Vermont Casting 1655, 1656, 1657, 1658, 1659 Stove User Manual
Contents
1. 5 Glass Door Left 1408630 6 Glass Retainer 30000474 7 Pan hd PH 10 24 x 3 8 Z 1200983 8 Hinge Strap Door Right Hand 30001222 9 Hinge Strap Door Left Hand 30001223 10 Pin Long Door 1600547 11 CS Hex Hd 1 4 20 x 3 8 Gr 5 Blk 1201337 12 Washer Flat 1 4 Z 1202474 Fallaway Handle Complete 0004342 14 Handle Ceramic 1600620 15 Oval Head Slotted Screw 1 4 20 x 3 375 1201294 Item Description Part Number 16 Griddle Opener Insert Door Handle 1600650 1 Door Right See Chart Pg 25 17 Door Handle Assy w set screw 30001759 2 Door Left See Chart Pg 25 18 SS Soc 7 16 20X1 Cup Pt Blk 1200334 3 Gasket Fiberglas 3 16 4nd Blk 1203556 4 Glass Door Right 1408629 Shell Enamel Parts Madison Model 1655 Top Classic 30000817 30001213 3001203 30001193 30001183 Left Side 30000797 30001211 30001201 30001191 30001181 Right Side 30000796 30001210 30001200 30001190 30001180 Flue Collar 7000969 2310969 30001258 7020969 2320969 Front 30000808 30001212 30001202 30001192 30001182 Ashlip 30000815 30001214 30001204 30001194 30001184 Left Door Subassembly 30001173 30001241 30001237 30001233 30001229 Left Door Only 30000810 30001216 30001206 30001196 30001186 Right Door Subassembly 30001172 30001240 30001236 30001232 300012282. Right Door Only 30000809 30001215 30001205 30001195 30001185 Single Leg 30000816 30001218 30001208 30001198 30001188 Load Door 30000811 30001217 30001207 30001197 30001187 25 Vermont Castings Madison 26 Warranty Limited 3 Year Warranty The Vermont Castings Majestic Products Company warrants that your Madison will be free of defects in material and workmanship for a period of three years from the date you receive it except that the handles glass door panel fireback arch inserts cement and gasketing shall be warranted as described below The Vermont Castings Majestic Products Company will repair or replace at its option any part found to be defective when the Madison is returned with shipping charges prepaid to an Authorized Dealer The customer must pay for any Authorized Dealer in home travel fees service charges or transportation costs for returning the stove to the Authorized Dealer It is the dealer s option whether the repair will be done in the dealer s shop or in the customer s home 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 Madison or part thereof that is 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
3. Sheet Steel gr273 Supports Fig 8 Wall Pass through using factory built insulated chimney section Vermont Castings Madison Placing a chimney connector pipe inside a section of 9 230 mm diameter solid insulated factory built chimney with two inches of air space between the chimney section and combustibles Fig 10 Canadian Requirements In Canada the Canadian Standards Association has established specific guidelines regarding wall pass though design Figure 11 shows one approved method in which all combustible material in the wall is cut away to provide the required 18 460 mm clearance around 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 noncombus tible spacers at least 1 25 mm clear of the wall Your local dealer or your local building inspector can provide details of other approved methods of passing a chimney connector through a combustible wall In Canada this type of installation must conform to CAN CSA B365 Installation Code for Solid Fuel Burning Appliances and Equipment Chimney clearance to sheet steel supports and combustibles 2 51mm Min Steel Thimble with two 1 25mm Ventilated Channels Glass Fiber Insulation 24 ga Sheet Steel Supports Chimney Flue Masonry Chimney constructed to NFPA 211 Fig 9 Wall Pass through using si
4. The Madison Woodburning Stove ZEE Models 1655 1656 1657 1658 1659 aa Homeowner s Installation and Operating Manual For use in the United States and Canada SAFETY NOTICE IF THIS APPLIANCE IS NOT PROPERLY INSTALLED OPERATED AND MAINTAINED A HOUSE FIRE MAY RESULT TO REDUCE THE RISK OF FIRE FOLLOW THE INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE BODILY INJURY OR EVEN DEATH CONTACT LOCAL BUILDING OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA Do Not Discard This Manual Retain for Future Use 30001453 10 02 Rev 1 Vermont Castings Madison Introduction Thank you for choosing a Vermont Castings Madison to meet your heating needs We re confident you will find the Madison to be an effective woodburning heater incorporating modern non catalytic combustion technology with the classic aesthetic appeal of its Vermont Castings lineage The Madison achieves high efficiency through precisely calibrated delivery of primary and secondary air into a refractory insulated firebox Properly operated and maintained according to the guidelines in this manual your Madison will provide safe dependable and economical heating for years to come The Madison Model 1655 Series has been tested and is listed by Canadian Standards Association CSA The test standards are ANSI UL 1482 for the United States a
5. Top exit heat shield on stove double wall chimney connector Rear exit no heat shields Rear exit heat shields Without Connector Heat Shields 19 483 mm 13 330 mm With Connector Heat Shields UNPROTECTED SURFACE Horizontal PROTECTED SURFACE Horizontal Single wall Connector 23 584 mm 23 584 mm FRONT CLEARANCE ALL INSTALLATIONS TO COMBUSTIBLES 48 1220mm A distance of 48 must be maintained between the stove and moveable combustible items such as drying clothes furniture firewood etc 12 Vermont Castings Madison Madison 1655 Series Clearance Diagram Top Exit Bottom Heat Shield always used floor protection minimum 18 457mm in front UNPROTECTED SURFACES PROTECTED SURFACES Stove Installed Stove in Corner Stove Installed Stove in Corner Parallel to Wall Parallel to Wall Top Exit Installations no heat shields Vermont Castings Madison Madison 1655 Series Clearance Diagram Rear Exit Installations Bottom Heat Shield floor protection minimum 18 457mm in front UNPROTECTED SURFACES PROTECTED SURFACES Stove Installed A Stove Installed Stove in Corner Stove in Corner Parallel to Wall Parallel to Wall Rear Exit Installations no heat shields Rear Exit Installations heat shields gt S c 14 Assembly You will need the following tools to assemble the Madi so
6. The larger the chimney in total mass the longer it will take to warm up Cold masonry will actually cool exhaust gases enough to diminish draft strength This problem is compounded if the chimney is located outside the home or if the chimney flue has a cross sectional size larger than the stove outlet Steel Chimney Most factory made Class A steel chimneys have a layer of insulation around the inner flue This insulation keeps the smoke warm and protects the surrounding structure from the high flue temperatures Because the insulation is less dense than masonry the inner steel liner warms up more quickly than a masonry chimney 22 Although steel chimneys are not as attractive as their masonry counterparts they are very durable and generally outperform masonry Inside Outside Location Because the chimney s function is to keep the smoke warm itis best to locate it inside the house This location uses the house as insulation for the flue and allows some radiant heat release from the flue into the home Since an interior chimney does not continuously lose its heat to the outdoors it takes less heat from the stove to get it warm and keep it warm The flue size for a controlled combustion appliance should be based on the cross sectional volume of the stove flue outlet In this case more is definitely not better Hot gases lose heat through expansion if a stove with a six inch flue collar 28 square inch area is vented i
7. burning treated wood saltwater driftwood 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 Majestic Products Company Authorized Dealer 5 Damage to the unit while in transit is not covered by this warranty but is subject to claim against the common carrier Contact the Authorized Dealer from whom you purchased your Madison Do not operate the Madison as this may negate the ability to process the claim with the carrier 6 Claims are not valid where the installation does not conform to local building and fire codes or in their absence to the recommendations in the Owner s Guide 7 The salt air environment of coastal areas or a high humidity environment can be corrosive to the porcelain enamel finish These conditions can cause rusting of the cast iron beneath the porcelain enamel 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 The Vermont Castings Majestic Products Company shall have no legal obligation to enhance or update any unit once manufactured IN NO EVENT SHALL THE VERMONT CASTINGS MAJESTIC PRODUCTS COMPANY BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES ALL IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY THIS WARRANTY SUPERSEDES ALL O
