Vermont Castings Intrepid II User manual

VERMONT CASTINGS, INC.
Intrepid II
Model No. V10R NAT. GAS
V10G
V10CB
Model No. V12R L.P.G
V12G
V12CB
GC No. 32-227-01
DECORATIVE COAL EFFECT GAS STOVE
Installation and Maintenance Instructions
Hand these instructions to the user
This appliance is only for use on Natural Gas (G20) at a supply
pressure of 20 mbar in GB / IE (Model No. V10)
or

2
Propane G31 at a supply pressure of 37mbar in GB / IE (Model
No. V12)

3
CONTENTS
PAGE
Section 1 Information and Requirements
1.0 Appliance Information 3
1.1 Conditions of Installation 4
1.2 Flue and chimney suitability 4
1.3 Clearance to Shelfs – Rear Flue Fitting 5
1.4 Clearance to Beams – Top Flue Fitting 5
1.5 Chimney inspection 5-6
1.6 Hearths 7
1.7 Spillage Monitoring System 7
1.8 Fitting of the removeable door handle 7
Section 2 Installation of the stove
2.1 Unpacking the stove 8
2.2 Installing the stove 8
2.3 Min. / Max. dimensions of builders opening 9
/ void for rear flue fitting
2.4 Min. / Max dimensions of Inglenook for top 10
Flue fitting
2.5 Installation into brick or stone built 11-13
chimney
2.6 Installation into brick or stone built chimney 14-16
utilising a closure plate.
2.7 Installation using metal flue pipe with no 17-19
chimney.
2.9 Rotation of the flue spigot collar 20-21
2.10 Fitting the flue pipe or elbow to the stove 21
2.11 Making the gas connection 22
2.12 Gas soundness & burner pressure 22
Section 3 Assembling Fuel Bed and Commissioning
3.1 Assembling the ceramics and fuel bed 23-26
3.2 Lighting the appliance 27
3.4 Checking for clearance of combustion 27-28
products
Section 4 Maintenance
4.1 Removal of the burner assembly 29
4.2 Removal of the control tap 29
4.3 Removal of the pilot assembly 30
4.4 Removing the spillage detection switch 30
4.5 Adjustment of the door latch 30
4.6 Flue pipe options 31

4
SECTION 1
INFORMATION AND REQUIREMENTS
1.0 APPLIANCE INFORMATION
Main injectors (2 off) Size 280-Nat gas / Size 120-LPG
Pilot Type S.I.T. Oxystop
Type (YA OP 9055) – Nat gas
(YA OP 9604) - LPG
Max. Gross Heat Input: 6.8 kW
Min. Gross Heat Input: 4.2 kW
Gas Rate 0.6 m3/hr
Inlet Pressure : (20+/-1.0mbar Nat gas) (8.0 +/- 0.4 in w.g.)
(37+/-1.0mbar LPG) (14.8 +/- 0.4 inw.g.)
Ignition Integrated piezo ignition on Valve
Electrode Spark Gap 4.5mm
Weight (not including packaging) 79 Kg
Stove Dimensions
Width: 545mm
Height: (Top vent) 642mm
Height: (Back vent) 610mm
Depth: (Top vent) 540mm
Flue collar size 150mm (diameter)
Gas Connection 8mm Compression
(Supplied with stove)
32mm to end
of horizontal
vent collar.
540mm
350mm
180mm
642mm
545mm
545mm
610mm
460mm
610mm
to top of
flue in
rear flue
position

5
INSTALLATION REQUIREMENTS
1.1 CONDITIONS OF INSTALLATION
It is the law that all gas appliances are installed only by a CORGI Registered Installer, in
accordance with these installation instructions and the Gas Safety (Installation and Use)
Regulations (current edition) and the rules in force. Failure to install appliances correctly
could lead to prosecution. It is in your own interest and that of safety to comply with the law.
The installation must also be in accordance with all relevant parts of the Local and National
Building Regulations where appropriate, the Building Regulations (Scotland Consolidation)
issued by the Scottish Development Department, and all applicable requirements of the
following British Standard Code of Practice.
1. B.S. 5871 Part 3 Installation of Decorative Fuel Effect Gas Fires
2. B.S. 6891 Installation of Gas Pipework
3. B.S. 5440 Parts 1 & 2 Installation of Flues and Ventilation
4. B.S. 715 Metal flue pipes for gas appliances
5. B.S. 6461 Part 1 Installation of Chimneys and flues
6. B.S. 1289 Clay Flue Blocks and Terminals
7. I.S. 813:1996 Domestic Gas Installations
No purpose made additional ventilation is normally required, for this appliance in GB.
NB. For appliances installed in Republic of Ireland, refer to Domestic Gas Installation
document listed above for specific ventilation requirements.
1.2 FLUE AND CHIMNEY SUITABILITY
Minimum diameter of circular flues 125mm
Minimum effective height of all flue types 2.5 metres
Maximum horizontal flue length 150mm
1.3 CLEARANCES TO SHELF’S – REAR FLUE FITTING

