 19 mm it is subject to the requirements for wall clearance The charts and sample installations that follow list all the clearances required for the various installation configurations of the Encore
25. areful 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 30005295 Once you have ruled out any other possible 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 Remove access door and inner fireback Remove the catalytic combustor by lifting and sliding it towards you Fig 47 i Access Door Inner Fireback Fig 47 Inspect the catalytic combustor To assure a long life for the combustor it is recom mended to service the combustor on a regular basis based on the amount of use This procedure takes about five 5 minutes and requires no tools except for a vacuum if cleaning is necessary Cleaning the Combustor 1 Check the combustor
26. at pass through the ceiling However this is not a clearance chart Final stove clearances must adhere to the guidelines stated in the clearance chart on Page 13 Dimensions indicated are valid for installations with either 6 or 8 flue collars Encore WITHOUT Chimney Connector Heat Shields Unprotected Surfaces Protected Surfaces Corner Corner Parallel Installations Installations Parallel Installations Installations Rear B Side A Side D Rear E Corner F 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 3514 in the United States and 3714 946 mm in Canada Encore WITH Chimney Connector Heat Shields Unprotected Surfaces Protected Surfaces Corner Corner Parallel Installations Installations Parallel Installations Installations Rear B Corner C Side D Rear E Corner F 13 22 19 2 9V 182 495 mm 235 mm 470 mm ST632a To locate center of flue collar for corner installation add 61 2 165 mm to the clearance distance from stove corner to wall Mark off the resulting distance from the corner along both walls Next measure the same distance from these two points out from the walls These last two measurements will meet at a point representing the center of the flue collar Refer to the dia grams above 14 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove 48 1 4
27. ating Appliance UL 103 Figure 2 illustrates the two types The chimney and chimney connector must be in good condition and kept clean A prefabricated double wall insulated chimney A tile lined masonry chimney Fig 2 Approved chimney types 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove If you use an existing masonry chimney it must be inspected to ensure it is in a safe condition before the stove is installed Your local professional chimney sweep building inspector or fire department official will be able to inspect the chimney or provide a referral to someone who can The chimney must extend at least 3 914 mm above the highest point where it passes through or near a roof and at least 2 610 mm higher than any part of a building within 10 3 m horizontally Fig 3 For proper draft and good performance any chimney used with a Encore should extend at least 16 5 m above the flue collar of the stove 0 To 10 gt 2 Min r 3 lt 0 To10 In i e oun I Min Reference Point AC617 Fig 3 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
28. be replaced Contact your nearest Vermont Castings Authorized Dealer for information about a replacement element NOTE Use only the replacement catalyst supplied by a Vermont Castings dealer 34 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove MHSC reserves the right to make changes in design materials specifications prices and discontinue colors and products at any time without notice Encore Noncatalytic Catalytic Woodburning Stove 30005295 35 Encore 2040 Non Catalytic Catalytic Woodburning Stove Encore Noncatalytic Catalytic Woodburning Stove Model 2040 continued QI N N N NKN N N N N S SJ ol o ls losl slol ololT o N N N N N N N N N N Z Z Z Z Z Z Z Z gt lolo o oJlo N 9 l SJ NS ZATOol T N ST JNT A J jleol seo lsls l ST IN TSJo oo N l SToo ST2aJo s O ejJLiN Sja SSLN Item Description Brick Support Bracket Griddle Gasket Back Refractory Rt End Refractory Lt End Refractory Support Gasket Fiber Refractory Support Back Insulation Board Outer Back Right Air Deflector Left Air Deflector Left Griddle Quadrant Right Griddle Quadrant Griddle HS Flue Collar Bracket Upper Side Catalyst Ceramic Damper Ashdoor Gasket Damper Ramp Damper Housing Damper Damper Tab Damper R
29. c tion with annual cleaning of the chimney connector Inspect the passage behind the combustion package a mirror will be helpful and vacuum away ash us ing a flexible vacuum hose inserted in the passage Fig 46 The Chimney Connector TWO WEEKS e Inspect the chimney connector and chimney Clean if necessary TWO MONTHS e Inspect the chimney and chimney connector Pay particular attention to the horizontal runs of chimney connector and the elbows Clean the system if nec essary ANNUAL SPRING CLEANING Disassemble the chimney connector and take it outdoors for inspection and cleaning Replace weak sections of connector e Inspect the chimney for signs of deterioration Re pairs to a masonry chimney should be made by a professional mason Replace damaged sections of prefabricated chimney Your local Vermont Castings dealer or a chimney sweep can help determine when replacement is necessary Thoroughly clean the chimney Clean out any ash build up g E O9 4 s D w Remove these components ST1162 Fig 46 Inspect and clean out ash accumulation behind the combustion system 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove The Catalytic Element This wood heater contains a catalytic combustor which needs periodic inspection and replacement for proper operation In the United States it is against the law to operate this wood heater in a manner inconsistent with the op
30. cally check the set screw and tighten as necessary How to Adjust the Door Latches The front door of the stove should close securely to prevent accidental opening and should close tightly to prevent air from leaking into the fire chamber The door handle will be positioned vertically when the door is closed Over a period of time the gasket around the door will compress and the latch may need adjustment To ad just the handle follow this procedure 1 Remove and retain the lock nut with a 9 16 wrench Fig 43 Loosen the set screw with a 1 8 Allen wrench Rotate the pawl 180 Replace the lock nut Tighten the set screw Additional adjustment can be made by removing the flat washer Or any combination of washer removal and or pawl rotation Test the door seal Close the door on a dollar bill and attempt to pull it free If the bill is freed with little re sistance the gasket isn t snug enough at that spot Continue to make small adjustments until the setting is right WO N a 30 Roller Set Screw Flat Washer Handle ST1154 Fig 43 Rotate pawl and or remove flat washer to adjust latch If additional adjusting of the latch does not enable the door to seal sufficiently in one area try adjusting the gasket in that area Pack more cement or a smaller diameter gasket into the channel beneath the gasket so the main gasket is raised and makes contact with the door frame If this p
31. doors most stove owners will prefer the convenience of top loading through the griddle Do not place fuel between the andirons and the doors Burn Only High Quality Wood The Encore is designed to burn natural wood only do not burn fuels other than that for which it was designed You ll enjoy the best results when burning wood that has been adequately air dried The wood should be 18 20 457 508 mm in length Avoid burning green wood that has not been properly seasoned Do not burn construction materials they often contain chemicals and metals that can damage the inside surfaces of the stove and pollute the air Do not burn ocean driftwood when it burns the salt it contains will attack the cast iron The best hardwood fuels include oak maple beech ash and hickory that has been split stacked and air dried outside under cover for at least one year If hardwood is not available you can burn softwoods that include tamarack yellow pine white pine 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 22 you will enjoy Even for short term storage be sure to keep wood a safe distance from the heater and keep it out of the areas around the heater used for refueling and ash removal A Surface Thermometer is a Valuable Guide to Operation An optional surface thermometer tells