8. or low Symptoms of too much draft include an uncontrollable burn or a glowing red stove part A sign of inadequate draft is smoke leaking into the room through the stove or chimney connector joints low heat and dirty glass In newer homes that are well insulated and weather tight poor draft may result from insufficient air in the house In such cases a slightly opened window near the stove on the windward side of the house will provide the fresh air needed 15 Vermont Castings Madison A more effective option for delivering ample 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 The optional Madison Outside Air Adaptor is available from your dealer When you first begin using the stove pay attention to 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 from various settings 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 Madison Control Settings Burn Rate Primary Air Control Shutter Position High Left most position Medium Fully Op
9. wood with a diameter of 3 4 75 100 mm Continue adding split logs of this size to the briskly burning fire until there is a glowing ember bed at least 2 50 mm deep A good ember bed is necessary for proper functioning and may take up to an hour to establish Step 5 Adjust the thermostatic air control for the desired heat output Refuel While the Embers Are Still Hot Reload the Madison 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 return to its operating temperature quickly Wear stove gloves and follow this procedure when you reload your stove Step 1 Open the thermostat lever Step 2 Open the doors and check the ash level in the ash pan If necessary dispose of the ashes and replace the pan Step 3 Use a fireplace tool to break up the charcoal and direct ash through the grate Pull the charcoal from the back to the front Step 4 Load wood smaller split pieces first Close the doors Ideal performance will be achieved by operating with the air control set in the maximum HIGH positon for several minutes after refueling Reset the primary air control for the desired heat output after the fire is re established Vermont Castings Madison 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 Using stove gloves pull the
10. Flue Using a section of double wall chimney with a 9 230 mm clearance to combustibles Fig 8 Placing a chimney connector pipe inside a steel double wall ventilated thimble which is then sepa rated from combustibles by 6 150 mm of fiber glass insulating material Fig 9 Vermont Castings Madison Chimney Connector Heat Shield KNote clearance requirement on pages 12 13 Fig 6 If the clearance between the chimney connector and either the ceiling or the mantel is inadequate a protective heat shield is required Fire clay liner Min 2 51mm Chimney clearance to brick and combustibles Masonry Chimney constructed to NFPA 211 connector Chimney Flue Fire clay liner A Minimum 12 305 mm brick construction between liner and combustible framing materials Fig 7 Masonry Wall Pass through with single wall chimney connector Solid insulated listed factory built chimney length set flush with flue i Min 9 230mm Chimney Connector x Space 24 ga Sheet Non soluble Steel refractory cement Supports Masonry Chimney constructed to NFPA 211 gt
11. ash pan out of the stove by its handle Remove the ash pan and properly dispose of the ashes Be sure to keep the pan level during disposal Empty the ash pan regularly typically every one to three days The frequency will vary depending on how you operate your Madison if you burn more wood at higher heat output settings ash will accumulate rapidly Dispose of ashes into a metal container with a tight fitting lid Kept outdoors 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 container until all cinders have thoroughly cooled You can use wood ash as a garden fertilizer CAUTION Never use your household or shop vacuum cleaner to remove ash from the stove always remove and dispose of the ash properly CAUTION AVOID SLAMMING THE STOVE DOOR OR STRIKING THE GLASS PANEL DO NOT OPERATE THE STOVE WITH THE GLASS PANEL MISSING DAMAGED OR BROKEN DO NOT INSTALL SUBSTITUTE MATERIALS SEE MAINTENANCE SECTION FOR REPLACEMENT INSTRUCTIONS Smoke Detectors The use of smoke detectors throughout the home is strongly advised if not required by building codes or insurance regulations Itis a good idea to install a smoke detector in the living areas and each bedroom You may not however wish to install a detector in the immediate vicinity of the
12. below along with their applications Gasket Size 3 8 Fiberglass Door Gasket 1203589 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 Step 1 Remove the existing gasket by grasping an end and pulling firmly Step 2 Use a wire brush or a screwdriver to clean the channel of any remaining cement or bits of gasket Remove stubborn deposits of cement with a cold chisel if necessary Step 3 Determine the correct length of the appropri ate sized gasket by laying it out in the channel Allow an extra 1 2 25 50 mm and mark the spot to be cut Step 4 Remove the gasket from the channel place it on a wood cutting surface and cut it at the marked spot with a utility knife Twist the ends slightly to discourage the gasket from unraveling Step 5 Lay an unbroken 1 8 3 mm bead of gasket cement in the newly cleaned channel Step 6 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 Step 7 Press the gasketed part firmly against its normal mating surface to seat the gasket evenly in its channel Close and latch the door to do this close the door on a piece of waxed paper to keep the cement from migrating onto the non gasketed part or mask other parts Step 8 Clean excess c
13. facing may overlap metal studs by only 1 It should not extend below the height of the noncombustible ceiling Fig 20 Alcove side section 11 Vermont Castings Madison Madison 1655 Series Clearance Chart Use the chart below together with the diagrams on the next page to determine the minimum clearance required for your particular installation In any case it is always advisable to locate the stove as far away from walls as pos sible in order to take full advantage of the radiant properties of cast iron Stove clearances are measured between the cast iron Top Plate of the stove and the combustible surface Note that the cast iron back on the Madison protrudes 5 130 mm out from the stovetop and will therefore be closer to the wall than the top of the stove Chimney Connector clearances are measured between the connector surface and the combustible surface For Douible wall Chimney Connector use the manufacturer s listed clearance specification Use NFPA 211 default clearance or manufacturer s installation specifications for those configurations not tested UNPROTECTED SURFACES PROTECTED SURFACES Corner Corner Parallel Installation Parallel Installation Installation STOVE CLEARANCE Installation Side Rear Corner Side Rear Corner Top exit no heat shields Top exit heat shields on stove no shields on single wall connector Top exit heat shield on stove heat shield on single wall connector
14. heat shield near a wall with no heat shield The least clearance is re quired when both the stove and the wall have heat shields Reducing a stove clearance may require installation of a listed heat shield on the chimney connector as well Clearances may be reduced only by means approved by the regulatory authority or in accordance with the clearances listed in this manual Vermont Castings Madison Wall Shields Wall shields should be constructed of 24 gauge or heavier sheet metal or another noncombustible material such as 1 2 13 mm insulation board Fig 14 or common brick laid on flat with the 31 2 90 mm side down Shields must be spaced out from the combustible surface 1 25 mm on noncombustible spacers The spacers should not be directly behind the stove or chimney connector Air must be able to flow between the wall and the shield At least 5096 of the bottom 1 25 mm of the shield should be open and the shield must be open at the top C Air flow Stud wall framing Wall shield Bc N Shield Noncombustible spacers and fasteners i Metal Spacer Drywall Air flow ST248a Fig 14 Approved Wall shield construction The following examples of wall shield construction illustrate common designs used to safely achieve reduced clearances to combustible wall materials Parallel installation vertical chimney connector two wall shields Fig 15 Reduc
