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Vermont Casting 1990 Indoor Fireplace User Manual

1. The Intrepid II Woodburning Stove Model 1990 Homeowner s Installation and Operating Manual For use in the United States and Canada SAFETY NOTICE IF THIS APPLIANCE IS NOT PROPERLY INSTALLED OPERATED AND MAIN TAINED A HOUSE FIRE MAY RESULT TO REDUCE THE RISK OF FIRE FOLLOW THE INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE BODILY INJURY OR EVEN DEATH CONTACT LOCAL BUILDING OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA NATIONAL We recommend that our woodburning FIREPLACE hearth products be installed and serviced by professionals who are certified in the U S by the National Fireplace Institute NFI as NFI Woodburning Specialists or who are certified in Canada by Wood Energy Technical Wood Energy ementa Training WETT es www Do Not Discard This Manual Retain for Future Use 2000966 2 07 Rev 19 Intrepid IT Woodburning Stove Congratulations on your choice of a Vermont Castings Intrepid Il With this purchase you made a commitment to make the hearth a place of warmth beauty and comfort in your home At CFM Corporation we share that joy and ap preciation of the hearth and we show it in all our cast iron stoves and fireplaces As you become acquainted with your new stove you will find the aesthetic appeal o
2. Intrepid IT Woodburning Stove Most installations will require that the bottom heat shield be attached Only when the stove is placed on a completely noncombustible surface such as unpainted concrete over earth may it be used with out the bottom heat shield Even with the bottom heat shield installed you must also use a floor protector In the United States the floor protector required under the stove must extend at least 16 from the front of the stove not from the ashlip Labeled E in Fig 11 and at least 6 from the sides and rear D Fig 11 To meet the requirement in the United States a floor protector must be at least 34 wide and 40 deep In Canada the floor protector required under the stove must extend 18 460mm to the front labeled E Fig 11 and 8 200mm from the sides and rear D Fig 11 To meet Canadian requirements a floor protector must be at least 38 965 mm wide and 44 1118 mm deep Floor protection also must extend under the chimney connector and 2 51 mm to either side C Fig 11 For 6 152 mm connector used with the Intrepid Il the protector must be a minimum of 10 254 mm wide centered under the connector ko gt Top Exit Rear Exit A Canada 965 mm al E 457 mm ST500 Fig 11 Required floor protector dimensions Intrepid IT Woo
3. 315 C range increasing efficiency and reducing creosote and emissions The catalytic reaction though advantageous does have some limitations of its own Primary among these it that the reactants the gases come into close physi cal contact with the catalyst itself To ensure the necessary contact the catalytic element in your Intrepid Il is composed of a ceramic base in the shape of a honeycomb On each of the honeycomb s many surfaces a coating of the catalyst usually a noble metal such as platinum or palladium is applied The large surface area exposed in this configuration ensures that the combustion gases have the greatest opportunity to come in contact with the catalyst Loss of catalytic activity will be apparent in several ways First you may notice an increase in fuel con sumption Second there will be a visible increase in the rate at which creosote builds up in your chimney con nector system You may also notice a heavy discharge of smoke from the chimney A number of catalytic problems which can cause loss of activity are described below Blockage While the honeycomb pattern ensures good contact it also increases the resistance to flow of the combustion gases and because of the many surfaces provides more places for creosote and fly ash to deposit It is important to follow the operating instructions in order to minimize these deposits and to periodically inspect your catalyst for signs of blockage
4. duce the risk of breaking the glass When you re not using the door handle store it in the holder behind the right front leg of the stove Open Position Closed Position Fig 37 To open the front doors turn handle clockwise Burn Only High Quality Wood The Intrepid Il 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 Avoid burning green wood that has not been properly seasoned The wood should be 16 410mm in length 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 2000966 Intrepid IT Woodburning Stove For areas that do not have a supply of hardwood com monly burned softwoods include tamarack yellow pine white pine Eastern red cedar fir and redwood These too should be properly dried Store firewood under cover to keep it dry Dry well sea soned wood is best for heating and fire viewing How ever avoid wood dried more than two years This wood burns very quickly reducing burn time Even for short term storage keep wood a safe distance from the heater and keep it out of the areas around the heater used for refueling and ash removal A Surface Thermometer is a Valuable Guide to Operation An optional surface thermometer tells you when to
5. with stove connector and wall shields Wall shields may meet at corner Connector heat shield extends 28 710mm above flue collar or below elbow whichever is less Wall pass through must comply with codes 1 25 mm 34 864 mm 48 1219 mm 3 DOmW gt 5 889 mm ST510a Fig 26 Corner installation vertical chimney connector two wall shields Reduced side clearances Wall shields MUST meet at corner 2000966 Intrepid IT 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 that pass through the ceiling However this is not a clearance chart Final stove clearances must adhere to the guidelines stated in the clearance charts on Page 14 Intrepid Il WITHOUT Stove and Chimney Connector Heat Shields Unprotected Surfaces Protected Surfaces Parallel Installations Comer Parallel Installations Gorner Installations Installations comer F 34 29 26 22 ER 737 mm 680 mm 578 mm 279 mm This distance from the center of the flue collar to the front edge of the hearth is the same for all installations on this page 31 in the United States and 33 840mm in Canada Intrepid Il WITH Stove and Chimney Connector Heat Shields Unprotected Surfaces Protected Sur
6. you may need to wait a few minutes for a change in the air control setting to have an effect on the fire If there s no change then the draft isn t strong enough yet to let you close the damper and you ll need to open it for a while longer and manage the fire with the air inlet until the draft strengthens If you keep track of your burning habits and relate them to their effects on the stove s operation you ll be rewarded with good performance and a safe system Negative Pressure Good draft also depends on a supply of air to the stove a chimney can t pull in more air than is available to it Sluggish draft results when a house is tight enough to prevent the ready flow of air to the stove or by competi tion 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 equipment If you need to crack a nearby window or door to enable the chimney to draw well that s a sign that you should install an outside air intake to bring combustion air directly to the stove Vermont Castings dealers carry adapters to attach to the stove to connect an air duct for outdoor combustion air Conclusion Wood burning is an art rather than a science Once the stove and chimney system
7. 2000966 Masking and Poisoning While the catalyst itself does not enter into the combus tion process it is possible for certain elements such as lead and sulfur to attach to the active sites on the surface of the honeycomb Though the catalyst is still there it is covered or masked by the contaminant and cannot function To avoid this situation it is important not to burn anything in your Intrepid Il that is a source of these contaminants Particularly avoid painted or treated wood coal household trash colored papers metal foils or plastics Chemical chimney cleaners may also contain harmful elements The safest approach is to burn only untreated natural wood Flame Impingement The catalytic element is not designed for exposure to direct flame If you continually overfire your Intrepid Il the chemistry of the catalyst coating may be altered inhibiting the combustion process A glowing stove part at the back of the firebox is a sign of over firing Thermal degradation of the ceramic base may also oc cur causing the element to disintegrate Stay within the recommended guidelines of the Operation section Mechanical Damage If the element is mishandled damage may occur Always treat the element carefully Remember the catalyst is made of a ceramic material treat it as you would fine china Hairline cracks will not affect the performance of the catalyst as long as the steel sleeve holds the element in the proper
8. Chimney Connector Shields These Clear ances ST244 Fig 7 Chimney connector enters chimney above the firep lace If the chimney connector from 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 e Check the clearance between the stove and the chimney connector and any combustible trim or the mantel Use the necessary combination of mantel trim and connector heat shields to achieve the required clearances e Check the clearance between the chimney con nector and the ceiling If no heat shields are used the clearance should be at least 26 660mm To find out how much this clearance may be reduced with heat shields see the clearance chart on Page 14 e The fireplace damper must be sealed to prevent room air from escaping up the flue However it must be possible to re open the damper to inspect or clean the chimney Intrepid IT Woodburning Stove Fireplace Chimney Installations Through a Fireplace If your fireplace height is at least 25 635mm you may install an Intrepid II with standard legs through the fireplace opening using a positive connection kit available from your local dealer These positive connec tion kits ensure a tight fit between the stove flue collar and the chimney flue Fig 8 Fireplace installations whether connected to t
9. Pg 36 Dealer 51 Leg See Chart Pg 36 52 Tie Rod 1601640 53 Leg Bolt 3 8 16 x 1 Hex Bolt 1201432 54 Right Air Manifold 1308654 Phone 55 Left Air Manifold 1308653 56 Handle Holder 1600600 Date Purchased 57 Front See Chart Pg 36 58 Left Door See Chart Pg 36 59 Left Glass Panel 1401157 Installer 60 Right Door See Chart Pg 36 61 Right Glass Panel 1401156 62 Handle Bolt 1 4 20 x 3 1201294 63 Ceramic Handle 20006381 Phone 64 Handle Insert 30002714 Date Installed 65 Front Door Handle 30002719 66 Griddle Handle Assembly 30002775 67 Gasket Fiberglas 3 16 Rnd Blk 1203556 68 Latch Assembly 5004025 69 Glass Clips Bottom 30000832 NOTES 70 Glass Clips Side 30000833 1 Part of assembly 0004345 71 Glass Clips Top 30000834 2 The glass panels have a heat reflective coating on the 72 Nut Jam 1203290 outside and are not interchangeable 73 Ashpan Assembly 5003522 74 Bottom Heat Shield Assy not shown 30004020 75 C Clip not shown 1204015 76 Wing Screw not shown 1201621 Shell Enamel Parts Intrepid Il Model 1990 Enamel Left Right Flue E Left Door Right Door Single Color Top Bottom Side Side Collar Only Only Leg Classic 1306333 Biscuit 30003180 30003174 30003176 30003175 30003181 30003177 30003179 30003178 30003182 Bordeaux 2328657 2326764 2328656 2328655 2326561 2328647 2328649 2328648 2326333 Chestnut Brown 30003190 30003184 30003186 30003185 3000319
10. Turn the door latch striker screw in or out to tighten or loosen the door latch 28 Tighten the Damper Handle as Needed The damper handle is attached to the damper rod with a set screw bearing against a flat spot on the rod Check the set screw periodically for tightness tighten as needed Damper Adjustment When the stove damper is closed the pressure of the rod against the damper plate assures a good seal be tween the damper and the damper housing Adjustment may be needed after a period of time to retain adequate pressure To make this adjustment start with the damper in the closed and locked position Fig 45 Loosen the 7 16 locking nut in the center of the damper Use a 1 8 Allen wrench to turn the Allen screw a full turn clockwise Test the damper for snugness and continue adjusting the Allen screw as needed Tighten the 7 16 locking nut when the damper operates smoothly but firmly Thermostat Cover D plate _ Ou tuator Damper Ac Rod Locking Nut Allen Head Ad justment Screw Fig 45 Tighten the damper adjustment screw for a snug seal 2000966 The Catalytic Combustion System Inspection and Cleaning This wood heater includes a catalytic combustor which needs periodic inspection and replacement for proper operation In the United States it is against the law to operate this wood heater in a manner inconsistent with the operating instructions in this manual or if the cata l
