Vermont Castings Encore FlexBurn 2040CE Installation And Operating 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.

For use in Europe

30005552 9/14 Rev. 10

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Welcome

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.

Specifi cations ........................................................3

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

Assembly .............................................................12

Operation .............................................................15

Maintenance ........................................................18

The Chimney System ..........................................20

The Catalytic Element .........................................22

Replacement Parts ..............................................24

Warranty ..............................................................27

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.

Table of Contents

Installation Accessories

Save These Instructions for Future Reference

2

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

44 mm

(16M”)

635 mm

(25”)

Top exit

flue collar

height

686 mm (27”)

654 mm

(256M”)

470 mm

(1856O”)

184 mm

(756M”)

686 mm (27”)

565 mm

(2256M”)

394 mm

(1556O”)

127 mm

(5”)

73 mm (2(6”)

603 mm

(236M")

381 mm

(15”)

95 mm

(36M”)

578 mm

(226M”)

Specifi cations

Encore Model 2040CE

Nominal heat out put ........7.8 - 8.0 kW (34,000 BTU/hr)

Minimum fl ue draught ........................12 Pa (0.048” WG)

Mean fl ue gas temp ................................339° C (642° F)

Effi ciency (Space heating) with Catalyst ...............75.9%

Effi ciency (Space heating) w/o Catalyst ................72.9%

Area heated ..................... Up to 167 sq. m (1800 sq. ft.)

Fuel size/type .......................457-559 mm (18-22”) wood

Fuel capacity .............................................22 kg (50 lbs)

Flue mass gas fl ow ............................................... 6.6 g/s

CO Emissions (@ 13% O

Loading .......................................................Front and top

Chimney connector:

for 8” fl ue collar ..........................203 mm (8”) diameter

for 6” fl ue collar ..........................152 mm (6”) diameter

Chimney fl ue size:

for 8” fl ue collar .........................203 mm (8”) minimum

for 6” fl ue collar .........................152 mm (6”) minimum

Flue exit position...........................Reversible, top or rear

Primary air ..... Manually set, thermostatically maintained

Secondary air .................................Fixed, self-regulating

Ash handling system .......................Removable ash pan

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

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.

Fig. 1 Encore 2040CE dimensions.

30005552

Drawings Not to Scale

3

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

30

25

20

15

0 2000 4000 6000 8000 10000 12000

Height (ft.)

Altitude (ft.)

6“

Installation

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.

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

What Kind of Chimney to Use

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).

5

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

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.

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Chimney

Elbow

Slip Pipe

Standard
Connector

Oval to
Round Adapter

Flue Collar

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.

30005552

7

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

T

DEFIANT

*

*

Check These

Clearances

Flexible Connector

* Check These
Clearances

Mantel

Seal
This Off

Mantel Shield

Fireplace Adapter
Kit “Positive Con­nection”

ST244a

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.

457 mm (18”) clear
space all around the
pipe

8

ST494

Fig. 9 An approved wall pass-through.

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Hearths

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 recess b) 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

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

In addition, furnishings and other combustible materials
must be kept away from the stove as well. In general, a
distance of 1219 mm (48”) must be maintained between
the stove and moveable combustible items such as dry­ing clothes, furniture, newspapers, fi rewood, etc. Keeping
those clearance areas empty assures that nearby surfaces
and objects will not overheat.

Safe Ways to Reduce Clearances

Clearances

As with any solid fuel heating stove, extremely high
surface temperatures can occur, particularly in the
event of uncontrolled operation, e.g. if the doors are
inadvertently left open. It is crucial that suffi cient clear-
ances are allowed to any combustible surfaces, e.g.
wooden mantels or lintels, and to timber framed (stud­ded) walls even if they are faced with noncombustible
board. Detailed information on fi replace and hearth
construction is provided in section 2 of Document
J, all installations must comply with these require­ments or with the relevant National or local building
standards.

Clearances to timber framed (studded) walls are included
below. There are no specifi c minimum clearances to solid
noncombustible surfaces (e.g. the sides and rear of Ingle­nook fi re openings constructed from solid masonry) other
than to allow safe access to the controls of the stove. For
this reason minimum side clearances of 125 mm, and a
minimum rear clearance of 50 mm are recommended.

Summary of Clearances

Minimum recommended side clearances to noncom­bustible surfaces 125 mm (5”).

Minimum recommended rear clearance to noncombus­tible surfaces 50 mm (2”).

NOTE: The minimum thickness of solid noncombustible

materials is specifi ed in section 2 of Document ‘J’, in rela-
tion to the clearance of the appliance from the surface.
As a general rule, the thickness of solid noncombustible
material forming the recess of a fi replace is a minimum of
200 mm.

Minimum rear clearance from combustible walls (e.g.
timber framed or studded walls) 254 mm (10”) mea­sured from the rear edge of the stove top. (Fig. 12, B)

Minimum side clearance from combustible walls 483
mm (19”) measured from the side edge of the stove
top. (Fig. 12, A)

Minimum distance from stove to movable combustible
materials (e.g. furniture, drying clothes, etc.) 1220 mm
(48”).

B

A

ST486a

Fig. 12 Minimum clearances.

Connecting Flue Pipe - Clearances

Single wall connecting fl uepipes can reach extremely high
temperatures; therefore, clearances from the connecting
fl uepipe (chimney connector) must comply with the require­ments of Part J of Building Regulations 2000 (Combus­tion Appliances and Fuel Storage Systems). This can be
achieved by following the recommendations of Approved
Document ‘J’. These are as shown in Figure 13.

10

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

at least
3 x D

at least

1.5 x D

Elevation
Without
Shield

D

at least 1.5
x D

Fig. 13 Connecting fl uepipe clearances.

at least

3 x D

Plan Without
Shield

Elevation
With Shield

at least 3 x D

Fluepipe

at least

D

1.5 x D

at least

1.5 x D

at least

1.5 x D

Air space of at least 12 mm
between noncombustible shield
and combustible material

Plan With
Shield

ST911

30005552

11

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Assembly

Set Up Your Stove

Cast iron stoves are heavy , and it will take two to four people
to move your Encore into position.