15. lets the smoke speed up before it must turn keeps some pipe in the room for heat transfer and allows long term flexibility for installing a different appliance without relocating the thimble There should be no more than eight feet of single wall stove pipe between the stove and a chim ney Longer runs can cool the smoke enough to cause draft and creosote problems Use double wall stove pipe for longer runs Single Venting Your stove requires a dedicated flue Do not connect the stove to a flue used by any other appliance Chimney draft is a natural form of energy and follows the path of least resistance If the stove is vented to a flue that also serves an open fireplace or another appliance the draft will also pull air in through those avenues The additional air flow will lower flue tem peratures reduce draft strength and promote creosote development overall stove performance will suffer The effect is similar to that of a vacuum cleaner with a hole in the hose In some extreme instances the other appliance can even impose a negative draft and result in a dangerous draft reversal Even the best stove installation will not perform well if poor fuel is used If available always use hardwood that has been air dried Seasoned 12 18 months Softwood burns more rapidly than hardwood and has a high resin content conducive to creosote production Decayed wood of any type has little heat value and should not be used All u
16. stove Depending on the sensitivity of the unit the alarm can be set off while you are tending the fire or emptying the ashes If you install a detector in the same room locate it as far away from the stove as possible 19 Vermont Castings Madison 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 Madison 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 Vermont Castings 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 accumulates on the glass surface should be removed regularly to prevent etching Follow this procedure to clean the glass Be sure the glass is completely cool Clean the glass with water or a cleaner made especially for this purpose Do not use abrasive cleaners Rin
17. warranty or six 6 months whichever is longer Limited 1 Year Warranty The following parts of the Madison are warranted to be free of defects in material and workmanship for a period of one year from the date you receive it These parts are the handles glass door panel all firebricks cement and gasketing Any of these items found to be defective will be repaired or replaced at no charge upon the return of said part to an Authorized Dealer with postage prepaid Exclusions amp Limitations 1 This warranty is transferable however proof of original retail purchase 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 stove plates to glow red Overfiring can later be identified by warped plates and areas where the paint pigment has burned off Overfiring in enamel stoves is identified by bubbling cracking chipping and discoloration of the porcelain enamel finish The Vermont Castings Majestic Products Company offers no warranty on chipping of enamel surfaces Inspect your stove for any damage to the enamel prior to accepting it 3 This warranty does not cover misuse of the Madison as described in the Owner s Guide nor does it cover a Madison which has been modified unless authorized by a Vermont Castings Majestic Products Company representative in writing This warranty does not cover damage caused by
18. 1601488 9 Firebrick 4 1601103 20 Pan Hd PH 1 4 20 x 3 8 1200993 10 Bottom Inner 30000799 21 Grate 30001445 11 Primary Air Flap 30000778 22 Secondary Manifold Right 30000801 N A Madison Woodburning Stove Model 1655 continued Item Description Part Number 23 Brick Support 30000804 24 Secondary Air Tube Rear 30001493 25 Secondary Air Tube Middle 30001494 26 Secondary Air Tube Front 30001495 27 Friction Spring 1201846 28 Leveller Bit Hx Hd 1 4 20 x 1 Z 1201745 29 Washer 1 4 pl 7 8 o d 1202470 30 Pan Hd PH 10 24 x 1 blk 1200907 31 Nut Square 1 4 20 Pln 1203329 32 Insert Door Handle Holder 1600600 33 Latch Door 1408628 34 Pan Hd 10 24 x 1 4 Z 1200996 35 FI Hd PH 1 4 20 x 1 Blk 1200830 36 Front Handle w Shift 5004245 37 Pawl Assy Ash Door 5004025 38 CS Hex Hd 1 4 20 x 5 8 Blk 1201372 39 FI Hd Allen 1 4 20 x 3 4 BIk 30001166 40 Ashpan Assy 30001167 41 Cover Plate Primary Air 30001393 42 Heat Shield Flue Collar 30001456 43 Thermostat Sub Assy 30001390 44 Thermostat Cover 30001414 45 FI Hd PH 1 4 20 x 2 50 Blk 30001444 Maintenance Kits Available from your Dealer 1884 Gasket Kit 1876 Thermostat Kit 3427 Gasket Kit for Glass Madison Doors Exploded View Madison Doors Exploded View Vermont Castings Madison Item Description Part Number
19. If a significant layer of creosote has accumulated 1 8 3 mm or more remove it to reduce the risk of a chimney fire Clean the chimney using a brush the same size and shape as the flue liner Flexible fiberglass rods are used to run the brush up and down the liner causing any deposits to fall to the bottom of the chimney where they can be removed through the clean out door The chimney connector should be cleaned by disconnecting the sections taking them outside and removing any deposits with a stiff wire brush Reinstall the connector sections after cleaning being sure to secure the 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 Vermont Castings Madison Annual Maintenance Perform a thorough cleaning inspection and repair each Spring at the end of the heating season Thoroughly clean the chimney and chimney connec tor Inspect the chimney for damage and deterioration Replace weak sections of prefabricated chimney Have a mason make repairs to a masonry chimney Inspect the chimney connector and replace any damaged sections Clean ash debris from under the primary air plate See procedure below Check gasketing for wear or compression and replace if necessary A paper test will guide you on this Close and lock the door on a slip of paper and then try to pu
20. THER ORAL OR WRITTEN WARRANTIES Some states do not allow the exclusion or limitations of incidental and consequential damages or limitations on how long an implied warranty lasts so the above limitations may not apply to you This warranty gives you specific rights and you may have other rights which vary from state to state How To Obtain Service If a defect is noted within the warranty period the customer should contact a Vermont Castings Authorized Dealer with the following information 1 Name address and telephone number of the purchaser 2 Date of purchase 3 Serial number from the label on the back of the stove 4 Nature of the defect or damage 5 Any relevant information or circumstances i e installation mode of operation when defect was noted A warranty claim will then start in process The Vermont Castings Majestic Products Company reserves the right to withhold final approval of a warranty claim pending a visual inspection of the defect by authorized representatives Vermont Castings Majestic Products 410 Admiral Blvd Mississauga Ontario Canada L5T 2N6 905 670 7885 www vermontcastings com Vermont Castings Majestic Products
21. THIS HEATER OVERFIRING MAY CAUSE A HOUSE FIRE OR CAN RESULT IN PERMANENT DAMAGE TO THE STOVE IF ANY PART OF THE STOVE GLOWS YOU ARE OVERFIRING The Madison features an automatic thermostat to ensure an even heat output at any manual setting you select As the fuel burns the thermostat reacts to the heat radiating from the stove surface and consequently adjusts the air shutter attached to it As the fire intensity and heat output builds the thermostat slowly closes the air shutter thereby restricting incoming combustion air As the fire intensity then wanes and heat output lessens the thermostat responds and gradually opens the air shutter which allows more combustion air to again enliven the fire This ebb and flow action functions continuously to prolong the burn cycle until the fuelbed is exhausted Vermont Castings Madison Another separate supply of oxygen is delivered to the upper area of the firebox to support combustion of gases released from the main fuel bed This Second ary Air enters the stove through two unrestricted inlets and is heated while passing through separate channels before being delivered through three stainless steel multi ported tubes located at the top of the firebox Burn Only High Quality Wood THE MADISON IS DESIGNED TO BURN NATURAL WOOD ONLY DO NOT BURN ANY OTHER FUELS You will enjoy the best results when burning wood that has been adequately air dried Avoid burning green wood that h
