Vermont Castings 2115 User manual

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1813-90-30007345i
Installation Manual
Installation & Appliance Set-Up
NOTE
To obtain a French translation of this manual, please
contact your dealer or visit www.vermontcastings.com
Pour obtenir une traduction française de ce manuel, s’il
vous plaît contacter votre revendeur ou visitez www.
vermontcastings.com
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
NOTICE: DO NOT DISCARD THIS MANUAL
If the information in these instructions is not
followed exactly, a re may result causing
property damage, personal injury, or death.
WARNING
!
• Donotstoreorusegasolineorotherammablevapors
and liquids in the vicinity of this or any other appliance.
• Donotoverre-Ifapplianceorchimneyconnector
glows, you are over ring. Over ring will void your
warranty.
• Comply with all minimum clearances to combustibles
asspecied.Failuretocomplymaycausehousere.
Installationandserviceofthisapplianceshouldbeperformedby
qualiedpersonnel.Hearth&HomeTechnologiesrecommends
HHTFactoryTrainedorNFIcertiedprofessionals.
HOT SURFACES!
Glass and other surfaces are hot
duringoperationANDcooldown.
Hot glass will cause burns.
WARNING
!
• Do not touch glass until it is cooled
• NEVERallowchildrentotouchglass
• Keep children away
• CAREFULLYSUPERVISEchildreninsameroomas
replace.
• Alert children and adults to hazards of high
temperatures
• High temperatures may ignite clothing or other
ammable materials.
• Keep clothing, furniture, draperies and other
ammablematerialsaway.
Intrepid FlexBurn® Wood Burning Stove
Model2115/2115-CAT
!WARNING
This product and the fuels used to operate this product
(wood), and the products of combustion of such fuels, can
expose you to chemicals including carbon black, which
isknowntotheState ofCaliforniatocausecancer,and
carbonmonoxide,whichisknowtotheStateofCalifornia
to cause birth defects or other reproductive harm. For
more information go to: www.P65Warnings.ca.gov

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/18 23-90-30007345i
TABLE OF CONTENTS
Safety Alert Key:
• DANGER! Indicatesahazardoussituationwhich,ifnotavoidedwill result in death or serious injury.
• WARNING!Indicatesahazardoussituationwhich,ifnotavoidedcould result in death or serious injury.
• CAUTION! Indicatesahazardoussituationwhich,ifnotavoided,could result in minor or moderate injury.
• NOTICE:Indicatespracticeswhichmaycausedamagetotheapplianceortoproperty.
Please read this entire manual before you install and use your new room heater. Failure to follow instructions may result in
property damage, bodily injury, or even death.
!
1 Important Safety Information
A. ApplianceCertication ............................................. 3
B. BTU&EfciencySpecications............................... 3
C. MobileHomeApproved(USAONLY) ...................... 3
D. GlassSpecications ................................................ 3
E. Non-CombustibleMaterials ..................................... 4
F. Combustible Materials ............................................. 4
2 Getting Started
A. DesignandInstallationConsiderations ................... 5
B. FireSafety ............................................................... 5
C. NegativePressure ................................................... 5
D. ToolsAndSuppliesNeeded..................................... 6
E. InspectApplianceandComponents ........................ 6
F. InstallChecklist........................................................ 7
3 Dimensions and Clearances
A. Appliance Dimensions ............................................. 8
B. HearthProtectionRequirements ............................. 9
C. Clearances to Combustibles.................................... 10
D. LocatingYourAppliance&Chimney........................ 11
E. ChimneyTerminationRequirements........................ 11
F. ChimneyLocation(2-10-3Rule).............................. 12
4 Chimney Systems
A. Venting&DraftManagement................................... 13
B. VentingComponents .............................................. 14
C. ChimneySystems.................................................... 14
D. InstallingChimneyComponents .............................. 16
5 Appliance Set-Up
A. RemovingUnitFromSkid........................................ 17
B. Assembly ................................................................. 17
C. InstallingOptionalCatalyst ...................................... 18
D. SmokeandCODetectors&SafetyTips.................. 19
E. ReversibleFlueCollar ............................................. 20
F. OutsideAirKitInstallation........................................ 20
6 Mobile Home Installation ......................................... 22
= Contains updated information


Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1833-90-30007345i
A. Appliance Certication
EPA Report #: 0135WS038E
EPA Certied Emissions: .6 g/hr (without catalyst)
.3 g/hr (catalytic)
*LHV Tested Efciency: 80.3% (without catalyst)
82.8% (catalytic)
**HHV Tested Efciency: 74.3% (without catalyst)
76.7% (catalytic)
***EPA BTU Output:
12,500-18,500
(without catalyst)
10,700-16,000
(catalytic)
****Peak BTU/Hour Output: 36,900 (without catalyst)
34,900 (catalytic)
Vent Size: 6Inch(152mm)
Firebox Size: 1.3 cu. ft.
