Vermont Castings Installation And Operating Manual
Specifications and Main Features
Frequently Asked Questions
User Manual
Encore® FlexBurn® Non-Catalytic/Catalytic
Wood Burning Stove
Installation and Operating Manual
Model 2040CE
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.
Congratulations on your choice of a Vermont Castings Encore stove. With this purchase you have made a commitment
to make the hearth a place of warmth, beauty and comfort in your home. At Vermont Castings Group, we share that
joy and appreciation for the hearth. We assure you that your cast-iron V ermont Castings stove has been made with the
utmost care and will provide you with many years of service.
As you become acquainted with your new stove, you will fi nd that its appearance is matched by its functionality, due to
cast iron’s unique ability to absorb and radiate heat.
Also, Vermont Castings Group products are among the cleanest-burning wood stoves and fi replaces available today . As
an owner of a Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning
depends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly
operate and maintain your stove.
At Vermont Castings Group, we are equally committed to your satisfaction as a customer. That is why we maintain
an exclusive network of the fi nest dealers in the industry. Our dealers are chosen for their expertise and dedication to
customer service. They are factory-trained and knowledgeable about every V ermont Castings Group product. Feel free
to contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its
performance.
This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore. It also
contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
Sincerely,
Vermont Castings Group
This manual describes the installation, operation, and maintenance of the Vermont Castings Encore Model 2040CE
Non-Catalytic / Catalytic wood burning heater. This heater
meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold on or after July 1, 1990.
Under specifi c test conditions this heater has been shown
to heat 9.6kW (34,000 Btu/hr).
The Encore Model #2040CE has been tested to current
standards. The test standards are ANSI/UL-1482-201 1 and
ANSI/UL-737 for the United States, and EN13240:2001 +
A2:2004 for Europe. The Encore is listed for burning wood
only. Do not burn other fuels.
We recommend that you hire a professional installer to
install your stove, or to advise you on the installation should
you attempt to install it yourself.
Please read this entire manual before you install and use
your new stove. Failure to follow instructions may result in
property damage, bodily injury, or even death.
Warming Shelf 8” Flue Collars
#0200 Classic Black #0555 Classic Black
#0205 Biscuit #0556 Biscuit
#0207 Ebony #0557 Brown Majolica
#0199 Bordeaux #0560 Bordeaux
#0208 Brown Majolica #0561 Twilight
#0198 Twilight
#3265* Outside Air Kit
#3185 Outside Air Adapter
#0336* Mobile Home Kit
#0127 Firescreen
FK26 Fan Kit
#3190 Connector Pipe Heat Shield
A line of porcelain enamel stove pipe is available in Biscuit,
Bordeaux, Ebony, Brown Majolica colors.
*If you order #3265 or #0336, you must also need #3185.
Weight ..................................................215 kg (475 lbs.)
) ..w/Cat. 0.09% w/o Cat. 0.42
2
1
Width (leg-to-leg) ........................................685 mm (27”)
Depth (leg-to-leg)........................................380 mm (15”)
Height to top of fl ue collar ...........................635 mm (25”)
1. This value can vary depending on how the stove is
1
operated, the type and moisture content of the fuel used,
as well as the design, construction and climatic location
of your home. Figures shown are based on nominal fuel
consumption obtained under laboratory conditions and on
average effi ciencies.
SAFETY NOTICE: IF YOUR ENCORE IS NOT PROPERL Y
INSTALLED, A HOUSE FIRE MA Y RESUL T. T O REDUCE
THE RISK OF FIRE, FOLLOW THE INSTALLATION INSTRUCTIONS. CONT ACT LOCAL BUILDING OR FIRE
OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION REQUIREMENTS IN YOUR AREA.
Before you begin an installation, be sure that:
• Y our stove and chimney connector will be far enough
from combustible materials to meet all clearance
requirements.
• The fl oor protector is large enough and is constructed
properly to meet all requirements.
• You have all necessary permits from local authori-
ties.