22. ances from nearby combustible material Note Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney connector are available to simplify assembly Slip pipes eliminate the need to cut individual connector sections Consult your local dealer about these special connector sections 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 Securing the Single wall Connector to a Prefabricated Chimney Follow the installation instructions of the chimney manufacturer exactly Special adaptors are available from your local dealer to make the connection between the prefabri cated chimney and the chimney connector The top of such adaptors attach directly to the chimney or to the chimney s ceiling support package The bottom of the adaptor is secured to the chimney connector The adaptor forms a union between the chimney and chimney connector that ensures any soot or creosote falling from the inner walls of the chimney will stay inside the chimney connector Securing the Single wall Connector to a Masonry Chimney The Madison may be connected to either a freestand ing masonry chimney or to a fireplace masonry chimney Freestanding Installations If the chimney connector must pass through a com bustible wall to reach the chimney follow the recom mendations for Wall Pass T
23. as not been properly seasoned The wood should be no longer than 18 460 mm in length however you will find that shorter wood lengths ease refueling and promote the most efficient combus tion 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 For areas that do not have a supply of hardwood commonly burned softwoods include tamarack yellow pine white pine Eastern red cedar fir and redwood These too should be properly dried Keep wood a safe distance from the heater and keep it out of the areas around the heater used for refueling and ash removal Use the Air Control Setting that Works Best for You No single air control setting will be appropriate for every situation Settings 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 the stove up through the chimney Draft is affected by such things as the length type and location of the chimney local geography nearby obstructions and other factors Too much draft may cause excessive temperatures in the Madison and could even damage it On the other hand too little draft can cause backpuffing into the room and or the plugging of the chimney How do you know if your draft is excessively high
24. avier steel and should be 6 150 mm in diameter Do not use galvanized chimney connector it cannot withstand the high temperatures that can be reached by smoke and exhaust 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 combustible wall is unavoidable refer to the recommendations in the section following on Wall Pass throughs Do not pass the connector through an attic a closet or any similar concealed space The whole chimney connector should be exposed and accessible for inspection and cleaning Install the single wall chimney connector not less than 23 585 mm from the ceiling Keep it as short and direct as possible with no more than two 90 degree turns If possible use 45 degree elbows Slope horizontal runs of connectors upward 1 4 per foot 20 mm per meter going from the stove toward the chimney The recommended maximum length of a horizontal run is 3 feet 1 meter and the total length of chimney connector should be no longer than 8 feet 2 5 meters In cathedral ceiling installations extend the prefab ricated chimney downward to within 8 feet 2 5 meters of the stove Flue gas direction Fig 4 Chimney connector SAFETY NOTE ALWAYS WEAR GLOVES AND PROTECTIVE EYEWEAR WHEN DRILLING CUTTING OR JOINING CHIMNEY CONNECTOR SECTIONS Vermont Castings Madison Double wall Chimney Connec
25. d to the stove bottom using the same phillips head screw previously re moved The corners of the shield will butt against the cast leg locators at each corner of the stove bottom 1 4 20 x 1 2 Pan Head Screw Fig 25 Attach the Bottom Heat Shield to the boss in the center of the stove bottom Storing the Handle Use the removable handle to open or close the doors After using it remove the handle so it will not get hot Store the handle in the handle holder installed behind the right front leg Fig 25a Bottom Heat Shield Door Handle Holder Leg Bolt and Washer Fig 25a Handle holder and heat shield positions When Installing Rear Heat Shield Models 1655 1656 1567 1658 1659 only Remove and retain the factory installed flue collar heat shield Loosen two phillips screws on either side of the flue collar approximately one turn each Slide heat shield away from the flue collar then push flue collar forward and retighten phillips screws 15 Vermont Castings Madison Install the Outside Air Adaptor The optional 1891 Outside Air Adaptor provides a collar to which a 3 inch diameter air duct may be attached directly to the air inlet area at the back of the stove This option can be installed in two different configurations with Rear Heat Shield 1893 and without the heat shield With Rear Heat Shield 1 Engage the Adaptor against the Air inlet opening in the Rear Heat Shield Align clearance holes i
26. ed clearances for both rear and side walls Wall shields may meet at corner if desired Shielding for connector is centered behind connector Parallel installation with rear wall pass through two wall shields Fig 16 Reduced clearances for both rear and side walls Wall shields may meet at corner if desired Shielding for connector is centered behind connector Wall pass through must comply with codes Corner installation vertical chimney connector two wall shields Fig 17 Reduced side clearances Wall shields MUST meet at corner Parallel installation with rear exit rear wall pass through rear wall shield Fig 18 Reduced clearances for rear wall Shielding for connector is centered behind connector Wall pass through must comply with codes 10 A 48 1219mm B Max C C 1 25 mm Fig 15 Parallel installation vertical chimney connector two wall shields A 48 1219 mm B 48 1219 mm C 1 25 mm Fig 16 Parallel installation with rear wall pass through two wall shields A 48 1219 mm B Max C C 1 25 mm Fig 17 Corner installation vertical chimney connector two wall shields A 48 1219 mm B 48 1219 mm C 1 25 mm Fig 18 Parallel installation rear wall pass through rear wall shield Vermont Castings Madison Alcove Installations Because of their restricted air flow and heat retenti
27. ement from around the chan nel Let the cement that holds the new gasket dry thoroughly The Chimney System Creosote Your Madison is designed to reduce creosote buildup significantly However regular chimney inspection and maintenance must still be performed For safety good stove performance and to protect your chimney and chimney connector inspect your chimney and chimney connector on a regular schedule Clean the system if necessary Failure to keep the chimney and connector system clean can result in a serious chimney fire When wood is burned slowly it produces tar organic vapors and moisture that combine to form creosote The creosote vapors condense in the relatively cool chimney flue As a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire within the flue system that can damage the chim ney and overheat adjacent combustible material If you do have a chimney fire promptly Close the thermostat lever Get everyone out of the house 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 viewing access
28. en Half Open Fully Closed Low Right most position Before you begin using the stove please read the Appendix on Draft Management starting on page 22 to learn how the characteristics of your particular installation will affect your stove s performance You and the stove are parts of a system other parts of the system have a strong effect on performance You may need to vary your firing technique to get the results you desire Starting and Maintaining a Fire 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 Madison minimize thermal stress by allowing the plates to adjust gradually during three or four initial break in fires following Steps 1 3 BURN SOLID WOOD FUEL ONLY AND BURNIT DIRECTLY ON THE GRATE DO NOT ELEVATE THE FUEL DO NOT BURN COAL OR OTHER FUELS WARNING OPERATE THIS STOVE ONLY WITH THE DOORS FULLY CLOSED The Primary Air Inlet must be open when starting a fire or when refueling 18 Step 1 Open the primary air control fully Lever at left most position Step 2 Place several sheets of crumpled newspaper in the stove Avoid using glossy or colored paper as these burn poorly At the front of the firebox place on the paper six or eight pieces of dry kindling split to a finge
