Vermont Casting 2080 User Manual

Winter Warm

Small Insert

Homeowner’s
Installation
and Operating
Manual

For Use in North America

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

2000888 5/06 Rev. 13

WinterWarm Small Insert

Introduction

Thank you for purchasing a Vermont Castings WinterWarm Small Insert, an efficient fireplace carefully engineered

to bring you the latest in wood combustion principles and modern foundry technology.

While it can be used to transform a traditional masonry fireplace into a powerful heater, it is also designed to be

installed into a listed factory-built fireplace where no masonry fireplace and chimney exists.

Whichever installation you have chosen, you can count on years of comfortable heating and pleasurable fire-view-

ing if you operate and maintain it according to the directions in this Owner’s Guide.

The WinterWarm Small Insert has been tested and listed by Inchcape Testing Services / Warnock Hersey Inc. of
Middleton, Wisconsin according to ANSI/UL 1482 for the United States and ULC S628 for Canada. The WinterWarm
Small Insert is listed to, and in compliance with, the standards set forth by the Federal Environmental Protection
Agency, 40 CFR Part 60.532(b), as stated on the permanent label attached to each appliance.

This manual describes the installation and operation of the WinterWarm Small Insert catalytic-equipped wood
heater. This heater meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold after
July 1, 1990. Under specific test conditions this heater has been shown to deliver heat at a rate ranging from 8,700 to
31,000 Btu/Hr.

For more complete details on WinterWarm Small Insert performance and specifications, please refer to Page 3.

The WinterWarm Small Insert is designed, tested and listed for burning wood. Do not burn other fuels.

We recommend that you hire a professional installer to install your WinterWarm Small Insert, or to advise you on
the installation should you attempt to install it yourself.

Please read the sections of this manual which apply to your installation before you install and use your Winter­Warm Small Insert.

Failure to follow these instructions may result in property damage, bodily injury or even death.

Save These Instructions for Future Reference

Table of Contents

Specifications .........................................................3

Installation ..............................................................4

Operation ................................................................9

Maintenance ......................................................... 14

Catalytic Combustor Appendix .............................

Replacement Parts ............................................... 21

Proposition 65 Warning: Fuels used in gas, wood­burning or oil fired appliances, and the products of
combustion of such fuels, contain chemicals known
to the State of California to cause cancer, birth de­fects and other reproductive harm.
California Health & Safety Code Sec. 25249.6

20

The WinterWarm Small Insert is designed,
tested and listed for burning wood. Do not
burn other fuels.

The WinterWarm Small Insert is not listed for
mobile home installations.

Failure to follow these instructions may
result in property damage, bodily injury or
even death.

WARNING

This fireplace has not been tested with an
unvented gas log set. To reduce the risk of
fire or injury, do not install an unvented gas
log set into this fireplace.

2

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WinterWarm Small Insert

26" (660mm)

25" (650mm)

21

"

(535mm)

21" (535mm)

13" (330mm)

6"

(160mm)

6"

(165mm)

21

"

(535mm)

16" (420mm)

WinterWarm Small Insert

Specifications

EPA Emissions Rating .......................gph, catalytic 2.1*

Range of heat output* ................. 8,700 - 31,100 Btu/hr

Maximum heat output** ........................... 30,000 Btu/hr

Area heated*** ............................................ 1,000 sq. ft.

Size of wood splits .................................... 18” (460mm)

Fuel Capacity ........................................ 30lbs. (13.5kg)

Loading ..................................................................Front

Flue size ..................................................... 6” (150mm)

Fireplace Insert weight ......................... 285lbs. (130kg)

Primary Air Control ........................Manual/thermostatic

Secondary Air Control ............................Self-regulating

Glass panel ......................... High-temperature ceramic

Flue exit position ..................................................... Top

Blower rating ...............................110cfm. (115V, 60Hz)

*Under specific test conditions used during EPA emis­sions standard testing.

**This value can vary depending on how the unit is
operated, and the type and moisture content of the fuel
used. Figure shown is based on maximum fuel con­sumption obtained under laboratory conditions and on
average efficiencies.