Wipe the protective
coating of oil from the
griddle with a clean
dry rag or a paper
towel.

Install the handle on
the griddle. First,
place the griddle up­side down at the edge
of a fl at surface and
assemble the handle as shown.

With the handle pointing 45° from its fi nal position, tighten
the nut as far as possible with the pliers. Move the handle to
its fi nal position while still holding the nut with the pliers.

Fig. 14 Attach the griddle handle.

Storing the Handle

ST516

ST857a

Fig. 16 Attach the bottom heat shield.

Adjust the Leg Levellers

Lift the stove slightly so there is no weight on the leg
while making the adjustment.

Bottom Heat Shield

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. 15)

Bottom Heat Shield

Door Handle Holder

Leg Bolt and Washer

Fig. 15 Handle holder and heat shield positions.

ST564

Install the Bottom Heat Shield

NOTE: The Bottom Heat Shield is required in most in-

stallations. Refer to Floor Protection, Page 9, for further
details.

1. Loosen the four 1/4-20 hex head bolts from the corners

of the ash drop on the stove bottom.

2. Align the bottom heat shield holes with the four bolts.

The outside air cutout hole should be toward the rear
of the stove. The unpainted side must face up towards
the stove.

3. Pass all four bolts through the large end of the keyholes

and then pulling the shield forward to engage the smaller
ends of the keyhole slots. (Fig. 16)

4. Attach the heat shield sides by passing the slots over

the bolt heads. Tighten the hex head bolts.

Reverse the Flue Collar (If necessary)

Reverse the fl ue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket around
the fl ue collar opening is in position when you screw the
collar back onto the stove.

Attach Flue Collar Heat Shield

WARNING: The fl ue collar heat shield must be attached

to the Encore stove. Use four #10 sheet metal screws
supplied to secure the fl ue collar heat shield to the rear of
the stove. (Fig. 17)

Attach the Damper Handle

Use the 1/4” -20 x 3” screw to attach the damper handle
to the damper stub on the left side.

Attach the Primary Air Thermostat Handle

The primary air thermostat handle is the smaller of the
two black handles. Secure the handle to the stub on the
right side of the stove with an 8-32 x 2” slot head machine
screw. (Fig. 18)

12

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Fan Kit Installation

Sheet
Metal
Screws

Flue Collar
Heat Shield

Sheet
Metal
Screws

ST1180

Fig. 17 Install fl ue collar heat shield.

WARNING: The fl ue collar heat shield must be installed

in all vertical installations. The fl ue collar heat shield is
not used when the fl ue collar is in the rear exit position.

1. Attach the fan assembly at the bottom edge of the in­ner back with two (2) 1/4-20 x 3/4” hex head screws.

2. Attach snapstat to the mounting holes on the underside
of the bottom with two (2) 1/4-20 pan head screws.

3. Attach the rheostat holder (provided with the stove)
under the right front wing of the bottom heat shield with
two (2) #10 sheet metal screws.

4. Attach the rheostat to its holder by inserting the rheo­stat control shaft through the holder hole. Install the
retaining ring and rheostat knob onto the shaft.

5. Secure the rheostat cable to the underside of the bot­tom heat shield using the wire tie provided and the
hole at the right rear edge of the heat shield.

6. Fan will not operate until stove reaches approximately
43° C (109° F).

7. Plug blower cord into a grounded outlet. Do not re­move ground prong from plug. Route power cord to
avoid heat from the stove or other damage. Do not
route cord under or in front of appliance.

ST635

Fig. 18 Attach the thermostat handle.

Assemble the Removable Insert Handle

The ceramic removable insert handle opens and closes the
front doors. Remove after each use, and store it in the handle
holder behind the right front leg. Assemble the handle by
passing the 3
the bright metal nub. (Fig. 19) Tighten carefully until snug.

3

⁄8" screw through the ceramic shaft and into

ST540

Hole for Wire
Tie to Secure
Cable

Rheostat
Knob

Rheostat
Holder

Rheostat

Fig. 20 Fan installation (Kit # 2767).

Snapstat

Screws

ST848

Fig. 19 Assemble the front door handle.

30005552

13

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Installing or Removing Catalyst

1. Remove the access cover by gently lifting up and pull­ing out from the bottom edge. (Fig. 21)

2. Remove the inner cover by pulling it straight out. (Fig.

22)

3. Remove the catalyst by gently pulling it straight out.
(Fig. 23) Place the catalyst where the catalyst’s ce­ramic components will not be damaged.

Access
Cover

ST1187

Fig. 21 Remove access cover.

Inner Cover

Remove Catalyst

Fig. 23 Remove catalyst.

ST1189

ST1188

Fig. 22 Remove inner cover.

14

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Operation

The Encore Controls

Two controls regulate the performance of the Encore: a

primary air control supplies oxygen for the fi re, and a
damper directs air fl ow within the stove to activate and

deactivate the catalytic combustor.
Symbols cast into the stove are reminders of the correct

directions for opening and closing the controls. The sym­bols assume that you are facing the front of the stove.

Low Heat

Damper Handle

Ashdoor
Handle

Andirons

Fig. 24 The Encore controls are conveniently located and
easy to operate.

Griddle Handle

Door Handle

Air Control
Lever

Door Handle
Holder (Be­hind leg)

ST636

A Single Air Control Regulates

Heat Output and Burn Time

The primary air control lever, located on the right side of
the stove, controls the amount of incoming air for starting,
maintaining, and reviving a fi re.

More air entering the stove makes the fi re burn hotter and
faster, while less air prolongs the burn at a lower heat level.
High and low settings appear in Figure 25.

For the greatest air supply and maximum heat output (but
the shortest burn time), move the lever toward the front
of the stove. For a fi re that will last longer with less heat,
move the lever toward the rear of the stove.

The Encore’s air control system also features an automatic
thermostat to ensure an even heat output at whatever
manual setting you select. The thermostat senses the
heating and cooling of the stove surface and adjusts the
air shutter accordingly.

