Vermont Castings 2460 Instruction Manual

Convection Heater Model 2460, 2461, 2462
7001135 1/07 Rev. 19
Homeowner’s Installation and Operating Manual
DO NOT DISCARD THIS MANUAL: Retain for future use
SAFETY NOTICE
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PLEASE NOTE
Please read this entire manual berfore you install and use your new room heater. Failure to follow instructins my result in property damage, bodily injury or loss of life. Save these instructions for future use.
The Dutchwest models covered in this Owner’s Guide have been tested and listed by Inchcape Testing Services / Warnock Hersey of Middleton, Wiscon­sin. The test standards utilized were ANSI/UL 1482 for the United States and CAN/CGA - B366.2 for Canada. Dutchwest models are not listed for mobile home installations.
Patents: U.S. - D288357, 4502395, 4646712; Canada - 1235969. Other foreign mechanical patents issued.
Accessories
Bottom Heat Shield
Clearance-reducing Rear Heat Shields
Clearance-reducing Heat Shields for single-wall
stove pipe
2” legs
Warming shelves (Small and Large Heaters only)
Two-speed convection blower
Automatic thermostat for the blower
Table of Contents
Specifications ............................................................ 3
Installation ..........................................................4
Clearances
.......................................................12
Assembly ..........................................................16
Operation
..........................................................17
Maintenance
.....................................................22
Illustrated Parts List ..........................................30
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
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1. Maximum burn times and heat outputs are based on laboratory testing using full loads of seasoned hardwoods, and may vary in individual use depending on how the stove is operated, type and moisture content of fuels, and other factors. Maximum burn times are achieved under different operating conditions than are maximum heat outputs.
2. These values are based on operation in building code-conforming homes under typical Winter climate conditions in the northeastern U.S. If your home is of nonstandard construction (e.g. unusually well-insulated, not insulated, built underground, 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 Dutchwest Authorized Dealer to determine realistic expectations for your home.
4. Under specific conditions used during EPA emissions testing.
5. Based on preliminary results obtained during EPA emissions testing.
Specifications
A
C
B
D
G
F
E
Fig. 1 Dutchwest Convection Heater specifications.
Stove Model Number 2460 2461 2462
A 22” (560 mm) 25³⁄₄” (654 mm) 28¹⁄₄” (717 mm) B 21” (530 mm) 24¹⁄₂” (620 mm) 27” (690 mm) C 29³⁄₄” (754 mm) 30” (760 mm) 33” (840 mm) D 16” (410 mm) 16” (410 mm) 18¹⁄₄” (467 mm) E 14³⁄₄” (375 mm) 14⁵⁄₈” (380 mm) 17” (430 mm) F 26³⁄₄” (683 mm) 27” (690 mm) 30¹⁄₈” (763 mm) G 29³⁄₄” (754 mm) 30” (760 mm) 33” (840 mm) Log length: 19” (480 mm) 22” (560 mm) 25” (640 mm) Maximum burn time1: 8 hrs. 9 hrs. 12 hrs. Average area heated (sq. ft.)2: 700-1,400 (65-130m2) 800-1,600 (75-150m2) 1,200-2,400 (112-224m2) Range of heat output4: 7,800 - 26,800 Btu/hr. 11,300 - 26,800 Btu/hr. 10,500-27,700 Btu/hr
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Maximum heat output: 35,000 Btu/hr. 40,000 Btu/hr. 55,000 Btu/hr. EPA emissions rating4 (g/h, catalytic): 1.1 1.4 1.3 Weight: 380 lbs. (172 kg) 436 lbs. (198 kg) 634 lbs. (288 kg) Loading: Side or front Side or front Side or front Flue exit position (reversible): Top or rear Top or rear Top or rear Air controls: 2 controls 2 controls 2 controls
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Installation
SAFETY NOTICE: IF YOUR DUTCHWEST CON­VECTION HEATER 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 the installation, review your plans to confirm 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 constructed properly to meet all requirements.
• You have obtained all necessary permits from local authorities.
Your local building official is the final authority for ap­proving your installation as safe and for determining that it meets local and state codes.
Clearance and installation information is printed on the metal label attached to the rear of the stove. 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 vary in different areas, however. Before starting the installation, review your plans with the local building authority. Your local dealer can provide any additional information needed.
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.