***These values are based on operation in building­code conforming homes under typical winter climate
conditions in New England. If your home is of nonstan­dard construction (e.g. unusually well insulated, not in­sulated, built under ground, etc.) or if you live in a more
severe or more temperate climate, these figures amy
not apply. Since so many variables affect performance,
consult your Vermont Castings’ Authorized Dealer to
determine realistic expectations for your home.

Fig. 1 WinterWarm Small Insert dimensions.

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0888

3

WinterWarm Small Insert

2' Min.

2' Min.

3'

Min.

0 To 10'

3'

Min.

0 To 10'

Installation

Installing the WinterWarm Small Insert into an existing
masonry or factory-built fireplace is an effective way to
add an efficient heater to your home. The existing fire­place and chimney must meet certain requirements.

Requirements for Existing Fireplaces

The WinterWarm Small Insert is listed for installation
within a properly built masonry or heat circulating, ma­sonry-type fireplace that is constructed in accordance
with the requirements of recognized building codes. A
heat-circulating masonry-type fireplace must conform
to building code standards for masonry fireplaces, and
must consist of a factory-built metal firebox with air
circulation pathways that are surrounded by masonry
materials. Air circulation pathways must not be blocked
by the insert or surround panels.

The fireplace and chimney must be clean and structur­ally sound. Have them inspected by a qualified pro­fessional chimney sweep, a mason, or your Vermont
Castings’ Authorized Dealer before the WinterWarm
Small Insert is installed. Any deterioration (cracks, loose
mortar or loose bricks) must be repaired.

Codes may permit removal of the damper in order to
make a positive connection for the vent between the
firebox and the chimney. However, the fireplace should
not be modified in any way without first checking with
your local building inspector or fire marshal. Provision
should be made to restore the fireplace to its original
condition if the insert is removed. Do not remove bricks
or mortar that may jeopardize the compliance of the
fireplace with local building codes.

The WinterWarm Small Insert is also listed for installa­tion in tested and listed factory-built fireplaces. Listings
for factory-built fireplaces include meeting standards
for both the firebox and chimney. Review the owner’s
manual, and inspect the fireplace for metal tags or
labels which give information concerning installation of
inserts into the factory-built fireplace. Codes may permit
removal of the damper in order to install a chimney
liner. Codes may also permit removal of external trim
pieces which do not affect the operation of the unit, as
long as the pieces are stored on or within the fireplace
for re-assembly if the insert is removed. Air flow within
and around the fireplace shall not be altered (louvers
or cooling air inlet or outlet ports may not be blocked).
Louvered surrounds are permitted. Again, check with

local authorities before making any modifications.

Requirements for Existing Chimneys

Chimney requirements differ for the U.S. and Canada.
Specifications for each are listed below. Connect the
insert to the chimney in accordance with local codes
and the requirements of the listing agency as specified
in this manual.

Chimney Height / U.S. and Canada

Chimney height should be no less than 15’ (4.5m)
above the hearth and no more than 35’ (10.5m).

The chimney should extend at least 3’ (914m) 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. 2)

Reference
Point

Fig. 2 The 2’-3’-10’ rule for chimneys.

Do not connect your WinterWarm small insert to a
chimney flue serving another appliance.

AC617

U.S.

In the U.S. (ANSI/NFPA 211, 1988), when
installed in a masonry fireplace:

• A connector must extend from the flue collar

to the flue liner.

• The cross sectional area of the flue must be less

than or equal to three times the area of the flue
collar. If larger, the chimney must be re-lined.

• Means must be provided to prevent room air

passing to the chimney cavity.

• Provision must be made for removal of the

insert to clean the chimney flue.

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WinterWarm Small Insert

When the insert is installed in a factory-built fire­place:

• The factory-built chimney must meet type HT

requirements of UL 103, ULC S629M or UL 127­1988, or be re-lined from the insert to the
chimney top.

General Considerations / U.S.

• While not required in most jurisdictions in the

U.S., CFM Corporation strongly recommends a
full stainless steel chimney liner be installed for­mthe insert to the chimney top to increase overall

performance and reduce yearly maintenance.