29. ey The greater the temperature difference the stronger the draft As the hot exhaust gas rises out of the chimney it generates suction that draws air into the stove for combustion A slow lazy fire with the stove s air inlets fully open indicates a weak draft A brisk fire supported only by air entering the stove through the normal inlets indicates a good draft The inlets are passive they regulate how much air can enter the stove but they do not move air into it The efficiency of a modern woodburning appli ance in which the amount of air available for combus tion is regulated depends on the chimney to keep exhaust gases warm all the way outdoors The charac teristics of your chimney whether it is steel or ma sonry interior or exterior matched or mismatched to the stove collar determine how quickly it will warm up and how well it will sustain the optimum temperatures necessary to maintain strong draft and efficient com bustion Here follows a description of various flue system characteristics and related effects on stove performance Masonry Chimney Although masonry is the traditional material used for chimney construction it can have distinct performance disadvantages when used to vent a controlled combus tion woodstove Masonry forms an effective heat sink that is it absorbs and holds heat for long periods of time The large mass however may take a long time to become hot enough to sustain a strong draft
30. his Madison is approved for venting into a masonry chimney with a nominal flue size of 8 x 8 200 x 200 mm and into a round flue size of 8 200 mm or 6 150 mm It may be vented into larger chimneys as well however chimneys with liners larger than 8 x 12 200 x 300 mm may experience rapid cooling of smoke and reduction in draft especially if they are located outside the home Such large chimneys may need to be insulated or relined for proper stove performance DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE NOTE DO NOT VENT THIS STOVE INTOA FACTORY BUILT ZERO CLEARANCE FIRE PLACE THIS STOVE HAS NOT BEEN TESTED AND LISTED FOR THAT TYPE OF INSTALLA TION FACTORY BUILT FIREPLACES AND THEIR CHIMNEYS ARE SPECIFICALLY DE SIGNED AS A UNIT FOR USE AS FIREPLACES IT MAY VOID THE LISTING OR BE HAZARDOUS TO ADAPT THEM FOR ANY OTHER USE DO NOT CONNECT THE STOVE TO ANY AIR DISTRIBUTION DUCT OR SYSTEM Vermont Castings Madison Chimney Connector Guidelines A chimney connector is the double wall or single wall pipe that connects the stove to the chimney The chimney itself is a masonry or prefabricated structure that encloses the flue Chimney connectors are used only to make the connection from the stove to the chimney They are for interior use only Double wall connectors must be tested and listed for use with solid fuel burning appliances Single wall connectors should be made of 24 gauge or he
31. hrough construction on pages 7 8 The opening through the chimney wall to the flue the breech must be lined with a ceramic or metal thimble which is securely cemented in place Fig 5 A metal pipe section called the thimble sleeve slightly smaller in diameter than standard connector and the thimbles will allow the removal of the chimney connector system for inspection and cleaning Thimble sleeves are available from your local dealer To install a thimble sleeve slide it into the breech until it is flush with the inner flue wall Be sure that it does not extend into the flue passage where it could interfere with the draft The thimble sleeve should protrude 1 2 25 50 mm into the room Use furnace cement and thin gasketing to seal the sleeve in place in the thimble Secure the chimney connector to the outer end of the sleeve with sheet metal screws Connection Above the Fireplace In this installation the chimney connector enters the fireplace flue through a thimble located above the fireplace Fig 6 The liner of the fireplace chimney should extend at least to the point at which the chim ney connector enters the chimney Follow all the guidelines for installing a chimney connector into a freestanding masonry chimney and pay special attention to these additional points The stove and chimney connector clearances to combustible mantel and trim materials are the same as clearances to combustible walls If nece
32. ing combustion air directly to the stove Consult your Vermont Castings Majestic Products dealer regarding an adapter to attach to the stove to connect an air duct for outdoor combustion air Conclusion Woodburning is more an art than a science Art in cludes technique and since installations homes and fuel vary the stove operator must also vary technique mostly timing to achieve satisfying results Over time you will become familiar with the intricacies and nuances of your particular installation and you will be able to identify cause and effect in a variety of sea sonal circumstances 23 Vermont Castings Madison The Vermont Castings Majestic Products Company reserves the right to make changes in design materials specifications prices and discontinue colors and products at any time without notice Madison Woodburning Stove Model 1655 Item Description Part Number Item Description Part Number 1 Bottom Outer 30000795 12 Fireback 30000813 2 End Left See Chart Pg 25 13 End Right See Chart Pg 25 3 Back 30000798 14 Primary Air Manifold 30001491 4 Secondary Manifold Left 30000802 15 Top See Chart Pg 25 5 Front See Chart Pg 25 16 Exhaust Flue See Chart Pg 25 6 Load Door See Chart Pg 25 17 Leg See Chart Pg 25 7 Ashlip See Chart Pg 25 18 Door Assy See Page 25 8 Door End Inner Shield 30000812 19 Damper Tab
33. lans to be certain that Your stove and chimney connector will be far enough from combustible material to meet all clearance requirements The floor protector is large enough and is con structed properly to meet all requirements You have all necessary permits from local authori ties Your local building official is the final authority for approving your installation as safe and determining that it meets local and state codes The metal label permanently attached to the back of the stove indicates that the Madison has been tested to current UL and ULC standards by CSA Clearance and installation information is also printed on the label Local authorities generally will accept the label as evidence that when the stove is installed according to the information on the label and in this manual the installation meets codes and can be approved Codes however vary in different areas Before starting the installation review your plans with the local building authority Your local dealer can provide any additional information needed For any unresolved questions about installation refer to the National Fire Protection Association s publication ANSI NFPA 211 1988 Standard for Chim neys Fireplaces Vents and Solid Fuel Burning Appli ances In Canada the equivalent publication is CSA CAN B365 Installation Code for Solid Fuel Burning Appliances and Equipment These standards are the bases for many national codes They are natio
34. ll the paper out If the paper pulls out with little or no resistance the gasket isn t snug enough at that spot If adjusting the latch doesn t result in a seal that makes it hard to pull the paper out replace the gasketing Check door handle for tightness Adjust 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 Clean the Primary Air Outlet 1 Remove the phillips head screws that retain the Primary Air Plate 2 Use a screwdriver to pry the plate out of the ce mented seams 3 Remove ash debris from the cavity 4 Use high temperature furnace cement to reseal the front seam and side seams and replace the plate Secure with the phillips head screws 21 Vermont Castings Madison Draft Management Your stove is only one part of a system that 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 stove works well Wood stove operation depends on natural unforced draft Natural draft occurs when exhaust gas is hotter and therefore lighter than the outdoor air at the top of the chimn