11. a bound or stretched chain need ing adjustment Fig 43 On a cold stove the shutter should be open no more than 1 8 3mm when the primary air control lever is pushed completely to the left closed as seen from the back of the stove When the lever is pushed completely to the right open the shutter should be open to an angle of approximately 70 from the stove back The ball chain should measure 81 2 216mm from connection to the thermostat coil to connection on the primary air flap If setting is incorrect the thermostat coil may be bent or broken Call your Vermont Castings Dealer for assis tance 27 Intrepid IT Woodburning Stove Thermostat Lever Primary Air Shutter Fig 43 The primary air shutter must move freely How to Adjust the Door Latch Over time the gasketing around the doors will com press and the latch may need adjustment To adjust the latch loosen the small locking nut extend the striker screw one turn while keeping the striker screw from turning Fig 44 Keep making adjustments a little at a time until the setting is right The front doors of the stove should close securely and tightly when the handle is in the closed position When the latch is properly adjusted there should be a slight resistance as the doors are moved to the completely closed position Pawl Small Lock ing Nut NX Large Lock ing Nut Striker Screw Set Screw Handle Stub Fig 44
12. adjust the air control when to refuel and helps to tell when your catalyst is operating properly For example when the thermometer registers at least 450 F 230 C after start up you know the stove is hot enough to begin catalytic combustion and it may be time to close the damper Place the thermometer in the center of the griddle as in Figure 38 and use the following temperature ranges as a guide to 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 e Atemperature reading over 750 F 400 C is a sign to cut back on the air supply to slow the burn rate e Readings in the 300 400 F 150 200 C range indi cate low to medium heat output e Readings of 500 650 F 260 340 C indicate high heat output Operating your Intrepid Il continuously at griddle temperatures of 750 F 400 C or higher may damage inner parts or the enamel finish ST523 Fig 38 Take temperature readings with a thermometer lo cated in the middle of the griddle 21 Intrepid IT Woodburning Stove Use the Air Control Settings that Work Best for You No single air control setting will fit every situation Set tings will differ depending on the quality of the fuel the amount of heat desired and how long you wish the fire to burn The control setting also depends on your particular installation s draft or the force that moves air from th
13. are in place the stove user can only vary technique mostly your timing to achieve good results If you keep track of your burning habits and relate them to their effects on the stove s operation you ll be rewarded with good performance and a safe system 2000966 Intrepid IT Woodburning Stove Maintenance Let the fire in the stove go out and allow the stove to cool completely before beginning any maintenance procedure Care of the Cast Iron Surface An occasional dusting with a dry rag will keep the painted cast iron of your Intrepid looking new The stove s paint can be touched up as needed First clean the areas to be painted with a wire brush Then touch up the stove with high temperature stove paint Apply the paint sparingly and keep in mind that two light coats of paint are better than a single heavy one Care of Porcelain Enamel Finish Use a dry or slightly damp rag or a soft brush to remove spills or stains For difficult jobs that require a cleaning agent use only a kitchen appliance cleaner or polish recommended for use on enamel surfaces Cleaning the Glass Most of the carbon deposits on the glass will burn off during hot fires However the ash residue that accumu lates on the glass surface should be removed regularly to prevent etching Follow this procedure to clean the glass e Be sure the glass is completely cool e Clean the glass with water or a cleaner made especially for this purpose Do n
14. be a disadvantage Hot gases cool off through expansion if we vent a stove with a six inch flue collar 28 square inch area into a 10 x 10 flue the gases expand to over three times their original size This cools the gases which weakens draft strength If an over sized flue is also outside the house the heat it absorbs gets transferred to the outdoor air and the flue usually stays cool It s common for a masonry flue especially one built for a fireplace to be oversized for an airtight stove It can take quite a while to warm up such a flue and the re sults can be disappointing The best solution to an over sized flue is an insulated steel chimney liner the same diameter as the stove or insert s flue outlet the liner keeps the smoke at its original volume and the result is a stronger draft An uninsulated liner is a second choice the liner keeps the smoke restricted to its original size but the smoke still must warm up the air around the liner This makes the warm up process take longer Pipe amp Chimney Layout Every turn the smoke must take in its travel from the stove to the chimney top will slow it down The ideal pipe and chimney layout is straight up from the stove to a completely straight chimney If you re starting from scratch use this layout if possible If the stove pipe must elbow to enter a chimney locate the thimble about midway between the stove top and the ceiling This achieves several goals it
15. or connector and away from the wall Shields are never used on double wall connectors Clearances may be reduced only by means approved by the regulatory authority and in accordance with the clearances listed in this manual NOTE ALCOVE INSTALLATION OF THE INTREPID ll IS NOT PERMITTED IN CANADA Stove Heat Shields The Intrepid Il Rear Heat Shield is one way to reduce the clearance to the rear wall The rear heat shield may be installed on either rear or top exiting stoves How ever since the chimney connector also radiates heat toward the wall in top exiting installations either single wall connector with connector heat shields or listed and approved double wall chimney connector should be used whenever the rear heat shield is used on top exit ing stoves Clearance reductions with the rear heat shield apply only to the wall to the rear in parallel installations Nei ther the side clearance requirement nor the clearance requirement in corner installations may be reduced Clearances may be reduced by using a wall shield constructed of 24 gauge or heavier sheet metal or of another non combustible material such as 1 2 13 mm insulation board or common brick laid on flat with the 34 90 mm side down Figure 13 shows such a wall shield Shields must be spaced out from the combustible surface 1 25mm on noncombustible spacers The spacers should not be directly behind the stove or chim ney connector Air m
16. 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 CFM Corporation reserves the right to withhold final approval of a warranty claim pending a visual inspection of the defect by authorized representatives a oN 39 CFM Corporation 410 Admiral Blvd Mississauga Ontario Canada L5T 2N6 800 668 5323 www cfmcorp com CFM Corporation
17. reduced by using heat shields on single wall connector or by using double wall connector Clear ances may also be reduced by using wall shields All shielding used to reduce clearances must be listed by a recognized testing laboratory and approved by the local regulatory body Clearance requirements are established for many dif ferent installations In general the greatest clearance is required when you are placing a stove and its connec tor with no heat shields near a wall with no heat shield For example when the Intrepid II is installed parallel to the rear wall and no shielding is used it must be at least 30 760 mm from the wall behind it and at least 24 610 mm from walls on either side If the Intrepid Il is installed in a corner and no shields are used the corners of the stove must be at least 20 510 mm from nearby walls The least clearance is required when both the stove and its connector as well as the wall have heat shields When shields are attached to the stove or chimney connector they are mounted 1 2 25 51 mm away from the stove or connector surface on non combustible spacers Air flowing between the stove and or chimney 2000966 connector and nearby shields carries away heat Do not block the air flow by filling this empty space with any insulating material The shiny shield surface facing the heat source must be left unpainted enabling it to reflect heat back towards the stove
18. the height of the noncombustible ceiling Fig 18 Cutaway perspective of alcove installation 2000966 13 Intrepid IT Woodburning Stove Intrepid Il Clearance Chart See Pages 15 and 16 for illustrations of these clearances Unprotected Surfaces Protected Surfaces Stove Clearance Stove Installed Stove in Stove Installed Stove in as E Raro to Wall ESSES RE aca to Wall SEC Somers somers gue 24 fea C 20 se 12 pe 16 10 610 mm E mm a mm 305 mm 406 mm E mm Top exit rear stove h s single wall chimney G 24 H 16 1 12 J 12 L 10 connector with connector 610 mm 406 mm 254 mm heat shields Rear exit rear stove M 24 N 14 n a P 12 Q 9 n a heat shield si mm 356 mm 305 mm 229 mm Top exit rear stove h s double wall chimney connector Chimney Connector Clearance Single wall chimney connector no 26 660 mm 12 305 mm connector heat shields Single wall chimney connector with 10 254 mm 5 127 mm connector heat shields Double wall 12 305 mm connector Front Clearance to Combustibles All Installations 48 1219 mm Clearances with double wall connectors and protected surfaces have not been tested for the Intrepid II 1 Shielding for a top exit stove must include the stove
19. to the ceiling and connects to a prefabricated insulated metal chimney the connector shield must extend to within an inch of the ceiling A ceiling heat shield must be installed that is 22 560mm in diameter and as explained above that extends 1 25mm below the ceiling The ceiling shield must be constructed of 24 gauge or heavier sheet metal must be centered on the chimney and must meet any wall protector that is also a part of the installation For double wall connector the tested and listed clearances given in this manual must be used Fireplace and Mantel Trim Shields A fireplace installation requires special clearance be tween the side of the stove and the right and left walls between the side of the stove and the decorative side trim on the fireplace face and between the top of the stove and the mantel 11 Intrepid IT Woodburning Stove Noncombustible shields installed 1 25 mm away from the combustible surface on noncombustible spacers called ventilated shields may be used to reduce clear ances Fig 14 1 4 6mm Fig 14 A custom formed mantel shield To protect a mantel from the heat of an Intrepid Ilin a fireplace installation the ventilated mantel shield must be at least 48 1220 mm long and it must be centered over the stove Ventilated shields for side trim must extend the full length of the trim An unprotected mantel A Fig 15 cannot be more than 9 23
20. to the side walls side decorative trim and fireplace mantle Refer to the information on fireplace and mantel trim shields in this section 10 Keep the Stove and Connector a Safe Distance from Surrounding Materials Both a stove and its chimney connector radiate heat in all directions when operating and dangerous overheat ing of nearby combustible materials can occur if they are too close to the heat A safe installation requires that adequate clearance be maintained between the hot stove and its connector and nearby combustibles Clearance is the distance between either your stove measured from the back edge of the stove s top plate or chimney connector and nearby walls floors the ceiling and any other fixed combustible surface Your stove has special clearance requirements that have been established after careful research and testing to UL and ULC standards These clearance requirements must be strictly observed In addition furnishings and other combustible materials must be kept away from the stove as well In general a distance of 48 1220 mm must be maintained between the stove and moveable combustible items such as dry ing clothes furniture newspapers firewood etc Keep ing those clearance areas empty assures that nearby surfaces and objects will not overheat Reducing Clearances Stove clearances may be reduced by using heat shields attached to the stove Chimney connector clearances may be