• A masonry chimney must be well-constructed

and must meet minimum code requirements.
The chimney flue should have a code-approved
liner made of masonry or pre-cast refractory
tiles, straight or flexible stainless steel pipe, or a
poured-in-place liner. An unlined chimney must
be relined professionally.

• The chimney must have a nominal flue size of 6”

(150mm) diameter, but no greater than 3 times
larger. A chimney larger than this must be re­lined.

Be aware that a chimney originally designed for fire­place use may perform differently when used to vent
an air-controlled appliance such as your WinterWarm
Small Insert - even if the flue is less than 3 times larger
than the flue collar. For example, a chimney on an
outside wall may not heat up enough to sustain an
adequate draft. Such a flue can often be improved if it
is relined to reduce its size and/or insulated to keep it
warmer.

• A positive flue connection must be made be-

tween the Insert and the first masonry tile or
prefabricated metal chimney section. A positive
flue connection consists of a plate that seals or
replaces the fireplace damper and a section of
chimney connector that passes through the plate
into the chimney. The chimney connector must be
a minimum equivalent to a 6” (150 mm) diameter
opening and must be 24 gauge or heavier stain­less steel.

Chimney Connection systems are available from a
variety of manufacturers. Your Vermont Castings dealer
can recommend a system that will best meet the re-

quirements of your particular installation.

Sealing Requirements / U.S.

• The chimney must be sealed off from room air,

either by a plate at the damper level or by sealing
the fireplace opening.

2000888

• Unused openings to the flue must be sealed with

masonry to the thickness of the chimney wall.
Openings sealed with pie plates or wallpaper are
a hazard. In the event of a chimney fire, flames
and smoke may be forced from the openings.

Canada

In Canada (CAN/CSA-B365-M91, Section 5), wheth­er installed in a m or factory built fireplace:

• A full chimney liner meeting ULC S635, Class III

(stainless steel) must be installed from the insert
to the chimney top, and securely attached to
both. The damper may be removed to accommo­date the liner.

• The opening of the fireplace around the insert

must be sealed to prevent room air passing to the
fireplace cavity.

• Existing air-circulation chambers in a fireplace

with a steel liner may not be blocked.

• Provision must be made for removal of the insert

to clean the chimney flue.

• A permanent metal warning label must be affixed

to the back of the fireplace stating the fireplace
may have been altered to accommodate the in­sert, and may be unsafe to use as a conventional
fireplace. (A Fireplace Modification Tag is includ­ed in the hardware bag inside the WinterWarm
Small Insert.)

Minimum Fireplace Dimensions

The WinterWarm Small Insert will fit most masonry and
factory-built fireplaces. To confirm that it will fit yours,
measure the lintel depth, plus the height, width, and
depth of your fireplace and hearth. Compare them to
the measurements in the accompanying chart. If you
choose to install a new hearth over an existing fireplace
hearth, be sure to take its thickness into consideration
when measuring both front and back height of the
fireplace.

The unit can be installed virtually flush with the fireplace
opening or it can extend up to 6³⁄₄” (172mm) onto the
hearth. Figure 3 gives minimum and maximum dimen­sions for fireplaces which will accommodate the Winter­Warm Small Insert.

NOTE: The clearance between the WinterWarm Small
Insert and the mantel, top trim and side trim cannot be
reduced by installing shields.

Another requirement to consider is the clearance for
movable items such as tables, bookcases, rugs, fur­nishings, and your woodbox. All combustible materials
of this type should be a minimum of 48” (1220mm) from
the front surface of the WinterWarm Small Insert. Be
sure that family members are aware of this requirement
as well, so they too will keep objects a safe distance
from the WinterWarm Small Insert.

5

WinterWarm Small Insert

A,I

B

C

D,

J

E

D,J

H

C

E

X

C

A

B

Fireplace Minimums

A. Width at Face 26¹⁄₂” (673mm)
B. Width at
9” depth 26
C. Depth1 14¹⁄₂” (370mm)
D. Height at Face 21
E. Height at
15¹⁄₂” depth 21¹⁄₂” (540mm)

Fireplace Maximums

H. Lintel depth 9¹⁄₂” (240mm)
I. Width2 44¹⁄₂” (1130mm)
J. Height2 31” (770mm)

¹⁄₂” (673mm)

¹⁄₂” (540mm)

FP1084

Measure
side trim
clearance
from here

FP1085

Fireplace Clearances

A. Mantel* 34” (865mm)
B. Top Trim* 34” (865mm)
C. Side Trim** 20¹⁄₈” (510mm)

* for more details on mantel and top trim, see Note below.
** Where side trim extends more than 2” (50mm) from the
fireplace facing, the side clearance must be no less than 20
(525mm).