Max. Wood Length: 16” Maximum
Fuel Orientation: East,West
Fuel SeasonedCordwood
(20% moisture)
* Weighted average LHV efciency using Douglas Fir
dimensional lumber and data collected during EPA
emissions test.
**Weighted average HHV efciency using Douglas
Fir dimensional lumber and data collected during EPA
emissions test.
***Efcienciesarebasedontestresultscalculatedusing
B415; these calculated efciencies are then used to
calculateoutputBTU’s.
****ApeakBTUoutoftheappliancecalculatedusingthe
maximumrsthourburnratefromtheHighEPATestand
theBTUcontentofcordwood(8600)timestheefciency.
The Intrepid FlexBurn® WoodAppliance meets the U.S.
EnvironmentalProtectionAgency’scribwoodemissionlimits
for wood appliances sold after May 15, 2020.
This wood appliance needs periodic inspection and repair for
properoperation.Itisagainstfederalregulationstooperate
this wood appliance in a manner inconsistent with operating
instructions in this manual.
B. BTU & Efciency Specications
C. Mobile Home Approved (USA ONLY)
• This appliance is approved for mobile home installations
in the USA when not installed in a sleeping room and
when an outside combustion air inlet is provided.
• Thestructuralintegrityofthemobilehomeoor,ceiling,
and walls must be maintained.
• Theunitmust beboltedtothe oor.Thiscanbedone
using an appropriate fastener for the application.
• The appliance must be properly grounded to the frame
of the mobile home with #8 copper ground wire, and
chimneymustbelistedtoUL103HToralistedUL-1777
full length six” (152mm) diameter liner must be used.
• Outsideairmustbeinstalledinamobilehomeinstallation.
• MobileHomeBracketKit#0003264mustbeinstalledin
a mobile home installation.
D. Glass Specications
This appliance is equipped with 5mm ceramic glass.
Replaceglassonlywith5mmceramicglass.Pleasecontact
your dealer for replacement glass.
1 Important Safety Information
MODEL: IntrepidFlexBurn® 2115/2115-CAT
LABORATORY: OMNITestLaboratories,Inc
REPORT NO. 0135WS038S/0135WS038E
TYPE: SolidFuelTypeRoomHeaters
STANDARD(s): UL1482-2011(R2015),ULC-S627-00
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be voided
by, the following actions:
WARNING
!
• Installationanduseofanydamagedappliance.
• Modicationoftheappliance.
• InstallationotherthanasinstructedbyHearth&Home
Technologies.
• Installation and/or use of any component part not
approvedbyHearth&HomeTechnologies.
• Operating appliance without fully assembling all
components.
• Operatingappliancewithoutlegsattached(ifsupplied
with it).
• DoNOTOverre-Ifapplianceorchimneyconnector
glows,youareoverring.
Anysuchactionthatmaycausearehazard.

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1843-90-30007345i
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
Forassistanceoradditionalinformation,consultaqualied
installer, service agency or your dealer.