21. 0 mm deep and must have a minimum clearance of 30 760 mm measured from the stove s top plate With a ventilated shield this clearance may be reduced safely to 14 360 mm Unprotected top trim B protruding 2 50mm or less from the face of the fireplace must be a minimum of 24 610 mm from the stove s top surface With a venti lated trim shield this clearance may be reduced safely to 14 360 mm Unprotected side trim C that protrudes 2 50mm or less from the face of a fireplace must have a minimum clearance of 15 380mm measured from the stove s top side edge With a ventilated trim shield the clear ance may be reduced safely to 10 254 mm If the trim extends more than 2 51 mm wall clearance require ments apply The charts and sample installations that follow list the clearances required for the various installation configu rations of the Intrepid II 12 ST253 Fireplace Mantel and Trim Clearances Measured from the top and sides of the stove Unprotected Protected A Mantel 30 762mm 14 356mm B TopTrim 24 610mm 14 356mm C SideTrim 15 381mm 10 254mm Fig 15 Maintain clearances to combustible components of the mantelpiece Alcove Installations Because of their restricted air flow and heat retention characteristics specific co
22. 1 30003187 30003189 30001888 30003192 Ebony 30003200 30003194 30003196 30003195 30003201 30003197 30003199 30003198 30003202 Forest Green 2318657 2316764 2318656 2318655 2316561 2318647 2318649 2318648 2316333 Midnight Blue 2378657 2376764 2378656 2378655 2376561 2378647 2378649 2378648 2376333 Sand 1328657 1326764 1328656 1328655 1326561 1328647 1328649 1328648 1326333 Suede Brown 30002571 30002567 30002569 30002568 30002508 30002570 30002506 30002505 30002509 Vt Classic Green 30003210 30003204 30003206 30003205 30003211 30003207 30003209 30003208 30003212 36 2000966 Intrepid IT Woodburning Stove 2000966 37 Intrepid IT Woodburning Stove 38 2000966 Warranty Limited 3 Year Warranty CFM Corporation warrants that this woodburning stove will be free of de fects in material and workmanship for a period of three years from the date you receive it except that the catalyst thermostat assembly handles glass door panels cement and gasketing shall be warranted as described below CFM Corporation 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 d
23. Flexible fiberglass rods are used to run the brush up and down the liner causing any deposits to fall to the bottom of the chimney where they can be removed through the clean out door The chimney connector should be cleaned by discon necting the sections taking them outside and removing any deposits with a stiff wire brush Reinstall the con nector sections after cleaning being sure to secure the individual sections with sheet metal screws If you cannot inspect or clean the chimney yourself contact your local Vermont Castings authorized dealer or hire a professional chimney sweep Annual Maintenance Perform a thorough cleaning inspection and repair each spring at the end of the heating season e Thoroughly clean the chimney and chimney connec tor e Inspect the chimney for damage and deterioration Replace weak sections of prefabricated chimney Have a mason make repairs to a masonry chimney e Inspect the chimney connector and replace any damaged sections e Check gasketing for wear or compression and replace if necessary A paper test will guide you on this Close and lock the door or damper on a slip of paper and then try to pull the paper out If the paper pulls out with little or no resistance the gasket is not snug enough at that spot If adjusting the damper or latch does not result in a seal that makes it hard to pull the paper out replace the gasketing 31 Intrepid IT Woodburning Stove 32 I
24. a dust mask safety glasses and gloves Refer to Figure 46 as a guide 1 Remove the andirons 2 Reach inside the stove with a pair of pliers and turn the two clamps that hold the fireback 90 Turn the left clamp clockwise and the right clamp counter clockwise 3 Grasp the fireback by its vertical ribs and remove it together with the attached throat hood Pull the left side out first 4 Carefully clean the left and right exhaust pockets of the refractory package Use a shop vacuum ideally one with a very fine filter and be careful to avoid damaging the refractory material This material can stand high temperatures but it is somewhat brittle physically 5 Carefully remove the refractory access panel in front of the catalytic element 6 Gently slide the catalytic element out of the refrac tory chamber Check the element and the bottom of the chamber for a buildup of fly ash 7 If the catalytic element is clogged take it outdoors for cleaning Blow gently through the honeycomb A large amount of fly ash may come out of the ele ment 8 Inspect the element Although small hairline cracks will not affect performance the element should be largely intact If the element is broken in pieces or has large sections missing replace it Call your dealer for a replacement element part no 160 2521 29 Intrepid IT Woodburning Stove Catalytic Block Upper Fireback with Throat Exhaust Pockets Refractory Acc
25. an enhance the versatility ap Specifications pearance and safety of your Intrepid Stove Installation 0307 Bottom Heat Shield 0172 Rear Heat Shield Chimney connector heat shields Assembly Heavy gauge enamel pipe to match the stove s Operation color Warming shelves 0098 Classic Black 1375 Suede Brown Maintenance 1362 Sand 1376 Biscuit Catalytic Combustor 1365 Green 1377 Chestnut Brown 1371 Bordeaux 1378 Ebony Parts List 1372 Midnight Blue 1379 Vt Classic Green 0136 Spark screen for open fireplace use z Short Legs Proposition 65 Warning Fuels used in gas wood 0868 Classic Black 1525 Suede Brown burning or oil fired appliances and the products of 1512 Sand 1527 Biscuit combustion of such fuels contain chemicals known 1510 Green 1530 Chestnut Brown to the State of California to cause cancer birth de 1515 Bordeaux 1535 Ebony fects and other reproductive harm 1520 Midniaht BI 1537 Vt Classic G California Health amp Safety Code Sec 25249 6 A ead PARIAR 3258 Outside air kit 3248 Mobile home kit Clearances Draft Management 2 2000966 Intrepid IT Woodburning Stove Specifications Intrepid Il Model 1990 Range of heat output 8 260 26 740 Btu s Hr 1 This value can vary depending on how the stove Maximum heat output 27 000 Btu s Hr is operated the type and moisture content of the fuel Area heated Up to 1200 sq ft 112 sq m used as well as
26. ause letting the smoke cool off and slow down is one of the keys to creosote production it makes sense to line a chimney to match the stove s outlet size for safety reasons as well as performance Canadian law requires a matching liner to serve any stove or insert vented through a fireplace chimney in the US the National Fire Protection Association recommends one if the flue is more than three times bigger in square area than the outlet on the stove or insert Some localities enforce the NFPA guidelines as part of their building codes Even the best stove installation will not perform well with poor fuel The best fuel is hardwood that has air dried 12 18 months Softwood burns but not as long as hardwood Fairly green wood has a good amount of moisture in it it will burn but some of the heat potential is used to drive the remaining moisture off the wood This reduces the amount that reaches your home and can contribute to a creosote problem There are mois ture meters available for firewood you can also judge your wood by its appearance and weight If you get it green lift a piece and get a sense of its weight it can lose a third or more of its weight as it dries Also look at the ends of a log as it dries it shrinks and often cracks The more weathered and cracked a piece is the drier it is Dry wood burns readily with a good chimney draft But with modern stoves especially catalytic ones the wood can be too dry Whil
27. back Clamp 1306724 23 Primary Air Flap 1306710 34 2000966 Intrepid IT Woodburning Stove CFM Corporation reserves the right to make changes in design materials specifications prices and discontinue colors and products at any time without notice Intrepid Il Woodburning Stove Model 1990 continued Item Description Part Number Item Description Part Number 24 Air Flap Pin 1601551 35 Refractory Access Panel 1602516 25 Clip 1601396 36 Andiron 1306717 26 10 24 x 3 8 Pan Head Bolt 1200983 37 Left Insert 1308651 27 10 24 x 1 4 Pan Head Bolt 1200980 38 Grate 1308652 28 Secondary Probe Assembly 1601489 39 Right Insert 1308650 29 Secondary Air Link 1601486 40 Ashpan Only 1400951 30 Phillips Bolt 1 4 20 x 5 8 1200896 41 Ashpan Front Only 1306493 31 Shim Ring 1201986 42 Ashpan Handle 30000973 32 Secondary Air Flap 1601490 43 Damper Tab 1601488 33 Refractory Chamber w Access Panel 1602527 44 Griddle 1306356 34 Catalyst Block 30001153 45 Right Griddle Quad 1301832 2000966 35 Intrepid IT Woodburning Stove Intrepid Il Woodburning Stove Model 1990 continued Item Description Part Number eee 46 Left Griddle Quad 1301807 Please record the following information 47 Top See Chart Pg 36 for future reference 48 Right Side See Chart Pg 36 Stove Serial No 49 Bottom See Chart Pg 36 50 Left Side See Chart
28. c combustor is deactivated or removed High Efficiency Wood Burning with Catalytic Combustion The catalytic combustion system in your Intrepid Il produces the best conditions for secondary combustion When the stove damper is closed smoke goes through the catalytic element burning at temperatures of 500 600 F 260 315 C half the temperature normally needed for unaided secondary combustion The catalytic element is a ceramic honeycomb coated with a noble metal usually platinum The element is in the secondary combustion chamber made of a spe cial high temperature insulating refractory material The chamber provides the correct environment neces sary for secondary combustion of the fuel smoke Closing the damper may also reduce draft Closing the damper too soon may put out the fire or deactivate the combustor Close the damper only when the fire is well established When starting a fire wait until there is an ember bed of at least 3 4 76 102mm before closing the damper Never kindle a fire with colored paper or paper that has colored ink or a glossy surface and never burn treated wood garbage solvents or trash All of these may poison the catalyst and prevent it from operating properly Never burn cardboard or loose paper except for kindling purposes Never burn coal doing so can 2000966 produce soot or large flakes of char or fly ash that can coat the combustor and cause smoke to spill into the r
29. d For safety good stove performance and to protect your chimney and chimney connector inspect the chimney and chimney connector on a regular schedule Clean the system if necessary Failure to keep the chimney and connector system clean can result in a serious chimney fire When wood is burned slowly it produces tar organic vapors and moisture that combine to form creosote The creosote vapors condense in the relatively cool chimney flue As a result creosote residue accumulates on the flue lining When ignited this creosote makes an 2000966 Intrepid IT Woodburning Stove extremely hot fire within the flue system that can dam age the chimney and overheat adjacent combustible material If you do have a chimney fire act promptly to e Close the damper and thermostat lever e Get everyone out of the house e Call the Fire department You should inspect the system every two weeks during the heating season as part of a regular maintenance schedule To inspect the chimney let the stove cool completely Then using a mirror and a strong light sight up through the flue collar into the chimney flue If it is not possible to inspect the flue system in this fashion the stove must be disconnected to provide better view ing access If a significant layer of creosote has accumulated 1 8 3mm or more remove it to reduce the risk of a chim ney fire Clean the chimney using a brush the same size and shape as the flue liner