Your local building offi cial is the fi nal authority for approv-
ing your installation as safe and determining that it meets
local and state codes.
The metal label permanently attached to the back of
every Vermont Castings’ stove indicates the stove has
been tested to current standards. The test standard is
EN13240:2001 + A2:2004 for Europe. Clearance and
installation information also is printed on the label. When
the stove is installed according to the information both on
the label and in this manual, local authorities in most cases
will accept the label as evidence that the installation meets
codes and can be approved.
However, codes vary in dif ferent countries. 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 INST ALLATION INSTRUCTIONS MA Y RESUL T IN A DANGEROUS
SITUA TION, INCLUDING A CHIMNEY OR HOUSE FIRE.
FOLLOW ALL INSTRUCTIONS EXACTL Y , AND DO NOT
ALLOW MAKESHIFT COMPROMISES TO ENDANGER
PROPERTY AND PERSONAL SAFETY.
Outside Air
In some modern, super-insulated homes, there is inadequate air for combustion because of insuffi cient air infi l-
tration into the building. Such air enters a home through
unsealed cracks and openings. Exhaust fans for kitchen
or bath can compete with the stove for available air and
compound the problem.
When poor draft is caused by a low infi ltration rate, open-
ing a ground fl oor window on the windward side of the
house and in the vicinity of the stove will usually alleviate
the problem.
For appliances with power outputs above 5 kW, a permanently open air vent is required by Section 2 of Document
J. Air inlet grilles should be positioned so that they will not
be blocked. Refer to local and national codes for recommended confi gurations.
Pressure variations within the house do not affect a stove
equipped with an outside air supply, and improved stove
performance often results. An Outside Air Adapter Kit for
the Encore is available from your local Vermont Castings
dealer.
Chimney Height
Altitude affects chimney performance. When using a 6”
fl ue collar on the Encore, refer to Figure 2 for suggested
chimney heights at various altitudes. Chimney height
should be measured from the fl ue collar to the top of the
chimney. The recommended minimum chimney height is
4.9 m (16’).
All local regulations, including those referring to national and European standards, need to be complied
with when installing this stove.
4
ST491
Fig. 2 Chimney height requirements for Encore when equipped
with a 152 mm (6”) chimney.
Y ou must connect the Encore to a code-approved masonry
chimney with a fl ue liner, to a relined masonry chimney that
meets local codes, or to a prefabricated metal chimney.
(Fig. 3) The chimney and chimney connector must be in
good condition and kept clean.
If you use an existing masonry chimney, it must be inspected to ensure it is in a safe condition before the stove is
installed. Y our local professional chimney sweep, building
inspector, or fi re department offi cial will be able to inspect
the chimney or provide a referral to someone who can.
The fl ue and chimney design must meet requirement J2,
Part J of the building regulations 2000 (Combustion Appliances and Fuel Storage Systems).
A prefabricated doublewall insulated chimney
A tile-lined
masonry
chimney
ST241
Fig. 3 Approved chimney types.
Masonry Chimneys
Prefabricated Chimneys
These should be an internal diameter of 150 mm (6”) and
be of the twin wall insulated construction that has been
approved for solid fuel use (e.g. Rite Vent ICS of ICID
Lite Chimney Systems). Diameters over 200 mm (8”) are
not recommended due to the large cross-section causing
excessive cooling of the fl ue gases.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
Chimney Size
An Encore with an 203 mm (8”) fl ue collar is approved for
venting into a masonry chimney with a nominal fl ue size
of 203 x 203 mm (8” x 8”) or 203 x 305 mm ( 8” x 12”), and
into a round fl ue with nominal fl ue size of 203 mm (8”).
An Encore with a 152 mm (6”) fl ue collar is approved for
venting into a masonry chimney with a nominal fl ue size of
203 x 203 mm (8” x 8”), and into a round fl ue with nominal fl ue of 152 mm (6”).
NOTE: When installed with a 6” fl ue collar , the Encore
may not be operated with the front doors open.