Hearth & Home Technologies WILL NOT warranty
appliancesthatexhibitevidenceofring.Evidenceofring
includes, but is not limited to:
• Warped Damper
• Deteriorated refractory
• Deteriorated interior components
E. Non-Combustible Materials
Material which will not ignite and burn, composed of any
combination of the following:
 -Steel   -Plaster
 -Brick   -Iron
 -Concrete  -Tile
 -Glass   -Slate
Materials reported as passing ASTM E 136, Standard
Test Method for Behavior of Metals, in a Vertical Tube
Furnace of 750° C.
F. Combustible Materials
Material made of/or surfaced with any of the following
materials:
 -Wood  -CompressedPaper
 -PlantFibers  -Plastic
 -Plywood/OSB  -SheetRock(drywall)
Anymaterialthatcanigniteandburn:ameproofedornot,
plasteredornon-plastered.
NOTE:Thisinstallationmustconformwithlocalcodes.
Intheabsenceoflocalcodesyoumustcomplywiththe
UL1482-11,UL737-11,(UM)84-HUDandNPFA211in
theU.S.A.andtheULC S627-00andCAN/CSA-B365
Installation Codes in Canada. NOT APPROVED FOR
MOBILE HOME INSTALLATIONS IN CANADA!
NOTE:Hearth&HomeTechnologies,manufacturerofthis
appliance, reserves the right to alter its products, their
specicationsand/orpricewithoutnotice.

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/18 53-90-30007345i
A. Design and Installation Considerations
Consideration must be given to:
 • Safety
• Convenience
 • Trafcow
• Chimney and chimney connector required
Itisagoodideatoplanyourinstallationonpaper,usingexact
measurementsforclearancesandoor protection,before
actuallybeginningtheinstallation.Ifyouarenot usingan
existing chimney, place the appliance where there will be a
clearpassageforafactory-builtlistedchimneythroughthe
ceiling and roof.
Werecommendthataqualiedbuildinginspectorandyour
insurance company representative review your plans before
and after installation.
Ifthisapplianceisinanareawherechildrenmaybenear
it is recommended that you purchase a decorative barrier
to go in front of the appliance. Remembertoalwayskeep
children away while it is operating and do not let anyone
operate this appliance unless they are familiar with these
operating instructions.
C. Negative Pressure
Negativepressureresultsfromtheimbalanceofairavailable
fortheappliancetooperateproperly.Itcanbestrongestin
lower levels of the house.
Causes include:
• Exhaustfans(kitchen,bath,etc.)
• Rangehoods
• Combustion air requirements for furnaces, water
appliances and other combustion appliances
• Clothes dryers
• Locationofreturn-airventstofurnaceorairconditioning
• ImbalancesoftheHVACairhandlingsystem
• Upperlevelairleakssuchas:
- Recessedlighting
- Attichatch
- Ductleaks
B. Fire Safety
To provide reasonable re safety, the following should be
given serious consideration:
1. Install at least one smoke detector on each oor of
your home to ensure your safety. They should be
located away from the heating appliance and close
to the sleeping areas. Follow the smoke detector
manufacturer’s placement and installation instructions,
and be sure to maintain regularly.
2 Getting Started
Check building codes prior to installation.
• InstallationMUSTcomplywithlocal,regional,stateand
national codes and regulations.
• Consult insurance carrier, local building, re ofcials
or authorities having jurisdiction about restrictions,
installation inspection, and permits.
CAUTION
!
Asphyxiation Risk
• DO NOT CONNECT THISAPPLIANCE TO
A CHIMNEY FLUE SERVICINGANOTHER
APPLIANCE.
WARNING
!
• DO NOT CONNECT TO ANY AIR DISTRIBUTION
DUCTORSYSTEM.
Mayallowuegasestoenterthehouse.
2. AconvenientlylocatedClassAreextinguishertocontend
withsmallresresultingfromburningembers.
