Vermont Castings WinterWarm Mounting instructions

Homeowner’s
Installation and
Operating
Manual
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
2000941 4/04 Rev. 10
WinterWarm
Fireplace Insert Or System
For Use in North America
410 Admiral Blvd. • Mississauga, Ontario, Canada L5T 2N6 • 905-670-7777
www.majesticproducts.com • www.vermontcastings.com
CFM Specialty Home Products

2
WinterWarm Fireplace Insert or System
2000941
Introduction
Thank you for purchasing a Vermont Castings’ WinterWarm, an efficient fireplace carefully engineered to bring you the
latest in wood combustion principles and modern foundry technology.
The WinterWarm masonry Fireplace Insert turns a traditional masonry fireplace into a powerful heater; the Winter-
Warm Fireplace System combines an insulated metal cabinet with the Fireplace Insert so that it may be installed in
close-clearance situations where no masonry fireplace and chimney exists.
Whichever you have purchased, you can count on years of comfortable heating and pleasureable fire viewing if you
treat it properly and operate it according to the directions in this owner’s guide.
The WinterWarm Fireplace Insert, and the WinterWarm Fireplace System that utilizes the WinterWarm Fireplace
Insert, are listed by Underwriter’s Laboratories of Canada, and are in compliance with the standards set forth by the
Federal Environmental Protection Agency, 40 CFR Part 60.532(b), as stated on the permanent label attached to each
appliance.
This manual describes the installation and operation of the WinterWarm catalytic-equipped wood heater. This heater
meets the U.S. Environmental Protection Agency’s emission limits for wood heaters sold after July 1, 1990. Under
specific test conditions this heater has been shown to deliver heat at a rate ranging from 10,300 to 30,000 Btu’s/hr.
For more complete details on WinterWarm performance and specifications, please refer to page 3.
The WinterWarm is designed, tested and listed for burning wood. Do not burn other fuels.
We recommend that you hire a professional installer certified by Wood Energy Technical Training (WETT) to install
your WinterWarm, or to advise you on the installation should you attempt to install it yourself.
Please read the appropriate sections of this manual before you install and use your WinterWarm. For information on
the installation of a WinterWarm into a masonry fireplace, read Sections III and V. To learn how to install the Winter-
Warm and its Cabinet that make up the fireplace system, read Sections IV and V. For information on Operation and
Maintenance of the WinterWarm, read Sections I and II.
Failure to follow instructions may result in property damage, bodily injury or even death.
Save These Instructions For Future Reference
Before you begin, here’s a timesaving tip
on using this manual.
•To learn how to operate and maintain the Winter-
Warm, read Sections I and II.
•To install a WinterWarm Fireplace Insert into a
masonry fireplace, read Sections III and V.
•To install a WinterWarm Fireplace System, read
Sections IV and V.
Table of Contents
Introduction ...................................................2
Specifications ................................................3
Operation ......................................................4
Maintenance..................................................9
Preparing a Masonry Chimney....................16
Installing the Fireplace System Cabinet......21
Appendices .................................................38
Proposition 65 Warning: Fuels used in gas,
woodburning or oil fired appliances, and the products
of combustion of such fuels, contain chemicals
known to the State of California to cause cancer, birth
defects and other reproductive harm.
California Health & Safety Code Sec. 25249.6

3
WinterWarm Fireplace Insert or System
2000941
Specifications
Range of heat output* ...............10,300 - 30,000 Btu/hr
Maximum heat output**........................... 50,000 Btu/hr
Area heated*** ............... Up to 1500 sq. ft. (140sq. m)
Size of wood splits .......................20-24” (508-610mm)
Fuel Capacity ...........................................40lbs. (18kg)
Loading ................................................................ Front
Flue size..................................................... 8” (200mm)
Fireplace Insert weight .........................475lbs. (216kg)
Fireplace System weight ......................840lbs. (380kg)
Primary Air Control ....................... Manual/thermostatic
Secondary Air Control ........................... Self-regulating
Glass panel ......................... High-temperature ceramic
Flue exit position .....................................................Top
Blower rating .............................. 106cfm. (115V, 60Hz)
*Under specific test conditions used during EPA emis-
sions standard testing.
**This value can vary depending on how the unit is
operated, and the type and moisture content of the fuel
used. Figure shown is based on maximum fuel con-
sumption obtained under laboratory conditions and on
average efficiencies.
***These values are based on operation in building-
code conforming homes under typical winter climate
conditions in New England. If your home is of non-
standard construction (e.g. unusually well insulated, not
insulated, built under ground, etc.) or if you live in a
more severe or more temperate climate, these figures
may not apply. Since so many variables affect perfor-
mance, consult your Vermont Castings’Authorized
Dealer to determine realistic expectations for your
home.
WinterWarm
37³⁄₄"
(959mm)
26⁵⁄₈"
(676mm)
8" (203mm)
12⁷⁄₈"
(327mm) 12⁷⁄₈"
(327mm)
15¹⁄₂"
(394mm)
4³⁄₄"
(121mm)
21³⁄₄"
(553mm)
6³⁄₄"
(172mm)
7⁷⁄₈"
(200mm) 36"
(914mm)
7¹⁄₂" (191mm)
29⁷⁄₈"
(759mm)
25¹⁄₂"
(648mm)
41"
(1041mm) 13³⁄₄"
(349mm)
7⁷⁄₈"
(200mm)
15⁷⁄₈"
(403mm)
23³⁄₄"
(603mm)
18¹⁄₂" (470mm)
Top View / System Cabinet
0941
Fig. 1 WinterWarm dimensions.