32. dry and moderately dry wood Two Ways to Add Fuel The Encore s griddle lifts for convenient top loading of logs and is the easiest way to add fuel Fig 33 Fig 33 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 Encore spark screen placed in the opening for open fire viewing The Encore is not approved for operation with the front doors open if equipped with a 6 152 mm chimney connector or chimney To open the front doors insert the handle into the door latch stub and turn it to the left and up Fig 34 Clockwise to Counter clockwise to Close Fig 34 To open the front doors turn the handle clockwise To close them always close the left door first Turn the handle in the right door to the left and up to the open position and close it Finally push on the door as you turn the handle to the right and down The doors will draw in slightly and the handle should offer some resis tance as you turn it to the closed position To reduce the risk of breaking the glass avoid striking the glass or slamming the doors When you are not using the door handle store it in the holder behind th
33. e 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 Encore 2040 Non Catalytic Catalytic Woodburning Stove In horizontal runs of un shielded chimney connector maintain a distance of 30 762 mm from the ceiling Keep it as short and direct as possible with no more than two 90 turns Slope horizontal runs of connector upward 1 4 per foot 6mm per meter going from the stove toward the chimney The recommended maxi mum 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 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 4 Using the holes in the flue collar as guides drill 1 8 3 ST242 mm holes in the bottom of the first section
34. e attached Only when the stove is placed ona completely noncombustible surface such as unpainted concrete over earth may it be used without the heat shield Even when the bottom heat shield are installed most installations require special thermal protection insula tion for the floor beneath Use an approved 1 25 mm noncombustible hearth pad with k 0 84 BTU in ft hr F or an equivalent material with an R value of at least 1 18 Refer to How to Determine if Alternate Floor Protection Materials are Acceptable section The floor protector may be covered with a decorative noncom bustible material if desired Do not obstruct the space under the heater When using a fire screen with doors open UL737 Standard for Fireplace Stoves use an approved 1 25 mm noncombustible hearth pad with k 0 84 Btu in ft hr F or an equivalent material with an R value of at least 1 18 Refer to How to Determine if alternate Floor Protection Materials are Acceptable section The floor protector may be covered with a decorative noncombustible material if desired Do not obstruct the space under the heater An 8 chimney and chimney connector is required an the bypass damper must be in the fully open position Important All installations on a combustible floor require the use of the supplied bottom heat shield Protection requirements vary somewhat between the Untied States and Canada as follows In U S installations the
35. e right front leg of the stove Be careful to not drop the handle since it is breakable 21 Encore 2040 Non Catalytic Catalytic Woodburning Stove WARNING Fireplace stoves equipped with doors should be operated only with doors fully open or doors fully closed If doors are left partly open gas and flame may be drawn out of the fireplace stove opening creating risks from both fire and smoke WARNING For safety and greatest efficiency oper ate your stove only with all doors griddles fully closed The test standard for your stove when it is operated in this mode is UL 1482 The Encore may be used as a fireplace with the front doors open or removed BUT only when it is equipped with 8 203 mm stove pipe and only when the optional spark screen is secured correctly in the opening to protect against the possibility of sparks and embers leaving the stove The test stan dard for your stove when it is operated in this mode is UL 737 1 floor protection is also required Refer to Floor Protection section on Pages 9 10 Use only the Encore spark screen Item 1907 with your Encore Encore spark screens are available from your Ver mont Castings Dealer Andirons Help Protect the Glass Your stove has andirons to keep logs away from the glass panels The andirons are essential to maintain clear fire viewing and should be left permanently in place Since the andirons may slightly hinder refueling through the front
36. e that accumulates on the glass surface should be removed regularly to prevent if ine etching To clean the glass follow this procedure e Be sure the glass is completely cool e Clean the glass with water or a cleaner made espe cially for this purpose Do not use abrasive cleaners Use cleaning agents sparingly and be sure to keep them off the outer surfaces of the stove Fig 41 Exploded view of the glass assembly for the right i door 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 30005295 29 Encore 2040 Non Catalytic Catalytic Woodburning Stove Adjust the Damper as Needed The tension on the Encore s damper is adjustable to compensate for compression of the gasket that seals the damper to the upper fireback To adjust the damper 1 Remove the griddle Loosen the lock nut at the cen ter of the damper Fig 42 2 Turn the pressure screw approximately one half turn clockwise with an Allen wrench provided with your stove 3 Tighten the lock nut Prevent the pressure screw from turning as you tighten the nut Re test the damper Pressure Ad justing Screw Lock Nut Damper Fig 42 Adjust the damper with the Allen wrench Tighten the Damper Handle as Needed A handle on the left side of the stove controls the damper The handle attaches to the damper rod with a set screw Periodi
37. e trim and fireplace mantel Refer to the information on fireplace and mantel trim shields in this section 10 Keep the Stove a Safe Distance From Surrounding Materials Both a stove and its chimney connector radiate heat in all directions when operating and nearby combustible materials can overheat dangerously if they are too close to the heat source A safe installation requires that ad equate clearance be maintained between the hot stove and its connector and nearby combustibles Clearance is the distance between either your stove or chimney connector and nearby walls floors the ceiling and any other fixed combustible surface The Encore has specific clearance requirements that have been established after careful research and testing These clearance requirements must be strictly observed In addition keep furnishings and other combustible materials away from the stove In general a distance of 48 1219 mm must be maintained between the stove and moveable combustible items such as drying clothes furniture newspapers firewood etc 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 pipe has no listed heat shield mounted on it e When the wall has no heat shield mounted on it e When the w
38. er the deflector After adjustment tighten the screws Attach Flue Collar Heat Shield WARNING The flue collar heat shield must be at tached to the Encore stove Use four 10 sheet metal screws supplied to secure the flue collar heat shield to the rear of the stove Fig 23 Air Deflector Air Deflector Sheet Metal Screws Flue Collar Heat Shield Screws Fig 23 Install flue collar heat shield WARNING The flue collar heat shield must be installed in all vertical installations The flue collar heat shield is not used when the flue collar is in the rear exit position 18 Attach the Damper Handle Use the 1 4 20 x 3 screw to attach the damper handle to the damper stub on the left side Attach the Primary Air Thermostat Handle The primary air thermostat handle is the smaller of the two black handles Secure the handle to the stub on the right side of the stove with an 8 32 x 2 slot head machine screw Fig 24 Assemble the Removable Insert Handle The ceramic removable insert handle opens and closes the front doors Remove after each use and store it in the handle holder behind the right front leg Assemble the handle by passing the 3 screw through the ceramic shaft and into the bright metal nub Fig 25 Tighten carefully until snug ST635 N ST540 Fig 25 Assemble the front door handle 30005295 Encore 2040 Non Catalytic Catalytic Woodburn