Chimney Types
Your Dutchwest Convection Heater must be connected to a sound masonry chimney that meets local codes, a relined masonry chimney that meets local codes, or to an approved prefabricated metal chimney. Whatever kind you use, the chimney and chimney connector must be in good condition and kept clean.
Masonry Chimneys
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 either to make the inspection or to direct you to some­one who can.
An inspection of the chimney must confirm that it has a lining. Do not use an unlined chimney. The chim­ney should also be examined for cracks, loose mortar, other signs of deterioration, and blockage. Repair any defects before the chimney is used with your stove.
Unused openings in an existing masonry chimney must be sealed with masonry to the thickness of the chimney wall, and the chimney liner should be repaired. 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 your local building code or, in the absence of a local code, to a recognized national code. Masonry chimneys must be lined, either with code-approved masonry or pre-cast refractory tiles, stainless steel pipe, or a code-approved, “poured-in-place” liner. The chimney’s clean-out door must seal tightly.
Prefabricated Double-Wall Insulated Chimney
Tile Lined Masonry Chimney
ST241
Fig. 2 If in sound condition and approved for use, either a masonry or a prefabricated chimney may be used.
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Prefabricated Chimneys
A prefabricated metal chimney must be one tested and listed for use with solid-fuel burning appliances.
A horizontal connector run should be inclined 1/4” per foot (20 mm per meter) from the stove toward the chimney. The recommended maximum length of a hori­zontal run is 3 feet (1m) and the total length of chimney connector should be no longer than 8 feet (2.5m).
Chimney Height
For proper draft and good performance, the chimney should extend at least 16’ (5 m) above the flue collar of the stove.
The chimney must also 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). (Fig. 2)
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
Chimney Size
The Model 2460 and 2461 heaters should be vented into a masonry chimney with a square flue with nomi­nal flue size of 8” x 8” (200 x 200 mm), or a round flue with nominal flue size of 6” (150 mm). The Model 2462 heater should be vented into a masonry chimney with a nominal flue size of 8” x 8” (200 mm x 200 mm) square, or 8” (200 mm) round.
Chimney liners larger than 8” x 12” (200 x 300 mm) may promote rapid cooling of smoke and reduction in draft, especially if they are located outside the home. These large chimneys may need to be insulated or have their flues relined for proper stove performance.
Accessories to help make the connection between stainless steel chimney liners and the stove are avail­able through your local dealer.
2' MIN.
2' MIN.
3'
MIN.
0 TO 10'
3'
MIN.
0 TO 10'
Reference Point
AC246
Fig. 3 The 2/3/10 rule for chimneys.
Guidelines for Installing
the Chimney Connector
The chimney connector is the single-wall pipe, or listed and approved double-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.
Do not pass the chimney connector through a combus­tible wall or ceiling, or through an attic, a closet or any similar concealed space. If passage through a combus­tible wall is unavoidable, follow the recommendations in the following section on Wall Pass-Throughs. Keep the passage as short and direct as possible, with no more than two 90 degree turns.
Two Types of Connector
You may use either a single-wall steel connector of the size and gauge described below, or a listed and ap­proved double-wall connector.
Single-Wall Connector
The single-wall chimney connector should be made of 24 gauge or heavier steel, and must have a minimum internal diameter of 6” (150 mm) for models 2460 and 2461, or 8” (200 mm) for model 2462.
Install single-wall chimney connector not less than 18” (450 mm) from the ceiling.
In cathedral ceiling installations, extend the prefabri­cated chimney downward to within 8 feet (2.5 meters) of the stove. The entire chimney connector should be exposed and accessible for inspection and cleaning.
Do not use galvanized chimney connector; it cannot withstand the high temperatures that can be reached by smoke and exhaust gases and it may release toxic fumes under high heat.
Chimney
Elbow
Slip Pipe
Standard Connector
Flue Liner
Flue
Thimble
Flue Collar
Floor Protector
ST418
Fig. 4 Sections of a steel chimney connector of at least 24 gauge thickness are fastened together with screws to connect the stove to the chimney.
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Double-Wall Connector
Information on assembling and installing double-wall connectors is provided by the manufacturer of the double-wall pipe. Follow the manufacturer’s installation instructions exactly. Most manufacturers of prefabri­cated double-wall insulated chimneys also offer double­wall connector pipes. Using a chimney and connector pipe from the same manufacturer helps simplify the assembly and installation.