4
WinterWarm Fireplace Insert or System
2000941
Section I Operation
Your WinterWarm’s Controls
and What They Do
Three controls regulate the performance of your
WinterWarm: A primary air control supplies oxygen for
the fire, a damper directs air flow within the fireplace,
and a variable-speed fan control, or rheostat, regulates
the warm air flow into the room. (Fig. 2)
Primary Air Control
A single air control regulates the amount of heat the fire
will produce and how long it will burn.
The primary air control is located above the upper left
corner of the door. It is the top-most of the two brass-
capped controls located there (the brass knob on the
bottom regulates the fan), and is the primary source of
air for starting, maintaining, and reviving the fire.
Generally, more air entering the stove makes the fire
burn hotter and faster, while less air prolongs the burn.
The WinterWarm’s air supply is open to the maximum
when the control lever is moved to the left, and closed
when moved to the far right. It may be set anywhere
between the two extremes, however, depending on the
amount of heat desired.
To complement the manual setting of the air control, the
WinterWarm has an internal automatic thermostat that
ensures an even delivery of heat at the manual setting
you select.
The Damper
The damper directs air flow within the fireplace.
The damper is operated by moving the lever located
above the upper right corner of the door. It has two
positions: Open, to start or revive the fire (Fig. 3); and
closed (Fig. 4), for normal operation. The damper is
open when the lever is to the far left, and closed when
to the far right. There are no intermediate settings for
damper position.
When the damper is closed, the front door automati-
cally locks to prevent the door being inadvertently
opened when the fireplace is in its catalytic mode. This
could cause smoke to spill into the room.
To open the damper, lift up on the lever and move it to
the far left. The lock will disengage, allowing you to
open the front door.
To close the damper, move the lever to the right,
continuing past the resistance to lock the damper in
position. (The door handle must be positioned verti-
cally before the lock mechanism will engage.)
Primary Air Control (Top Lever)
Fan Speed Control
(Rheostat) (Bottom
Lever) Damper Control
Door Handle
Optional Outside
Air Control
FP1070
Fig. 2 All WinterWarm controls are located conveniently on
the front.
Damper Closed
Catalytic
Combustor
FP1072
Fig. 4 Damper is closed: Smoke is channelled through the
catalytic combustor where much of it can be burned.
Damper
Open
FP1071
Fig. 3 The damper is open; Smoke is vented directly to the
chimney.

5
WinterWarm Fireplace Insert or System
2000941
The Fans
Two fans deliver a steady stream of warm air.
Heated air from your WinterWarm is forced into the
room by two internal fans. The control for the fans is
below the brass primary air control knob, just above the
upper left corner of the door. (Fig. 5)
“Off” is to the far left.
“High” is just to the right of “Off.”
“Low” is to the far right.
Variable adjustment of the fans is possible with any
setting between “high” and “low.”
For best results, coordinate fan speed with the setting
of your thermostat. For example, when the thermostat
lever is set at “low,” also set the fans at “low.” With the
thermostat set for maximum heat, set the fans at “high.”
Air Control Lever,
High Air Setting
Medium Low Air Setting
Fan Control
Lever (Fan Off) Fan On FP1073
Fig. 5 Variable settings for both the fans and the air control
are possible between the two extreme settings.
Burn Only High-Quality Wood
The WinterWarm is designed to burn natural wood only;
do not burn fuels other than that for which it was
designed.
You’ll enjoy the best results when burning wood that
has been adequately air-dried. Avoid burning “green”
wood that has not been properly seasoned.
The best hardwood fuels include oak, maple, beech,
ash, and hickory that has been split, stacked, and air-
dried outside under cover for at least one year.
For areas that do not have a supply of hardwood,
commonly burned softwoods include tamarack, yellow
pine, white pine, Eastern red cedar, fir, and redwood.
These too should be properly dried. Your WinterWarm
will accept wood up to 24" (610mm). Longer wood
pieces work better than short ones.
Wood should be stored under cover to maintain dry-
ness, and should be dried at least six months for
optimum heating and fire-viewing performance. Even
for short-term storage, however, keep wood a safe
distance from the heater and keep it out of the areas
around the heater used for refueling and ash removal.
Use the Air Control Settings
that Work Best for You
No single air control setting will fit every situation. Each
installation will differ depending on the quality of the
fuel, the amount of heat desired, and how long you
wish the fire to burn.
The control setting also depends on your particular
installation’s “draft,” or the force that moves air from the
stove up through the chimney. Draft is affected by such
things as the length, type, and location of the chimney,
local geography, nearby obstructions, and other factors.
Too much draft may cause excessive temperatures in
the WinterWarm, and could even damage the combus-
tor. On the other hand, too little draft can cause
backpuffing into the room and/or the “plugging” of the
chimney or combustor.
How do you know if your draft is excessively high or
low? Symptoms of too much draft include an uncontrol-
lable burn or a glowing-red part of the WinterWarm
front. A sign of inadequate draft is smoke leaking into
the room through the stove or chimney connector joints,
low heat, and dirty glass.
In some newer homes that are well-insulated and
weather-tight, poor draft may result from insufficient air
in the house. In such instances, an open window near
the stove on the windward side of the house will
provide the fresh air needed.
Another option for getting more combustion air to the
stove is to duct air directly from the outside to the stove.
In fact, in some areas provisions for outside combustion
air are required in all new construction.
Your WinterWarm is designed so that it is possible to
incorporate outside air for combustion. Directions for
installing the optional outside air duct may be found
beginning with Step 4 on Page 31.
When first using the stove, keep track of the settings of
the air controls. You will quickly find that a specific
setting will give you a fixed amount of heat. It may take
a week or two to determine the amount of heat and the
length of burn you should expect from various settings.
Most installations do not require a large amount of
combustion air, especially if adequate draft is available.
Do not for any reason attempt to increase the firing
of your heater by altering the air control adjustment
range outlined in these directions.