30. d most thimbles will facilitate the removal of the chimney con nector system for inspection and cleaning Thimble sleeves should be available from your local dealer Fig 5 Slip Pipe Pe Standard Chimney Connector ST492a Fig 6 Chimney connection in a freestanding installation To install a thimble sleeve slide it into the breach until it is flush with the inner flue wall Do not extend it into the actual flue passage as this could interfere with the draft The thimble sleeve should protrude 1 2 25 50mm into the room Use furnace cement and thin gasketing to seal the sleeve in place in the thimble Secure the chim ney 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 breach to the inner face of the flue liner and cemented securely in place Additional pieces of connector are then attached with sheet metal screws 2000966 Intrepid IT Woodburning Stove Fireplace Chimney Installations Above a Fireplace The Intrepid Il may be connected to a chimney above a fireplace opening also In such installations the stove is positioned on the hearth in front of the fireplace and the chimney connector rises from the stove top and then angles ninety degrees back into the chimney Fig 7 The chimney liner should extend to the point at which the chimney connector enters the chimney X K
31. dburning Stove Floor Protection for Fireplace Installations Do not assume 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 as in Figure 12 Because heat passes through brick or concrete readily 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 Wood framing requires protection from radiant heat ST247a Fig 12 Supporting timbers under fireplace hearth are consid ered to be combustible Keep in mind that many raised hearths will extend less than the required clearance from the front of the heater when it is installed In such cases sufficient floor protection as described above must be added in front of the hearth to satisfy the minimum floor protector re quirement from the front of the stove 18 460mm from the front in Canada Fireplace hearths must also offer the required protection of 8 203 mm on either side Optional 3 76 mm short legs may be used only on such hearths that meet the width and depth require ments outlined previously under floor protection Hearth rugs do not satisfy the requirements for floor protection Fireplace installations also have special clearance requirements
32. e s open and closed positions When closing the damper push firmly and snap it into the locked position to ensure that the stove remains in the catalytic mode Side View Open Updraft Mode S ak Closed Catalytic Mode J lt Fig 34 The damper is either open or closed There are no intermediate positions Glass Door Panels The glass panels in the doors have a heat reflective coating on the outside surface Heat reflected back to the inside of the glass helps keep the inner surface at a higher temperature than the outside In combination with pre heated primary combustion air washing over the inside of the glass this helps provide clear fire viewing at most operating levels 20 Your stove has andirons to keep logs away from the glass panels The andirons are important to maintain clear fireviewing and should be removed only while reloading through the front doors Wear heavy stove gloves when removing the andirons and place them on a noncombustible surface until you replace them in the stove Most stove owners will prefer the convenience of top loading through the griddle and will leave the andirons in place permanently Fig 35 Remove the andirons for front loading Two Ways to Add Fuel The Intrepid II s griddle lifts for convenient top loading of logs and is the easiest way of regularly adding fuel However the front doors open as well for adding an oc casional
33. e stove up through the chimney Draft is affected by such things as the length type and location of the chimney local geography nearby obstructions and other factors Too much draft may cause excessive temperatures in the Intrepid Il and could even damage the combustor On the other hand too little draft can cause backpuffing into the room and or the plugging of the chimney or combustor How do you know if your draft is excessively high or low Symptoms of too much draft include an uncontrol lable burn or a glowing red stove part A sign of inad equate draft is smoke leaking into the room through the stove or chimney connector joints low heat and dirty glass In some newer homes that are well insulated and weather tight poor draft may result from insufficient air in the house In such instances an open window near the stove on the windward side of the house will provide the fresh air needed Another option for getting more combustion air to the stove is to duct air directly from outdoors to the stove In fact in some areas provisions for outside combustion air are required in all new construction Your Intrepid II will accept a duct carrying outside air for combustion 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 some time to determine the amount of heat and the length of burn you should expect fro
34. e doors and close them on a piece of waxed paper to keep the cement from migrating onto the stove front or tap other parts with the rubber mallet or hammer block of wood Clean excess cement from around the channel Let the cement that holds the new gasket dry thoroughly O q Oo Adjust the Door if Necessary The door latch or damper mechanism may need adjust ment after you have regasketed them Initially it may require loosening to accommodate the new gasket af ter a few weeks it may need tightening to compensate for compression of the new gasket The directions for adjusting the latch and damper are on Page 27 Permanent Gaskets Other gaskets seal between non moving parts but these are not subject to the same wear and deteriora tion 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 The diameter of the gasket that seals these non moving parts is 5 16 and the areas sealed are the flue collar to the stove back and the lower fireback to the sides The glass panels use a special die cut flat gasket refer to Page 24 for information on these The Chimney System Creosote Your Intrepid Il is designed to reduce creosote buildup significantly However regular chimney inspection and maintenance must still be performe
35. e extra dry wood has little creosote in it the remainder can gas out from the wood quickly and densely enough to overload the catalytic burner If you hear a rumbling or roaring noise like a propane torch from the stove that is a sign that the catalyst is seriously overfiring The catalyst is a platinum film on a ceramic base the metal can get to higher temperatures than the ceramic can take and overfiring the catalyst can break it Dry wood can also burn out faster than you want If your dry wood burns out too quickly or overloads the catalyst you can mix in greener wood to slow the fire down 26 Back puffing Back puffing results when the fire produces volatile gases faster than the chimney draft pulls them out of the firebox The gases back up in the firebox till they re dense enough and hot enough to ignite If your stove back puffs you should open up the damper to let the smoke rise to the flue more quickly let more air into the firebox and avoid big loads of firewood Run your stove with enough primary air so that you always see lively dancing flames in the firebox a lazy smoky fire is inefficient and can contribute to creosote buildup in the chimney Draft Testing An easy way to test your chimney draft is to close the stove s damper wait a few minutes to let the airflow stabilize then see whether you can vary the strength of the fire by swinging the air control open and closed Re sults are not always instant
36. e material in the wall is cut away from the single wall connector to provide the required 12 305mm clearance Any material used to close up the opening must be noncombustible Three other methods are also recommended by NFPA e Using a section of double wall chimney with a 9 230mm clearance to combustibles e Placing a section of chimney connector inside a ven tilated thimble which in turn is separated from combus tibles by 6 150mm of fiberglass insulating material e Placing a section of chimney connector inside a section of 9 230mm diameter solid insulated factory built chimney with 2 50mm of air space between the chimney section and combustibles Wall Stud Chimney Connector Noncombustible Material Protection ST493a Fig 9 An approved wall pass through for the United States In Canada The Canadian Standards Association has established installation guidelines The following il lustration shows one method in which all combustible material in the wall is cut away to provide the required 18 460 mm clearance for the connector The resulting space must remain empty A flush mounted sheet metal cover may be used on one side only If covers must be used on both sides each cover must be mounted on noncombustible spacers at least 1 25 mm clear of the wall 2000966 Your local dealer or your local building inspector can provide details for other approved methods of
37. ealer s option whether the repair work will be done in the cus tomer s home or in the dealer s shop If upon inspection the damage is found to be the fault of the manufacturer repairs will be authorized at no charge to the customer for parts and or labor Any woodburning stove or part thereof that is repaired or replaced dur ing the limited warranty period will be warranted under the terms of the limited warranty for a period not to exceed the remaining term of the original limited warranty or six 6 months whichever is longer Limited 1 Year Warranty The following parts of the woodburning stove are warranted to be free of defects in material and workmanship for a period of one year from the date you receive it The thermostat assembly handles glass door panels cement and gasketing Any of these items found to be defec tive will be repaired or replaced at no charge upon the return of the part with postage prepaid to a Vermont Castings Authorized Dealer Any part repaired or replaced during the limited warranty period will be warranted under the terms of the limited warranty for a period not to exceed the remaining term of the original limited warranty or six 6 months whichever is longer Limited Catalyst Warranty The catalyst will be warranted for a six year period as follows If the original catalyst or a replacement catalyst proves defective or ceases to maintain 70 of its particulate emission reduction activity as measu
38. emissions Height to top of flue collar testing with regular legs 25 635 mm top exit oaran EAE T SNOS 24 610 mm rear exit with optional short legs 21 535 mm top exit EA EAA 19 500 mm rear exit Si 510 mm DRAWINGS NOT TO SCALE 640 mm A A TA Woes 520 mm xX x 369 Top exit flue collar height we KKK mats 7 a Sa TV kK 21 13 _ 545 mm 350mm Fig 1 Intrepid II 1990 dimensions 2000966 3 Intrepid IT Woodburning Stove Installation SAFETY NOTICE IF YOUR STOVE IS NOT PROP ERLY INSTALLED A HOUSE FIRE MAY RESULT TO REDUCE THE RISK OF FIRE FOLLOW THE INSTAL LATION INSTRUCTIONS CONTACT LOCAL BUILD ING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA Before you begin an installation review your plans to see that e Your stove and chimney connector will be far enough from combustible material to meet all clearance requirements e The floor protector is large enough and is con structed properly to meet all requirements e You have all necessary permits from local author ities Your local building official is the final authority for ap proving your installation as safe and determining that it meets local a
39. ess Panel Fig 46 Removing the catalytic element 9 Use a flashlight and a mirror inserted into one of the exhaust pockets of the refractory chamber to in spect the probe The end of the probe should extend about 1 into the combustion chamber and should not show any signs of deterioration Use the stove in your usual manner for two weeks inspecting the chimney and the chimney connector frequently If creosote does not build up as quickly as before it is likely that the performance change was caused by fly ash deposits on the catalytic element However moni tor the chimney system for a few weeks to ensure that proper performance continues If you continue to find a significant creosote buildup or if you continue to see excessive smoke from the chimney the catalytic element will need to be replaced Call your dealer for information about a replacement NOTE Use only replacement catalyst part no 160 2521 Replace Refractory Package Refer to Figure 46 1 Remove andirons 2 Reach inside the stove with pair of pliers and turn the two clamps that hold the fireback 90 Turn the let clamp clockwise and the right clamp counter clockwise The bolts that hold these clamps are tapped into the back as well as capped by chrome acorn nuts in the back 3 Grasp the upper fireback by its vertical ribs and re move it together with the attached throat hood Pull the left side out first 4 Carefully remove the refract
