Vermont Castings Encore Flexburn 2040 Installation instructions

13-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
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.
The French language version of this manual is available online:www.vermontcastings.com
La version française de ce manuel est disponible en ligne : www.vermontcastings.com
Please read this entire manual before
installation and use of this wood-burning
room heater.
Failure to follow these instructions could
result in property damage, bodily injury
or even death.
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andliquidsinthevicinityofthisoranyotherappliance.
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your warranty.
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WARNING
!
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only. Do Not Burn Wet or Green Wood. Burning any other
type of fuel will void your warranty.
CAUTION
!
Installation & Operating Manual
Installation and Appliance Setup - Care and Operation
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
Call your dealer for questions on Installation, Operation, or Service.
For use in the
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Encore®FlexBurn®Non-Catalytic/
Catalytic Wood Burning Stove
Model 2040
NOTICE: SAVE THESE INSTRUCTIONS
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23-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
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Encore®stove. With this purchase you have made a
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joy and appreciation for the hearth. We assure you that your
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utmost care and will provide you with many years of service.
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iron’s unique ability to absorb and radiate heat.
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depends on both the manufacturer and the operator. Please
read this manual carefully to understand how to properly
operate and maintain your stove.
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satisfaction as a customer. That is why we maintain an
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a particular question about your stove or its performance.
Thismanualcontainsvaluableinstructionsonthe installation
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containsuseful information on maintenance.Pleaseread the
manual thoroughly and keep it as a reference.
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meetsthe U.S. Environmental ProtectionAgency’semission
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Please read this entire manual before you install and use
your new stove. Failure to follow instructions may result in
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Installation Accessories
Warming Shelf 8” Flue Collar
#0200 &ODVVLF%ODFN #0555 &ODVVLF%ODFN
#0205 Biscuit #0556 Biscuit
#0199 %RUGHDX[ #0560 %RUGHDX[
#0208 Brown Majolica #0557 Brown Majolica
#0198 Twilight #0561 Twilight
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#3185 2XWVLGH$LU$GDSWHU
#0127 Firescreen
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A line of porcelain enamel stove pipe is available in Biscuit,
Bordeaux, Brown Majolica colors.
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Dimensions ......................................4
,nstallation
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Floor Protection ................................10
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Assembly
Setting up your Stove............................ 18
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Adjust Leg Levelers .............................19
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 ,QVWDOOLQJ5HPRYLQJ&DWDO\VW .....................20
Smoke Alarm / Safety Tips .........................21
Operation
 $LU&RQWUROV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Damper Adjustments ............................22
 :RRG%XUQLQJ2SHUDWLRQ .........................23
Ash Disposal ..................................27
Draft Management ................................28
Maintenance..................................... 30
The Catalytic Element .............................34
Service Parts List ................................36
Warranty ........................................ 42
Table of Contents
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33-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
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This wood heater needs periodic inspection and repair for
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this wood heater in a manner inconsistent with operating
instructions in this manual.
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Non-Catalytic Information
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(3$'HIDXOW(I¿FLHQF\ 73.0%
$FWXDOWHVWHG(I¿FLHQF\ 67.6%
***EPA BTU Output: 
****Peak BTU/Hour Output: 
Catalytic Information
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(3$'HIDXOW(I¿FLHQF\ 80.0%
$FWXDOWHVWHG(I¿FLHQF\ 74.3%
***EPA BTU Output: 
****Peak BTU/Hour Output: 
Other Important Information
Vent Size: ,QFKPP
,QFKPP
Firebox Size: 2.3 cu. ft.
Max. Wood Length: 0D[LPXP
Ideal Wood Length: 7RS/RDG
Fuel 6HDVRQHG&RUGZRRG
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Area Heated...................................6TXDUHIHHW
Loading..........................................................Front and top
Chimney Connector: .........................................................
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Flue Exit Position ............................................Top or Rear
Primary Air ............
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Secondary Air ...................................)L[HGVHOIUHJXODWLQJ
Ash Handling System........................ Removable ash pan
Glass Panels .............................+LJKWHPSHUDWXUHFHUDPLF
Weight......................................................OEVNJ
MODEL: Encore®0RGHO
LABORATORY: 201,7HVW/DERUDWRULHV,QF
REPORT NO. 6
TYPE: 6ROLG)XHO5RRP+HDWHU:RRG
Burning Type
STANDARD(s): 8/8/
8/&6
ELECTRICAL
RATING:
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Mobile Home Approved
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walls must be maintained. The appliance must be properly
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be installed in a room designated for sleeping. The unit must
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a mobile home.