39. erating instructions in this manual 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 for fly ash accumulation and physical damage three times per year Clean the com bustor as needed The refractory package that houses the catalytic combustor should be inspected for a buildup of fly ash and cleaned if necessary This may be done when you examine the combustor When to Suspect a Combustor Problem The best way to evaluate the performance of your Encore s combustor is to observe the amount of smoke leaving the chimney both when the combustor has lighted off and when it has not Follow these steps With a fire going and the combustor properly 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 c
40. ers available for firewood you can also judge your wood by its ap pearance and weight If you get it green lift a piece and 30005295 get a sense of its weight it can lose a third or more of its weight as it dries Also look at the ends of a log as it dries it shrinks and often cracks The more weathered and cracked a piece is the drier it is Dry wood burns readily with a good chimney draft But with modern stoves wood can be too dry and too volatile Smoke and combustible gases can gas out from the wood quickly and densely enough to overload the combustion system If you hear a rumbling or roar ing noise like a propane torch from the stove that is a sign that the stove is overfiring Back puffing Back puffing results when the fire produces volatile gases faster than the chimney draft pulls them out of the firebox The gases back up in the firebox until they are concentrated enough and hot enough to ignite If your stove back puffs the stove needs to cool down You should open the damper to let the smoke rise to the flue more quickly allow more air into the firebox avoid big loads of firewood and check that the wood moisture is not too low Draft Testing An easy way to test your chimney draft is to close the stove s damper wait a few minutes to let the airflow stabilize then see whether you can vary the strength of the fire by swinging the air control open and closed Re sults are not always instant you ma
41. feet Fuel IGA ya NNDMNmNzN gt pMBz m M m Mm MM 22 Fuel capacity isiro 50 pounds hardwood bela EEE EEE N E E Front and top Chimney Connector for 6 flue collar 6 152 mm diameter for 8 oval flue collar 8 203 mm diameter Chimney Flue Size with 8 Chimney Connector 8 203 mm minimum with 6 Chimney Connector 6 152 mm minimum Flue exit position cceeeceseeeeeeeeeeeees Top or Rear Primary Air Manually Set Thermostatically Maintained Secondary Aif ccce Fixed self regulating Ash handling system Removable ash pan Glass panels 0000 High temperature ceramic Weight r easier Ravers 475 Ibs 215 kg Width leg to leg i u 27 686 mm Depth leg to leg 15 381 mm Height to top of flue collar 25 635 mm Drawing Not to Scale Fig 1 Encore 2040 dimensions 30005295 635 mm Top exit flue collar N 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 maximu
42. fire As a result creosote residue accumulates on the flue lining When ignited this creo sote makes an extremely hot fire within the flue system that can damage the chimney and overheat adjacent combustible material If a significant layer of creosote has accumulated 1 8 3 mm or more it should be removed to reduce the risk of a chimney fire You can never be too safe Contact your local fire authority for information on what to do in the event of a chimney fire and have a clearly understood plan on how to handle one If you do experience a chimney fire act promptly to Close the damper and air control lever Get everyone out of the house e Call the Fire Department 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 31 Encore 2040 Non Catalytic Catalytic Woodburning Stove Clean the chimney using a brush the same size and shape as the flue liner Flexible fiberglass rods are used to run the brush up and down the liner causing any deposits to fall to the bottom of the chimney where they can be removed through the clean out door Clean the chimney connector by disconnecting the sec ti
43. flue with nominal flue size of 8 203 mm An Encore with a 6 152 mm flue connector is approved for venting into a masonry chimney with a nominal flue size of 8 x 8 203 x 203 mm and into a round flue with nominal flue of 6 152 mm NOTE When installed with a 6 flue collar the Encore may not be operated with the front doors open Whatever the flue collar size an Encore may be vented into larger chimneys as well However chimneys with liners larger than 8 x 12 203 x 305 mm may experience rapid cooling of smoke and reduction in draft especially if the chimneys are located outside the home These large chimneys may need to be insulated or have their flues relined for proper stove performance Accessories to help make the connection between stainless steel chimney liners and your Encore 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 possibl
44. gation 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 incidental and consequential damages or limitations on how long an implied warranty lasts so the above limitations may not apply to you This warranty gives you specific rights and you may have other rights which vary from state to state How to Obtain Service If a defect is noted within the warranty period the customer should con tact 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 STN ON 39 Encore 2040 Non Catalytic Catalytic Woodburning Stove MHSC 149 Cleveland Drive Paris Kentucky 40361 www mhsc com 40 30005295
45. h a tight fitting lid Store the container outdoors away from all combustible material Return the ash pan to its original position in the stove and close and latch the ash door Fig 40 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 Encore ash will accumulate faster at higher heat outputs Remove ash frequently and place it outdoors ina 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 25 Encore 2040 Non Catalytic Catalytic Woodburning Stove Draft Management A stove is part of a system which includes the chimney the operator the fuel and the home The other parts of the system will affect how well the stove works When there is a good match between all the parts the system works well Wood stove
46. hori 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 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
47. ines when approving installations Figure 9 shows one NFPA recommended method All combustible material in the wall is cut away from the single wall connector to provide the required 12 305 mm clearance Any material used to close up the open ing must be noncombustible Wall Stud Chimney Connector lt Noncombustible Material Floor Protec tion Fig 9 An approved wall pass through for the United States 8 Three other methods are also approved by the NFPA Placing a section of chimney connector inside a ventilated thimble which in turn is separated from combustibles by 6 152 mm of fiberglass insulat ing material Placing a section of chimney connector inside a section of 9 230 mm diameter solid insulated factory built chimney with 2 51 mm of air space between the chimney section and combustibles Using a section of solid insulated double wall high temperature chimney with an inside diameter the same as the chimney connector at least one inch of solid insulation and a minimum of 9 229 mm air space between the outer wall of the chimney section and combustibles In Canada The Canadian Standards Association has established different guidelines for wall pass throughs Figure 10 shows one method in which all combustible material in the wall is cut away to provide the required 18 457 mm clearance for the connector The resulting space must remain emp