NOTE: For installations using double-wall connec­tors, minimum clearances must conform to listed clearances in the Stove and Chimney Connector Clearance Charts on page 12 and 13 of this manual.
Assembling Single-Wall
Chimney Connector
SAFETY NOTE: Always wear gloves and safety goggles when drilling, cutting or joining sections of chimney connector.
For double-wall connectors, follow the manufacturer’s instructions exactly. For single-wall connectors, follow the instructions below.
1. Insert the crimped end of the first section into the stove’s flue collar, and keep each crimped end pointing toward the stove (Fig.5). Using the holes in the flue col­lar as guides, drill 1/8” (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.
Toward Stove
Flue Gas Direction
ST242
Fig. 5 Crimped sections always point toward the stove so that any liquid condensation will not leak out.
2. Secure each joint between sections of chimney con­nector, including telescoping joints, with at least three sheet metal screws.
3. Secure the chimney connector to the chimney. In­structions for various installations follow below.
4. Confirm that the installed stove and chimney con- nector are correct distances from nearby combustible material. See the clearance charts on pages 12 and 13.
NOTE: Special slip pipes and thimble sleeves that form telescoping joints between sections of chimney con­nector are available to simplify installations. They can eliminate the need to cut individual connector sections. Consult your local dealer about these special pieces.
Securing the Connector
to a Prefabricated Chimney
Follow the installation instructions of the chimney manufacturer exactly as you install the chimney. The manufacturer of the chimney will supply the acces­sories to support the chimney, either from the roof of the house, at the ceiling of the room where the stove is installed, or from an exterior wall.
Special adaptors are available from your local dealer to make the connection between the prefabricated chimney and the chimney connector. (Fig. 6) The top of such adaptors attach directly to the chimney or to the chimney’s ceiling support package, while the bottom of the adaptor is screwed to the chimney connector.
These adaptors are designed so the top end will fit outside the inner wall of the chimney, and the bottom end will fit inside the first section of chimney connector. Any soot or creosote falling from the inner walls of the chimney will stay inside the chimney connector.
Prefab (Insulated) Chimney
Ceiling Support Package
Prefab Chimney Adapter
Chimney Connector (Stovepipe)
ST419
Fig. 6 Joining the chimney connector to a prefabricated chimney.
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Securing the Connector
to a Masonry Chimney
The Dutchwest Convection heaters may be connected to either a freestanding masonry chimney or a masonry fireplace chimney.
Freestanding Installations
If the chimney connector must pass through a combus­tible wall to reach the chimney, follow the recommenda­tions in the wall pass-through section that follows.
The opening through the chimney wall to the flue (the “breech”) must be lined with either a ceramic or metal cylinder, called the “thimble”, which is securely cemented in place. (Fig. 7) Most chimney breeches incorporate thimbles, but check to be sure the fit is snug and the joint between thimble and chimney wall firmly cemented.
A special piece called the “thimble sleeve,” slightly smaller in diameter than the standard connector and most thimbles, will ease the removal of the chimney connector system for inspection and cleaning. Thimble sleeves should be available from your local dealer.
To install a thimble sleeve, slide it into the breech until it is flush with the inner flue wall. Don’t extend it into the actual flue passage, as that 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.
Fireplace Installations -
Above the Fireplace
In this installation, the chimney connector rises from the stove, turns ninety degrees, and goes back into the fireplace chimney. The liner of the fireplace chimney should extend at least to the point at which the chimney 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:
Check the stove and chimney connector clearances
to combustible mantel or trim materials. Use the necessary combination of mantel, trim, and connec­tor heat shields to provide the required clearances. (Fig. 8)
Double-check connector clearance from the ceiling.
The fireplace damper must be closed and sealed
to prevent room air from being drawn up the flue, reducing the draft. However, it must be possible to re-open the damper to inspect or clean the chimney.
Flue Liner
Extend Chimney Con­nector to the First
Tile of
the Flue Liner
Observe Miniumum Clearances
Damper Plate is Remvoed or Locked in Open Position
Close Of
f the Damper Opening with Sheet Metal and Sealant
ST245a
Fig. 9 The connector passes through the fireplace to enter flue. Special Fireplace Adapter Kits to simplify fireplace instal­lations are available from your local dealer.