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!WARNING
This product and the fuels used to operate this product
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to cause birth defects or other reproductive harm. For
more information go to: www.P65Warnings.ca.gov
California safety information
Proposition 65 Warning:)XHOVXVHGLQJDVZRRGEXUQLQJ
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reproductive harm.
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43-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
Stove Dimensions
Figure 1(QFRUH®2040 dimensions.
Drawing Not to Scale
3-3/4
95 mm
22-3/4
5 8 mm
25
35 mm
o exit
lue collar
eig t
2
8 mm
25-3/4
54 mm
18-1/2
4 0 mm
-1/4
184 mm
2
8 mm
22-1/4
5 5 mm
15-1/2
394 mm
5
12 mm
2- /8 3 mm
23-3/4
03 mm
15
381 mm
40-5/1
1024mm
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53-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
Installation
SAFETY NOTICE: IF YOUR ENCORE® IS NOT PROPERLY
INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE
THE RISK OF FIRE, FOLLOW THE INSTALLATION
INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE
OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION
INSPECTION REQUIREMENTS IN YOUR AREA.
%HIRUH\RXEHJLQDQLQVWDOODWLRQEHVXUHWKDW
• Yourstoveandchimneyconnectorwillbefarenoughfrom
combustible material to meet all clearance requirements.
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properly to meet all requirements.
• You have all necessary permits from local authorities.
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your installation as safe and determining that it meets local
and state codes.
The metal label permanently attached to the back of every
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information also is printed on the label. When the stove is
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as evidence that the installation meets codes and can be
approved.
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Your local dealer can provide any additional information
needed.
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AppliancesandEquipment.These standardsare thebasis for
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IMPORTANT: Failure to follow these installation
instructions may result in a dangerous situation, including
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and do not allow makeshift compromises to endanger
property and personal safety.
Outside Air
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to take place. Whatever combustion air is consumed by the
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GRRUVDQGZLQGRZVDQRXWVLGHDLUVRXUFHLVQHHGHG
Items Needed for Installation (not supplied)
 2XWVLGH DLU DGDSWHU DYDLODEOH DW \RXU DXWKRUL]HG
9HUPRQW&DVWLQJVGHDOHU
• Phillips head screw driver
• Silicone sealant
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 +RVH&ODPSV
• Drills and saws necessary for cutting holes through
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WKHDSSOLDQFHXVLQJVFUHZV)LJXUH
 )ORRU5HDU,QVWDOODWLRQ&XWD´PPKROHLQRXWVLGH
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PP DOXPLQXP PHWDO ÀH[RUULJLG SLSLQJ WR GLUHFWO\
connect outside air to appliance intake. Use the supplied
termination cap with a rodent screen. Seal between the
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penetration.
:KHQSRRUGUDIWLVFDXVHGE\DORZLQ¿OWUDWLRQUDWHRSHQLQJD
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near the stove will usually alleviate the problem.
A better solution is to install a permanent outside air supply
WRWKHVWRYHDQGRUURRP,QIDFWEULQJLQJDLUIRUFRPEXVWLRQ
from outside the home directly to the air inlet of the stove is
required for new construction in some areas.
Types of Chimney to Use
You must connect the Encore®WRDFRGHDSSURYHGPDVRQU\
FKLPQH\ZLWKDÀXHOLQHUWRDUHOLQHGPDVRQU\FKLPQH\WKDW
PHHWVORFDOFRGHVRUWRDSUHIDEULFDWHGPHWDOFKLPQH\WKDW
FRPSOLHVZLWKWKHUHTXLUHPHQWVIRU7\SH+7FKLPQH\VLQWKH
6WDQGDUGIRU&KLPQH\V)DFWRU\%XLOW5HVLGHQWLDO7\SHDQG
%XLOGLQJ+HDWLQJ$SSOLDQFH8/)LJXUHLOOXVWUDWHVWKH
two types. The chimney and chimney connector must be in
good condition and kept clean.

63-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
2' Min.
2' Min.
3'
Min.
0 To 10'
3'
Min.
0 To 10'
Reference
Point
Figure 37KH¶¶¶&KLPQH\5XOH
Masonry Chimneys
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Do not use an unlined chimney. The chimney should have
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blockage. Repair any defects before the chimney is used
with your stove.
8QXVHGRSHQLQJVLQDQH[LVWLQJPDVRQU\FKLPQH\PXVWEH
VHDOHGZLWKPDVRQU\WRWKHWKLFNQHVVRIWKHFKLPQH\ZDOO
DQGWKHFKLPQH\OLQHUVKRXOGEHUHSDLUHG2SHQLQJVVHDOHG
with pie plates or wallpaper are a hazard and should be
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FKLPQH\¿UHÀDPHVDQGVPRNHPD\EHIRUFHGRXWRIWKHVH
unused thimbles.