48. ing It s an organic tar that can condense in the flue if it is pres ent in the exhaust slow moving and cools to less than 290 F 130 C Condensed creosote is volatile and can generate chimney fires if it gets hot enough All the features that affect chimney draft also affect creosote condensation so use whatever combination of installa tion features and operational steps that will encourage good draft and minimize creosote production Because letting the exhaust cool off and slow down is one of the keys to creosote accumulation it makes sense to line a chimney to match the stove s outlet size for safety reasons as well as performance Canadian law requires a matching liner to serve any stove or insert vented through a fireplace chimney in the US the National Fire Protection Association NFPA recom mends a chimney liner if the flue is more than three times bigger in square area than the outlet on the stove or insert Some localities enforce the NFPA guide lines 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 Green wood has a lot of moisture in it it will burn but some of the heat potential is used to boil the extra moisture from the wood This reduces the amount of heat that reaches your home and can contribute to a creosote problem There are moisture met
49. ing Stove Fan Kit Installation 1 Attach the fan assembly at the bottom edge of the in ner back with two 2 1 4 20 x 3 4 hex head screws 2 Attach snapstat to the mounting holes on the un derside of the bottom with two 2 1 4 20 pan head screws 3 Attach the rheostat holder provided with the stove under the right front wing of the bottom heat shield with two 2 10 sheet metal screws 4 Attach the rheostat to its holder by inserting the rheo stat control shaft through the holder hole Install the retaining ring and rheostat knob onto the shaft 5 Secure the rheostat cable to the underside of the bottom heat shield using the wire tie provided and the hole at the right rear edge of the heat shield 6 Fan will not operate until stove reaches approximate ly 109 F Fig 27 Remove access cover Access Cover 7 Plug blower cord into a grounded outlet Do not Inner Cover remove ground prong from plug Route power cord to avoid heat from the stove or other damage Do not route cord under or in front of appliance Hole for Wire Tie to Secure Yay p as as Pa Fig 26 Fan installation Kit 2767 Installing or Removing Catalyst 1 Remove the access cover by gently lifting up and pulling out from the bottom edge Fig 27 2 Remove the inner cover by pulling it straight out Fig 28 3 Remove the catalyst by gently pulling it straight out Fig 29 Place the catalyst where the catalyst s
50. ire loosening 30005295 the latch to accommodate the new gasket after a few weeks it may need tightening to compensate for com pression of the new gasket The directions for adjusting the latches are on Page 30 All Gasketed Construction Gaskets Other gaskets form seals between all other non moving parts but these are not subject to the same wear and deterioration as gaskets on moving parts It is unlikely that you will ever need to replace these gaskets unless the involved parts are disassembled and then put back together If this is the case the job should be done only by a qualified service technician 5 16 diameter gasket seals the following parts The lower fireback to the back panel The left and right air plates inner sides All connections between the stove plates The Chimney System EEE Creosote Creosote Your Encore is designed to reduce creosote build up significantly However regular chimney inspection and maintenance must still be performed For safety good stove performance and to protect your chimney and chimney connector inspect your chimney and chimney connector on a regular schedule Clean the system if necessary Failure to keep the chimney and connector system clean can result in a serious chimney fire When wood is burned slowly it produces tar organic vapors and moisture that combine to form creosote The creosote vapors condense in the relatively cool chimney flue of a slow burning
51. k of rapid and extreme temperature change The cast plates expand and contract with changes in temperature When you first begin using your Encore minimize thermal stress by letting the plates adjust gradually during three or four initial break in fires follow ing Steps 1 3 below Non Catalytic Wood Burning Burn only solid wood in the Encore and burn it directly on the grate Do not elevate the fuel Do not burn coal or other fuels The bypass damper must be open when starting a fire or when refueling Do not use chemicals or fluids to start the fire Do not burn garbage Never use flammable fluids such as gasoline gasoline type lantern fuel kerosene charcoal lighter fluid naptha engine oil or similar liquids to start or freshen up a fire in this heater Keep all such liquids well away from the heater while it is in use 1 Open the stove bypass damper and open the prima ry air control fully 2 Place several sheets of crumpled newspaper in the stove Place six or eight pieces of dry kindling split to a finger width size on the paper On the kindling lay two or three larger sticks of split dry wood approximately 1 2 25 51 mm in diameter Fig 36 Fig 36 Start the fire with newspaper and dry kindling 3 Light the newspaper and close the door Gradu ally build up the fire by adding a few 3 5 80 120 mm diameter pieces of split firewood If this is one of the first few break in fires le
52. m fuel consumption rates obtained under labo ratory 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 2214 565 mm 15 2 lt 394 mmy gt 4 Z mj 5 127 mm 27 a 73 mm 23 4 603 mm 15 381 mm Encore 2040 Non Catalytic Catalytic Woodburning Stove Installation SAFETY NOTICE IF YOUR ENCORE 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 OFFICIALS ABOUT RESTRIC TIONS AND INSTALLATION INSPECTION REQUIRE MENTS IN YOUR AREA Before you begin an installation be sure that Your stove and chimney connector will be far enough from combustible material to meet all clear ance requirements The floor protector is large enough and is construct ed properly to meet all requirements You have all necessary permits from local aut
53. mble and the chimney wall must be cemented firmly A special piece called the thimble sleeve slightly smaller in diameter than standard connectors and most thimbles will facilitate the removal of the chimney connector system for inspection and cleaning Fig 6 Thimble sleeves are available from your local dealer 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 Thimble Sleeve Chimney Connector Keep sleeve end flush with flue tile Fig 6 The thimble made of either ceramic or metal must be cemented securely in place The thimble sleeve should protrude 1 2 25 50 mm into the room Use furnace cement and thin gasketing to seal the sleeve in place in the thimble Secure the chimney connector to the outer end of the sleeve with sheet metal screws 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 Encore may be connected to a chimney above a fireplace opening Fig 7 In such installations the stove is positioned on the hearth in fro
54. ment or bits of gasket Remove stubborn deposits of cement with a cold chisel if necessary Fig 44 ST560 Fig 44 Remove gasket then clean channel with wire brush 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 ona wood cutting surface and cut it at the marked spot with a utility knife Twist the ends slightly to keep the gasket from unravel ing 5 Lay an unbroken 1 8 3 mm bead of silicone or ce ment in the newly cleaned channel Fig 45 Fig 45 Lay a bead of gasket silicone or cement then press gasket in place 6 Starting at one end press the gasket into the chan nel Fig 45 Ensure a good joint where the gasket meets before trimming any excess Do not overlap the gasket ends or leave ends with ragged edges 7 Press the gasketed part firmly against its normal mating surface to seat the gasket evenly in its channel Close and latch the door to do this or tap other parts with the rubber mallet or hammer block of wood 8 Clean any excess cement from around the chan nel then let the cement that holds the new gasket dry thoroughly 9 The stove s doors may need adjustment after you have regasketed them Initially it may requ
