Vermont Castings 2190 User manual

Fireback Kit #5926
Installation Instructions
for use on
Deant Encore Model 2190
Please read these instructions before beginning the
repair procedure.
General Information
The Model 5926 Deant Encore Fireback Kit is for use with
Model 2190 Deant Encore stoves. These stoves allow
access to the catalytic combustor through the rebox by
removing a hood and the lower reback. As you face the
left end of the stove, the damper handle mounts closer to
the front of the stove than to the rear. If there is a question
about the model number of the stove, check the steel label
fastened to the stove back.
Material provided:
(1) Upper reback and damper assembly
(1) Lower reback
(1) Combustion throat hood
(1) Secondary probe assembly
(1) Refractory (insulating) assembly
(2) 1/4”-20 x 1¹⁄₂” hex head bolts
(1) Tube of gasket cement
(1) 5/16” x 36” berglass gasket
Tools required:
Phillips screwdriver Standard (at) screwdriver
7/16” hex ratchet wrench 5/32” Allen wrench
Hammer 3/16” drill bit
Dust mask Goggles
Knife Putty knife
You may also need a le or grinder
Before starting the repair procedure, be sure the stove is
cold. Note that ashes and embers can stay hot for a long
time; remove them and store them properly in a sealed
metal container on a noncombustible surface away from
all nearby combustibles. The empty ashpan will be a handy
storage spot for hardware, tools and small parts.
Work in a clean, well-lighted area. Protect your work area
with tarps or drop cloths. Protect yourself with goggles
and dust mask.
Dis-Assembly
1. Remove the griddle and the front doors. Lift each door
until the bottom hinge pin clears the bottom hinge hole;
then swing the bottom of the door away from the stove,
and lower it so the top hinge pin clears the top hinge hole.
Set the doors face down on a padded surface.
2. Unbolt the andirons from the lower front panel of the
stove, and set them aside. Lift out the grate and set it
aside.
3. Lift the lower edge of the throat hood (Fig. 6, Item 10)
toward the front and slide the hood to the left or right. If you
slide it to the right, the support pin will then drop off the left
bracket on the upper reback; then slide it back toward the
left to disengage the hood from the upper reback.
4. Use the hammer to tap the two wedges (Fig. 6, Item 11)
upward from their brackets, and remove the wedges.
2003064 4/11 Rev. 6
ST643
Encore
catalyst hood
remove
3/01
Hood
Fireback ST643
Fig. 1 Remove the throat hood.
ST644
Encore release
lower fireback
3/01
Left Wedge
Fireback
Right Wedge
ST644
Fig. 2 Tap the wedges out with a hammer.
In these instructions, ‘right’ and ‘left’ are given as you face
the front of the stove.
You may need to le or grind some edges on the new cast
iron parts to enable them to t properly.
5. Remove the lower reback (Fig. 6, Item 12) by pulling
the upper edge toward the front. Then lift it and angle it out
of the stove through the front door or through the griddle
opening. Scoop out any ashes or charcoal in the bottom
groove where the lower edge of the lower reback ts.
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6. Remove the left and right inner walls (Fig. 6, Items 5,
13) of the stove. Hex bolts at the top and bottom hold them
in place. These walls have rope gaskets, forming seals
between the inner walls and the outer walls of the stove.
With the bolts removed, pry the forward edges of the in-
ner walls toward the center of the rebox. The panels will
come out through the front opening or through the griddle
opening.
7. Use the Allen wrench to loosen the Allen bolt (Fig. 6,
Item 14) in the base of the damper handle (Item 15). Leave
the loosened bolt in the handle to keep from misplacing it.
Pull the handle off the J-shaped damper handle rod. (Fig.
6, Item 16) Push the rod into the rebox.
8. With the damper open, remove the damper activating
link (Fig. 6, Item 17) on the left side of the rebox. This
piece is shaped like a hockey stick and has a hole in each
end. The forward hole engages the damper activating arm
and the rear hole engages the damper torsion bar (Item
7).
9. If the stove has a steel rear outer heat shield, remove
it. Four bolts hold it to spacers threaded to the back of the
stove. Leave the spacers in place.
10. A hex bolt (Fig. 6, Item 1) on each side of the stove
back holds the upper reback assembly (Item 6) in place.
Remove and discard these bolts. Keep the washers. From
inside the rebox, pull the right-hand end of the upper
reback toward yourself; you may need to use a at screw-
driver to pry the reback loose from the panel behind it.