The chimney should be thoroughly cleaned before use.
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VWDQGDUGVRI\RXUORFDOEXLOGLQJFRGHRULQWKHDEVHQFHRID
ORFDOFRGHWRDUHFRJQL]HGQDWLRQDOFRGH0DVRQU\FKLPQH\V
PXVWEHOLQHGHLWKHUZLWKFRGHDSSURYHGPDVRQU\RUSUHFDVW
UHIUDFWRU\ WLOHV VWDLQOHVV VWHHO SLSH RU D FRGHDSSURYHG
³SRXUHGLQSODFH´OLQHU7KHFKLPQH\¶VFOHDQRXWGRRUPXVW
VHDO WLJKWO\ $ ORRVH RU OHDN\ FOHDQRXW GRRU FDQ ZHDNHQ
FKLPQH\GUDIWFDXVLQJSHUIRUPDQFHSUREOHPV
Prefabricated Chimneys
A prefabricated metal chimney must be one tested and
OLVWHGIRUXVHZLWKVROLGIXHOEXUQLQJDSSOLDQFHVWRWKH+LJK
7HPSHUDWXUH+7&KLPQH\6WDQGDUG8/)
IRUWKH8QLWHG6WDWHVDQG+LJK7HPSHUDWXUH&6WDQGDUG
8/&6IRU&DQDGD
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
Chimney Size
An Encore®ZLWKDQPPÀXHFROODULVDSSURYHGIRU
YHQWLQJ LQWR D PDVRQU\ FKLPQH\ ZLWK D QRPLQDO ÀXH VL]H
RI[[PPRU[[PPDQG
LQWRDURXQGÀXHZLWKQRPLQDOÀXHVL]HRIPP$Q
Encore®ZLWKDPPÀXHFRQQHFWRULVDSSURYHGIRU
YHQWLQJLQWRDPDVRQU\FKLPQH\ZLWKDQRPLQDOÀXHVL]HRI
[[PPDQGLQWRDURXQGÀXHZLWKQRPLQDO
ÀXHRIPP
127(:KHQLQVWDOOHGZLWKDÀXHFROODUWKH(QFRUH®
may not be operated with the front doors open.
:KDWHYHUWKHÀXHFROODUVL]HDQ(QFRUH®maybe vented into
ODUJHUFKLPQH\VDVZHOO+RZHYHUFKLPQH\VZLWKOLQHUVODUJHU
WKDQ[[PPPD\H[SHULHQFHUDSLGFRROLQJ
RIVPRNHDQGUHGXFWLRQLQGUDIWHVSHFLDOO\LIWKHFKLPQH\V
are located outside the home. These large chimneys may
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stove performance.
Accessories to help make the connection between stainless
steel chimney liners and your Encore®are available through
your local dealer.
Chimney Connector Guidelines
$FKLPQH\FRQQHFWRULVWKHVLQJOHZDOO SLSHWKDWFRQQHFWV
the stove to the chimney. The chimney itself is the masonry
RUSUHIDEULFDWHGVWUXFWXUH WKDWHQFORVHVWKH ÀXH&KLPQH\
connectorsareusedonlytoconnectthestovetothechimney.
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heavier steel. Do not use galvanized connector; it cannot
withstand the high temperatures that can be reached by
VPRNH DQG H[KDXVW JDVHV DQG PD\ UHOHDVH WR[LF IXPHV
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PPLQGLDPHWHU
,ISRVVLEOH GR QRW SDVV WKHFKLPQH\ FRQQHFWRU WKURXJK D
FRPEXVWLEOHZDOORUFHLOLQJ,ISDVVDJHWKURXJKDFRPEXVWLEOH
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7KURXJKV'RQRWSDVVWKHFRQQHFWRUWKURXJKDQDWWLFDFORVHW
or similar concealed space. The whole connector should be
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$SUHIDEULFDWHGGRXEOHZDOO
insulated chimney
$WLOHOLQHG
masonry chimney
Figure 2$SSURYHGFKLPQH\W\SHV
,I\RXXVHDQH[LVWLQJPDVRQU\FKLPQH\LWPXVWEHLQVSHFWHG
toensure it is in a safe conditionbeforethe stove is installed.
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RU¿UHGHSDUWPHQWRI¿FLDOZLOOEHDEOHWRLQVSHFWWKHFKLPQH\
or provide a referral to someone who can.