55. ncore 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 stove you will find that its appearance is matched by its functionality due to cast iron s unique ability to absorb and radiate heat Also MHSC products are among the cleanest burning wood stoves and fireplaces available today As an owner of a Vermont Castings stove you make a strong statement for pollution free energy However clean burning depends on both the manufacturer and the operator Please read this manual carefully to understand how to properly operate and maintain your stove At MHSC we are equally committed to your satisfaction as a customer That is why we maintain an exclusive network of the finest dealers in the industry Our dealers are chosen for their expertise and dedication to customer service They are factory trained and knowledgeable about every MHSC product Feel free to contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its performance This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore It also contains useful information on maintenance
56. ner cover access cover and fireback In addition all cast iron parts are war ranted against breakage cracking or burn through and glass door panels against thermal breakage Coverage is provided only to the original pur chaser MHSC will also pay labor associated with repairing or replacing the component described above for up to five years Limited 5 Year Warranty The porcelain finish is warranted to be free of defects in material and workmanship for a period of five years from the date you purchase the stove Warranty excludes chipping scratching or other surface damage to the porcelain that might result from normal wear and tear and also excludes failure of porcelain coating due to misuse or overfiring Limited 1 Year Warranty The following parts of the woodburning stove are warranted to be free of defects in material and workmanship for a period of one year from the date you purchase the stove handles gasketing and thermostat assembly As designated in the descriptions above MHSC will repair or replace at its option any part found to be defective upon inspection by a Vermont Castings Authorized Dealer The customer must return the defective part or the stove with shipping prepaid to the Authorized Dealer or pay for any Authorized Dealer in home travel fees or service charges for in home repair work It is the dealer s option whether the repair work will be done in the customer s home or in the dealer s shop If upon in
57. ng of enamel surfaces Inspect your woodburning stove prior to accepting it for any damage to the enamel 3 This warranty does not cover misuse of the stove as described in the Owner s Guide nor does it cover an stove which has been modified unless authorized by a MHSC representative in writing This warranty does not cover damage to the stove caused by burning salt saturated wood chemically treated wood or any fuel not recommended in the Owner s Guide 4 This warranty does not cover a stove repaired by someone other than a Vermont Castings Authorized Dealer 5 Damage to the unit while in transit is not covered by this warranty but is subject to a claim against the common carrier Contact Vermont Castings Authorized Dealer from whom you purchased your stove or MHSC if the purchase was direct Do not operate the stove as this may negate the ability to process the claim with the carrier 6 Claims are not valid where the installation does not conform to local building and fire codes or in their absence to the recommendations in our Owner s Guide 7 The salt air environment of coastal areas or a high humidity environ ment can be corrosive to the porcelain enamel finish These condi tions 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 humid ity environment 8 MHSC shall have no obli
58. nt of the fireplace and the chimney connector rises from the stove top and then angles ninety degrees back into the chimney The chimney liner should extend to the point at which the chimney connector enters the chimney If the chimney connector in your installation enters the chimney above a fireplace follow all the guidelines mentioned above for freestanding installations In addi tion give special consideration to the following points 30005295 Check These Clearances Seal This Off HIR HEZA HERI HON ESTE HAR HEAR MTR HE EA KE METE ES Ham MET ST244 Fig 7 In this installation the chimney connector attaches to the chimney above the fireplace opening Check the clearance between the mantel and the chimney connector and any combustible trim or the mantel Check the clearance between the chimney connec tor and the ceiling The clearance should be at least 30 7 62 mm with unshielded connectors Consult the clearance charts for other installation options The fireplace damper must be sealed to prevent room air from escaping up the flue However it must be possible to re open the damper to inspect or clean the chimney Through the Fireplace If your fireplace opening height is at least 29 737 mm you may install a Encore through the opening using a positive connection kit available from your local deal er Positi
59. od Griddle Handle Assy Gasket Fiber Back Refractory Rheostat Bracket Refractory Engine E D Damper Handle Screw Damper Handle Damper Handle w Screw Assy Left Side Left Air Manifold Right Air Manifold Right Side Thermostat Handle Base Assy Washer Damper Rod Fireback Plate S S Inner Bottom Ashdoor Hinge Upper Door Handle Bracket Bottom Outer Ashlip Gasket Fireback Refractory Fireback Retainer Inner Cover Refractory Refractory Inner Cover Andiron Refractory Access Cover Leg Leveller Ashdoor Handle Shaft Pawl Assy Ashdoor Part Number 30005279 1203668 30005289 30005497 30005498 30005233 30005237 30005269 30005261 30005314 30005315 30002399 30002401 30002386 30005266 30005267 30005353 1203588 1301811 30005293 30002389 1601488 1600851 30002775 30005270 30002863 30005202 1201310 1600664 30002720 See Chart Pg 37 30002408 30005290 See Chart Pg 37 30002716 1202560 30005217 30005291 30002403 30002909 30005292 See Chart Pg 37 30005209 30005302 30005248 30005205 30002397 30005303 1201745 1600622 30005157 30002392 51 52 53 54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71 72 73 74 74a 74b T5 76 77 78 79 80 81 82 83 83a 83b 84 85 86 87 88 Item Description Ashdoor Handle Wood Ashdoor Hinge Rod Cotter Pin Ashdoor
60. od paper products etc are combustible and must not be used The floor protection specified includes some form of thermal designation such as R value thermal resistance or k factor ther mal conductivity Procedure 1 Convert specifications to R value i R value given no conversion needed ii k factor is given with a required thickness T in inches R xT iii K factor is given with a required thickness T in inches R xT xX iv r factor is given with a required thickness T in inches R rxT 2 Determine the R value of the proposed alternate floor protector i Use the formula in Step 1 to convert values not expressed as R ii For multiple layers add R values of each layer to determine overall R value Encore 2040 Non Catalytic Catalytic Woodburning Stove 3 If the overall R value of the system is greater than the R value of the specified floor protector the alter nate is acceptable EXAMPLE The specified floor protector should be 1 2 inch thick material with k factor of 0 84 The proposed alternate is 4 brick with an r factor of 0 2 over 1 8 mineral board with a k factor of 0 29 Step a Use mie has convert specification to R value R R k T 51 x 0 5 0 59 Step b Calculate R of proposed system 4 brick of r 0 2 therefore R rix 0 2 X 4 0 8 1 8 mineral board of k 0 29 therefore x 0 125 0 431 R ninereiboara 0 29 R 0 8 0 431 1 231 Step c Com