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The stove may be fitted below a combustible shelf providing there is a minimum distance of
250mm above the top of the stove and the shelf does not project more than 150mm. If the
shelf overhangs more than 150mm the distance between the fire and the shelf must be
increased by 15mm for every 25mm of additional overhang over 150mm. See Graph below
1.4 CLEARANCES TO COMBUSTIBLE BEAMS WITHIN INGLENOOKS – TOP FLUE
FITTING
The stove may be below a combustible beam providing there is a minimum distance of
610mm above the top of the stove and that it does not extend in front of the stove. There
must be a minimum distance of 300mm to any combustible side or rear surface, and 100mm
to any non-combustible side or rear surface.
1.5 FLUE / CHIMNEY INSPECTION
Forward Shelf Projection Allowed (mm)
Shelf Height
Above Top of
Stove (mm)
0 150 175 200 225
295
280
265
250
0
Stove Must Not be
fitted below a Shelf
Height of 250mm

7
Before commencing installation, a flue or chimney should be inspected to ensure that all the
following conditions are satisfied.
1. Check that the chimney / flue only serves one fireplace and is clear of any obstruction.
Any dampers or register plates must be removed or locked in the open position.
2. Brick/stone built chimneys or any chimney or flue which has been used for an appliance
burning fuel other than gas must be thoroughly swept. The base of the chimney / flue must
also be thoroughly cleared of debris etc.
3. Any under-floor air supply to the fireplace must be completely sealed off.
4. Ensure that the inside of the chimney / flue is in good condition along it’s length and
check that there is no leakage of smoke through the structure of the chimney during and
after the smoke pellet test.
5. The stove can be installed into various flue pipes (in accordance with BS. 715) with a
minimum internal diameter of 125mm.
6. Using a smoke pellet, check that there is an up-draught in the chimney / flue and
that the smoke can be seen issuing from the terminal / chimney pot outside. There
must be no leakage of smoke through the structure of the chimney during or after the
smoke pellet test and it is important to check inside upstairs rooms adjacent to the
chimney / flue. Check the chimney pot / terminal and general condition of the brickwork or
masonry. If the chimney or flue is in poor condition or if there is no up-draught do not
proceed with the installation. If there is a history of down-draught conditions with the
chimney / flue, a Tested and Certificated flue terminal or cowl suitable for the relevant flue
type should be considered.
A spillage test must always be carried out during commissioning of the
appliance, see page 30 & 31 for details.

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1.6 HEARTHS
The hearth used with this product should extend 75mm in front of stove and 150mm either
side of the stove
1.7 SPILLAGE MONITORING SYSTEM
This appliance is fitted with a draft diverter and thermal switch. This is designed to shut the
fire off in the event of a partial or complete blockage of the flue causing a build up of
combustion products in the room in which the stove is operated. The following are
important warnings relating to this spillage monitoring system :-
1) The spillage monitoring system must not be adjusted by the installer.
2) The spillage monitoring system must not be put out of operation under any
circumstances.
3) When the spillage monitoring system is exchanged only a complete original
manufacturers part may be fitted. It is not possible to replace individual parts on this
appliance, only a complete assembly may be fitted.
1.8 FITTING THE REMOVEABLE HANDLE TO THE STOVE DOOR
The door handle which comes with the stove is designed to be removeable to prevent
overheating during long periods of use. To use the handle, simply slide the collar into
the door handle and open the doors. When you have either opened or shut the doors,
remove the handle and store in a safe place.
IMPORTANT NOTICE : PLEASE INFORM THE CUSTOMER THAT THIS
STOVE MUST NOT BE RUN WITH THE DOORS
IN THE OPEN POSITION, OR IF THE GLASS IS
BROKEN OR MISSING.
A LABEL STATING THIS MESSAGE IS ADHERED TO THE GLASS DOORS OF THE
APPLIANCE PLEASE ASK THE CUSTOMER TO REMOVE THIS LABELTO
ENSURE THAT THEY ARE AWARE OF THIS BEFORE LIGHTING THE STOVE FOR
THE FIRST TIME.