Whatever the fl ue collar size, an Encore may be vented
into larger chimneys as well. However, chimneys with
liners larger than 203 x 305 mm (8” x 12”) may experience
rapid cooling of smoke and reduction in draft, especially if
the chimneys are located outside the home. These large
chimneys may need to be insulated or have their fl ues
relined for proper stove performance.
Accessories to help make the connection between stainless steel chimney liners and your Encore are available
through your local dealer.
An inspection of the chimney must confi rm that it has a lin-
ing. Do not use an unlined chimney. The chimney should
have no cracks, loose mortar, other signs of deterioration,
and blockage. Repair any defects before the chimney is
used with your stove.
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 fi re, fl ames 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.
30005552
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 the masonry or prefabricated structure that encloses the
fl ue. Chimney connectors are used only to connect the
stove to the chimney, as in Figure 5.
Connecting Flue Pipes
Connector pipes should meet the requirements of the building regulations. This can be achieved by the use connecting
fl uepipes included in the following categories:
a) Vitreous enamelled steel pipe complying with BS 6999:
1989 (1996);
b) Pipes made from stainless steel as descirbed in BS EN
1008-1:1995 grades 1.4401, 1.4404, 1.4432 or 1.4436 with
fl ue wall thickness of at least 1 mm;
c) Mild steel fl uepipes complying with BS 1449: Part 1:
1991, with a fl ue wall thickness of at least 3 mm;
d) Cast iron fluepipes complying with BS 41: 1973
(1998).
Flue Pipes with a spigot and socket joint should be fi tted
with the socket facing upwards, to contain condensates
and moisture within the fl ue. Joints should be made gas
tight using proprietary jointing accessories, or, where appropriate, by packing joint with noncombustible rope and
fi re cement.
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 heavier steel. Do not use
galvanized connector; it cannot withstand the high temperatures that can be reached by smoke and exhaust gases,
and may release toxic fumes under high heat. The connector may be 152 mm (6”) or 203 mm (8”) in diameter.
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 section on Wall
Pass-Throughs. Do not pass the connector through an
attic, a closet or similar concealed space. The whole connector should be exposed and accessible for inspection
and cleaning.
In horizontal runs of chimney connector, maintain a distance of 610 mm (24”) from the ceiling. Keep it as short and
direct as possible, with no more than two 90° turns. Slope
horizontal runs of connector upward 6 mm per metere
(1/4” per foot) going from the stove toward the chimney.
The recommended maximum length of a horizontal run
is 914 mm (36”), and the total length should be no longer
than 2.4 m (8’). In cathedral ceiling installations, extend
the prefabricated chimney downward to within 2.4 m (8’)
of the stove.
Wear gloves and protective eyewear when drilling, cutting or joining sections of chimney connector.
Double-wall Chimney Connectors
Single-wall Chimney Connectors
• Begin assembly at the fl ue collar of the stove. Insert the
fi rst crimped end into the stove’s fl ue collar, and keep
each crimped end pointing toward the stove. (Fig. 4)
Using the holes in the fl ue collar as guides, drill 3 mm
(1/8”) holes in the bottom of the fi rst section of chimney
connector and secure it to the fl ue collar with three #10
x 1/2” sheet metal screws.
• Secure each joint between sections of chimney con-
nector, including telescoping
joints, with at least three (3)
sheet metal screws. The
pre-drilled holes in the top
of each section of chimney
connector serve as guides
when you drill 3 mm (1/8)
holes in the bottom of the
next section.
• Secure the chimney connec-
tor to the chimney. Instructions for various installations
follow.
• Be sure the installed stove
and chimney connector are
correct distances from nearby combustible materials.
NOTE: Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney connector
are available to simplify installations. They often eliminate
the need to cut individual connector sections. Consult your
local dealer about these special pieces.
Fig. 4 the crimped end
of the connector points
toward stove.
Securing the Single-wall Connector to a
Prefabricated Chimney
Information on assembling and installing double-wall connectors is provided by the manufacturer of the double-wall
pipe. Follow the manufacturer’s instructions exactly as
you assemble the connector and attach it to the stove
and chimney. Using chimneys and connectors from the
same manufacturer makes the assembly and installation
straightforward.