3. ACOdetectorshouldbeinstalledintheroomwiththe
appliance.
4. A practiced evacuation plan, consisting of at least two
escape routes.
5. Aplantodealwithachimneyreasfollows:
In the event of a chimney re:
a. Evacuatethehouseimmediately
b. Notifyredepartment.
Notice: Hearth & Home Technologies assumes no
responsibility for the improper performance of the
appliance system caused by:
• Inadequatedraftduetoenvironmentalconditions
• Down drafts
• Tight sealing construction of the structure
• Mechanical exhausting devices
• Overdraftingcausedbyexcessivechimneyheights
• Idealperformanceiswithachimneyheightof16Feet
(4.88m) measured from the base of the appliance.
Asphyxiation Risk
• Negative pressure can cause spillage
of combustion fumes, soot and carbon
monoxide.
• Appliance needs to draft properly for safety.
WARNING
!

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1863-90-30007345i
D. Tools And Supplies Needed
Before beginning the installation be sure the following tools
and building supplies are available:
E. Inspect Appliance and Components
• Removeapplianceandcomponentsfrompackagingand
inspect for damage.
• Reporttoyourdealeranypartsdamagedinshipment.
• Read all the instructions before starting the installation.
Follow these instructions carefully during the
installation to ensure maximum safety and benet.
To minimize the effects of negative air pressure:
• Installtheoutsideairkitwiththeintakefacingprevailing
winds during the heating season
• Ensureadequateoutdoorairforall combustion appliances
and exhaust equipment
• Ensurefurnaceandairconditioningreturnventsarenot
located in the immediate vicinity of the appliance
• Avoid installing the appliance near doors, walkways or
small isolated spaces
• Recessedlightingshouldbea“sealedcan”design
• Attic hatches weather stripped or sealed
• Attic mounted duct work and air handler joints and seams
taped or sealed
• Basement installations should be avoided
•Reciprocatingsaw •Framingmaterial
• Pliers • Hightempcaulkingmaterial
•Hammer •Gloves
• Phillips screwdriver • Framing square
•Flatbladescrewdriver •Electricdrillandbits
•Plumbline •Safetyglasses
•Level •Tapemeasure
• Misc. screws and nails
•1/2-3/4in.length,#6or#8self-drillingscrews
• Installationanduseofanydamagedappliance.
• Modicationoftheappliance.
• InstallationotherthanasinstructedbyHearth&Home
Technologies.
• Installation and/or use of any component part not
approvedbyHearth&HomeTechnologies.
• Operating appliance without fully assembling all
components.
• Operatingwiththefrontdoorsopen.
• Operatingappliancewithoutlegsattached(ifsupplied
with appliance).
• DoNOTOverre-Ifapplianceorchimneyconnector
glows,youareoverring.
Any such action that may cause a re hazard.
Fire Risk.
Hearth&HomeTechnologiesdisclaimsany
responsibility for, and the warranty will be
voided by, the following actions:
WARNING
!
Fire Risk
Inspectapplianceandcomponentsfor
damage. Damaged parts may impair safe
operation.
• DoNOTinstalldamagedcomponents.
• DoNOTinstallincompletecomponents.
• DoNOTinstallsubstitutecomponents.
Reportdamagedpartstodealer.
WARNING
!
When this room heater is not properly installed, a house
re may result. To reduce the risk of re, follow the
installation instructions. Contact local building or re
ofcials about restrictions and installation inspection
requirements in your area.
WARNING
!

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/18 73-90-30007345i
ATTENTION INSTALLER:
Follow this Standard Work Checklist
This standard work checklist is to be used by the installer in conjunction with, not instead of, the instructions contained in this installation manual
Customer:
Date Installed:
Lot/Address:
Location of Appliance:
Installer:
Dealer/ Distributor Phone #:
Serial #:
Model :
WARNING! Risk of Fire or Explosion! Failure to install appliance according to these instructions can lead to a fi re or explosion.
Appliance Install YES IF NO, WHY?