61. 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 Toward Flue Gas Direction Fig 4 Chimney connector Fasten each joint between sections of chimney connector including telescoping joints with at least three 3 sheet metal screws The pre drilled holes in the top of each section of chimney connector serve as guides when you drill 1 8 3 mm holes in the bottom of the next section Fasten the chimney connector to the chimney Instructions for various installations follow Figure 5 illustrates the general layout of chimney connector parts Be sure the installed stove and chimney connector are correct distances from nearby combustible mate rials NOTE Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney con nector are available to simplify installations They often eliminate the need to cut individual connector sections Consult your local dealer about these special pieces Z Flue In B ner Slip Pipe Standard Connector Oval to Round Adapter Fig 5 An exploded view of the chimney connection in a free standing masonry installation Securing the Single wall Connector to a Prefabricated Chimney Follow the installation instructions of
62. ons 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 Maintenance Schedule The Stove DAILY Clear any ash build up from around the air holes and combustion flow path in the lower fireback e Ashes should be removed before they reach the top of the ash pan Check accumulation at least once a day Keep the area around the stove clear of any com bustible materials such as wood furniture or cloth ing TWO MONTHS Check door handle to be sure it is working properly Gasketing becomes compressed after a period of time Adjust handle tightness if necessary Check leg bolts and heat shield screws tighten if necessary ANNUAL SPRING CLEANING Check gasketing for wear and replace if necessary e Remove ashes from the ash pan and replace with a moisture absorbing material such as kitty litter to keep the interior of the stove dry Clean the dust from the inner sides of bottom rear or pipe heat shields if your stove is equipped with them Clean surfaces are better heat reflectors than dirty surfaces Touch up the black paint e Inspect for and remove ash build up behind the com bustion package This should be done in conjun
63. 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 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 33 Avoid using a full load of very dry wood in the firebox This may result in continuous very high temperatures in the secondary combustion area and damage the combustor Wood which has been split and stored 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 30005295 combustor Also do not use a full load of dry slab wood or scrap wood For long burns use a mix of
64. ove 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 griddle or doors are opened 20 Low Heat High Heat Fig 31 The handle may be positioned anywhere between the two extremes for different heat levels The damper is closed when the handle points forward Smoke travels through the non catalytic combustion system where it can be further burned before passing up the chimney Fig 32 The damper should always be either fully open or fully closed There are no intermediate positions When closing the damper be sure to pull firmly enough to snap the handle into the locked position Damper Positions Open Updraft Mode Closed High Efficiency Mode Fig 32 The damper is either open or closed There are no intermediate positions High Efficiency Wood Burning with Catalytic Combustion A Encore leaves the factory with the combustor pack aged separately In the United States it is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual The components of the cata lytic combustion system in your Encore work together to produce optimum conditions for secondary combustion
65. ove s durability Remove ash before it reaches the top of the ash pan Check the level at least once a day Every few days clear any ash from the outer edges of the firebox Most of the ash will fall through the grate Slice or stir the ash with a shovel or poker so that it falls through the grate slots IMPORTANT Check the level of ash in the ash pan before reloading the stove If the ash level is close to the top edge of the pan empty the pan according to this procedure Open the damper Open the griddle or front doors and use a shovel or poker to stir excess ash through the ash slots in the grate down into the ash pan e Close the griddle or doors and unlatch the ash door Fig 39 It will pivot swinging the ash pan out of the stove Fig 39 Turn the ashdoor handle clockwise to open and coun terclockwise to close Slide the cover onto the pan making sure it is se curely closed Fig 40 Remove the ash pan making sure to keep it level 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 If the stove is in operation close the ash door while disposing of the ash You may need to lift the latch end of the door slightly to align the latch with the mating part on the stove bottom 30005295 Fig 40 Be sure the cover is securely attached before remov ing the ash pan Properly dispose of the ash in a metal container wit
66. owndraft 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 faster as they travel slower through a chimney if we vent a stove with a six inch flue collar 28 square inch area into a 10 x 10 flue the gases slow to one third their original speed This allows the gases to cool more rapids which weakens draft strength If an oversized flue is also outside the house the heat it absorbs gets transferred to the outdoor air and the flue usually stays cool It is common for a masonry flue especially one serving a fireplace to be oversized for the stove It can take quite a while to warm up such a flue and the results can be disappointing The best solution to an oversized flue is an insulated steel chimney liner the same diam eter as the stove or insert s flue outlet the liner keeps the exhaust warm and the result is a stronger draft An non insulated liner is a second choice the liner keeps the exhaust restricted to its original size but the hot gases still must warm up the air around the liner This makes the warm up process take longer Pipe amp Chimney Layout Every turn the exhaust must take as it travels to the chimney top will slow it down The ideal pipe and chim ney layout is
67. pare proposed system Rtotal of 1 231 to specified R of 0 59 Since proposed system Rtotal is greater than required the system is acceptable total Rik mineralboard Definitions _ ft hr F _ Btu in _ R Bu K ame lt 12 _ Btu ft r OCP 1 f hr CF Btu in k Floor Protection for Fireplace Installation Do not assume that your fireplace hearth is completely noncombustible Many fireplace hearths do not satisfy the completely noncombustible requirement because the brick or concrete in front of the fireplace opening is supported by heavy wood framing Because heat passes readily through brick or concrete it can easily pass through to the wood As a result such fireplace hearths can be a fire hazard and are considered a com bustible floor For all fireplace installations follow the floor protection guidelines described above including the need for a bottom shield Keep in mind that many raised hearths will extend less than the required clearance from the front of the heater In such cases sufficient floor protec tion as described above must be added in front of the hearth to satisfy the minimum floor protector require ment 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 decorativ
68. r and heat shield positions Install the Bottom Heat Shield NOTE The Bottom Heat Shield is required in most in stallations Refer to Floor Protection Page 9 for further details 1 Loosen the four 1 4 20 hex head bolts from the cor ners of the ash drop on the stove bottom 2 Align the bottom heat shield holes with the four bolts The outside air cutout hole should be toward the rear of the stove The unpainted side must face up towards the stove 3 Pass all four bolts through the large end of the key holes and then pulling the shield forward to engage the smaller ends of the keyhole slots Fig 22 4 Attach the heat shield sides by passing the slots over the bolt heads Tighten the hex head bolts NU i Bottom Heat Shield ST857a Fig 22 Attach the bottom heat shield 17 Encore 2040 Non Catalytic Catalytic Woodburning Stove Adjust the Leg Levellers Lift the stove slightly so there is no weight on the leg while making the adjustment Reverse the Flue Collar If necessary Reverse the flue collar by removing the two screws that attach it to the back of the stove Be sure the gasket around the flue collar opening is in position when you screw the collar back onto the stove Adjust Air Deflector If you have the optional fan kit you may decide to adjust the air deflector to blow heat across the top of your stove Fig 23 Loosen the two 2 screws on each side and raise or low