NOTE: For installations using double-wall connectors,
minimum clearances must conform to the listed clearances
in the clearance chart on Page 14.
If the Encore is equipped with the 203 mm (8”) fl ue collar,
an oval-to-round adapter will be needed. Double-wall ovalto-round adapters are available from some manufacturers.
Your local dealer can help you select the right connector.
6
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 adapters are available from your local dealer to
make the connection between the prefabricated chimney
and the chimney connector. The top of such adapters
attaches directly to the chimney or to the chimney’s ceiling support package, while the bottom of the adapter is
screwed to the chimney connector.
These adapters are designed so the top end will fi t outside
the inner wall of the chimney, and the bottom end will fi t
inside the fi rst section of chimney connector. When as-
sembled in this way, any soot or creosote falling from the
inner walls of the chimney will stay inside the chimney
connector.
Fig. 5 Chimney connection in a freestanding masonry installation.
Flue
Flue Liner
Thimble
ST492
Securing the Single-wall Connector to a
Masonry Chimney
Both freestanding masonry chimneys and fi replace masonry
chimneys may be used for your installation.
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 fl ue (the
“breech”) must be lined with either a ceramic or metal
cylinder, called the “thimble”, which is cemented securely
in place. Most chimney breeches incorporate thimbles, but
the fi t must be snug and the joint between the thimble and
the chimney wall must be cemented fi rmly.
A special piece called the “thimble sleeve,” slightly smaller
in diameter than standard connectors and most thimbles,
will facilitate the removal of the chimney connector system
for inspection and cleaning. Thimble sleeves should be
available from your local dealer.
To install a thimble sleeve, slide it into the breech until it is
fl ush with the inner fl ue wall. Do not extend it into the actual
fl ue passage, as this could interfere with the draft.
The thimble sleeve should protrude 1-2” (25-50mm) into
the room. (Fig. 6) 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.
Thimble Sleeve
Chimney Connector
Fig. 6 The thimble, made of either ceramic or metal, must be
cemented securely in place.
Flue
Keep
sleeve
end fl ush
with fl ue
tile
ST243
Without a thimble, a suitable length of chimney connector
can be extended through the breech to the inner face of
the fl ue liner, and cemented securely in place. Additional
pieces of connector are then attached with sheet metal
screws.
Fireplace Installations
The chimney connector may be connected to the chimney
above the fi replace opening or through the fi replace.
Above the Fireplace
The Encore may be connected to a chimney above a
fi replace opening. (Fig. 7) In such installations, the stove
is positioned on the hearth in front of the fi replace and the
chimney connector rises from the stove top and then angles
ninety degrees back into the chimney. The chimney liner
should extend to the point at which the chimney connector
enters the chimney.
If the chimney connector from your installation enters the
chimney above a fi replace, follow all the guidelines men-
tioned above for freestanding installations. In addition, give
special consideration to the following points:
• Check the clearance between the stove and the chimney
connector, and any combustible trim or the mantel. Use
the necessary combination of mantel, trim, and connector heat shields to achieve the required clearances.
• Check the clearance between the chimney connector
and the ceiling. If no heat shields are used, the clearance should be at least 610 mm (24”).
• The fi replace damper must be sealed to prevent room
air from escaping up the fl ue. However, it must be
possible to re-open the damper to inspect or clean the
chimney.
Fig. 7 In this installation, the chimney connector attaches to
the chimney above the fi replace opening.
Through the Fireplace
If your fi replace opening height is at least 737 mm (29"), you
may install an Encore through the opening using a “positive
connection” kit, available from your local dealer. These positive connection kits ensure a tight fi t between the stove fl ue
collar and the chimney fl ue. (Fig. 8)
Fireplace installations, whether connected to the fl ue above
or through the fi replace opening, have special clearance
requirements to adjacent trim and the mantel. You’ll fi nd the
required safe clearances for Encore fi replace installations
on Page 11.