35. lue gases out of the chimney system as fast as the fire is generating more Volatile gases build up within the firebox until reaching a density and temperature at which they ignite With this ignition you may hear a muffled popping sound and see a bit of smoke forced out of the air inlets This condition is most likely to occur in the spring or fall when moderate outdoor temperatures and low intensity fires combine to inhibit draft strength If your stove backpuffs open the air inlets to induce a livelier fire and speed airflow through the stove Avoid large loads of firewood at one time You should always see lively dancing flames in the firebox a lazy smoky fire is inefficient and will promote draft problems Negative Pressure Good draft also depends on a sufficient supply of air to the stove The chimney cannot pull more air than is available Sluggish draft can be caused by a house that is tight enough to prevent the ready flow of air to the stove or by competition between the stove and other appliances that vent indoor air to the outside i e exhaust fans for range hoods clothes dryers bath room etc If the chimney draws well when all such equipment is turned off or sealed in the case of the fireplaces and or other stoves you simply need to be attentive in timing the use of the other appliances If you need to crack a nearby window or door to enable the chimney to pull well you should install an outside air intake to br
36. n 9 16 open end wrench safety glasses amp gloves flat head screwdriver power drill w 1 8 3mm bit stub handle phillips screwdriver Unpack the Stove Remove the shipping straps and plastic wrap N the stove and contents for shipping damage or missing parts Immediately notify your dealer of any damage Do not install this stove if any damage is evident or any parts are missing Hardware Bag contents Stove Legs 4 3 8 16 x 1 hex head Leg Bolts with washers 4 Owner s Registration Card Touch up Paint Porcelain enamel stoves only Install Stove Legs Remove and discard the four large slot head screws from the stove bottom Install the stove legs using the hex head bolts from the parts bag Use 3 8 washers with all four legs the door handle holder installs on the right front leg Position the holder so the hole to accept the handle hub faces out from the right side of the stove Tighten the bolts firmly CAUTION Overtighten ing can strip tapped threads Leg Bolt and Washer Leg Leveller Fig 24 Attach the stove legs with leg levellers Install the Bottom Heat Shield The 1892 Bottom Heat Shield must be used in the U S and Canada in any installation on a floor that is not comprised of unpainted cement on earth 1 Remove the 1 4 20x 1 2 phillips screw from the central mounting boss in the stove bottom Fig 25 Vermont Castings Madison 2 Mount the bottom heat shiel
37. n the adaptor with pilot holes in the Rear Heat Shield as shown at the bottom of Figure 26 Use two sheet metal screws provided in the kit to attach the Adaptor to the Rear Heat Shield at the aligned holes Without Rear Heat Shield 1 Facing the rear of the stove loosen the pan head screw located a the upper left hand corner of the primary air inlet two revolutions Position the Adaptor over the air inlet opening in the rear of the stove with the pan head screw passing through the slotted tab in the Standoff Make certain that the damper tab is located between the stove and the standoff and is oriented as it was before the screw was loosened Tighten the pan head screw using the access hole in the standoff The Thermostat and Primary Air Flap should operate freely n2 N Engage the Adaptor against the air inlet opening in the Outside Air Standoff Align clearance holes in the adaptor with pilot holes in the Standoff as shown at the top of Figure 26 ao Use two sheet metal screws provided in the kit to attach the Adaptor to the Outside Air Standoff at the aligned holes Without Rear Heat Shield Stove Back Outside Air Standoff Outside Air Adaptor Primary Air Flap Rear Heat Shield Oustide Air Adpator Fig 26 Outside Air Adaptor options Attach the Chimney Connector Insert the crimped end of the first section of chimney connector into the flue collar Using the holes in the collar as guides d
38. nally recognized and are accepted by most local authorities Your local dealer or your local building official may have a copy of these regulations IMPORTANT FAILURE TO FOLLOW THESE INSTALLATION INSTRUCTIONS MAY RESULT IN A DANGEROUS SITUATION INCLUDING A CHIMNEY OR HOUSE FIRE FOLLOW ALL INSTRUCTIONS EXACTLY AND DO NOT ALLOW MAKESHIFT COMPROMISES TO ENDANGER PROPERTY AND PERSONAL SAFETY Your stove must be connected either to a sound masonry chimney that meets local codes to a relined masonry chimney that meets local codes or to an approved prefabricated metal chimney Whichever of those types you use the chimney and chimney con nector must be in good condition and kept clean 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 building inspector or fire department official will be able to make the inspection or direct you to someone who can The chimney should extend at least 3 900 mm above the highest point where it passes through a roof and at least 2 600 mm higher than any portion of a building within 10 3 m To assure proper draft and good performance any chimney used with this stove should extend at least 16 5 m above the flue collar of the stove Reference Point Fig 2 The 2 3 10 Chimney Rule Masonry Chimneys An existing masonry chimney must be inspected to confirm that it has a lining D
39. nd ULC S627 and CAN CSA B366 2 for Canada The Madison Model 1655 Series is listed for burning wood fuel only Do not burn other fuels C US The Madison Model 1655 Series is approved for installation in manufactured mobile homes in the Unties States only using the optional Mobile Home Kit 1894 in accordance with the instructions in that kit an any local codes The Madison Model 1655 Series complies with the standards set forth by the Federal Environmental Protection Agency 40 CFR Part 60 532 b 2 as stated on the permanent label attached to each stove The Madison Model 1655 Series meets Washington State requirements We recommend that you hire a professional solid fuel stove technician to install your Madison or to advise you on the installation should you attempt to install it yourself Consult the authority having local jurisdiction such as a municipal building department fire department fire prevention bureau etc before installation to determine the need for a building permit Also consult your insurance agent to be sure your installation complies with specific requirements that may vary locally In addition to directions on installation and operation this manual includes directions on maintenance and assembly Please read this entire manual before you install or operate your new room heater Save These Instructions For Future Reference Installation Table of Contents Accessories TOM 1891 Outside Air Kit Specication
40. ngle wall chimney connector with a ventilated steel thimble Chimney clearance to sheet stee Ruas 2 51mm supports and combustibles Min 2 51mm Min allsspace 2 51mm Min lt Chimney Connector Chimney Flue Chimney N Prefab Section coney 24 ga Sheet 24 ga Sheet Steel Supports Steel Supports Masonry Chimney constructed to NFPA 211 Fig 10 Wall Pass through with ventilated steel thimble Min 18 460mm Chimney clearance to sheet steel 2 51mm supports and combustibles m Min 460mm Chimney Connector ji 24 ga Sheet Steel Support 24 ga Sheet Masonry Chimney Steel Support one side only constructed to CAN CSA B o ir gt E E lt o Fig 11 CSA approved Wall Pass through Floor Protection A tremendous amount of heat radiates from the bottom plate of your Madison The floor area directly under and around the stove will require protection from radiant heat as well as from stray sparks or embers that may escape the firebox Heat protection is provided through the use of a Vermont Castings Bottom Heat Shield 1892 Spark and ember protection must be provided by a floor protector constructed with noncombustible material as specified 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 wi