11. Remove the catalyst access panel (Item 18), part
of the refractory package (Item 3) that houses the catalytic
combustor (Item 19). It is friction-t into place. Wiggle it
slightly to loosen it. Notice its positioning; this will be im-
portant when you install the catalyst in the new refractory
package.
12. Remove the catalytic burner carefully, inspect and clean
it, and set aside. To clean it, take outdoors and blow gently
through it. Do not use compressed air; do not run anything
through the honeycomb. The catalyst is a thin coat of plati-
num on the ceramic honeycomb, and friction can remove
the coating, shortening the unit’s life. Check your Encore
owner’s manual for details on evaluating the catalyst.
13. Remove the refractory package. Pull it straight toward
yourself, and slide it out through the front door opening.
Put it in a closed bag to contain any airborne dust.
14. On the outer back side of the stove, there is a steel
plate (Fig. 6, Item 23) held in place with two Phillips bolts.
Remove the bolts and the steel plate.
15. Behind the steel plate, there is a secondary probe as-
sembly (Item 22). This consists of a probe and a bimetal
coil secured by a phillips screw. There is a slender steel
rod between the end of the coil and a pivoting valve plate
(Item 21). Remove the phillips screw and pull the coil and
probe partway out of the stove back. When the probe is
halfway out of the stove back (about 1” showing), remove
the slender rod from the tab at the end of the coil. Leave
the rod hanging from its tab on the secondary valve. Leave
the secondary valve, Item 21, in place.
16. Remove the two steel heat deectors (Items 4, 20) from
back of the rebox; these were originally on each side of
the refractory package.
Re-Assembly
Use a hammer and a cold chisel or old screwdriver to re-
move any remaining cement from the upper rear area of
the rebox, where the upper reback attaches. Remove
any debris from the stove’s back chamber.
1. Remove the catalyst access panel (Fig. 6, Item 18) from
the new refractory chamber. Install the chamber in the back
of the stove, with the opening facing forward.
2. Reinstall the two steel heat deectors, (Fig. 6, Items 4,
20) one on each side of the refractory package. The shorter
arm of each goes at the bottom of the deector, with the
longer arm against the cast iron back sides of the rear
chamber. These deectors provide important protection
from the very hot gases leaving the refractory chamber.
3. Slide the catalytic combustor (g. 6, Item 19) into place
within the refractory chamber. Notice that the openings of
the honeycomb must be on the top and bottom horizontal
surfaces of the combustor, as shown in Figure 6.
4. Install the refractory access panel in front of the catalyst.
It friction-ts into place.
5. Install the new upper reback assembly. Swing its left
end (with the damper torsion bar protruding) into the re-
box and place it on its supports. Swing the right end into
position, and secure the assembly with two new 1/4”-
20 x 1¹⁄₂” bolts. Be sure to use the original washers. Do
not overtighten these bolts, especially if the stove back is
enamelled. Overtightening these bolts can cause excess
tension on them and/or the upper reback assembly.
6. Join the rear hole in the damper activating link (the
‘hockey stick’) (Fig. 6, Item 17) to the end of the damper
torsion bar. (Fig. 6, item 7) Note the positioning of the link;
the blade of the ‘hockey stick’ goes toward the front of the
stove, aiming downward. This is the only position in which
the link will close and lock the damper.
ST645
Encore
remove fireback
3/01
Fireback
ST645
Fig. 3 Lift out the lower reback.
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2003064
7. Join the damper activating arm (Fig. 6, Item 16) to the
link. Note the proper positioning; the short segment of the
arm goes under the link when the damper is closed.
8. Attach the damper handle (Fig. 6, Item 15) to the activat-
ing arm (Item 16) and secure it with the Allen bolt. Be sure
the handle stub seats fully onto the J-arm. (Fig. 6, Item 16)
Test the action of the handle to ensure the damper works
smoothly. The damper should ‘lock’ closed when the handle
is aimed fully to the rear and the bottom edge of the link
hits the top of the activating arm.
9. Reinstall the left and right inner walls of the rebox, se-
curing each with the two 1/4”-20 x 1¹⁄₂” bolts and washers
you originally removed. These panels have rope gasketing
on their (hidden) back sides; generally this does not need
to be replaced. Use cement to keep it in place if it has
loosened from its channels.
10. Retest the action of the damper handle, and make any
adjustments necessary.