Floor protection requirements also apply to fi replace instal-
lations. This information is on Page 9.
Wall Pass-Throughs
Whenever possible, design your installation so the connector does not pass through a combustible wall. If you are
considering a wall pass-through in your installation, check
with your building inspector before you begin. Also, check
with the chimney connector manufacturer for any specifi c
requirements.
Accessories are available for use as wall pass-throughs.
If using one of these, make sure it has been tested and
listed for use as a wall pass-through.
ST245
Fig. 8 In this installation, the chimney connector enters the
fi repalce opening and then connects to the chimney.
Figure 9 shows one method of passing a connector through
a wall. All combustible material in the wall is cut away to
provide the required 457 mm (18”) clearance for the connector. The resulting space must remain empty. A fl ush-
mounted sheet metal cover may be used on one side only .
If covers must be used on both sides, each cover must be
mounted on noncombustible spacers at least 25 mm (1”)
clear of the wall.
Y our local dealer or your local building inspector can provide
details for other approved methods of passing a chimney
connector through a combustible wall in your area.
DO NOT CONNECT AN ENCORE TO ANY AIR DISTRIBUTION DUCT OR SYSTEM.
This appliance must be installed on to hearth that meets
the requirements of Part J of the Building Regulations 2000
(Combustion Appliances and Fuel Storage Systems). This
can be achieved by ensuring that the hearth is constructed
and sized in accordance with the guidelines included in section 2 of approved document ‘J’. The size and clearances
of the hearth are as follows:
The constructed hearth should be constructed in accordance with the recommendations in document J, and
should be of minimum width 840 mm and minimum depth
840 mm (if a free standing hearth b) above) or a minimum
projection of 150 mm from the jamb (if a recessed hearth
a) above).
Unless the stove hearth is completely noncombustible,
the bottom heat shield
should be installed to
provide radiant protection for framing which
may be below the
hearth. (Fig. 11)
Appliance
Doors
Costructional Hearth
Dimensions as below
Wood framing requires protection from radiant heat
Fig. 11 Combustible supporting timbers may lie beneath fi re-
place hearths, requiring additional fl oor protection.
At least 150 mm
or to a suitable
heat resistant wall
Appliance
Doors
ST247e
At least
150 mm
Perimeter should be
clearly marked e.g.
edge of superimposed
hearth
a) Fireplace recessb) Free standing
Fig. 10 Noncombustible hearth surface dimensions.
Floor Protection for Fireplace Installations
Do not assume that your fi replace hearth is completely
noncombustible.
Many fi replace hearths do not meet the “completely non-
combustible” requirement because the brick or concrete in
front of the fi replace opening is supported by heavy wood
framing. (Fig. 11) Because heat passes through brick or
concrete readily, it can easily pass through to the wood.
As a result, such fi replace hearths can be a fi re hazard and
are considered a combustible fl oor.
Keep in mind, also, that many raised hearths will extend
less than the required clearance from the front of the heater
when it is installed. In such cases, suffi cient fl oor protection
as described above must be added in front of the hearth to
satisfy the minimum fl oor protector requirement from the
front of the stove: 406 mm (16”) from the front.
Hearth Surface
Free of Combustible Material
Perimeter should be
clearly marked e.g.
At least
300 mm
edge of superimposed
hearth
ST912
Hearth rugs do not satisfy the requirements for fl oor pro-
tection.
Keep the Stove a Safe Distance
from Surrounding Materials
Both a stove and its chimney connector radiate heat in all
directions when operating, and dangerous overheating
of nearby combustible materials can occur if they are too
close to the heat. A safe installation requires that adequate
clearance be maintained between the hot stove and its
connector and nearby combustibles.
Clearance is the distance between either your stove (measured from the bottom edge of the stove’s top plate) or
chimney connector, and nearby walls, fl oors, the ceiling,
and any other fi xed combustible surface. Your stove has
special clearance requirements that have been established
after careful research and testing to both US and European
standards. These clearance requirements must be strictly
observed.
30005552
9
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