41. nseasoned green wood has a high mois ture content Much of its heat value will be used to evaporate moisture before the wood can burn This significantly reduces not only the amount of energy available to warm your home but also the intensity of the fire and temperature of the exhaust gas Incom plete combustion and cool flue temperatures promote creosote formation and weak draft You can judge the moisture content of wood by its appearance and weight or use a commercially avail able moisture meter for an exact measurement Unseasoned wood will be a third heavier than dry wood Also look for cracks checking in the ends of the log that result from contraction as the wood dries The longer and wider the cracks the dryer the wood is Purchase your fuel from a reputable dealer Creosote Creosote is a by product of low temperature stove operations weak draft or both It is a tar that results when unburned gases condense inside the flue system at temperatures below 290 F Creosote is volatile and can generate chimney fire All of the installation characteristics that adversely affect chimney draft also promote creosote condensation Consequently you can minimize creosote accumulation with an effective Vermont Castings Madison chimney design and the use of operational techniques that encourage good draft and complete combustion Backpuffing Backpuffing is a condition that results when the draft is too weak to pull f
42. nto a 10 x 10 flue the gases will expand to over three times their original volume As gases cool with expansion draft strength decreases If an over sized flue is also outside the house the heat it absorbs will be conducted to the outdoor air and the flue will remain relatively cool It is common for a masonry flue to be oversized for the stove Such a chimney can take quite a while to warm up and the stove performance will likely be disappointing The best solution to an oversize flue problem is the installation of an insulated steel chimney liner of the same diameter as the appliance flue outlet The liner keeps the exhaust gas warm and the result is a stronger draft An uninsulated liner is a second choice although the liner will keep the exhaust restricted to its original volume the air around the liner will require time and heat energy to warm up Check your local codes You may be required to install a flue liner in any oversize or masonry flue Pipe amp Chimney Layout Every bend in the flue will act as a brake on the exhaust as it flows from the firebox to the chimney cap The ideal pipe and chimney layout is straight up from the stove through a completely straight chimney Use this layout if at all possible as it will promote optimum stove performance and simplify maintenance If the stovepipe must elbow to enter a chimney locate the elbow about midway between the stove top and the chimney thimble This configuration
43. o not use an unlined chimney The chimney also should be examined for cracks loose mortar other signs of deterioration and blockage Repair any defects before the chimney is used with your stove A prefabricated double wall insulated chimney A tile lined masonry chimney Fig 3 Standard Chimney Types Masonry Chimneys cont d Unused openings in an existing masonry chimney must be sealed with masonry to the thickness of the chimney wall and the chimney liner should be repaired Openings sealed with pie plates or wallpaper are a hazard and should be sealed with mortar or refractory cement In the event of a chimney fire flames and smoke may be forced out of these unused thimbles The chimney should be thoroughly cleaned before use A newly built masonry chimney must conform to the standards of local building code or in the absence of a local code to a recognized national code Masonry chimneys must be lined either with code approved masonry or precast refractory tiles stainless steel pipe or a code approved poured in place liner The chimney clean out door must seal tightly to ensure a good draft Prefabricated Chimneys A prefabricated metal chimney must be one that is tested and listed for use with solid fuel burning appli ances to the High Temperature H T Chimney Stan dard UL 103 1985 2100 F for the United States and High Temperature 650 C Standard ULC S 629 for Canada Chimney Size T
44. of the fuel used as well as the design construction and climatic location of your home Figures shown are based on maximum fuel consumption obtained under laboratory conditions and on average efficiencies These values are based on operation in building code conforming homes under typical winter climate condi tions in New England If your home is of nonstandard construction e g unusually well insulated not insu lated built under ground etc or if you live in a more severe or more temperate climate these figures may not apply Since so many variables affect performance consult your Vermont Castings Majestic Products Company authorized dealer to determine realistic expectations for your home z 18 gt 470mm Fig 1 Madison 1655 dimensions 29 uox 740mm Vermont Castings Madison Installation SAFETY NOTICE If your stove is not properly installed operated and maintained a house fire may result For safety follow all installation operation and maintenance directions Contact local building officials about restrictions and installation inspection requirements in your area Before you begin an installation review your p
45. on characteristics specific construction 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 MADISON IS NOT PERMITTED IN CANADA Construction Requirements The following illustrations show non combustible ceiling framing and maximum and minimum permitted dimen sions for alcove construction 7 16 Durock or equivalent spaced 1 off wood studs on noncombustible spacers Existing Combustible 36 Use recommended Framing Max floor protection Metal studs support 7 16 Fig 19 Alcove floor plan Sheetrock on front face butts to icu equivalent Durock or equivalent alcove lining l Joist Shield Supplied by Chimney Manufacturer 48 Min ae ST505 Fig 22 Reflected ceiling plan Ceiling support package extends 2 below Durock or equivalent ceiling Combustible 1 air gap top and bottom on both facing may overlap metal sides and d by only back wall 7 16 Durock or equivalent sides and back wall NOTE From 62 to 65 must be covered by a noncom bustible material Fig 23 Front view 65 minimum clearance form hearth to combustibles on front face Combustible
46. pporting timbers under fireplace hearths are considered to be combustible Clearance to Surrounding Combustible Materials When the stove is operating both the stoveplate and the chimney connector radiate heat in all directions A safe installation requires that adequate clearance be maintained between the stove and nearby combustible materials to ensure that those materials do not overheat Clearance is the distance between either your stove or chimney connector and nearby walls floors the ceiling and any other fixed combustible surface Keep furnishings and other combustible materials 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 drying clothes furniture newspapers firewood etc Keep this area empty of any combustible material Safe Ways To Reduce Clearances The Madison clearance requirements listed and diagramed on pages 12 13 have been established through testing to UL and ULC standards to meet most installation configurations These involve four basic variables When neither the chimney connector nor the wall has a heat shield installed When only the chimney connector has a heat shield installed When only the wall has a heat shield mounted on it When a heat shield is installed on both the chimney connector and wall In general the greatest clearance is required when the stove will be positioned with no
47. r width size and on the kindling lay two or three larger sticks of split dry wood approxi mately 1 2 25 50 mm in diameter Fig 27 Fig 27 Start a fire with small dry kindling Step 3 Light the newspaper and close the doors Gradually build up the fire by adding a few 3 5 80 120 mm diameter splits Fig 28 If this is one of the first few break in fires let the fire burn brightly and then let it die out During the break in fires 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 necessary to control the fire Some odor from the stove s hot metal the paint and the cement is normal for the first few fires Fig 28 Gradually add larger pieces of wood until all the wood is burning well NOTE Some chimneys need to be primed or warmed up before they will draw sufficiently to sustain 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 strong draft Once the draft is established open the front doors and light the rest of the fuel bed at the bottom Do not light the main bed of fuel until the chimney begins drawing Step 4 After the stove has been broken in using Steps 1 3 continue to build the fire gradually Add larger