11. Check the tube of gasket cement. This is a clay-based,
water-solvent material, and the water can separate from
the clay during storage. Before you open the tube, knead
it in your hands to ensure the cement and the water are
thoroughly mixed. Cut off the tip of the tube. Apply a thin
bead of gasket cement to the back of the new lower re-
back, in the channel shown in Figure 4. Twist the ends of
the berglass gasket, to keep it from unraveling. Press the
gasket into the channel. Do not cut the gasket to nal length
until you have positioned it in the cemented channel.
14. On the back of the stove, gently hand-turn a 3/16” drill
bit through the hole where the original secondary probe
was, and into the new refractory chamber. Turn the bit till
it does not meet resistance.
15. Attach the slender steel rod to the tab at the end of the
bimetal coil, part of the new secondary probe assembly.
Carefully press the secondary probe into place through the
hole you made in the refractory chamber. Do not jam the
probe into place, as this can break pieces off the refractory
chamber. Secure the probe with the phillips pan-head bolt
you removed in disassembly step 15. The right positioning
for the probe is shown in Figure 5. Note that the tab on
the end of the coil is in the 4 o’clock to 5 o’clock position,
when the stove is cold.
12. Clear the lower reback’s channel in the bottom of the
rebox of ashes and charcoal. Install the lower reback
(with the seashell design forward). Be sure it sets fully
down into its channel. Secure the reback with the two
iron wedges. Tap these wedges in till they are snug, but
not tight.
13. Install the new combustion throat hood (Fig. 5, item 10).
Slide a protruding pin on one end fully onto the correspond-
ing support bracket on the upper reback, then slide the
pin in on the trailing end of the hood onto the other support
bracket. Center the hood left-to-right on the reback, and
let its lower edge hang against the lower reback.
KT376
probe position
4/2/03 djt
KT376
Fig. 5 Rear view of stove.
16. Join the bimetal coil to the secondary air valve. The
U-curved end of the slim steel rod joins to the coil, and the
L-shaped end of the rod goes through the small bracket
on the pivoting valve plate.
17. Replace the steel cover over the secondary air valve
assembly with two Phillips bolts.
18. If the stove has a steel rear heat shield, replace it by
attaching it to its four spacers.
19. Replace the slotted grate (Fig. 6, Item 9); the wider
openings face downward, toward the ashpan.
20. Replace the andirons and the griddle.
21. Replace the doors. Handle them carefully, especially if
they are enamelled. Slide the top hinge pins into the upper
holes in the stove front, then swing the bottom edge of the
door toward the stove and slide the bottom hinge pins into
their holes. Make sure the doors settle fully into their cor-
rect position. Check the latching of the doors; do not let the
right door swing loosely toward the stove, as the protruding
latch may chip the enamel on the stove front.
22. When you rere the stove, you must ‘cure’ the new cast
iron panels, as you did when the stove was new. Build a
series of small res, with each one 100°F hotter and an
hour longer than the previous one, until you have reached
a normal operating temperature of 600°F. Then you can
resume normal ring.
KT375
fireback gasket
4/2/03 djt
KT375
Fig. 4 Fiberglass gasket on back of lower reback.
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3064
Fireback
parts
4/3/03 djt
MHSC reserves the right to make changes in design, materials, specications, prices and discontinue colors and products at any time, without
notice.
Fig. 6 Firebox parts diagram, Deant Encore Model 2190 stove.
1. Upper reback bolts
2. Outer back
3. Refractory chamber*
4. Right heat deector
5. Right inner side
6. Upper reback assembly*
7. Damper torsion bar*
8. Andiron (2)
9. Grate
10. Fireback throat*
11. Wedge (2)
12. Lower reback*
13. Left inner side
14. Damper handle Allen bolt
15. Damper handle
16. Damper activating arm
17. Damper activating link (the ‘hockey stick’)
18. Catalyst access panel (refractory)*
19. Catalyst
20. Left heat deector
21. Secondary thermostat valve
22. Secondary probe thermostat*
23. Secondary thermostat cover
* Included in the #5926 kit.
23. Dispose of the original cast parts and the original
refractory chamber by sending them to a landll. The
refractory is ceramic ber, and will not burn. Wear a dust
mask whenever you handle the chamber; it will be easier
to handle if you put it in a closed plastic bag.
MHSC
149 Cleveland Drive • Paris, Kentucky 40361
www.mhsc.com
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