Verifi ed clearance to combustibles.
Appliance is leveled and connector is secured to appliance.
Hearth extension size/height decided.
Outside Air Kit Installed.
Floor protection requirements have been met.
If appliance is connected to a masonry chimney, it should be cleaned and
inspected by a professional. If installed to a factory built metal chimney,
the chimney must be installed according to the manufacturer’s instructions
and clearances.
Chimney
Chimney confi guration complies with diagrams.
Chimney installed, loked and secured in place with proper clearance.
Chimney meets recommended height requirements (16 Feet).
Roof fl ashing installed and sealed.
Terminations installed and sealed.
Clearances
Combustible materials not installed on non-combustible areas.
Verifi ed all clearances meet installation manual requirements.
Mantels and wall projections comply with installation manual requirements.
Protective hearth strips and hearth extensions installed per manual
requirements.
Appliance Setup
All packaging and protective materials removed.
Firebrick, baffl e and ceramic blanket insalled correctly
All labels have been removed from the door.
All packaging materials are removed from inside/under the appliance.
Manual bag and all of its contents are removed from inside/under the
appliance and given to the party responsible for use and operation.
Hearth & Home Technologies recommends the following:
• Photographing the installation and copying this checklist for your fi le.
• That this checklist remain visible at all times on the appliance until the installation is complete.
Comments: Further description of the issues, who is responsible (Installer/Builder/Other Trades, etc.) and corrective action needed:
Comments communicated to party responsible by on
(Builder/Gen. Contractor) (Installer) (Date)
F. Install Checklist

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1883-90-30007345i
3 Dimensions and Clearances
A. Appliance Dimensions NOTE:FlueCollarsizeis6”(152mm)diameter(ID)
Figure 3.1 - Front View
22-7/8”
581mm
14-5/16”
364mm
22-3/8”
568mm
12-1/4”
311mm
25-3/4”
654mm
24-7/16”
632mm
8-3/4”
222mm
7-1/4”
184mm
21-7/8”
556mm
15”
381mm
4-1/4”
108mm
Figure 3.2 - Top View
22-7/8”
581mm
14-5/16”
364mm
22-3/8”
568mm
12-1/4”
311mm
25-3/4”
654mm
24-7/16”
632mm
8-3/4”
222mm
7-1/4”
184mm
21-7/8”
556mm
15”
381mm
4-1/4”
108mm
Figure 3.2 - Side View
22-7/8”
581mm
14-5/16”
364mm
22-3/8”
568mm
12-1/4”
311mm
25-3/4”
654mm
24-7/16”
632mm
8-3/4”
222mm
7-1/4”
184mm
21-7/8”
556mm
15”
381mm
4-1/4”
108mm
Figure 3.4 - Side View with horizontal ue
21-1/4”
540mm
14-5/16”
364mm

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/18 93-90-30007345i
B. Hearth Protection Requirements
FLOOR PROTECTION:Itisnecessarytoinstall aType I
oorprotector.
In the US:Theunitmaybeinstalledonacombustibleoor
if the bottom heat shield is installed and non-combustible
spark&emberprotectionisused.Thebottomheatshield
is required unless the unit will be installed on a completely
non-combustiblesurface(example:unpaintedconcreteover
bareearth).ThereisnorequiredRorKvalue.Theoor
protector should extend 8” (203 mm) from either side of the
loading door, 16” (406 mm) from the front of the unit and 6”
(152mm)totherearoftheunit.Theoorprotectormust
extend underneath any horizontal run of chimney connector
and extend 2” (51mm) beyond each side.
In Canada,similaroorprotectionmustbeprovided18”(457
mm) in front, 8” (203 mm) from the sides and 6” (152 mm) to
the rear of the appliance. Figure 3.8
*EXCEPTION: Non-combustible floor protections must
extendbeneaththeuepipewheninstalledwithhorizontal
venting and extend 2” (51 mm) beyond each side. See
Figure 3.8.
