Vermont Castings 5927 User manual

Fireback Kit #5927
Installation Instructions
for use on
Encore Model 2550
Please read these instructions before beginning the
repair procedure.
General Information
The Model 5927 Encore Fireback Kit is for use with Mod-
el 2550 Encore stoves. These stoves allow access to the
catalytic combustor through the firebox by removing a
hood and the lower fireback. As you face the left end of
the stove, the damper handle mounts closer to the rear
of the stove than to the front. 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 fireback and damper assembly
(1) Lower fireback
(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” fiberglass gasket
Tools required:
Phillips screwdriver Standard (flat) 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 file 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.
In these instructions, ‘right’ and ‘left’ are given as you
face the stove.
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 sur-
face.
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 fireback; then slide it back
toward the left to disengage the hood from the upper
fireback.
4. Use a hammer to tap the two wedges (Fig. 6, Item 11)
upward from their brackets, and remove the wedges.
2003101 5/06 Rev. 3
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.
5. Remove the lower fireback (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
fireback fits.
You may need to file or grind some edges on the new
cast iron parts to enable them to fit properly.

2
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 inner walls toward the center of the firebox; it will
also help to slide the bottom edges of the inner walls to-
ward the center of the firebox. 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 mis-
placing it. Pull the handle base off the damper rod. (Fig.
6, Item 7)
8. If the stove has a steel rear outer heat shield, remove
it. Four bolts hold it to spacers threaded into the back of
the stove. Leave the spacers in place.
9. A hex bolt (Fig. 6, Item 1) on each side of the stove
back holds the upper fireback assembly (Item 6) in
place. Remove and discard these bolts. Keep the wash-
ers. From inside the firebox, pull the right-hand end of
the upper fireback forward; you may need to use a flat
screwdriver to pry the fireback loose from the panel be-
hind it. With the upper fireback assembly removed from
the stove, save the #22 spacer and the #23 washer (Fig.
6) for reuse.
10. Remove the catalyst access panel (Item 16), part of
the refractory package (Item 3) that houses the catalytic
combustor (Item 17). It is friction-fit into place. Wiggle
it slightly to loosen it. Notice its positioning; this will be
important when you install the catalyst in the new refrac-
tory package.
11. 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 platinum on the ceramic honeycomb, and
friction can remove the coating, shortening the unit’s life.
Check your Encore owner’s manual for details on evalu-
ating the catalyst.
12. Remove the refractory package. (Fig. 6, Item 3) 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.
13. On the outer back side of the stove, there is a steel
plate (Fig. 6, Item 21) held in place with two Phillips
bolts. Remove the bolts and the steel plate.
14. Behind the steel plate, there is a secondary probe
assembly (Item 20). This consists of a probe and a bi-
metal coil secured by a phillips screw. (Fig. 5) There is a
slender steel rod between the end of the coil and a pivot-
ing valve plate (Item 19). 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 19, in
place.
15. Remove the two steel heat deflectors (Items 4, 18)
from the back of the firebox; 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 firebox, where the upper fireback attaches. Remove
any debris from the stove’s back chamber.
1. Remove the catalyst access panel (Fig. 6, Item 16)
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 deflectors, (Fig. 6, Items
4, 18) one on each side of the refractory package. The
shorter arm of each goes at the bottom of the deflector,
with the longer arm against the cast iron back sides of
the rear chamber. These deflectors provide important
protection from the very hot gases leaving the refractory
chamber.
3. Slide the catalytic combustor (Fig. 6, Item 17) into
place within the refractory chamber. Notice that the
openings of the honeycomb must be on the top and bot-
tom horizontal surfaces of the combustor, as shown in
Figure 6.
4. Install the refractory access panel in front of the cata-
lyst. It friction-fits into place.
5. Install the new upper fireback assembly. Place the
#22 spacer and the #23 washer on the protruding end of
the damper rod. (Fig. 6) Swing the assembly’s left end
into the firebox, with the end of the damper rod passing
through the hole in the left outer stove side. 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 origi-
nal washers. These bolts should be snug but not tight,
especially if the stove back is enamelled. Overtightening
these bolts can cause excess tension on them and/or
the upper fireback assembly.
ST645
Encore
remove fireback
3/01
Fireback
ST645
Fig. 3 Lift out the lower fireback.