40. etail pur chase is required 2 This warranty does not cover misuse of the stove Misuse includes overfiring which will result if the stove is used in such a manner as to cause one or more of the plates to glow red Overfiring can be identified later by warped plates and areas where the paint pigment has burned off Overfiring in enamel fireplaces is identified by bub bling cracking chipping and discoloration of the porcelain enamel finish CFM Corporation offers no warranty on chipping of enamel surfaces Inspect your woodburning stove prior to accepting it for any damage to the enamel 3 This warranty does not cover misuse of the stove as described in the Owner s Guide nor does it cover an stove which has been modified unless authorized by a CFM Corporation 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 CFM Corporation 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 insta
41. f cast iron is matched only by its superb capacity to absorb and radiate heat Also CFM Corporation products are among the cleanest burning wood stoves and fireplaces available today As an owner of a CFM Corporation stove you are making a strong statement for pollution free energy But clean burning depends on both the manufacturer and the operator Please read this manual carefully to understand how to properly operate your stove At CFM Corporation we are equally committed to your satisfaction as a customer and that is why we maintain an exclusive network of the finest dealers in the industry Chosen for their expertise and dedication to customer service our dealers are factory trained and know each CFM Corporation product in detail Feel free to contact your Authorized Vermont Castings Dealer anytime you have a question about your stove or its performance We have built your Vermont Castings Intrepid Il with the utmost care With normal use and proper care it will provide you with many years of service This manual contains valuable instructions on the installation and operation of your Vermont Castings stove You will also find useful information on assembly and maintenance procedures We urge you to read the manual thoroughly and to keep it as a reference Sincerely All of us at CFM Corporation Save These Instructions For Future Reference Table of Conte nts Ask your Vermont Castings dealer how these instal lation accessories c
42. f the first section of chimney connector and secure it to the flue collar with three 10 x 1 2 sheet metal screws e Secure each joint be tween sections of chimney connector including tele scoping joints with at least three sheet metal screws The pre drilled holes in the top of each section of chimney connector serve as guides when you drill 1 8 3mm holes in the bottom of the next section e Secure the chimney connector to the chimney Fig 4 The crimped end of the connector points toward Instructions for various stove installations follow e Be sure the installed stove and chimney connector are correct distances from nearby combustible material NOTE Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney 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 Securing the Single wall Connector to a Prefabricated Chimney For prefabricated chimneys follow the installation instructions of the chimney maker exactly as you install the chimney The maker of the chimney will supply the accessories to support the chimney either from the roof of the house at the ceiling of the room where the stove is installed or from an exterior wall Special adapters are available from your local dealer to make the connection between the prefabricated chim ne
43. faces Parallel Installations Corner Parallel Installations Corner Installations Installations 34 15 18 2234 8 16 883 mm 381 mm 476 mm 578 mm 203 mm 426 mm ST511a To locate center of flue collar for corner installation add 7 180mm to the clearance distance form stove corner to wall Mark off the resulting distance from the corner along both walls Next measure the same distance form these two points out from the walls These last two measure ments will meet at a point representing the center of the flue collar Refer to the diagrams above 2000966 17 Intrepid IT Woodburning Stove Assembly Clean the Griddle Before Use At the factory the griddle is coated with vegetable oil to prevent rusting while the stove is in transit and storage Remove the oil with a dry rag or paper towel before you use the stove Set Up the Stove Remove any loose parts from inside the stove Place a protective pad on the floor arrange some sections of 4 x 4 lumber on the pad for support and carefully tip the stove onto them on its back Remove and discard the four large slot head screws from the stove bottom Fig 27 and install the stove legs using the hex head bolts from the parts bag Use 3 8 washers with three of the legs the door damper handle holder installs in place of a washer on the right front leg Position the holder so the hole to accept the handle nub
44. faces out from the right side of the stove Tighten the bolts firmly Slotted Screws Fig 27 Remove the slotted screws from the stove bottom Install the Bottom Heat Shield A bottom heat shield must be used unless the stove is to be situated on a completely noncombustible hearth such as unpainted concrete over earth To install the bottom heat shield loosen the leg bolts and slip the bottom heat shield C clips onto the bolts Attach the bottom heat shield to the C clips with the wing nuts and tighten the leg bolts Align the shield as shown in Figure 28 18 Fig 28 Attach bottom heat shield Storing the Handle Use the removable handle to open or close the front doors or to change the position of the damper After using it remove it so it won t get hot and store it in the handle holder installed behind the right front leg Fig 29 INTREPID II Door Handle Holder sd Bottom Heat Shield if No Bracket Wing Bolt ST514 Fig 29 Handle holder and heat shield positions Reversing the Flue Collar You can reverse the flue collar by removing the two screws that attach the collar to the back of the stove Fig 30 Be sure the gasket around the flue collar opening is in position when you screw the collar back on to the stove 2000966 Flue Collar Screws Fig 30 Reversing the f
45. he flue above or through the fireplace opening have special clearance requirements to adjacent trim and the mantel You ll find the required clearances for the Intrepid II fireplace installations on Page 14 Floor protection requirements also apply to fireplace installations Floor protection information is on Page 9 Flexible Connector Mantel Shield Fireplace Adaptor Kit ua ell DE nea OU E a m e m m e e e e es m FEB Se Ee Bee Ee ee a ee S245 Fig 8 Chimney connector enters chimney through the fire place opening Wall Pass Throughs Whenever possible design your installation so the con nector does not pass through a combustible wall If you are considering a wall pass through in your installation check with your building inspector before you begin Also check with the chimney connector manufacturer for any specific requirements Accessories are available for use as wall pass throughs If using one of these make sure it has been tested and listed for use as a wall pass through In the United States the National Fire Protection As sociation NFPA has established guidelines for passing chimney connectors through combustible walls Many building code inspectors follow these guidelines when approving installations Figure 9 shows one NFPA recommended method All combustibl
46. id II s combustion system is to watch the amount of smoke leaving the chimney both when the combustor has achieved light off and when it has not Follow this procedure With a fire going and the combustor activated with the damper closed to send smoke through the combustor as described in the Operation Section go outside and watch the smoke leaving the chimney Then open the stove damper and again watch the smoke leaving the chimney 2000966 Intrepid IT Woodburning Stove You should see significantly more smoke after the sec ond step when the stove damper is open and smoke does not go through the combustor However do not confuse smoke with steam form wet wood steam dis appears rapidly in the air smoke does not If this test indicates a problem consider other possible factors as well such as the time of year or a change in the quality of your fuel In spring and fall draft is weaker than it is during colder winter weather and fires can burn sluggishly Small hot fires are a good solution under these conditions Green insufficiently seasoned wood will burn more poorly than properly seasoned fuel You may have to run your stove hotter with more primary air to achieve good performance if you are burning green or wet wood Also consider any changes in your burning routine Once you have ruled out any other possible causes for decline in performance you may inspect the combus tor and probe Wear
47. l Shield Requirements for Some Common Intrepid II Installations moov Fig 21 Parallel installation vertical chimney connector two wall shields Reduced clearances for both rear and side walls Wall shields may meet at corner if desired Shielding for con nector is centered behind connector onmo Hou Ww ou i ou ou Fig 22 Parallel installations with rear wall pass through two wall shields Reduced clearances for both rear and side walls Wall shields may meet at corner if desired Shielding for con nector is centered behind connector Wall pass through must comply with codes 1 25 mm 34 864 mm 48 1219 mm 35 889 mm A B C D i ST510 Fig 23 Corner installation vertical chimney connector with rear stove connector and wall shields Wall shields MUST meet at corner Connector heat shield extends 28 710mm above flue collar A 24 610mm diameter ceiling heat shield must surround the chimney and be suspended 1 25mm from ceiling 16 moo ST508a Fig 24 Parallel installation vertical chimney connector with stove connector and wall shields Maximum reduction for rear and side walls Wall shields may meet at corner A heat shield 24 610mm in diameter suspended 1 25mm below the ceil ing must surround the chimney onmo Hou Ww ou oi wou 40 30 44 ST509a Fig 25 Parallel installation with rear wall pass through
48. lets the smoke speed up before it must turn it leaves some pipe in the room for heat transfer and it gives you long term flexibility for installing a taller 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 smoke enough to cause draft and creosote problems Use double wall stove pipe for long runs Single Venting Each airtight stove requires its own flue If an airtight stove is vented to a flue that also serves an open fire place or a leakier stove it s easier for the chimney draft to pull air in through those channels than it is to pull air through the airtight and performance suffers Imagine a vacuum cleaner with a hole in the hose to see the ef fect here In some cases the other appliance can even cause a negative draft through the airtight and result in a dangerous draft reversal 25 Intrepid IT Woodburning Stove Creosote Creosote is a by product of slow wood burning It s an organic tar that can condense in the flue if it s dense in the smoke and slow moving and cools off to less than 290 F Condensed creosote is volatile and can generate chimney fires if it gets hot enough All the features that affect chimney draft also affect creosote condensation so use whatever combination of installa tion features and operational steps will encourage good draft and minimize creosote production Bec
49. llation 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 en vironment can be corrosive to the porcelain enamel finish These conditions can cause rusting of the cast iron beneath the porcelain enamel finish which will cause the porcelain enamel finish to flake off This warranty does not cover damage caused by a salt air or high humidity environment 8 CFM Corporation shall have no obligation to enhance or update any unit once manufactured IN NO EVENT SHALL CFM CORPORATION BE LIABLE FOR INCI DENTAL AND CONSEQUENTIAL DAMAGES ALL IMPLIED WAR RANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANT ABILITY AND FITNESS ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY THIS WARRANTY SUPERCEDES ALL OTHER ORAL OR WRITTEN WARRANTIES Some states do not allow the exclusion or limitations of incidential and consequential damages or limitations on how long an implied warranty lasts so the above limitations may not apply to you This warranty gives you specific rights and you may have other rights which vary from state to state How to Obtain Service If a defect is noted within the warranty period the customer should contact a Vermont Castings Authorized Dealer or CFM Corporation if the purchase was direct with the following information 1 Name address and telephone number of the purchaser Date of