48. rill 1 8 8mm holes through the connector pipe Use the three 10 x 1 2 sheet metal screws provided to secure the chimney connection to the flue collar If applicable attach Chimney Connector Heat Shields following the instructions included with those parts How the Madison Works NN How the Madison Works Combustion control is achieved in the Madison through two separate air delivery systems The primary air control lever located at the left rear corner of the stove controls the amount of incoming primary air for starting maintaining and reviving the fire More air entering the stove makes the fire burn hotter and faster 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 most position 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 upper and lower extremes DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS SUCH AS GASO LINE NAPTHA 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 MADISON WHILE IT IS IN USE CAUTION THE MADISON WILL BE HOT WHILE IN OPERATION KEEP CHILDREN CLOTHING AND FURNITURE AWAY CON TACT MAY CAUSE SKIN BURNS DO NOT OVERFIRE
49. s 1892 Bottom Heat Shield Kit Installation Requirements 1893 Rear Heat Shield Kit Clearances 1894 Mobile Home Kit Assembly Operation Proposition 65 Warning Fuels used in gas Maintenance woodburning or oil fired appliances and the products Draft Management of combustion of such fuels contain chemicals Parts List known to the State of California to cause cancer birth defects and other reproductive harm California Health amp Safety Code Sec 25249 6 Vermont Castings Madison Specifications Madison Model 1655 Series Maximum heat output 39 700 Btu s hr Area heated Up to 1600 sq ft Fuel size type 18 46 cm logs Loading 2t He e tenerte Front amp Side Chimney connector 6 150 mm diameter Chimney flue size 6 150 mm minimum Flue exit position Top or Rear Primary air Manually set thermostatically maintained Ash handling system Removable ash pan Glass panel High temperature Infra red Weight ebria ds 420lbs Width Left leg Right leg 29 59 0 cm Depth Front Plate Flue Collar 25 64 0 cm aec 28 79 5 cm Drawings not to scale This value can vary depending on how the stove is operated the type and moisture content
50. s do not satisfy the completely noncombustible requirement because the brick or concrete in front of the fireplace opening is supported by heavy wood framing Fig 13 Because heat is readily conducted by brick or concrete it can easily pass through to the wood As a result such fireplace hearths can be a fire hazard and are consid ered a combustible floor For all fireplace installations follow the floor protection guidelines described above 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 protec tor requirement from the front of the stove 18 460 mm from the front in the United States and 18 460 mm from the front in Canada Hearth rugs do not satisfy the requirements for floor protection as they are only fire retardant not fire proof Floor Protection Requirements Rear Vent lt F gt Top Vent U S Canada 48 54 1372mm 48 52 1321mm 4 8 203mm 18 18 460mm 16 18 460mm 10 10 254mm ST500a Fig 12 These dimensions are minimum requirements only Use greater dimensions whenever possible Vermont Castings Madison Wood framing requires protection from radiant heat ST247a Fig 13 Su
51. se the glass thoroughly Dry the glass completely Glass Replacement Replace glass only with Vermont Castings glass panels The glass panel rests on a cushion provided by a gasket and is held in place by two clips The glass is coated on one side which is slightly colored Remove the door from the stove and place it on a sturdy level work surface Use a towel to protect the porcelain enamel finish 1 Remove the Retainer Clips Two phillips head screws on each clip Inspect the Gasket If the window gasket is in good condition you can leave it in place If you replace it use only Vermont Castings gasket 1203556 Be sure the channel around the window opening is clean and free of dust Place the gasket into the panel inset N N 0 3 Install the Glass Lay the glass on the inner gasket with the coated side down marked This Side Out toward the outside of the door Tighten the screws snugly but loose enough to allow for a little move ment 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 Gasket Replacement Your Madison uses rope type fiberglass 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
52. ssary use a combination of mantel trim and connector heat shields to provide the required clearances Refer to page 12 Double check connector clearance to the ceiling The fireplace damper must be closed and sealed to prevent room air from being drawn up the flue which could reduce performance However it must be possible to reopen the damper to inspect or clean the chimney Floor protection requirements also apply to fireplace installations Wall Pass throughs Whenever possible design the installation so that the connector does not pass through a combustible wall If you must include a wall pass through in your installa tion check with your building inspector before you begin Also check with the chimney connector manu facturer for any specific requirements Consult with your dealer regarding special connec tion components available for use as wall pass throughs Use only parts that have been tested and listed for use as a wall pass through U S Requirements The National Fire Protection Association NFPA has established guidelines for use in the United States for passing chimney connectors through combustible walls Many building code inspectors follow these guidelines Figure 7 shows one NFPA approved method All combustible material in the wall is cut away to provide 12 300 mm clearance to the connector Brick and mortar are used to enclose the clearance area Alternate methods approved by the NFPA Chimney
53. thout the heat shield Even when the bottom heat shield is installed you must provide special protection to the floor beneath For installations with the heat shield attached use a noncombustible floor protector such as 1 4 non asbestos mineral board or equivalent or 24 gauge sheet metal The floor protector may be covered with a noncombustible decorative material if desired Do not obstruct the space under the heater Protection requirements vary somewhat between the United States and Canada as follows For U S installations the floor protector is re quired under the stove and must extend at least 18 from the front of the stove D Fig 12 at least 4 from the right side and rear C Fig 12 and 16 from the left side E Fig 12 It must also extend under the chimney connector and 2 to either side F Fig 12 To meet these requirements a floor protector must be at least 48 wide A Fig 12 and 48 deep B Fig 12 In Canada a noncombustible floor protector is required under the heater also The floor protector must extend 18 460 mm to the front D and 8 203 mm from the right side C and rear C and 18 460mm from left side E To meet these requirements a floor protector must be at least 54 1372mm wide A Fig 12 and 52 1320mm deep B Fig 12 Fireplace Hearth Protection Do not assume that your fireplace hearth is completely noncombustible Many fireplace hearth
54. tors The Madison is approved for installation in the U S and Canada with double wall chimney connectors that have been tested and listed for use with solid fuel burning appliances by a recognized testing laboratory Follow the instructions for assembling and install ing double wall connectors provided by the manufac turer of the double wall chimney To ease assembly and help assure safety use chimney components manufactured by a single source NOTE For installations using double wall connectors minimum clearances must conform to those listed in the clearance chart on Page 12 Single wall Chimney Connectors 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 3 mm holes in the bottom of the first section of chimney connector and secure it to the flue collar with three 10 x 1 2 sheet metal screws Secure each joint between sections of chimney connector including telescoping joints with at least three sheet metal screws The predrilled holes in the top of each section of chimney connector serve as guides when you drill 1 8 3 mm holes in the bottom of the next section Secure the chimney connector to the chimney Instructions for various installations follow Be sure the installed stove and chimney connector are correct dist
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