A Damper Directs Air Flow

Within the Stove

The damper handle on the left side of the stove operates
the damper to direct air fl ow within the stove.

The damper is open when the handle points to the rear,
enabling smoke to pass directly into the chimney. The

High Heat

ST637

Fig. 25 The handle may be positioned anywhere between the
two extremes for different heat levels.

damper must be open when starting or reviving a fi re, and
whenever the griddle or doors are opened.

The damper is closed when the handle points forward.
Smoke travels through the non-catalytic combustion sys­tem where it can be further burned, before passing up the
chimney. (Fig. 26)

The damper should always be either fully open or fully
closed. There are no intermediate positions. When
closing the damper, be sure to pull fi rmly enough to
snap the handle into the locked position.

Damper Positions

Open
(Updraft Mode)

Closed
(High Effi ciency
Mode)

ST638

Fig. 26 The damper is either open or closed. There are no
intermediate positions.

High-Effi ciency Wood Burning

with Catalytic Combustion

An Encore leaves the factory with the combustor packaged
separately.

In the United States, it is against the law to operate this
wood heater in a manner inconsistent with operating in­structions in this manual. The components of the catalytic

30005552

15

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Defiant

combustion system in your Encore work together to pro­duce optimum conditions for secondary combustion.

When the damper is closed, smoke travels through the cat­alytic element, which causes ignition of smoke at tempera­tures of 260°-315°C (500°-600° F), half the temperature
normally required for unaided secondary combustion.

The catalytic element is a ceramic “honeycomb” coated
with the catalytic material. The element is located in the
secondary combustion chamber, molded from a special
high-temperature insulating refractory material. The
chamber provides the correct environment necessary for
secondary combustion of the fuel (smoke).

Closing the damper exposes the smoke to the combustor.
If the combustor is at least 315°C (600°F), it will begin to
burn the smoke.

Closing the stove damper may also reduce the draft, so
to avoid putting out the fi re or deactivating the combustor,
close the damper only when a fi re is well-established and
the chimney is thoroughly warmed. When starting a fi re,
wait until the fi re is well established and there is an ember
bed of at least 75 - 100 mm (3-4 inches) before closing
the damper.

Never kindle a fi re with colored paper or paper that has
colored ink or a glossy surface, and never burn treated
wood, garbage, solvents, or trash. All of these may poison
the catalyst and prevent it from operating properly. Never
burn cardboard or loose paper except for kindling purposes.
Never burn coal; doing so can produce soot or large fl akes
of char or fl y ash that can coat the combustor and cause
smoke to spill into the room. Coal smoke also can poison
the catalyst so that it won’t operate properly.

IMPORT ANT: Do not burn any type of artifi cial or syn-
thetic materials such as fi re starter logs (containing
wax) in this appliance. Never burn liquid-based fuels
such as kerosene, gasoline or alcohol.

Burning any materials not allowed in these instruc­tions, or over-fi ring the stove, may void the warranty.

In general, the fi re must be suffi ciently well-established to
ensure that catalytic activity is initiated. When fi rst starting a
fi re, a medium- to high- fi ring rate must be maintained until
the stove, catalyst, and fuel are all stabilized at the proper
operating temperatures, and the chimney is warmed.

Even though it is possible for the fi re to get quite hot within
a few minutes after a fi re is started, the combustor may
stop working or the fi re may go out if the fi re dies down
immediately as a result of the damper being closed. Once
the combustor starts working, heat generated by burning
the smoke will keep it working.

T o determine whether the combustor is operating, observe
the amount of smoke leaving the chimney when the damper
is activated and when it is not. This procedure is described
on Page 22.

Avoid using a full load of very dry wood in the fi rebox. This
may result in continuous very high temperatures in the
secondary combustion area and damage the combustor.
Wood which has been split, and stored under cover for
more than 18 months may be considered very dry. If you
must burn extra-dry wood, mix it with greener wood for a
longer fi re and less stress on the combustor. Also, do not
use a full load of dry slab wood or scrap wood. For long
burns, use a mix of dry and moderately dry wood.

Two Ways to Add Fuel

The Encore’s griddle lifts for convenient top-loading of logs,
and is the easiest way to add fuel. (Fig. 27)
However, the front doors open as well for adding an oc­casional log to a fi re. If the stove is equipped with 8” (203
mm) stove pipe, the front doors may be opened (or even
removed) and the optional Encore spark screen placed
in the opening for open-fi re viewing. The Encore is not

approved for operation with the front doors open if
equipped with a 152 mm (6”) chimney connector or
chimney.

ST521

Fig. 27 Top loading is the best way to add fuel during regular
use. Front loading is useful for kindling a fi re.

T o open the front doors, insert the handle into the door latch
stub and turn it to the left and up. (Fig. 28)

To close them, always close the left door fi rst. Turn the
handle in the right door to the left and up (to the open po­sition) and close it. Finally, push on the door as you turn
the handle to the right and down. The doors will draw in
slightly, and the handle should offer some resistance as
you turn it to the closed position.

To reduce the risk of breaking the glass, avoid striking the
glass or slamming the doors.

When you are not using the door handle, store it in the
holder behind the right front leg of the stove. Be careful to
not drop the handle, since it is breakable.

16

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Clockwise to
Open

Counter­clockwise
to Close

ST544

Fig. 28 To open the front doors, turn the handle clockwise.

CAUTION: The Encore will be hot while in operation.
Keep children, clothing and furniture away. Contact
may cause skin burns.

DO NOT OVERFIRE THIS HEATER. Overfi ring may

cause a house fi re, or can result in permanent dam-
age to the stove and to the catalytic combustor. If any
part of the Encore glows, you are overfi ring.

Ash Disposal

Y ou should remove ash before it reaches the top of the ash
pan. Check the level at least once a day. Every few days,
clear any ash from the outer edges of the fi rebox. Most of
the ash will fall through the grate. Slice or stir the ash with
a shovel or poker so that it falls through the grate slots.
IMPORTANT: Check the level of ash in the ash pan before
reloading the stove. If the ash level is close to the top edge
of the pan, empty the pan according to this procedure:

• Open the damper.