50. llowing the plates to adjust gradually during three or four initial break in fires follow ing Steps 1 3 below Starting and Maintaining a Wood Fire Burn solid wood fuel only in the Intrepid Il and burn it directly on the grate Do not elevate the fuel Do not burn coal or other fuels The damper must be open when starting a fire or when refueling 1 Open the stove damper and open the primary air control fully Place several sheets of crumpled newspaper in the stove Do NOT use glossy advertisements or colored paper as they can poison the catalyst Place on the paper six or eight pieces of dry kindling split to a finger width size and on the kindling lay two or three larger sticks of split dry wood approximately 1 2 25 50mm in diameter Fig 39 N 2000966 Intrepid II Woodburning Stove Fig 39 Start the fire with newspaper and dry kindling DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE DO NOT BURN GARBAGE OR FLAMMA BLE FLUIDS SUCH AS GASOLINE NAPHTHA OR ENGINE OIL Also never use gasoline type lantern fuel kerosene charcoal lighter fluid or similar liquids to start or freshen up a fire Keep all such liquids well away from the Intrepid Il while it is in use 3 Light the newspaper and close the door Gradu ally build up the fire by adding a few 3 5 76 127 mm diameter splits If this is one of the first few break in fires let the fire burn brightly and then le
51. log to a fire Fig 36 You can open or even remove the front doors and place the optional Intrepid Il spark screen in the front opening for open fire viewing Fig 36 Top loading is the best way to add fuel during regular use Front loading is useful for kindling a fire 2000966 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 Your stove may be used as a fireplace with the front doors open or removed only when the spark screen is placed correctly in the opening to protect against the possibility of sparks and embers leaving your stove The test standard for your stove when it is operated in this mode is UL 737 Use only the Intrepid Il spark screen part 0136 with your Intrepid II Intrepid Il spark screens are available from your Vermont Castings Authorized Dealer To open the front doors insert the handle into the door latch stub and turn it to the left and up 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 the door Push on the door as you turn the handle to the right and down The doors will draw in slightly and the handle should offer some resistance as you turn it to the closed position Fig 37 Avoid striking the glass or slamming the doors to re
52. lue collar Attach the Griddle Handle Install the handle on the griddle Place the griddle upside down at the edge of a flat surface and assemble the handle as shown Fig 31 With the handle pointing 45 from its final position tighten the nut as far as possible with pliers Move the handle to its final position while still holding the nut with the pliers Take care not to overtighten as tab may snap Door Handle Holder Behind Leg Ash Pan Andiron Fig 32 The Intrepid Il controls 2000966 Intrepid IT Woodburning Stove Your Intrepid Ils Controls and What They Do The stove has two controls to regulate performance a primary air control supplies oxygen for the fire and a damper directs air flow within the stove to activate and deactivate the catalytic combustor Additional air for catalytic combustion is regulated auto matically and does not require operator control Symbols cast into the stove are reminders of the correct directions for opening and closing the controls In these directions left and right assume that you are facing the front of the stove A Single Air Control Regulates the Amount of Heat the Fire Will Produce and How Long it Will Burn The primary air control lever located at the right rear corner 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 fas
53. m the stove toward the chim ney The recommended maximum length of a horizontal run is 3 914mm The recommended total length of chimney connector is 8 2 4m In cathedral ceiling installations extend the prefabri cated chimney down to within 8 2 4m of the stove SAFETY NOTE ALWAYS WEAR GLOVES AND PRO TECTIVE EYEWEAR WHEN DRILLING CUTTING OR JOINING SECTIONS OF CHIMNEY CONNECTOR Double wall Chimney Connector The listing for the Intrepid Il for the U S and Canada includes use of double wall chimney connectors that have been tested and listed for use with solid fuel burn ing appliances by a recognized testing laboratory Information on assembling and installing double wall connector is provided by the manufacturer of the double wall pipe Follow the manufacturer s instructions exactly as you assemble the connector and attach it to the stove and chimney Using connectors and chim neys from the same manufacturer makes the assembly and installation straightforward NOTE For installations using double wall con nectors minimum clearances must conform to the listed clearances in the clearance chart on Page 14 Single wall Chimney Connector e Beginning at the flue collar of the stove assemble the chimney connector Insert the first crimped end into the stove s flue collar and keep each crimped end pointing toward the stove Using the holes in the flue collar as guides drill 1 8 3mm holes in the bottom o
54. m various settings Please read the Draft Management section beginning on Page 25 for more information on how installation features affect draft Most installations do not require a large amount of com bustion 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 22 Intrepid Il Control Settings Burn Rate Primary Air Control Low From far right to 1 3 the distance to left From 1 3 to 2 3 the distance to left High From 2 3 the distance to left to far left Before you start using the stove please read the Draft Management section starting on Page 25 to see how the features of your installation will affect the stove s performance You and the stove are parts of a system and other parts of the system have a strong effect on operation you may need to vary your firing technique to get the performance you want How to Build a Wood Fire and Keep it Going An Intrepid Il leaves the factory with the combustor installed Medium In the United States it is against the law to operate this wood heater in a manner inconsistent with operating instructions in this manual or if the catalyti
55. ment 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 ma sonry 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 2000966 Intrepid IT Woodburning Stove Prefabricated Chimneys A prefabricated metal chimney must be one tested and listed for use with solid fuel burning appliances to the High Temperature 650 C Standard ULC S 629 for Canada DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE Chimney Size An Intrepid II is approved for venting into a masonry chimney with a maximum flue size of 8 x 8 200 x 200mm and into a round flue size of 6 150mm It may not be vented into larger chimneys without a liner to reduce the effective flue size to 6 150mm diam eter Larger chimneys must have their flues relined for proper stove performance Accessories to make the connection between stainless steel chimney liners and your Intrepid Il are available through your local dealer Chimney Connector Guidelines Chimney connector is the double wall or single wall pipe that connects the stove t
56. mney must keep the smoke warm all the way to the outdoors Some chimneys do this better than others Here s a list of features and their effects Masonry Chimney Masonry is a traditional material for chimneys but it can perform poorly when it serves an airtight stove Masonry is a very effective heat sink it absorbs a lot of heat It can cool the smoke enough to diminish draft The bigger the chimney the longer it takes to warm up It s often very difficult to warm up an outdoor masonry chimney especially an oversized one and keep it warm enough to maintain an adequate draft Steel Chimney Most factory made steel chimneys have a layer of in sulation around the inner flue This insulation keeps the smoke warm The insulation is less dense than mason ry so the inner steel liner 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 a little heat release into the home An indoor chimney won t lose its heat to the outdoors so it takes less heat from the stove to get it warm and keep it warm 2000966 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 more is not better in fact it can
57. nd state codes The metal label permanently attached to the back of every Vermont Castings stove indicates the stove has been tested to current ULC standards by Canadian Standards Association CSA The test standards are ANSI UL 1482 and ANSI UL 737 for the United States and ULCS627 and CAN CSA B366 2 for Canada 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 in most cases will accept the label as evidence that the installation meets codes and can be approved However codes vary in different areas Before starting the installation review your plans with the local building authority You local dealer can provide any additional information needed For any unresolved installation issues refer to CSA CAN B365 Installation Code for Solid Fuel Burning Ap pliances and Equipment These standards are the basis for many national codes They are nationally recog nized 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 IN STALLATION INSTRUCTIONS MAY RESULT INA DANGEROUS SITUATION INCLUDING A CHIMNEY OR HOUSE FIRE FOLLOW ALL INSTRUCTIONS EXACTLY AND DO NOT ALLOW MAKESHIFT COM PROMISES TO ENDANGER PROPERTY AND PER SONAL SAFETY Outside Air In some modern super insulated homes there is
58. ney types A prefabricated double wall insu lated chimney A tile lined ma sonry chimney Fig 2 Standard chimney types 2000966 If you use an existing masonry chimney it must be inspected to ensure safe condition before the stove is installed Your local professional chimney sweep build ing 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 914mm above the highest point where it passes through a roof and at least 2 610mm higher than any portion of a building within 10 3m Fig 3 For proper draft and good performance any chimney used with an Intrepid Il should extend at least 16 5m above the flue collar of the stove 0To10 0T010 MEN 2 Min 3 Min Reference Point 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 or blockage Repair any defects before using the chimney with your stove Seal any unused openings in an existing masonry chim ney with masonry to the thickness of the chimney wall and repair the chimney liner Openings sealed with pie plates or wallpaper are a hazard seal them with mortar or refractory ce
59. not enough air for combustion because of insufficient air infiltration into the building Such air enters a home through unsealed cracks and openings Kitchen or bath exhaust fans 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 in the vicinity of the stove will usually alleviate the problem Another solution is to install a permanent outside air supply to the stove and or room In some areas in fact bringing air for combustion from outside the home directly to the air inlet of the stove is required for new construction An outside air supply is not affected by pressure varia tions within the house and improved stove perfor mance often results An Outside Air Adaptor Kit for the Intrepid Il is available from your local Vermont Castings dealer What Kind of Chimney to Use Your Intrepid Il must be connected to a code approved masonry chimney with a flue liner to a relined masonry chimney that meets local codes or to a prefabricated metal chimney that complies with the requirements for Type HT chimneys in the Standard for Chimneys Factory Built Residential Type and Building Heating Appliance UL 103 or the High Temperature 650 C Standard ULC S 629 for Canada Whatever kind you use the chimney and chimney connector must be in good condition and kept clean Figure 2 shows the two chim