Masonry Wall
Ceramic Flue Liner
Chimney Connec­tor Shield
Block-Of
f Plate
Chimney Connector
ST244a
Fig. 8 The connector enters flue above the fireplace. If the clearance between the chimney connector and either the mantel and/or the ceiling is inadequate, special protective shields will be required.
Thimble Sleeve
Elbow
Flue
Keep Sleeve End Flush with Flue Tile
Thimble
Flue Liner
Chimney Connector
ST243
Fig. 7 The thimble, made of either ceramic or metal, must be cemented in place securely.
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Fireplace Installations -
Through the Fireplace
The Convection heaters may be installed either without legs* as a fireplace insert, or with standard legs at­tached - depending on the safety regulations that apply to your situation, the height of the fireplace opening and your own preference. For either situation, the chimney connector/positive connection kit extends back from the stove, enters the fireplace cavity, and turns upward. It then passes through the fireplace damper opening and smoke chamber and connects to the chimney flue. In such installations, a “positive connection” must be made to the chimney flue with a special kit available from your local dealer. Also, special clearance and floor protection provisions must be observed. These provi­sions are discussed in the Clearance and Floor Protec­tion sections respectively.
Wall Pass-Throughs
Whenever possible, design your installation so the con­nector does not pass through a combustible wall. If you must use a wall pass-through in your installation, check with your building inspector before you begin and con­struct it in accordance with local building codes. Also check with the chimney connector manufacturer for any specific requirements.
Accessories are available for use as wall pass­throughs. If using one of these, make sure it has been tested and listed for use as a wall pass-through.
All combustible material in the wall is cut away a suffi­cient distance from the single-wall connector to provide the required 12” (305 mm) clearance for the connector. Any material used to close up the opening must be non­combustible.
The following wall pass-through methods may be ap­proved in your area:
Use a section of listed factory-built chimney with a
nine-inch clearance to combustibles.
Place a chimney connector pipe inside a ventilated
thimble, which is then separated from combustibles by six inches (152 mm) of fiberglass insulating mate­rial.
If the stove is installed without legs, we recommend
the use of noncombustible tiles or pavers as shims to allow air flow into the convection air inlets under the stove. Make sure not to block air slots instove bottom with shims or remove fan cover.
Place a chimney connector pipe inside a section of
listed solid-insulated, factory-built chimney, with an inside diameter 2 inches (51 mm) larger than the
chimney connector and having 1 inch (25.4 mm) or more of insulation and maintaining a minimum 2 inch air space between the outer wall of the chimney and combustibles.
In Canada: The Canadian Standards Association has established different guidelines. Figure 11 shows one method, in which all combustible material in the wall is cut away to provide the required 18” (450 mm) clear­ance for the connector. The resulting space must remain empty.
DO NOT CONNECT THE HEATER TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
18” (450mm) Empty Space All Around the Chimney Connector
Sheet Metal Cover (One side only)
ST421
Fig. 11 Hollow wall pass-through.
Chimney Con­nector
12”
(305mm)
12”
(305mm)
ST420
Fig. 10 Wall pass-through enclosed with noncombustible materials.
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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 non-combustible spacers at least 1” (25 mm) clear of the wall. Your Dutchwest 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.
NOTE: Do not vent your Dutchwest stove into a factory­built (zero-clearance) fireplace. These appliances and their chimneys are specifically designed as a unit for use as fireplaces. It may void the listing or be hazard­ous to adapt them for any other use.
Floor Protection
A tremendous amount of heat radiates from the bottom plate of your Dutchwest stove. The floor area directly under and around the stove will require protection from radiant heat as well as from stray sparks or embers that may escape the firebox.
Heat protection is provided through the use of a CFM Corporation Bottom Heat Shield. 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 without the heat shield.
Even when the bottom heat shield is installed, you must provide special protection to the floor beneath. For installation 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 decorative noncombustible material if desired. Do not obstruct the space under the heater.
Protection requirements vary somewhat between the United States and Canada as follows:
U.S. Installations: The floor protector is required under the stove and must extend at least 16 inches from the front and left (loading door) side of the stove, and at least 6 inches from the right side and rear. (Fig. 12) Refer to Figure 12 for minimum noncombustible floor protection dimensions for each stove model.