3
6. Attach the damper handle (Fig. 6, Item 15) to the
damper rod (Item 7), and secure it with the Allen bolt.
Test the action of the handle to ensure the damper works
smoothly. The damper should ‘lock’ closed when the
handle is aimed fully forward. Adjust as needed, follow-
ing the directions in the Encore Owner’s Guide.
7. Reinstall the left and right inner walls of the firebox
(Fig. 6, Items 5, 13), securing each with the two 1/4”-
20 x 1¹⁄₂” bolts and washers originally removed. These
panels have rope gasketing on the (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.
8. Retest the action of the damper handle, and make
any adjustments necessary.
9. Check the tube of gasket cement. This is a clay-
based, water-solvent material, and the water can sepa-
rate 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 fireback, in the channel shown in Figure
4. Twist the ends of the fiberglass gasket, to keep it from
unraveling. Press the gasket into the channel. Do not cut
the gasket to final length until you have positioned it in
the cemented channel.
10. Clear the lower fireback’s channel in the bottom of
the firebox of ashes and charcoal. Install the lower fire-
back (with the seashell design forward). Be sure it sets
fully down into the channel. Secure the fireback with the
two cast iron wedges. Tap these wedges in until they are
snug, but not tight.
11. Install the new combustion throat hood (Fig. 5, item
10). Slide a protruding pin on one end fully onto the
corresponding support bracket on the upper fireback,
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 fireback, and let its lower edge hang against the
lower fireback.
12. 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.
KT376
probe position
4/2/03 djt
KT376
Fig. 5 Rear view of stove.
13. Attach the slender steel rod to the tab at the end of
the bimetal coil, part of the new secondary probe as-
sembly. 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 phil-
lips pan-head bolt you removed in disassembly step 14.
The correct positioning for the probe is shown in Figure
5. Note the tab on the end of the coil is in the 4 o’clock to
5 o’clock position, when the stove is cold.
KT375
fireback gasket
4/2/03 djt
KT375
Fig. 4 Fiberglass gasket on back of lower fireback.
14. 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.
15. Replace the steel cover over the secondary air valve
assembly with two Phillips bolts.
16. If the stove has a steel rear heat shield, replace it by
attaching it to its four spacers.
17. Replace the slotted grate (Fig. 6, Item 9); the wider
openings face downward, toward the ashpan.
18. Replace the andirons and the griddle.
19. 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 correct 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.
20. Dispose of the original cast parts, and the original
refractory chamber, by sending them to a landfill. The
refractory is ceramic fiber, 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.
21. When you refire the stove, you must ‘cure’ the new
cast iron panels, as you did when the stove was new.
Build a series of small fires, 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 firing.

4
3101
CFM Corporation reserves the right to make changes in design, materials, specifications, prices and discontinue colors and products at any time,
without notice.
Fig. 6 Firebox parts diagram, Defiant Encore Model 2550 stove.
1. Upper fireback bolts
2. Outer back
3. Refractory chamber*
4. Right heat deflector
5. Right inner side
6. Upper fireback assembly*
7. Damper torsion bar*
8. Andiron (2)
9. Grate
10. Fireback throat hood*
11. Wedge (2)
12. Lower fireback*
13. Left inner side
14. Damper handle Allen bolt
15. Damper handle
16. Catalyst access panel (refractory)*
17. Catalyst
18. Left heat deflector
19. Secondary thermostat valve
20. Secondary probe thermostat
21. Secondary thermostat cover
22. Spacer**
23. Washer**
* Included in the #5927 kit.
** Not included in the #5927 kit.
21
20
2
17
3
18
19
16
11
11
10
12
13
5
9
8
4
3101
Fireback 5927
Encore parts
4/03
15
14
6
22
23
7
2695 Meadowvale Blvd. • Mississauga, Ontario, Canada L5N 8A3
800-668-5323 • www.cfmcorp.com
CFM Corporation