60. nspect and clean the catalytic block and vacuum out the ash at the bottom of the back plate after removing the lower fireback Lightly clean the refrac tory assembly that houses the element Be careful not to damage the refractory material which is very fragile Inspect the secondary probe thermometer refer to Page 30 Check door and damper handles for tightness Ad just if needed Check heat shield screws Tighten as necessary Clean dust from the inner sides of bottom rear and connector heat shields Remove ashes from the ash pan and replace with moisture absorbing material such as cat litter to keep the stove interior dry Close the stove door to keep cats from using the litter Touch up the paint on black stoves 2000966 Intrepid IT Woodburning Stove Appendix Catalytic Combustor In any chemical reaction including the combustion process there are certain conditions which must be met before the reaction can take place For example a reaction may require a certain temperature or a certain concentration of the reactants the combustion gases and oxygen or a certain amount of time Catalysts though not changed themselves during the reaction have the ability to act at a molecular level to change these requirements In the Intrepid Il s secondary combustion chamber the catalyst reduces the tempera ture at which secondary combustion can start from the 1000 1200 F 540 650 C range to the 500 600 F 260
61. nstruction requirements and special clearances apply to installations into alcoves No stove or chimney connector heat shields are used in alcove installations ALCOVE INSTALLATION OF THE INTREPID II IS NOT PERMITTED IN CANADA Construction Requirements The following illustrations show noncombustible ceiling framing and maximum and minimum permitted dimen sions for alcove construction i Use recommended Max floor protection 7 16 Durock or equivalent spaced 1 off wood studs on noncombustible spacers CE It E ENA UES Fig 16 Alcove floor plan Sheetrock on front face butts to Durock or equivalent alcove lining 2000966 Intrepid IT Woodburning Stove Joist Shield plied by Chimney Manufacturer Existing Combustible Framing Metal studs support 7 16 Combustible 1 air gap top facing may and bottom overlap metal studs by only 1 ST505 on both sides and back wall Fig 19 Reflected ceiling plan 7 16 Durock or PA equivalent Ceiling sup port package extends 2 below Durock or equivalen ceiling sides and back wall NOTE From 62 to 65 must be covered by a noncom bustible Ciia E E Fig 20 Front view 65 minimum clearance form hearth to combustibles on front face Combustible facing may overlap metal studs by only 1 It should not extend below
62. o the chimney The chim ney is a masonry or prefabricated structure that enclos es the flue Chimney connectors are used only to make the connection from the stove to the chimney Double wall chimney connectors must be tested and listed for use with solid fuel burning appliances Sin gle wall chimney connectors should be made of 24 gauge or heavier steel and should be 6 150 mm in diameter Do not use galvanized connector it cannot withstand the high temperatures that can be reached by smoke and gases and may release toxic fumes under high heat If possible do not pass the chimney connector through a combustible wall or ceiling If passage through a com bustible wall is unavoidable refer to the section follow ing on Wall Pass Throughs Do not pass the chimney connector through an attic a closet or any similar con cealed space The whole connector should be exposed and accessible for inspection and cleaning In horizontal runs of single wall chimney connector without protective shields maintain a clearance of at least 26 660mm from the ceiling For information on reduced clearances using shields on single wall chim ney connector or using double wall connectors see the clearance chart on Page 10 Intrepid IT Woodburning Stove Keep the horizontal run of chimney connector as short and direct as possible with no more than two 90 turns Slope horizontal runs of connector upward 1 4 per foot 20mm per m going fro
63. oom 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 catalytic activity is initiated When first starting a fire maintain a medium to high firing rate for at least twenty minutes This ensures the stove catalyst and fuel are all stabilized at the proper operating tempera tures This may be long enough to warm the chimney well enough to support a good draft some installations may need more time Please read the Draft Manage ment information starting on Page 25 to see if your installation has features that may require more time to warm up Even though it is possible for the fire to get quite hot within a few minutes the combustor may stop working or the fire may go out if the fire is allowed to die down immediately as a result of closing the damper Once the combustor starts working heat generated 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 29 Conditioning Your Stove Cast iron is extremely strong but it can be broken with a sharp blow from a hammer or from the thermal shock of rapid and extreme temperature change The cast plates expand and contract with changes in temperature When you first begin using your Intrepid II minimize thermal stress by a
64. oor See page 24 for information on replacing the glass panel or its gasket If you need to change a gasket first obtain an appropri ate replacement from your Vermont Castings 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 the gaskets is the same regardless of the gasket location 1 Remove the existing gasket by grasping an end and pulling firmly 2 Use a wire brush or a screwdriver to clean the chan nel of any remaining cement or bits of gasket Re move stubborn deposits of cement with a cold chisel if necessary 3 Determine the correct length of the appropriate sized gasket by laying it out in the channel Allow an extra 1 2 25 50mm 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 unraveling 2000966 5 Lay an unbroken 1 8 3mm bead of gasket cement in the newly cleaned channel Starting at one end press the gasket into the channel Ensure a good joint where the gasket meets before trimming any excess Do not overlap the gasket ends or leave ends with ragged edges Press the gasketed part firmly against its normal mating surface to seat the gasket evenly in its chan nel For doors replace th
65. ory access panel in front of the catalytic block 5 Gently slide the catalytic block out of the refractory chamber 30 6 Remove the damper housing It is held in place by two weld screws and two chrome acorn nuts in the back of the stove Loosen the chrome acorn nuts and rotate the tabs to release the damper housing You may find it necessary to remove or loosen the thermostat cover to access the one of acorn nuts installed behind the cover 7 Remove the rear airtube in the back of the stove which is held in place with two phillips screws 8 Take out the secondary probe by removing the upper phillips screw and sliding the probe out of the hole 9 Lift the damaged refractory chamber up and out of the firebox 10 Reverse the procedure for installing the new refrac tory chamber Replace the Stove Gaskets as Needed The Intrepid uses fiberglass rope gaskets to make a tight seal between some parts With use particularly on those parts that move gaskets can become brittle and compressed and can begin to lose their effectiveness These will need periodic replacement The sizes of replaceable gasket are listed below along with their applications Gasket Diameter And the Parts it Seals 5 16 wire gasket The griddle to the stove top 5 16 The damper to the upper fire back the front doors to the stove front and the door halves to each other There is a flat die cut gasket between each glass panel and its d
66. ot use abrasive cleaners e Rinse the glass thoroughly e Dry the glass completely Glass Replacement Replace glass only with Part no 140 1156 right side and 140 1157 left side glass panels The glass panel rests on a cushion provided by a rope gasket part no 1203556 and is held in place by clips Fig 42 The glass is IR coated on one side which is marked THIS SIDE OUT 1 Remove the door from the stove and place it ona sturdy level work surface Use a towel to protect the porcelain enamel finish 2 Remove the retainer clips Two phillips head screws on each clip 3 Inspect the gasket If the window gasket is in good condition you can leave it in place If you replace it use only Part No 1203556 Be sure the channel around the window opening is clean and free of dust 2000966 4 Install the glass Lay the glass on the inner gasket with the coated side down toward the outside of the door Tighten the screws snugly but loose enough to allow for a little movement of the glass when the stove is in operation Overtightening can crack the glass immediately or cause it to crack if it is unable to expand when hot Fig 42 Door glass installation Check the Operation of the Primary Air Shutter The primary air shutter is visible from the back of the stove The shutter must open and close freely when you move the thermostat lever If it does not check for any obstruction or for
67. 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 18 460mm clearance all around the pipe Flush Mounted Sheet Metal Cover ST494a Fig 10 An approved wall pass through for Canada NOTE Do not vent your Intrepid Il 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 AN INTREPID II TO ANY AIR DISTRIBUTION DUCT OR SYSTEM Floor Protection A tremendous amount of heat radiates from the bottom plate of an Intrepid Il and the floor beneath requires two kinds of special protection Heat protection is provided by a Bottom Heat Shield part 0307 Spark and ember protection is provided by a floor pro tector which may be any noncombustible material For a new hearth we recommend a noncombustible floor protector such as 1 4 non asbestos mineral board or its equivalent or 24 gauge sheet metal If carpeting is present it must be removed before installation of the floor protector The floor protector may be covered with a noncombustible decorative material if desired When using brick tile or stone individual pieces must be mortared so sparks cannot fall through 2000966
68. position Peeling Peeling of the surface coat may occur if the catalytic element is frequently subjected to excessive tempera tures Follow the operating instructions carefully to avoid this type of damage Every CFM Corporation product is equipped with either a Corning Long Life or a Technical Glass Products Honeycomb The products are equivalent If for any reason you must ship your catalytic element remem ber its fragile nature Place the element in a plastic bag and package it with a generous amount of shock absorbing material 33 Intrepid IT Woodburning Stove CFM Corporation reserves the right to make changes in design materials specifications prices and discontinue colors and products at any time without notice Intrepid Il Woodburning Stove Model 1990 Item Description Part Number Item Description Part Number 1 Secondary Air Cover 1306762 12 3 8 16 x 1 Hex Bolt 1201456 2 Flue Collar See Chart Pg 36 13 Lower Fireback 1306704 3 Back Panel 1308662 15 Rear Air Tube 1308658 4 Damper Rod 1602523 16 Thermostat Cover 1306711 5 Damper Clip 1306725 17 Damper Handle Assembly 5004265 6 Damper 1306701 18 Friction Spring 1201846 7 Damper Housing 1306702 20 Thermostat Clip 1601408 8 Throat Hood 30001649 21 Ball Chain Fitting 2 1201972 9 Weld Screw 1201583 22 Ball Chain 1201960 10 Upper Fireback 1306703 22a Thermostat Assembly 5005506 11 Fire
69. rear heat shield insert to protect the area behind the flue collar 2 Chimney connector heat shields in an installation that goes through a combustible ceiling must extend to 1 25 mm below the ceiling heat shield which is 22 559 mm in diameter The ceiling heat shield should be 24 gauge or heavier sheet metal centered on the chimney connector and mounted on noncombustible spacers 3 Rear exit horizontal from flue collar directly back through wall 4 The ceiling heat shield required when chimney connector shields are used should meet the wall protector This will require trim ming the ceiling shield along the line of intersection with the wall protector 5 In top exit installations this clearance requires the use of the rear heat shield with the shield insert installed 14 2000966 Intrepid IT Woodburning Stove Intrepid II Clearance Diagrams See the chart on Page 14 for dimensions indicated by letter in the diagrams below Unprotected Surfaces Protected Surfaces Stove Installed Stove in Stove Installed Stove in Parallel to Wall Corner Parallel to Wall Corner Top Exit Installations no heat shields Va Va ry ria Al Va E gt pje F a Top Exit Installations rear heat shield and chimney connector heat shields or double wall connector V Va Va Va S e irin H A irida gt al A Rear Exit Installations rear heat shields 16 2000966 15 Intrepid IT Woodburning Stove Wal