In Canada: a noncombustible floor protector is required under the heater also. The floor protector must extend 18 inches (457mm) from the front and left (loading door) side of the stove, and at least 8 inches (203mm) from the right side and rear. (Fig. 12)
ST422
Fig. 12 Be sure to follow exactly the floor protection require­ments on all four sides of the stove.
Minimum Dimensions for Noncombustible Floor Protectors (Depth x Width):
Model U.S. Canada
2460 38” x 44” 42” x 48” (1067mm x 1219mm) 2461 38” x 48” 42” x 52” (1067mm x 1320mm) 2462 42” x 52” 46” x 56” (1168mm x 1422mm)
B
B
A
A
U.S. Canada A. 16” 18” (457 mm)
B. 6” 8” (203 mm)
A
ST423
Fig. 13 Combustible supporting timbers (A) may lie beneath fireplace hearths; such situations require additional floor protection.
Due to the side loading door, floor protector require­ments call for more protection on the left side than on the right. If you wish a more balanced look, increase the other side of the hearth as well. Do not reduce
side protection under any circumstances.
Fireplace Installations
You may install your Dutchwest Convection Heater in an existing fireplace as a fireplace insert with no legs,* or with the standard legs attached.
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To install the heater without legs as a fireplace insert, the floor must be completely noncombustible, such as an unpainted concrete floor over earth.
Many fireplaces do not satisfy the “completely non­combustible” requirement because the brick or con­crete hearth in front of the fireplace opening usually is supported by heavy wooden framing as in Figure 13. Because heat passes readily through brick or concrete, it can easily pass through to the wood. As a result, such fireplace hearths are considered a combustible floor. You may not install a heater on a combustible
hearth without legs. Standard leg installations must include the bottom heat shield. The floor protector
must also meet standard requirements for freestanding installations.
Floor Protection for Fireplace
Installations with Standard Legs
Fireplace installations with the standard legs and the bottom heat shield must have a floor protector of the same construction as that specified for freestanding in­stallations: 1/4” non-asbestos mineral board or equiva­lent, or 24 gauge sheet metal (that may be covered with a decorative noncombustible material if you desire). The floor protector must extend at least 16” (406 mm) [18” / 457 mm in Canada] from the front of the stove and from the left (loading door) side, and at least 6” (152 mm) from the right side and rear. It must also provide protection beneath any horizontal runs of the chimney connector, including 2” to either side.
Many raised hearths will extend less than the required distance from the front of the heater when it is installed. In such cases, sufficient floor protection, as described above, must be added to extend the hearth 16” (406 mm) [18” (457 mm) in Canada].
Hearth rugs do not satisfy the requirements for floor protection.
Fireplace insert installations also have specific clear­ance requirements to the side walls, side decorative trim, and fireplace mantel. This information is found in
“Fireplace Installation Clearances” in this section.
REMINDER- FIREPLACE INSERT INSTALLATIONS WITHOUT LEGS ARE PERMISSIBLE ONLY IF THE HEARTH IS COMPLETELY NONCOMBUSTIBLE, SUCH AS UNPAINTED CONCRETE OVER EARTH.
Keep the Stove a Safe Distance
From Surrounding Materials
Both a stove and its chimney connector radiate heat in all directions when operating. A safe installation re­quires that adequate clearance be maintained between the stove and nearby combustible materials to ensure that such 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. Keeping those clearance areas empty assures that nearby surfaces and objects will not overheat.
Safe Ways To Reduce Clearances
Your stove has specific clearance requirements that have been established through careful research and testing to UL and ULC standards.
Clearance requirements have been established to meet every installation possibility, and they involve the combi­nation of basic variables:
When the stove has no listed heat shield
When the stove has a listed heat shield
When the wall has no heat shield
When the wall has a heat shield
When the stove has a double-wall chimney con-
nector.
When the stove has a single-wall connector
wit heat shields, or without heat shields.
In general, the greatest clearance is required when you locate a stove with no heat shield near a wall with no heat shield. The least clearance is required when both the stove and the wall have heat shields. Reducing a stove clearance may require a listed heat shield on the chimney connector as well, or a double-wall connector.
Clearances may be reduced only by means approved by the regulatory authority and in accordance with the clearances listed in this manual. The charts and sample installations that follow list all the clearances required for the various installation configurations of Dutchwest Convection Heaters.
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