• Open the griddle or front doors, and use a shovel or

poker to stir excess ash through the ash slots in the
grate down into the ash pan.

• Close the griddle or doors, and unlatch the ash door. It

will pivot, swinging the ash pan out of the stove.

• Slide the cover onto the pan, making sure it is securely

closed. (Fig. 29)

• Remove the ash pan, making sure to keep it level.

• To keep the cover from sliding off and to keep ash from

falling on the fl oor, do not tilt the ash pan forward.

If the stove is in operation, close the ash door while

disposing of the ash.

ST566

Fig. 29 Be sure the cover is securely attached before removing
the ash pan.

• Properly dispose of the ash in a metal container with a

tight-fi tting lid. Store the container outdoors away from
all combustible material.

• Return the ash pan to its original position in the stove,

and close and latch the ash door.

• Do not operate the stove with the ash door open. This

will result in over-fi ring, and could cause damage to the
stove, void the warranty, or even lead to a house fi re.

Empty the ash pan regularly, typically every one to three
days. The frequency will vary depending on how you op­erate your Encore: ash will accumulate faster at higher
heat outputs.

Remove ash frequently and place it outdoors in a metal
container with a tight-fi tting lid. Place the closed container
of ash on a noncombustible fl oor or on the ground, well
away from all combustible materials, pending fi nal disposal.
If the ash is disposed of by burial in soil or otherwise locally
dispersed, it should be kept 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.

30005552

Open

Close

ST545

Fig. 30 Turn the handle to the ash pan compartment clockwise
to open and counterclockwise to close.

17

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Maintenance

Keep Your Stove Looking New

and Working Its Best

Let the fi re 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 Encore looking new.

The stove’s paint can be touched up as needed. First, mask
the areas, such as enamelled parts, glass, or handles,
around the spot to be painted. Clean the spot with a wire
brush. Remove the griddle and set it aside. It is normal
for the griddle to darken after use. You can clean it with a
fi ne-bristle wire brush, or steel wool.

Then, touch up the stove with Vermont Castings’ high
temperature stove paint. Apply the paint sparingly; two light
coats of paint are better than a single heavy one.

Care of the Porcelain Enamel Surface

Use a dry or slightly damp rag or soft brush to remove spills
or stains. For diffi cult jobs that require a cleaning agent, use
only a kitchen appliance cleaner or polish recommended
for use on enamel surfaces.

If porcelain enamel becomes chipped or scratched during
use, apply “enamel epoxy” to the damaged area and allow
to dry. Once the epoxy has dried, sand the area to blend
with surrounding area and apply appropriate color touch-up
paint. Allow to dry completely before operating stove.

Replace Broken Glass Immediately

Do not operate your stove if the glass in the doors is dam­aged.

If you need to replace the glass, use only the high tempera­ture 5 mm ceramic glass supplied by Vermont Castings.

Do not use substitutes.

Removing the Glass

1. Remove the right and left door assemblies by raising
the door until the lower hinge pin clears its hole; then,
angle the door bottom slightly outward and pull down to
release the upper hinge pin. Place the doors face down
on a padded work surface. Be especially careful with
enamelled doors.

2. Remove the screws that hold the glass retainer clips in
place, and remove the clips.

3. Carefully lift the broken glass panel from the door.

Installing the Glass

Check the gasket around the window; it should be soft
and resilient so that the glass will seal properly against
the door. Replace the gasket if it has hardened or if it is
compressed.

1. Center the glass on the gasket.

2. Secure the glass on both doors with the retainer clips.
Tighten all screws. (Fig. 31)

3. Replace the doors on the stove.

4. Open and close the doors to check that they fi t and work
properly. Adjust as necessary.

Cleaning the Glass

Most of the carbon deposits on the glass will burn off dur­ing hot fi res.

However, the ash residue that accumulates on the glass
surface should be removed regularly to prevent etching.
To clean the glass, follow this procedure:

• 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. Use
cleaning agents sparingly and be sure to keep them off
the outer surfaces of the stove.

• Rinse the glass thoroughly.

• Dry the glass completely.

18

Right Door

Gasket

Glass Panel

Retainer
Clips (4)

ST854

Fig. 31 Exploded view of the glass assembly for the right door.

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Adjust the Damper as Needed

The tension on the Encore’s damper is adjustable to com­pensate for compression of the gasket that seals the damper
to the upper fi reback. To adjust the damper:

1. Remove the griddle. Loosen the lock nut at the center
of the damper. (Fig. 32)

2. Turn the pressure screw approximately one half turn
clockwise with an Allen wrench provided with your
stove.

3. Tighten the lock nut. Prevent the pressure screw from
turning as you tighten the nut. Re-test the damper.

Pressure Ad­justing Screw

Allen
Wrench

Fig. 32 Adjust the damper with the Allen wrench.

Lock Nut

Damper

ST554

Tighten the Damper Handle as Needed

A handle on the left side of the stove controls the damper.
The handle attaches to the damper rod with a set screw. Pe­riodically check the set screw and tighten as necessary.

How to Adjust the Door Latches

The front door of the stove should close securely to prevent
accidental opening and should close tightly to prevent air
from leaking into the fi re chamber. The door handle will be
positioned vertically when the door is closed.

Over a period of time, the gasket around the door will
compress and the latch may need adjustment. To adjust
the handle, follow this procedure:

1. Remove and retain the lock nut with a 9/16” wrench.
(Fig. 33)

2. Loosen the set screw with a 1/8” Allen wrench.

3. Rotate the pawl 180°. Replace the lock nut. Tighten the
set screw.

4. Additional adjustment can be made by removing the fl at
washer. Or any combination of washer removal and/or
pawl rotation.

Test the door seal. Close the door on a dollar bill and at­tempt to pull it free. If the bill is freed with little resistance,
the gasket isn’t snug enough at that spot. Continue to make
small adjustments until the setting is right.

If additional adjusting of the latch does not enable the door
to seal suffi ciently in one area, try “adjusting” the gasket in
that area. Pack more cement or a smaller diameter gasket
into the channel beneath the gasket so the main gasket

Roller

Lock Nut

Set Screw

Flat Washer

Fig. 33 Rotate pawl and/or remove fl at washer to adjust latch.