70. red 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 re placement catalyst and the cost of labor necessary for its installation at the time of replacement For stove purchases made after June 30 1990 a third year 25 36 months of no charge replacement will be made when combus tor failure is due to thermal degradation of the substrate crumbling of ceramic material The customer must pay for any in home travel fees service charges or transportation costs for returning the stove to the Authorized Dealer Amount of Time Credit Towards Since Purchase Replacement Cost 0 24 months 100 25 36 months 50 37 48 months 30 49 60 months 20 61 72 months 10 Any replacement catalyst will be warranted under the terms of the catalyst warranty for the remaining term of the original warranty The purchaser must provide the following information in order to receive a replacement catalyst under the terms of this limited warranty 1 Name address and telephone number 2 Proof of original purchase date 3 Date of failure of catalyst 4 Any relevant information or circumstances regarding determina tion of failure 5 In addition the owner must return the failed catalyst 2000966 Exclusions amp Limitations 1 This warranty is transferable however proof of original r
71. s 3 75mm deep CAUTION The Intrepid II will be hot while in opera tion Keep children clothing and furniture away Contact may cause skin burns DO NOT OVERFIRE THIS HEATER Overfiring may cause a house fire or can result in permanent damage to the stove and to the catalytic combustor If any part of the Intrepid Il glows you are overfiring Ash Disposal Remove ash before it reaches the top of the ash pan Check the level at least once a day and before each re fueling If the ash is close to the top edge of the pan empty it according to this procedure 1 Open the damper 2 Open the front doors fully 3 Using stove gloves pull the ash pan out of the stove by its handle 4 Remove the ash pan and properly dispose of the ashes Be sure to keep the pan level during dispos al 5 Return the ash pan to the stove Empty the ash pan regularly typically every one to three days The frequency will vary depending on how you operate your Intrepid Il if you burn more wood at higher heat output settings ash will accumulate rapidly Remove ash frequently and place it outdoors in a metal container with a tight fitting lid Put the closed container of ash on a noncombustible floor or on the ground well away from all combustible materials pending final disposal If the ash is disposed of by burial in soil or otherwise locally dispersed keep it in the closed con tainer until all cinders have thoroughly cooled You can u
72. se 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 2000966 Intrepid IT 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 operation depends on natural unforced draft Natural draft occurs when the smoke is hotter and therefore lighter than the outdoor air at the top of the chimney The bigger the temperature difference the stronger the draft As the smoke rises from the chimney it provides suction or draw that pulls air into the stove for combustion A slow lazy fire with the stove s air inlet fully open indicates a weak draft A brisk fire supported only by air entering the stove through the normal inlet indicates a good draft The stove s air inlet is passive it regulates how much air can enter the stove but it doesn 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 chi
73. t it die out During the break in fires don t let the stove get hotter than 500 F 260 C as measured on an optional stove top thermometer Adjust the air control lever as neces sary to control the fire Some odor from the stove s hot metal the paint and the cement is normal for the first few fires NOTE Some chimneys need to be primed or warmed up before they will draw sufficiently to start a fire To correct this situation roll up a couple pieces of newspaper place them on top of the kindling and toward the back of the stove light them and close the doors This should heat the chimney enough to initiate a 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 Intrepid Il has been broken in previously using Steps 1 3 continue to build the fire gradually Add larger wood with a diameter of 3 4 76 102 mm Fig 40 23 Intrepid IT Woodburning Stove Fig 40 Add larger pieces of wood as the fire begins to burn well Continue adding split logs of this size to the briskly burning fire until there is a glowing ember bed at least 3 75mm deep A good ember bed is neces sary for proper functioning of the catalytic system and may take an hour or more to establish 5 Close
74. ter while less air prolongs the burn at a lower heat level For the greatest air supply and maximum heat output but the shortest burn time move the lever to the left For a fire that will last longer with less heat move the lever to the right You can set the lever anywhere in between the left and right extremes Fig 33 The Intrepid Il features an automatic thermostat to en sure an even heat output at any setting you select The thermostat senses the heating and cooling of the stove surface and adjusts the air shutter accordingly High Heat Low Heat Rear View Fig 33 The thermostat handle may be positioned anywhere between the two extremes for different heat levels 19 Intrepid IT Woodburning Stove A Damper Directs Air Flow Within the Stove The damper handle opens and closes the damper to direct air flow within the stove and is next to and to the right of the primary air control lever on the right side of the stove Fig 34 When the handle points to the floor the damper is open letting smoke pass directly into the chimney The damper must be open when starting or reviving a fire and whenever the griddle or doors are opened When the handle points to the front the damper is closed Smoke from the fire travels through the catalytic combustion system where it can burn further for greater efficiency before passing up the chimney The damper has no intermediate positions Figure 28 shows the handl
75. the damper when the griddle temperature reaches 450 F 230 C 6 Adjust the air control for your desired heat output Refuel While the Embers are Still Hot Reload the Intrepid Il while it is still hot and there are plenty of glowing embers to re kindle the fire Include some smaller pieces of wood in the new load of fuel to help the stove rebuild its operating temperature quickly Wear stove gloves and follow this procedure when you reload your stove 1 Open the thermostat lever 2 Open the damper 3 Check the ash level in the ash pan empty if neces sary and replace the pan 4 Open the griddle 5 Position the charcoal in the middle of the firebox Fig 41 then load wood smaller split pieces first Increase the amount of fuel you load into the stove as you become familiar with your stove and the heating needs of your home NOTE If the remaining charcoal bed is relatively thick and if your fuel is well seasoned it is possible to add fresh fuel smaller pieces first close the door and damper and reset the primary air thermostat for the desired heat output Do not break the charcoal into very small pieces or pound or compress the charcoal bed It is important that air can circulate under the wood for the fire to be quickly revived WARNING Operate your Intrepid Il only with the doors either fully open or fully closed 24 ST264a Fig 41 Add full size logs when the ember bed i
76. the design construction and climatic Fuel size type ce ceeececceeseeeeeeeeeeeees 16 410 mm logs location of your home Figures shown are based on EPA emissions rating g h catalytic 21 maximum fuel consumption obtained under laboratory Elo o la o PER TR NEN RR NR RERA Front or top conditions and on average efficiencies Chimney connector 6 152 mm diameter 2 These values are based on operation in building Chimney flue size 6 152 mm minimum code conforming homes under typical winter climate Flue exit position Reversible top or rear conditions in New England If your home is of nonstan Primary air Manual set thermostatically maintained dard construction e g unusually well insulated not in Secondary AM sa ssssss tcaccassnannssssesencactaniwons Self regulating sulated built underground etc or if you live in a more Ash handling system Removable ash pan severe or more temperate climate these figures may Glass panels High temperature ceramic not apply Since so many variables affect performance WIM ies DAE CR RDI a E 223 Ibs 101kg consult your Vermont Castings Authorized Dealer to Width leg to leg eessseesenenerrinersrern 21 545 mm determine realistic expectations for your home Depth leg to leg n e 13 350 mm 3 Under specific conditions used during EPA
77. ust be able to flow between the wall and the shield At least 50 of the bottom 1 25 mm of the shield should be open and the shield must be open at the top Fig 13 The wall shield for a stove must extend 10 254 mm above the top of the stove or a height of 35 890 mm The wall shield for the chimney connector must be 36 914 mm wide centered behind the connector for installations that use an approved prefabricated chim ney to pass through the ceiling the chimney connector shield used with single wall connector must stop 1 25mm below the ceiling 2000966 Intrepid IT Woodburning Stove 7 Air Flow L Stud Wall Framing Wall Shield o No Shield Metal Spacer Noncombustible spacers and fasteners E t Drywall AL Air Flow Fig 13 Approved wall shield construction Chimney Connector Clearance Reductions Chimney connector clearances may be reduced by using heat shields on single wall connector or by using double wall connector One of these methods should be used whenever the rear heat shield is used in top exit installations or in any other situation when it is neces sary to protect nearby combustibles from the heat of the chimney connector The ceiling above horizontal runs of chimney connector must be protected as well if the clearance is inadequate Refer to the Clearance Charts In top exiting installations in which the single wall connector extends
78. y and the chimney connector The top of such adapt ers attaches directly to the chimney or to the chimney s ceiling support package while the bottom of the adap tor is screwed to the chimney connector These adapters are designed so the top end will fit outside the inner wall of the chimney and the bottom end will fit inside the first section of chimney connector When assembled in this way any soot or creosote fall ing from the inner walls of the chimney will stay inside the chimney connector Securing the Single wall Connector to a Masonry Chimney For masonry chimneys both freestanding and fireplace chimneys may be used for installation of your Intrepid II Thimble Sleeve Chimney Connector Keep sleeve end flush with flue tile Fig 5 The thimble made of either ceramic or metal must be cemented securely in place Freestanding Chimney Installations If the chimney connector must pass through a combus tible wall to reach the chimney follow the recommenda tions in the Wall Pass through section that follows 2000966 The opening through the chimney wall to the flue the breach must be lined with either a ceramic or metal cylinder called the thimble which is cemented firmly in place The fit must be snug and the joint between the thimble and the chimney wall must be cemented Fig 6 A special piece called the thimble sleeve slightly smaller in diameter than standard connector an
79. ytic element is deactivated or removed Under normal operating conditions the catalytic element should remain active for two to six years depending on the amount of wood burned However it is important to monitor the combustor periodically to ensure that it is functioning properly as well as to determine when it needs to be replaced A probe thermostat passing through the back of the stove into the catalytic combustion chamber automati cally regulates the catalytic combustion air supply Deterioration of the probe may result in decreased catalytic combustor performance A poorly functioning catalytic combustion system will result in a loss of heating efficiency and an increase in creosote and emissions The combustor should be visually inspected in place for fly ash accumulation and physical damage three times per year Do not remove the combustor unless a more detailed inspection is warranted because of diminished performance as outlined below or to inspect the probe thermostat The refractory package that houses the catalytic com bustor should be inspected annually for a buildup of flay ash and cleaned if necessary This may be done during examination of the combustor The probe thermostat should be inspected annually or more often if decreased catalytic combustion perfor mance is not due to a defective combustor When to Suspect a Combustion System Problem The best way to evaluate the performance of your In trep

Vermont Casting 1990 Indoor Fireplace User Manual

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