69. rance to Combustible in Front of Stove All Installations S 48 1219 mm The provided rear shroud must be used in all installations The flue collar heat shield must be used in all vertical installations 1 A ceiling heat shield 24 610 mm in diameter and suspended 1 25 mm from the ceiling must surround the pipe in installations where chimney penetrates the ceiling 2 The connector pipe heat shield must extend 36 914 mm above flue collar 3 Using listed double wall oval to round adapter when installing optional 8 oval flue collar 6 Chimney Connector ONLY Top Exit single wall 6 connector without A 19 B 15 C 181 shields vertical flue col 483 mm 381 mm 470 mm lar heat shield installed 12 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Encore 2N1 Clearance Diagrams For use with either 6 or 8 flue collar chimney connector Unprotected Surfaces Protected Surfaces Stove Installed Stove in Corner Stove Installed Stove in Corner Parallel to Wall Parallel to Wall Top Exit Installations No Stove Heat Shields collar heat shield installed 30005295 13 Encore 2040 Non Catalytic Catalytic Woodburning Stove Distance from the Center of the Flue Collar to the Wall in Top Exit Installations The information on this page is helpful in planning stove placement for top exiting installations particularly those in stallations with chimneys th
70. riddle First place the griddle upside down at the edge of a flat surface and assemble the handle as shown With the handle pointing 45 from its final position tighten the nut as far as possible with the pliers Move the handle to its final position while still holding the nut with the pliers Fig 19 Attach the griddle handle Install Stove 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 20 using the hex head bolts from the parts bag Use 3 8 washers with all four legs the door handle holder installs on the right front leg Position the holder so the hole to accept the handle hub faces out from the right side of the stove Tighten the bolts firmly CAUTION Overtightening can strip tapped threads NOTE When moving the stove lift the stove to take weight off the legs whenever possible Dragging or sliding the stove especially across rough surfaces can cause the legs to loosen or even break p Leg Bolt and Washer Fig 20 Attach the stove legs 30005295 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 21 Bottom Heat Shield Door Handle Holder Leg Bolt and Washer Fig 21 Handle holde
71. rocedure doesn t solve the problem replace the gasket Instructions for gasket replacement are given later in this section Replace the Stove Gaskets as Needed Your Encore uses fiberglass rope gaskets to make a tight seal between some parts With use 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 3 8 the front doors to the stove front and the doors to each other 3 8 The ash door to the front of the bottom panel 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 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 re gardless of the gasket location Follow these steps 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove 1 Remove the existing gasket by grasping an end and pulling firmly Fig 44 2 Use a wire brush or the tip of a screwdriver to clean the channel of any remaining ce
72. s instructions when installing the flue system for use in a mobile home NOTE Offsets from the vertical not exceeding 45 are allowed per Section 905 a of the Uniform Me chanical Code UMC Offsets greater than 45 are considered horizontal and are also allowed provid ing the horizontal run does not exceed 75 of the vertical height of the vent Construction clearance and termination must be in compliance with the UMC Table 9C This installation also complies with NFPA 211 NOTE Top sections of the chimney must be removable to allow maximum clearance of 13 5 ft 411 cm from ground level for transportation purposes 10 Burn wood only Other types of fuels may generate Floor Protection Outside Air Kit H Connector Spark Arrestor Cap Storm Collar Roof Flashing Joint Shield Firestop Listed Chimney Connector J m Outside Air Floor Vent i KT1190 poisonous gases e g carbon monoxide Fig 18 Mobile home installation 16 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Assembly Set Up Your Stove Cast iron stoves are heavy and it will take two to four people to move your Encore into position Wipe the protective coating of oil from the griddle with a clean dry rag or a paper towel Install the handle on the g
73. sition 65 Warning Fuels used in gas woodburn ing or oil fired appliances and the products of combus tion of such fuels contain chemicals known to the State of California to cause cancer birth defects and other reproductive harm California Health amp Safety Code Sec 25249 6 Table of Contents Specifications Installation Clearance Charts Mobile Home Installation Assembly Operation Draft Management Maintenance The Catalytic Element Replacement Parts Warranty Installation Accessories Warming Shelf 0200 Classic Black 0205 Biscuit 0207 Ebony 0201 Bordeaux 0208 Brown Majolica 3265 Outside Air Kit 3185 Outside Air Adapter 0336 Mobile Home Kit 0127 Firescreen FK26 Fan Kit 3190 Connector Pipe Heat Shield A line of porcelain enamel stove pipe is available in Biscuit Bordeaux Ebony Brown Majolica colors If you order 3265 or 0336 you must also need 3185 Save These Instructions for Future Reference 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Specifications Encore Model 2040 EPA Emissions rating Noncatalytic 1 6 g hr Range of heat output Noncatalytic 9 900 34 000 EPA Emissions rating Catalytic 1 1 g hr Range of heat output Catalytic y n 11 800 to 30 000 BTU hr Peak heat output UUU U UUUUUUjU 65 000 BTU hr Area heated Up to 1 800 Square
74. 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 Outside Air In some modern super insulated homes there may be inadequate air supply for combustion because of insuf ficient air infiltration into the building Such air enters a home through unsealed cracks and openings Exhaust fans in kitchens or bathrooms can compete with the stove for available air and compound the problem When poor draft is caused by a low infiltration rate opening a ground floor window on the windward side of the house and near the stove will usually alleviate the problem A better solution is to install a permanent outside air supply to the stove and or room In fact bringing air for combustion from outside the home directly to the air inlet of the stove is required for new construction in some areas Pressure variations within the house do not affect a stove equipped with an outside air supply and im proved stove performance often results An Outside Air Kit for the Encore is available from your local dealer What Kind of Chimney to Use You must connect the Encore to a code approved masonry chimney with a flue liner to a relined masonry chimney that meets local codes or to a prefabricated metal chimney that complies with the requirements for Type HT chimneys in the Standard for Chimneys Factory Built Residential Type and Building He
75. spacers should not be directly behind the stove or chimney connector Air must be able to flow between the wall and the shield At least 50 of the bottom 1 25 mm of the shield must be open and the shield must be open at the top Metal screening across the top will keep small stray objects from being trapped behind the shield Fig 12 C Air Flow E Screen N 4 Wall Shield Stud Wall Framing Noncombus tible Spacers and Fasteners a Shield iS Metal Spacer 4 Drywall lee Air Flow Fig 12 Approved wall shield construction The shield must be a minimum of 48 1219 mm tall and must extend at least 19 483 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 must stop 1 25 mm below the ceiling With 8 connections and chimneys because of potentially higher pipe temperatures the shield must extend the full height of the wall up to 9 2 7 m and stop 1 25 mm below the ceiling Fireplace and Mantel Trim Shields A fireplace installation requires special clearance between the side of the stove and the right and left walls between the side of the stove and the decorative side trim on the fireplace face and between the top of the stove and the m