Shoulder Screw

Handle Stub

ST1154

is raised and makes contact with the door frame. If this
procedure doesn’t solve the problem, replace the gasket.
Instructions for gasket replacement are given later in this
section.

Replace the Stove Gaskets as Needed

Your Encore uses fi berglass rope gaskets to make a tight
seal between some parts. With use, particularly on moving
parts, gaskets can become brittle and compressed and can
begin to lose their effectiveness. These will need periodic
replacement.

The sizes of replaceable gasket are listed below, along
with their applications.

Gasket Diameter... ...And the Parts it Seals

5/16” The griddle to the stove top

(wire reinforced gasket)
5/16” The damper to the upper fi reback

3/8” the front doors to the stove front; and
the doors to each other.

3/8” The ash door to the front of the bottom
panel

3/16” The outer glass panes to the door
If you need to change a gasket, fi rst obtain an appropri-

ate replacement from your Vermont Castings’ Authorized
Dealer.

Wait until the fi re is out and the stove has cooled. Be sure
to follow the standard safety procedure for working with
dusty materials: wear safety goggles and a dust mask.

The procedure for replacing gaskets is the same, regard­less of the gasket location. Follow these steps:

1. Remove the existing gasket by grasping an end and
pulling fi rmly. (Fig. 34)

2. Use a wire brush or the tip of 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. (Fig. 34)

30005552

19

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Cement

Stove Gasket

All Gasketed Construction Gaskets

Other gaskets form seals between all other non-moving
parts, but these are not subject to the same wear and
deterioration as gaskets on moving parts. It is unlikely
that you will ever need to replace these gaskets unless
the involved parts are disassembled and then put back
together. If this is the case, the job should be done only

ST560

Fig. 34 Remove gasket then clean channel with wire brush.

3. Determine the correct length of the appropriate-sized
gasket by laying it out in the channel. Allow an extra 1-2”
(25-50 mm), and mark the spot to be cut.

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 keep the gasket from unravel­ing.

5. Lay an unbroken 1/8” (3 mm) bead of silicone or cement
in the newly-cleaned channel. (Fig. 35)

ST561

Fig. 35 Lay a bead of gasket silicone or cement then press
gasket in place.

6. Starting at one end, press the gasket into the channel.
(Fig. 35) Ensure a good joint where the gasket meets before
trimming any excess. Do not overlap the gasket ends or
leave ends with ragged edges.

7. Press the gasketed part fi rmly against its normal mating
surface to seat the gasket evenly in its channel. Close and
latch the door to do this, or tap other parts with the rubber
mallet (or hammer/block of wood).

8. Clean any excess cement from around the channel, then
let the cement that holds the new gasket dry thoroughly.

9. The stove’s doors may need adjustment after you have
regasketed them. Initially, it may require loosening the
latch to accommodate the new gasket; after a few weeks,
it may need tightening to compensate for compression of
the new gasket. The directions for adjusting the latches
are on Page 19.

by a qualifi ed service technician.
5/16” diameter gasket seals the following parts:

• The lower fi reback to the back panel

• The left and right air plates (inner sides)

• All connections between the stove plates.

The Chimney System

Your Encore is designed to reduce creosote build-up
signifi cantly. 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 fi re.

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 fl ue of a
slow-burning fi re. As a result, creosote residue accumulates
on the fl ue lining. When ignited, this creosote makes an
extremely hot fi re within the fl ue system that can damage
the chimney and overheat adjacent combustible material.
If a signifi cant layer of creosote has accumulated —1/8”
(3 mm) or more — it should be removed to reduce the risk
of a chimney fi re.

You can never be too safe. Contact your local fi re author-
ity for information on what to do in the event of a chimney
fi re, and have a clearly understood plan on how to handle
one.

If you do experience a chimney fi re, act promptly to:

• Close the damper and air control lever.

• Get everyone out of the house.

• Call the Fire Department.
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 fl ue
collar into the chimney fl ue. If you cannot inspect the fl ue
system in this fashion, the stove must be disconnected to
provide better viewing access.

Creosote

20

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Clean the chimney using a brush the same size and shape
as the fl ue liner . Flexible fi berglass 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.

Clean the chimney connector 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 joints between
individual sections with sheet metal screws.

If you cannot inspect or clean the chimney yourself, con­tact your local Vermont Castings dealer or a professional
chimney sweep.

Maintenance Schedule

The Stove

DAILY:

• Clear any ash build-up from around the air holes and

combustion fl ow path in the lower fi reback.

• Ashes should be removed before they reach the top of

the ash pan. Check accumulation at least once a day.

• Keep the area around the stove clear of any combustible

materials such as wood, furniture or clothing.

TWO MONTHS:

• Check door handle to be sure it is working properly.

Gasketing becomes compressed after a period of time.
Adjust handle tightness if necessary.

• Check leg bolts and heat shield screws; tighten if nec-

essary.

ANNUAL SPRING CLEANING:

• Check gasketing for wear, and replace if necessary.

• Remove ashes from the ash pan and replace with a

moisture absorbing material (such as kitty litter) to keep
the interior of the stove dry.

• Clean the dust from the inner sides of bottom, rear or

pipe heat shields if your stove is equipped with them.
Clean surfaces are better heat refl ectors than dirty sur-
faces.

• Touch up the black paint.

• Inspect for and remove ash build-up behind the com-

bustion package. This should be done in conjunction
with annual cleaning of the chimney connector. Inspect
the passage behind the combustion package (a mirror
will be helpful) and vacuum away ash using a fl exible
vacuum hose inserted in the passage. (Fig. 36)

The Chimney Connector

TWO WEEKS:

• Inspect the chimney connector and chimney. Clean if

necessary.

TWO MONTHS:

• Inspect the chimney and chimney connector. Pay

particular attention to the horizontal runs of chimney
connector, and the elbows. Clean the system if neces­sary.