Measure the side clearance (C) from the exact center of your fire
place opening on the hearth (X). Measure the top trim (B) and/or
mantel clearances (A) from the finished hearth surface. Measure
the front clearance (to furnishings, etc.) from the fireplace face.

⁵⁄₈”

-

1. The minimum depth must be maintained from the floor of the
fireplace to a height of 21

2. Though the WinterWarm Small Insert will fit into larger fireplaces,
the decorative optional CFM Corporation Surround Panels will not
completely cover the fireplace opening if these dimensions are
exceeded. Custom made trim pieces may be used.

Fig. 3 Use these measurements to confirm that the Winter­Warm Small Insert will fit into your masonry fireplace.

¹⁄₂” (540mm)

Clearance Requirements

After confirming that your fireplace is the right size,
check the clearance to combustibles. First mark with
tape the exact center of your fireplace opening on the
hearth. Measure the side clearance from this point.
Measure the top trim and/or mantel clearances from the
finished hearth surface. Measure the front clearance (to
furnishings, etc.) from the fireplace face. (Fig. 4)

Fig. 4 Observe these clearances to combustible trim.

Hearth Requirements

In some fireplaces, the hearth in front of the fireplace
opening is brick, stone, slate, or some other non-com­bustible material that is in direct contact with concrete
poured over earth. These are the only hearths that are
considered noncombustible. In other fireplaces, the
brick or concrete hearth in front of the fireplace opening
is supported by heavy wooden framing. Because nei­ther brick nor concrete has good insulating properties,
heat radiated by the fire will pass downward through
the hearth to the wooden framing. Such hearths are
considered combustible.

Unless the fireplace and hearth are constructed over a
completely non-combustible surface (such as unpainted
concrete over dirt), a floor protector must be used
in front of and to the sides of the door as protection
against spilled coals and embers. Floor protectors must
extend at least 8” (203mm) from the side of the door
opening, making the protector 41” (1041mm) wide. In
addition, the floor protector must extend from the front
door opening a minimum of 16” (406mm) in the United
States and 18” (457mm) in Canada. (Fig. 5)

6

2000888

K of new material (per inch)

K of listed material (per inch)

thickness
of listed
material

= x

IWF291
MBUF
6/19/96

(K factor
of alternate
material)

(0.84)

X (7/16" [11mm]) =

(Required thickness of

alternate material)

(5.0)

(0.84)

X (7/16" [11mm]) = 2.6" (65mm)

A

B

C

D

E

F

A

B

C

B

Shadow
Tray

United States Canada

A. 16“ (410 mm) 18” (460 mm)
B. 8” (203 mm) 8” (203 mm)
C. 41” (1040 mm) 41” (1040 mm)

Fig. 5 Unless your fireplace and hearth are constructed over
a dirt floor (or unpainted concrete over dirt), you must use a
floor protector that satisfies the above requirements.

The approved construction of a floor protector calls
for a minimum of 24 gauge galvanized sheet metal or
equivalent such as 7/16” Durock® or Wonderboard® or
other listed floor protector. The floor protector may be
covered with a noncombustible decorative material if
desired.

Custom-made floor protectors may be used if they
offer the same protection as the approved floor protec­tor described in the preceding paragraph. Durock® or
Wonderboard® have a standard K value of 0.84. Cus­tom-built floor protectors must have a K value equal to,
or less than 0.84, meaning that heat will transfer at the
same rate or more slowly than the tested standard.

To calculate the thickness required for an alternate
material to result in a K value of 0.84, first determine
the alternate material’s K factor. This information should
be available from your local building supply yard. Then,
use the following formula to calculate the value:

Let’s use brick as an example, since it is a commonly
used hearth material. Its K factor is 5.0.