76. spection the damage is found to be the fault of the manufacturer repairs will be au thorized at no charge to the customer for parts and or labor Labor rates will be determined by MHSC s published labor rates in effect at the time labor is performed Any parts repaired or replaced during the limited warranty period will be warranted under the terms of the limited warranty for a period not to ex ceed the remaining term of the original limited warranty or six 6 months whichever is longer Limited Catalyst Warranty The catalyst will be warranted for a six year period as follows If the original catalyst or a replacement catalyst proves defective or ceases to maintain 70 of its particulate emission reduction activity as measured by an approved testing procedure within 24 months from the date the stove is received the catalyst itself will be replaced free From 25 72 months a pro rated credit will be allowed against a replace ment catalyst and the cost of labor necessary for its installation at the time of replacement A third year 25 36 months of no charge replacement will be made when combustor failure is due to thermal degradation of the substrate crumbling of ceramic material The customer must pay for any in home travel fees service charges or transportation costs for returning the stove to the Authorized Dealer Amount of Time Credit Towards Since Purchase Replacement Cost 0 24 months 100 25 36 months 50
77. t 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 23 Encore 2040 Non Catalytic Catalytic Woodburning Stove Some odor from the stove s hot metal and the paint is normal for the first few fires NOTE Some chimneys must be primed or warmed up before they will draw sufficiently to start a fire To correct this situation roll up a couple pieces of 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 4 If your Encore 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 burn ing fire until there is a glowing ember bed 2 3 51 75 mm deep Fig 37 A good ember bed is necessary for proper functioning of the non catalytic system and may take an hour or more to establish
78. the broken glass panel from the door 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 Check the gasket around the window it should be soft temperature stove paint Apply the paint sparingly two and resilient so that the glass will seal properly against light coats of paint are better than a single heavy one the door Replace the gasket if it has hardened or if it is compressed Care of the Porcelain Enamel Surface 1 Center theglasson the gasket Use a dry or slightly damp rag or soft brush to remove 2 Secure the glass on both doors with the retainer spills or stains For difficult jobs that require a cleaning clips Tighten all screws Fig 41 agent use only a kitchen appliance cleaner or polish recommended for use on enamel surfaces oO Replace the doors on the stove Open and close the doors to check that they fit and If porcelain enamel becomes chipped or scratched work properly Adjust as necessary during use apply enamel epoxy to the damaged area and allow to dry Once the epoxy has dried sand the area to blend with surrounding area and apply appropri Right Door ate color touch up paint Allow to dry completely before operating stove R Gasket Cleaning the Glass NV bo Glass Panel Most of the carbon deposits on the glass will burn off during hot fires A However the ash residu
79. ty A flush mounted sheet metal cover may be used on one side only If covers must be used on both sides each cover must be mounted on noncombustible spacers at least 1 25 mm clear of the wall 18 460mm clear ance between pipe and sides top bottom of opening Fig 10 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 Encore into a factory built zero clearance fireplace These appliances and their chimneys are specifically designed as a unit for use as fireplaces It may void the listing or be hazardous to adapt them for any other use DO NOT CONNECT THE ENCORE TO ANY AIR DIS TRIBUTION DUCT OR SYSTEM 30005295 Encore 2040 Non Catalytic Catalytic Woodburning Stove Floor Protection A tremendous amount of heat radiates from the bottom plate of your stove The floor area directly under and around the stove will require protection from radiant heat as well as from stray sparks or embers that may escape the firebox Heat protection is provided with the use of the Bottom Heat Shield supplied with the stove Most installations will require the bottom heat shield to b
80. unding wire or equivalent and terminated at each end with N E C approved grounding device 4 Stove must be installed with an approved UL103 tion air WARNING NEVER DRAW COMBUSTIBLE AIR FROM A WALL FLOOR OR CEILING CAVITY OR FORM ANY ENCLOSED SPACE SUCH AS AN AT TIC OR GARAGE CAUTION THE STRUCTURAL INTEGRITY OF THE MOBILE HOME FLOOR WALL AND CEILING ROOF MUST BE MAINTAINED i e DO NOT CUT THROUGH FLOOR JOIST WALL STUD CEILING TRUSS etc WARNING HT ventilated chimney connector UL103 HT chim DO NOT INSTALL IN SLEEPING ROOM ney and terminal cap with spark arrestor Never use a single wall connector stove pipe in a mobile home installation Use only double wall connector pipe Dura Vent DVL Selkirk metalbestos DS Se curity DL double wall connector or any listed double wall pipe connector 5 Refer to Pages 12 13 and 14 of this manual or the serial number label on the back of the stove for clearances to combustibles 6 Floor protection requirements on Page 9 must be followed precisely 7 In Canada this appliance must be connected to a 6 inch 152 mm factory built chimney conforming to CAN ULC 629M STANDARD FOR FACTORY BUILT CHIMNEYS Floor protection referenced on Page 10 must be followed 8 Use silicone to create an effective vapor barrier at the location where the chimney or other component penetrates to the exterior of the structure 9 Follow the chimney and chimney connector man ufacturer
81. ve connection kits ensure a tight fit between the stove flue collar and the chimney flue Fig 8 Fireplace installations whether connected to the flue above or through the fireplace opening have special clearance requirements to adjacent trim and the man tel You ll find the required safe clearances for Encore fireplace installations on Page 12 Floor protection requirements also apply to fireplace installations This information is on Page 9 Wall Pass Throughs Whenever possible design your installation so the 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 Encore 2040 Non Catalytic Catalytic Woodburning Stove Flexible Connector Fireplace Adapter Kit Positive Connection Fig 8 Through the fireplace installation 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 guidel
82. y need to wait a few minutes for a change in the air control setting to have an effect on the fire If there s no change then the draft isn t strong enough yet to let you close the damper and you ll need to open it for awhile longer and manage the fire with the air inlet until the draft strengthens If you keep track of your burning habits and relate them to their effects on the stove s operation you ll be rewarded with good performance and a safe system Negative Pressure Good draft also depends on a supply of air to the stove a chimney can t pull in more air than is 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 air consuming equipment If you need to crack a nearby window or door to enable the chimney to flow well it may be a good idea to install an outside air intake to bring combustion air directly to the stove An outside air kit is available to connect the stove directly to a source of outdoor combustion air Encore 2040 Non Catalytic Catalytic Woodburning Stove smmm Conclusion Wood burning is an art

Specifications - Maine Coast Stove & Chimney

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Specifications - Maine Coast Stove &amp; Chimney

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Specifications - Maine Coast Stove & Chimney