ANNUAL SPRING CLEANING:

• Disassemble the chimney connector and take it outdoors

for inspection and cleaning. Replace weak sections of
connector.

• Inspect the chimney for signs of deterioration. Repairs to

a masonry chimney should be made by a professional
mason. Replace damaged sections of prefabricated
chimney . Y our local V ermont Castings dealer or a chim­ney sweep can help determine when replacement is
necessary.

• Thoroughly clean the chimney.

Clean

out any

ash build

up

Remove these components

Fig. 36 Inspect and clean out ash accumulation behind the
combustion system.

ST1162

30005552

21

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

The Catalytic Element

This wood heater contains a catalytic combustor, which
needs periodic inspection and replacement for proper
operation. In the United States it is against the law to op­erate this wood heater in a manner inconsistent with the
operating instructions in this manual.

Under normal operating conditions, the catalytic combus­tor should remain active for two to six years (depending
on the amount of wood burned). However, it is important
to monitor the combustor periodically to ensure that it is
functioning properly , as well as to determine when it needs
to be replaced. A non-functioning combustor will result in
a loss of heating effi ciency, and an increase in creosote
and emissions.

Inspection and Cleaning

Inspect the combustor for fl y ash accumulation and physi-
cal damage three times per year. Clean the combustor as
needed.

The refractory package that houses the catalytic combustor
should be inspected for a buildup of fl y ash and cleaned
if necessary. This may be done when you examine the
combustor.

Once you have ruled out any other possible causes for a
decline in performance, inspect and clean the combustor
if necessary. Be sure to protect any surface you use for
setting the stove parts aside.

Inspecting the Combustor

Remove access door and inner fi reback. Remove the
catalytic combustor by lifting and sliding it towards you.
(Fig. 37)

Catalyst

When to Suspect a Combustor Problem

The best way to evaluate the performance of your Encore’s
combustor is to observe the amount of smoke leaving the
chimney — both when the combustor has “lighted-off” and
when it has not. Follow these steps:

• With a fi re going and the combustor properly activated,

with the damper closed to route smoke through it as
described in the Operation Section, go outside and
observe the smoke leaving the chimney.

• Then, open the stove damper and once again check

the smoke leaving the chimney.
You should see signifi cantly more smoke when the stove
damper is open and exhaust does not pass through the
combustor. However , be careful not to confuse smoke with
steam from wet wood. Steam dissipates in the air quickly;
smoke does not.

If this test indicates a problem, consider other possible fac­tors as well, such as the weather or a change in the quality
of your fuel. In warm weather, draft is weaker than it is in
colder winter weather, and fi res can burn sluggishly . Small,
hot fi res are a good solution under these conditions.

Burning “green” (insuffi ciently seasoned) wood will result in
poorer performance than burning properly seasoned fuel.
Y ou may have to run your stove hotter (more air) to achieve
acceptable performance using green or wet wood.

Also, consider any changes in your operating routine.

Inner Fireback

Fig. 37 Inspect the catalytic combustor.

To assure a long life for the combustor, it is recommended
to service the combustor on a regular basis based on the
amount of use. This procedure takes about fi ve (5) minutes
and requires no tools except for a vacuum if cleaning is
necessary.

Access Door

ST1180

Cleaning the Combustor

1. Check the combustor’s honeycomb-like element for a
buildup of fl y ash. If any is evident, take the combustor
outside and clean it by blowing air gently through it. Do
not push anything through the honeycomb; do not use
compressed air to clear the passages. Such abrasion
can scrape the thin coating of platinum (the catalyst)
off the ceramic base, shortening the catalyst’s life and
reducing its effectiveness.

2. Inspect the element for damage or degradation. Al­though small hairline cracks will not affect performance,
the element should be essentially intact. If the element
is broken in pieces or has sections missing, it should be
replaced. Call your local Vermont Castings Authorized
Dealer for a replacement element.

22

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

3. If the element is in good condition and clean, re-install
it in the stove and replace the refractory inner fi reback
and access door.

Operate the stove in your usual manner for two weeks, in­specting the chimney and the chimney connector frequently
during this period.

If creosote does not build up as fast, it is likely that the
performance change was caused by fl y ash deposits on
the catalytic element. However, continue the inspections of
the chimney system for a few weeks to ensure that proper
performance continues.

If you continue to fi nd a signifi cant creosote buildup or if
you continue to see excessive smoke from the chimney,
the catalytic element will need to be replaced. Contact your
nearest Vermont Castings’ Authorized Dealer for informa­tion about a replacement element.

NOTE: Use only the replacement catalyst supplied by a
Vermont Castings dealer.

30005552

23

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Encore Non-catalytic/Catalytic Wood Burning Stove Model
2040CE

85

89

25

23

60

86

26

9

15

76

28 73

14

21

56

19

80

3

16

18

23

46

6

36

7

74

29

24

39

77

30

34

17

20

22

10

58

8

35

84

42

43

45

37

41

12

2

1

4

27

26

87

40

44

82

75

49

63

11

88

33

57

78

32

13

38

31

65

71

72

68

72

67b

90

27

65

61b

69

62

Vermont Castings Group reserves the right to make changes in design, materials, specifi cations, prices and discontinue colors and products at any time, without notice.

24

61a

81

47

83b

79

59

83

79

83a

55

53

54

52

67a

50

16

49

82

48

51

70

5

30005552

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Encore Non-catalytic/Catalytic Wood Burning Stove Model
2040CE (continued)