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KLJKHVWSRLQWZKHUHLWSDVVHVWKURXJKRUQHDUDURRIDQGDW
OHDVW¶PPKLJKHUWKDQDQ\SDUWRIDEXLOGLQJZLWKLQ
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)RUSURSHUGUDIWDQGJRRGSHUIRUPDQFHDQ\FKLPQH\XVHG
with a Encore®VKRXOGH[WHQGDWOHDVW¶PDERYHWKH
ÀXHFROODURIWKHVWRYH

73-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
,QKRUL]RQWDOUXQVRIXQVKLHOGHGFKLPQH\FRQQHFWRUPDLQWDLQ
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PPSHUPHWHUJRLQJIURPWKHVWRYHWRZDUGWKHFKLPQH\
7KHUHFRPPHQGHGPD[LPXPOHQJWKRIDKRUL]RQWDOUXQLV¶
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P,QFDWKHGUDOFHLOLQJLQVWDOODWLRQVH[WHQGWKHSUHIDEULFDWHG
FKLPQH\GRZQZDUGWRZLWKLQ¶PRIWKHVWRYH7KLVZLOO
KHOSPDLQWDLQDJRRGGUDIWE\NHHSLQJWKHVPRNHZDUPVR
that it rises readily.
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joining sections of chimney connector.
Single-wall Chimney Connectors
 %HJLQDVVHPEO\DWWKHÀXHFROODURIWKHVWRYH,QVHUWWKH
¿UVW FULPSHG HQG LQWR WKH
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keep each crimped end
pointing toward the stove.
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LQWKHÀXHFROODUDVJXLGHV
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ERWWRPRIWKH¿UVWVHFWLRQRI
chimney connector and
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ZLWKWKUHH[VKHHW
metal screws. Lift off the
JULGGOH DQG VKLHOG WKH
stove’s surface between
thegriddle openingand the
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the front hole.
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LQFOXGLQJWHOHVFRSLQJMRLQWVZLWKDWOHDVWWKUHHVKHHW
PHWDO VFUHZV 7KH SUHGULOOHG KROHV LQ WKH WRS RI HDFK
section of chimney connector serve as guides when you
GULOOPPKROHVLQWKHERWWRPRIWKHQH[WVHFWLRQ
 )DVWHQWKHFKLPQH\FRQQHFWRUWRWKHFKLPQH\,QVWUXFWLRQV
for various installations follow. Figure 5 illustrates the
general layout of chimney connector parts.
• 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
WKHQHHGWRFXWLQGLYLGXDOFRQQHFWRUVHFWLRQV&RQVXOW\RXU
local dealer about these special pieces.
&KLPQH\
Elbow
Slip Pipe
Standard
&RQQHFWRU
)OXH&ROODU
Thimble
)OXH,QQHU
Flue
Figure 5 $Q H[SORGHG YLHZ RI WKH FKLPQH\ FRQQHFWLRQ LQ D
freestanding masonry installation.
Flue Gas
Direction
Toward
Stove
Figure 4 -&KLPQH\FRQQHFWRU
Securing the Single-wall Connector to a Prefabricated
Chimney
Followtheinstallationinstructionsofthechimneymanufacturer
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Special adapters are available from your local dealer to
makethe connectionbetweenthe prefabricatedchimneyand
the chimney connector. The top of such adapters attaches
directly to the chimney or to the chimney’s ceiling support
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chimney connector.
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Securing the Single-wall Connector to a Masonry
Chimney
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chimneys may be used for your installation.
Freestanding Installations
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the joint between the thimble and the chimney wall must be
FHPHQWHG¿UPO\

83-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
Figure 7,QWKLVLQVWDOODWLRQWKHFKLPQH\FRQQHFWRUDWWDFKHVWR
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Mantel
Seal
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Thimble Sleeve
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Flue
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cemented securely in place.
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Through the Fireplace
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may install a Encore®through the opening using a “positive
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required safe clearances for Encore®¿UHSODFHLQVWDOODWLRQV
on Page 12.
Floor protection requirements also apply to fireplace
installations. Refer to the "Floor Protection" section in this
manual.
Wall Pass-Throughs
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requirements.
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room. Use furnace cement and thin gasketing to seal the
sleevein place in the thimble. Securethe chimney connector
to the outer end of the sleeve with sheet metal screws.
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of connector are then attached with sheet metal screws.
Fireplace Installations
The chimney connector may be connected to the chimney
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Above the Fireplace
The Encore®may be connected to a chimney above a
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chimney connector rises from the stove top and then angles
ninety degrees back into the chimney. The chimney liner
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enters the chimney.