2000888

FP1095

WinterWarm Small Insert

That is, when using brick for the hearth extension, the
brick must be a minimum of 2.6” (65mm) thick. Once
you know the K factor of a given material, you can use
this same formula to calculate its required thickness for
approved hearth protection.

The WinterWarm Small Insert has two leveling screws
at the front to accomodate hearth irregularities.

Optional Surround Packages

Custom-made surround panels may be made from any
noncombustible material.

CFM Corporation offers both steel and cast iron Sur­round panel kits, each in two sizes.

Enclosure Area
Steel Surround Trim Kits:

6”, #2970 .........................36¹⁄₂” x 27” (927 x 686 mm)

10”, #2971 ..................... 44¹⁄₂” x 31” (1130 x 787 mm)

Cast Iron Surround Trim Kits:

7”, #2972 ......................40” x 28¹⁄₂” (1016 x 724 mm)

10”, #2973 ....................... 45” x 31” (1143 x 787 mm)

Installing the WinterWarm Small Insert

The hardware bag included with your WinterWarm
contains the Draw-down assembly components that
provide a means to secure the chimney connector to
the Insert. Be sure you have the following items:

1, 1/4-20 x 6³⁄₄” Threaded Rod (A)
2, 1/4” Washers (B)
2, Hex Head Nuts (C)
1, 1/4-20 x 2” Hook (D)
1, 1” x 6” Steel Bar (E)
1, 1/4-20 Wing Nut (F)

1. Remove or Disable the Fire
place Damper.

If codes allow, remove the damper. Many dampers can
be removed simply by removing a cotter pin and/or a
set screw.

If it is not permissible or possible to remove the damper,
secure the damper in the fully open position.

~ NOTE: CANADIAN INSTALLATIONS ~

In accordance with CAN/CSA B365-M91, you must
permanently secure the Fireplace Modification Tag
to the rear of the fireplace cavity

fied the fireplace in any way to accommodate instal­lation of a fireplace insert. This tag is in the hardware

bag included with your Insert.

2. Install the Chimney Connector System. Be sure
any chimney connector or adapter is properly in-

stalled and secured in place.

-

if you have modi-

7

WinterWarm Small Insert

1"

(35mm)

3. Install the Chimney Connector Starter Pipe. (Not
supplied)

• Mark and drill two 5/16”, (8mm) holes 1⁵⁄₈”

(41mm) from the lower edge of the pipe. Locate
the holes on an axis that will be perpendicular to
the fireplace opening when the pipe is installed.
(Fig. 6)

8. Join the Chimney Connector to the Flue Collar.

• Assemble the draw-down hook and bar (D,E,F).

• From inside the firebox, reach up through the flue

collar and engage the hook over the threaded
rod inside the starter pipe. Position the steel bar
behind the two tabs within the flue collar and then
turn the wing nut clockwise to draw the starter
pipe down. (Fig. 7)

9. Connect the Blower power cord to the power
supply.

This completes installation of your WinterWarm Small
Insert.

Fireplace
Front

FP1097

Fig. 8 Install the threaded rod inside the Starter Pipe (not a
supplied item, starter pipe is available from the Chimney Con­nector manufacturer).

• Install the threaded rod (A), into the starter pipe

using washers and hex nuts (B,C),on the outside
of the pipe. Tighten the nuts, but do not distort the
pipe opening. (Fig. 6)

• Secure the starter pipe to the chimney connector.

(Fig. 7)

4. Install the Floor Protector. Make sure the floor pro
tector satisfies the requirements discussed on Page

6.

5. Install the Optional Outside Air Adapter.

the instructions provided with the kit.

6. Install the Optional Surround Kit.

Follow the in-

structions provided with the kit.

7. Slide the Firebox into Position. At least two people
will be needed to move the firebox. Position the
firebox so the flue collar lines up with the connector.
Use the leveling screws at the front of the Insert to
adjust the level. Route the power cord to the side
nearest the power supply and test the fans.

Follow

Seat the Starter
Pipe on the two
tabs inside the flue
collar

-

Fig. 7 Attach starter pipe to flue collar.

Starter Pipe

Draw-down
Bar Assem­bly

FP1098

8

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