Item Description Part Number

1. Brick Support Bracket 30005279

2. Griddle Gasket 1203668

3. Back 30005289

4. Refractory Rt End 30005497

5. Refractory Lt End 30005498

6. Refractory Support 30005233

7. Gasket, Fiber, Refractory Support 30005237

8. Back Insulation Board 30005269

9. Outer Back 30005261

10. Left Griddle Quadrant 30002399

11. Right Griddle Quadrant 30002401

12. Griddle 30002386

13. HS Flue Collar 30005266

14. Bracket Upper Side 30005267

15. Catalyst, Ceramic 30005353

16. Damper Ashdoor Gasket 1203588

17. Damper Ramp 1301811

18. Damper Housing 30005293

19. Damper

20. Damper Tab1 1601488

21. Damper Rod1 1600851

22. Griddle Handle Assy 30002775

23. Gasket, Fiber Back Refractory 30005270

24. Rheostat Bracket 30002863

25. Refractory, Engine - E/D 30005202

26. Damper Handle Screw 1201310

27. Damper Handle 1600664

28. Damper Handle w/Screw Assy 30002720

29. Left Side See Chart Pg. 26

30. Left Air Manifold 30002408

31. Right Air Manifold 30005290

32. Right Side See Chart Pg. 26

33. Thermostat Handle Base 30002716

34. Washer Damper Rod 1202560

35. Fireback Plate, S/S 30005217

36. Inner Bottom 30005291

37. Ashdoor Hinge Upper 30002403

38. Door Handle Bracket 30002909

39. Bottom Outer 30005292

40. Ashlip See Chart Pg. 26

41. Gasket, Fireback 30005209

42. Refractory, Fireback 30005302

43. Retainer, Fireback Refractory 30005248

44. Refractory, Inner Cover 30005205

45. Andiron 30002397

46. Refractory, Access Cover 30005303

47. Leg Leveller 1201745

48. Ashdoor Handle Shaft 1600622

1

30006467

Item Description Part Number

49. Pawl Assy 30005157

50. Ashdoor 30002392

51. Ashdoor Handle (Wood) 1600663

52. Ashdoor Hinge Rod 30002473

53. Cotter Pin, Ashdoor 30001749

54. Ashdoor Hinge Lower 30002404

55. Ashpan Bracket 1601039

56. Lower Side Bracket 30005268

57. Thermostat Handle 1600660

58. Front Manifold 30002407

59. Front See Chart Pg. 26

60. Flue Collar Gasket 30002422
61a. Left Door See Chart Pg. 26
61b. Left Door See Chart Pg. 26

62. Door Hinge Strip 1308634

63. Top See Chart Pg. 26

65. Glass Clip Long 1601396

66. Front Door Handle & Shaft 30002717
67a. Right Door See Chart Pg. 26
67b. Right Door See Chart Pg. 26

68. Door Gasket 1203588

69. Glass Gasket 1203556

70. Left Door Glass 30005300

71. Right Door Glass 30005299

72. Door Hinge Pin 30002727

73. Spacer (for Damper rod) 1201779

74. Primary Air V alve Assy . 30005324
74a. Primary Air Frame 1307411
74b. Primary Air Rod 30005260

75. Complete Handle Assy 30004175
75a. Handle Base Stub 30002714

76. Thermostat Friction Spring 1201846

77. Thermostat Cable 5005471

78. Thermostat Handle Bolt 1201243

79. Ash Pan Assy 5005746

80. Flue Collar See Chart Pg. 26

81. Leg See Chart Pg. 26

82. Hex Head Jam Nut 1203290

83. Bottom Heat Shield 30002470
83a. Bottom Heat Shield Rt Wing 30005030
83b. Bottom Heat Shield Lt Wing 30005031

84. Grate Bottom 30005294

85. Thermostat Assy. 5005470

86. Washer 1202471

87. Handle Base Stub 30002714

88. Thermostat Handle Assy 30007067

89. Primary Air Cover 30007069

90. Primary Air Base 30007071

30005552

25

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Encore Non-catalytic/Catalytic Wood Burning Stove Model
2040CE (continued)

SHELL ENAMEL PARTS: ENCORE® MODEL 2040

Classic

Part Name

Top 30002387 30003055 30006682 30003075 30004879 30007030
Left Side 30002388 30003052 30006679 30003072 30004876 30007027
Right Side 30002405 30003053 30006680 30003073 30004877 30007028
Flue Collar 1305050 30003160 30006683 30003162 30004873 30007031
Front 30002393 30003054 30006681 30003074 30004878 30007029
Ashlip 30002402 30003051 30006678 30003071 30004875 30007026
Left Door Sub

Assembly*
Left Door (61a) 30003938 30003958 30006685 30003962 30004884 30007033
Right Door Sub

Assembly*
Right Door (67a) 30003939 30003959 30006684 30003963 30004883 30007032
Single Leg 30002396 30003050 30006677 30003070 30004874 30007025

Black Biscuit Bordeaux Ebony

30003974 30003984 30006687 30003988 30004882 30007072

30003975 30003985 30006686 30003989 30004881 30007073

Majolica

Brown Twilight

TRANSITION DOOR ENAMEL PARTS: ENCORE® MODEL 2040

Classic

Part Name

Left Door Assembly 30007165 30007167 30007169 30007171 30007173
Left Door (61b) 30007081 30007083 30007087 30007085 30007107
Right Door Assembly 30007166 30007168 30007170 30007172 30007174
Right Door (67b) 30007080 30007082 30007086 30007084 30007106

*Does not contain glass or glass gasket.

Black Biscuit Bordeaux

Majolica

Brown Twilight

NOTES:

In the diagram and throughout this manual, ‘left’ and ‘right’ mean as you face the front of the stove.
When ordering parts, be sure to mention the stove’s model number. When ordering external parts, be sure to specify color.
The hardware in the Encore is in standard sizes; most bolts are 1/4” diameter by 20 threads per inch. Most hardware stores can supply replacement

hardware if you specify bolt diameter, number of threads per inch and length. Fasteners inside the fi rebox should be replaced with stainless steel for
ease of future disassembly.

26

30005552

Warranty

Encore® 2040CE Non-Catalytic / Catalytic Wood Burning Stove

Limited 3 Year Warranty

Vermont Castings Group warrants that this wood burning stove will
be free of defects in material and workmanship for a period of three
years from the date you receive it, except that the catalyst, thermostat
assembly, handles, glass door panels, cement, and gasketing shall
be warranted as described below.