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consideration to the following points:
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FKLPQH\ FRQQHFWRU DQG DQ\ FRPEXVWLEOH WULP RU WKH
mantel.
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WKHFHLOLQJ7KHFOHDUDQFHVKRXOGEHDWOHDVW
PPZLWKXQVKLHOGHGFRQQHFWRUV&RQVXOWWKHFOHDUDQFH
charts for other installation options.
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LQ GLDPHWHU WKDQ VWDQGDUG FRQQHFWRUV DQG PRVW WKLPEOHV
will facilitate the removal of the chimney connector system
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available from your local dealer.

93-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
)OH[LEOH
&RQQHFWRU
Mantel Shield
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Figure 87KURXJKWKH¿UHSODFHLQVWDOODWLRQ
Wall Stud
&KLPQH\
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Floor
Protection
12" of
Noncombustible
Material
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PPFOHDUDQFH
between pipe and
VLGHVWRSERWWRPRI
opening
Figure 10$QDSSURYHGZDOOSDVVWKURXJKIRU&DQDGD
Your local dealer or your local building inspector can provide
details for other approved methods of passing a chimney
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Equipment.
NOTE: Do not vent your Encore®LQWRDIDFWRU\EXLOW]HUR
FOHDUDQFH¿UHSODFH7KHVHDSSOLDQFHVDQGWKHLUFKLPQH\V
DUHVSHFL¿FDOO\GHVLJQHGDVDXQLWIRUXVHDV¿UHSODFHV,W
may void the listing or be hazardous to adapt them for any
other use.
DO NOT CONNECT THE Encore® TO ANY AIR
DISTRIBUTION DUCT OR SYSTEM.
Three other methods are also approved by the NFPA:
•Placinga section ofchimneyconnector inside aventilated
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•Placing a section of chimney connector inside a section
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chimney section and combustibles.
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outer wall of the chimney section and combustibles.
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clearancefortheconnector.Theresultingspacemustremain
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cover must be mounted on noncombustible spacers at least
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connectors through combustible walls. Many building
code inspectors follow these guidelines when approving
installations.
Figure 9 shows one NFPA recommended method. All
combustible material in the wall is cut away from the
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clearance. Any material used to close up the opening must
be noncombustible.

10 3-90-30005295Vermont Castings • Encore® Flexburn Installation Manual_R43 • 11/18
U.S. Canada
A39" PP
B45" PP
C12"
10" PP&RQQHFWRU PP&RQQHFWRU
D6" PP
E6" PP
F16" PP
Floor Protection
Atremendous amount of heat radiates from the bottom plate
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stovewill require protection from radiant heat as well as from
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Shield supplied with the stove.
Most installations will require the bottom heat shield to be
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noncombustible surface such as unpainted concrete over
earth may it be used without the heat shield.
With the bottom heat shield installed the Encore®2040
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noncombustiblematerial ifdesired.Do notobstructthe space
under the heater.
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with a decorative noncombustible material if desired. Do
not obstruct the space under the heater.An 8" chimney and
chimney connector is required and the bypass damper must
be in the fully open position.
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the use of the supplied bottom heat shield.
ProtectionrequirementsvarysomewhatbetweentheUntied
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In U. S. installationsWKHÀRRUSURWHFWRULVUHTXLUHGXQGHU
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,Q UHDU YHQWLQJ FRQ¿JXUDWLRQV ÀRRU SURWHFWLRQ PXVW DOVR
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³&´)LJXUH)RUWKHPPFRQQHFWRUWKHSURWHFWRU
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The protector must be centered under the connector.
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39" wide and 45" deep.
In Canada:$ QRQFRPEXVWLEOH ÀRRU SURWHFWRU LV UHTXLUHG
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WKHVLGHVDQGUHDU³'´DQG³(´)LJXUH
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D
E
A
B
A
E
C
F
E
E
F
Figure 115HTXLUHGÀRRUSURWHFWLRQGLPHQVLRQV
How to Determine if Alternate Floor Protection Materials
are Acceptable
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PXVW QRW EH XVHG 7KH ÀRRU SURWHFWLRQ VSHFL¿HG LQFOXGHV
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Procedure:
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LL.IDFWRULVJLYHQZLWKDUHTXLUHGWKLFNQHVV7LQLQFKHV
LLL.IDFWRULVJLYHQZLWKDUHTXLUHGWKLFNQHVV7LQLQFKHV
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5 U[7
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protector:
i. Use the formula in Step 1 to convert values not
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acceptable.
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.