28-1/4 in.
minimum
44-7/8 in.
minimum
16 in
(FRONT DOOR OPENING)
8
in
USA
6 in
Figure 3.5
Fire Risk
Hearth pads must be installed exactly as
specied. High temperatures or hot embers
may ignite concealed combustibles.
WARNING
!
Figure 3.6
50-3/4 in.
31-1/4 in.
40 in.
16 in.
(front door opening)
USA
Corner hearth pad dimensions with single wall pipe
1289MM
794MM
1016MM
457mm
(front door opening)
CANADA
Figure 3.7
457MM
(FRONT DOOR OPENING)
203MM
152MM
Must extend 51mm
beyond each side
of pipe (shaded area)
CANADA
962mm
minimum
1191mm
minimum
51-1/2 in.
31-3/4 in.
40-1/2 in.
16 in.
(front door opening)
USA
Figure 3.8
Corner hearth pad dimensions with double wall pipe
1308MM
806MM
1029MM
457mm
(front door opening)
CANADA

Vermont Castings • Intrepid FlexBurn®Installation Manual_R2 • 2018 - ___ • 07/1810 3-90-30007345i
C. Clearances to Combustibles
Minimum Clearances to Combustible Materials using 6” Connections
A B C D E F G H*
Top Flue - Single Wall
Pipe
12”
(305mm)
14”
(356mm)
15”
(381mm)
22-1/2”
(572mm)
6-1/2”
(165mm)
12”
(305mm)
58-1/2”
(1486mm) N/A
Top Flue - Single Wall
chimney connector heat
shield1,verticalue
collar h.s. installed
8”
(203mm)
10”
(254mm)
15”
(381mm)
22-1/2”
(572mm)
6”
(152mm)
11-1/2”
(292mm)
58-1/2”
(1486mm) N/A
Top Flue - Double Wall
Pipe
10”
(254mm)
11-1/2”
(292mm)
11”
(280mm)
18”
(457mm)
6”
(152mm)
11”
(280mm)
58-1/2”
(1486mm) N/A
Alcove Double Wall,
Top Flue, Ceiling Exit
12”
(305mm)
13-1/2”
(343mm)
17”
(432mm)
24”
(610mm) N/A N/A 37-1/2” (953mm) N/A
Top Flue, 90° Elbow
Wall Exit
11”
(280mm)
13”
(330mm)
15”
(381mm)
22-1/2”
(572mm) N/A N/A 58-1/2” (1486mm)
18”*
(457mm)
Rear Flue Backwall
Exit
13”
(330mm) N/A 15” (381mm)
22-1/2”
(572mm) N/A N/A 58-1/2” (1486mm) N/A
ForFactoryAlcove:6”diameterlistedDoublewallairinsulatedconnectorpipewithUL103HTlistedfactorybuiltClassAChimneyor
Masonry chimney. Maximum depth Alcove shall be no more than 48” (1219 mm) and the referenced Alcove clearances. Canada must
complywithCAN/ULC-S269M87forthe650°factorybuiltchimney.
*Follow pipe manufacturers clearances as required.
1.Theconnectorpipeheatshieldmustextend36”(914mm)aboveuecollar.
2.TheIntrepidFlexburnwasnottestedforclearancestoprotectedsurfaces.Forclearancereductionmethods,refertoNFPA211or
LocalCodes.
Side View
G
A
Top View
C
D
B
A
Figure 3.9
Alcove Top View
Center Dimension
40-1/2”
1029mm
Corner Installation
F
E
Top Vent Installation
Fire Risk
• Comply with all minimum clearances to
combustiblesasspecied.
• Failuretocomplymaycausehousere.
WARNING
!
G
H*
Appliance to
Ceiling Clearance
Figure 3.10
Rear Flue Horizontal - Wall Exit
Top and Side View
Top Flue 90° Elbow - Wall Exit
Side View
25-1/2”
648 mm
A
Center Dimension