Vermont Castings Group will repair or replace, at its option, any part found
to be defective upon inspection by a Vermont Castings, Authorized Dealer .
The customer must return the defective part or the stove, with shipping
prepaid, to the Authorized Dealer or pay for any Authorized Dealer in-home
travel fees or service charges for in-home repair work. It is the dealer’s
option whether the repair work will be done in the customer’s home or
in the dealer’s shop. If, upon inspection, the damage is found to be the
fault of the manufacturer, repairs will be authorized at no charge to the
customer for parts and/or labor.

Any wood burning stove 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 warranty or six (6) months, whichever is longer.

Limited 1 Year Warranty

The following parts of the wood burning stove are warranted to be free
of defects in material and workmanship for a period of one year from
the date you receive it: The thermostat assembly, handles, glass door
panels, cement, and gasketing. Any of these items found to be defective
will be repaired or replaced at no charge, upon the return of the part with
postage prepaid to a Vermont Castings Authorized Dealer.

Any part repaired or replaced during the limited warranty period will
be warranted under the terms of the limited warranty for a period not
to exceed the remaining term of the original limited warranty or six (6)
months, whichever is longer.

Limited Catalyst Warranty

The catalyst will be warranted for a six year period as follows: If the
original catalyst or a replacement catalyst proves defective or ceases to
maintain 70% of its particulate emission reduction activity (as measured
by an approved testing procedure) within 24 months from the date the
stove is received, the catalyst itself will be replaced free.

From 25 - 72 months a pro-rated credit will be allowed against a replace­ment catalyst and the cost of labor necessary for its installation at the
time of replacement.

For stove purchases made after June 30, 1990, a third year
(25 - 36 months) of no charge replacement will be made when combus­tor failure is due to thermal degradation of the substrate (crumbling of
ceramic material). The customer must pay for any in-home travel fees,
service charges, or transportation costs for returning the stove to the
Authorized Dealer.

Amount of Time Credit Towards
Since Purchase Replacement Cost
0 - 24 months 100%
25 - 36 months 50 %
37 - 48 months 30%
49 - 60 months 20%
61 - 72 months 10%

Any replacement catalyst will be warranted under the terms of the catalyst
warranty for the remaining term of the original warranty. The purchaser
must provide the following information in order to receive a replacement
catalyst under the terms of this limited warranty:

1. Name, address and telephone number.

2. Proof of original purchase date.

3. Date of failure of catalyst.

4. Any relevant information or circumstances regarding determination

of failure.

5. In addition, the owner must return the failed catalyst.

Exclusions & 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
overfi ring which will result if the stove is used in such a manner as
to cause one or more of the plates to glow red. Overfi ring can be
identifi ed later by warped plates and areas where the paint pigment
has burned off. Overfi ring in enamel fi replaces is identifi ed by bub-
bling, cracking, chipping and discoloration of the porcelain enamel
fi nish. Vermont Castings Group offers no warranty on chipping of
enamel surfaces. Inspect your wood burning stove prior to accepting
it for any damage to the enamel.

3. This warranty does not cover misuse of the stove as described in the
Owner’s Guide, nor does it cover an stove which has been modifi ed
unless authorized by a Vermont Castings Group representative in
writing. This warranty does not cover damage to the stove caused
by burning salt saturated wood, chemically treated wood, or any fuel
not recommended in the Owner’s Guide.

4. This warranty does not cover a stove repaired by someone other
than a Vermont Castings Authorized Dealer.

5. Damage to the unit while in transit is not covered by this warranty but
is subject to a claim against the common carrier. Contact Vermont
Castings Authorized Dealer from whom you purchased your stove or
Vermont Castings Group if the purchase was direct. (Do not operate
the stove as this may negate the ability to process the claim with the
carrier.)

6. Claims are not valid where the installation does not conform to local
building and fi re codes or, in their absence, to the recommendations
in our Owner’s Guide.

7. The salt air environment of coastal areas, or a high-humidity en­vironment, can be corrosive to the porcelain enamel fi nish. These
conditions can cause rusting of the cast iron beneath the porcelain
enamel fi nish, which will cause the porcelain enamel fi nish to fl ake
off. This warranty does not cover damage caused by a salt air or
high-humidity environment.

8. Vermont Castings Group shall have no obligation to enhance or
update any unit once manufactured.

IN NO EVENT SHALL Vermont Castings Group BE LIABLE FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES. ALL IMPLIED
WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MER­CHANTABILITY AND FITNESS, ARE LIMITED T O THE DURA TION OF
THIS WRITTEN WARRANTY. THIS WARRANTY SUPERCEDES ALL
OTHER ORAL OR WRITTEN WARRANTIES.

Some states do not allow the exclusion or limitations of incidential and
consequential damages or limitations on how long an implied warranty
lasts, so the above limitations may not apply to you. This warranty gives
you specifi c rights and you may have other rights which vary from state
to state.

How to Obtain Service

If a defect is noted within the warranty period, the customer should contact
a Vermont Castings Authorized Dealer or V ermont Castings Group if the
purchase was direct 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.

4. Nature of the defect or damage.

5. Any relevant information or circumstances, e.g., installation,

mode of operation when defect was noted.

A warranty claim will then start in process. Vermont Castings Group
reserves the right to withhold fi nal approval of a warranty claim pending
a visual inspection of the defect by authorized representatives.

30005552

27

PRESTANDADEKLARATON

Produkt: Vermont Encore Flexburn Katalytisk
Produktens Typ-och/eller Serienummer: Enligt följesedel och faktura
Avsedd användning: Som intermittent, sekundär värmekälla

Tillverkare: Vermont Casting Group

Distributör: CaminaEcotec Sweden AB
Box 2103
511 02 Skene
Sweden

Anmält organ: GASTEC at CRE Limited
The Orchard Business Centre
Cheltenham
Gloucestershire
GL52 7RZ United Kingdom
Anmält organ nr. XXXX

Prestandan för ovanstående produkt överensstämmer med den prestanda som anges i tabellen ovan.

Denna prestandadeklaration utfärdas på eget ansvar av CaminaEcotec Sweden AB
Undertecknat för tillverkaren av:

............................................................................

Thomas Nuorimaa, VD
Skene 2013-07-01

149 Cleveland Drive • Paris, Kentucky 40361

www.vermontcastingsgroup.com