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SECTION 2
INSTALLATION OF THE STOVE
2.1 UNPACKING THE STOVE
Carefully remove the stove from its packaging taking care not to damage the gas controls
located beneath the appliance . Remove the loose items from inside the stove. Check the
contents as listed :-
NOTE: This appliance is extremely heavy so care should be taken when lifting the
stove from its packaging.
Packing Check List
1off Handle (enamel stoves)
2off Handle ( cast iron stoves)
1off Boxed hard ceramic fuelbed and 23 synthetic coals
(18 Large and 5 Small)
1off each User instruction book and Installation book
1off Touch-up paint (enamel stoves only)
1off Black Closure Plate
7off Closure Plate Fixing Screws (for use with closure plate)
1off Spigot Extension (for use with closure plate)
NOTE: NO OPTIONAL SHORT LEGS ARE AVAILABLE FOR THE INTREPID II GAS
STOVE.
CLEAN THE GRIDDLE BEFORE USE
At the factory we coat the griddle with vegetable oil to prevent rusting while the stove is in
transit or storage. Remove the oil with a dry rag or paper towel before you use the stove.
2.2 INSTALLING THE STOVE
Due to the weight of this appliance (79kg) it does not require any additional fixing methods.
There are several methods of installing the flue system for use with the Intrepid II stove.
Please follow the installation criteria stated below dependent upon which type of flue you
are planning to install the Intrepid II gas stove into :- See page 31 for flue pipe / elbow
options.
If you have a stone or brick built chimney, please refer to pages 11 to 13 for method
of installation.
If you have a stone or brick built chimney with or without an integral clay flue liner
fitted and are planning to fit the stove using a closure plate, please refer to pages 14-
16 for method of installation.
If you have no chimney, and are planning to fit the factory manufactured flue pipe or
an alternative flue pipe, please refer to pages 17 to 19 for method of installation.

10
2.3 MINIMUM AND MAXIMUM DIMENSIONS OF BUILDERS OPENING / VOID –
REAR FLUE FITTING
NOTE : Maximum dimensions when measured on individual installations must not
calculate to exceed a void volume of 247dm3, or be less than 12 dm3. See page 14
for example calculation.
Flat Surface Area
Width = 525mm
Height = 660mm
Height
Min = 635mm
Max = 660mm
Width
Min = 450mm
Max = 500mm
Depth
Min = 200mm
Max = See Note
Below

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2.4 MINIMUM AND MAXIMUM DIMENSIONS OF INGLENOOK – TOP FLUE FITTING
Minimum “A” Dimension = 745mm into Non Combustible Surround
Minimum “B” Dimension = 1145mm into Combustible Surround
Minimum “C” Dimension = 742mm into Non Combustible Surround
Minimum “D” Dimension = 560mm into Non Combustible Surround
Minimum “E” Dimension = 760mm into Combustible Surround
NOTE : Maximum dimensions are not specified due to limiting installation possibilities
Height
Min C = 742mm
For Max.
Dimensions See
Note Below
Width
Min A = 745mm
Min B = 1145mm
For Max.
Dimensions See
Note Below
Depth
Min D = 560mm
Min E = 760mm
For Max.
Dimensions See
Note Below

12
2.5 DIRECTLY HORIZONTAL OR VERTICAL INSTALLATION OF STOVE INTO A
STONE OR BRICK BUILT CHIMNEY.
If you require to fit the Intrepid II gas stove into a stone or brick built chimney, you should
first check that the flue has a positive up-draught as described on page 5 of this book.
A minimum effective flue height of 2.5m from the centre of the flue outlet spigot is
required, and a flue terminal conforming to the requirements of BS 5440 : Part 1 will
need to be fitted.
The flue spigot outlet has been fitted to the appliance from the factory in the vertical
position, if you require to fit the flue pipe in the horizontal position, you must rotate the flue
outlet spigot as shown on page 20-21
A debris / register plate must be fitted around the flue pipe and the flue pipe must be sealed
to both the debris / register plate and to the base of the chimney where the flue pipe enters
the chimney. This should be sealed using a suitable fire cement or proprietary sealing
compound.
If you are fitting the flue pipe directly horizontal on the stove, you will need to reverse the
outlet spigot on the stove, as it is factory set in the vertical position. See page 20-21 for
details of how to reverse this spigot back to the horizontal position.
With the debris / register plate sealed into position and any sealing compound cured, and
with the flue outlet spigot in the correct position, set the stove to its required position and
connect the flue pipe to the chimney spigot / collar. Once this is complete, proceed with
the connection of the gas supply, fuelbed layout and commisioning of the stove.
On the following two pages, diagrams are shown to illustrate a vertical installation
(page 12) and a horizontal installation (page 13), with relevant dimensional information.
See page 31 for flue pipe / elbow options.
A closure plate is enclosed with the product.

13
INSTALLATION OF AN INTREPID II GAS STOVE DIRECTLY VERTICAL INTO A
BRICK OR STONE BUILT CHIMNEY.
FLUE PIPES TO BE
SEALED TO DEBRIS /
REGISTER PLATE AND
TO THE ENTRANCE TO
THE CHIMNEY WITH
SUITABLE TAPE.
FLUE OF MINIMUM 5” (125MM)
DIAMETER
MINIMUM EFFECTIVE
FLUE HEIGHT
2.5 METRES
FLUE SYSTEM TO TERMINATE
WITH A CHIMNEY ;POT OR FLUE
TERMINAL COMPLYING WITH BS
5440 : PART 1
MINIMUM CLEARANCE
50MM
MINIMUM 100mm

14
INSTALLATION OF AN INTREPID II GAS STOVE DIRECTLY VERTICAL VIA A
HORIZONTAL COLLAR INTO A BRICK OR STONE BUILT CHIMNEY.
FLUE PIPES TO BE
SEALED TO DEBRIS /
REGISTER PLATE AND
TO THE ENTRANCE TO
THE CHIMNEY WITH
SUITABLE TAPE.
FLUE OF MINIMUM 5” (125MM)
DIAMETER
MINIMUM EFFECTIVE
FLUE HEIGHT
2.5 METRES
150MM
FLUE SYSTEM TO TERMINATE
WITH A CHIMNEY ;POT OR FLUE
TERMINAL COMPLYING WITH BS
5440 : PART 1
MINIMUM CLEARANCE
50MM
MINIMUM 100mm

15
2.6 DIRECTLY HORIZONTAL INSTALLATION OF STOVE INTO A STONE OR BRICK
BUILT CHIMNEY WITH & WITHOUT INTEGRAL CHIMNEY LINER, UTILISING A
CLOSURE PLATE.
If you require to fit the Intrepid II gas stove into a stone or brick built chimney without a
chimney liner fitted, you will have to fit a minimum 5” (125mm) diameter flue pipe to run
the entire height of the flue, you should also check that the flue has a positive up-draught
as described on page 5 of this book. If the chimney liner is fitted, you do not require to fit a
flue pipe, but the flue will need to be tested for positive up-draught, as described on page
5.
A minimum effective flue height of 2.5m from the centre of the flue outlet spigot is
required, and a flue terminal conforming to the requirements of BS 5440 : Part 1 will
need to be fitted.
A debris / register plate must be fitted around the flue pipe and the flue pipe must be sealed
to both the debris / register plate and to the base of the chimney where the flue pipe enters
the chimney. This should be sealed using a suitable fire cement or proprietary sealing
compound.
The flue spigot outlet has been fitted to the appliance from the factory in the vertical
position.
You must ensure that the void volume behind the catchment area is a minimum of 12 dm3
The void, including that which may be created by any ledge, should not be so large as to
adversely affect performance of the flue by creating abnormal flow. Where an oversized
void is encountered, it may be reduced in size by lining the void with bricks or blocks,
or alternatively by inserting a metallic flue box. The nominal dimensions of the void must
not exceed 650mm wide x 475mm deep x 800mm in height. The metallic flue box as stated
above should conform to BS 715.
To calculate the void volume, measure the height, width and depth of the void in millimetres
(mm)
e.g. 450mm height x 300mm width and 250mm depth
450 x 300 x 250 = 33,750,000mm3
To convert this figure into dm3, divide by 1,000,000
This gives a nominal void volume of 33.75 dm3.
The void volume must not exceed the dimensions stated above, or work out to more than
247 dm3.
INSTALLATION OF THE CLOSURE PLATE

16
When sealing the closure plate (which is supplied) to the wall, use the screws and
Rawlplugs supplied. The foam seal which is supplied should be fitted to the rear of the
closure plate to ensure an airtight seal is obtained between the closure plate and the flat
sealing area of the wall. See diagram below.
Dimensions stated are for closure plate supplied
With the debris / register plate sealed into position and any sealing compound cured, and
with the flue outlet spigot in the correct position, set the stove to its required position and
insert and seal the flue pipe into the closure plate. Once this is complete, proceed with
the connection of the gas supply, fuelbed layout and commissioning of the stove.
See page 31 for flue pipe/elbow options.
A closure plate and fixings are supplied with the product.
Flat Sealing
Area
Closure
Plate
Screw
Fixing
Holes
660
mm
525mm

17
INSTALLATION OF AN INTREPID II GAS STOVE DIRECTLY VERTICAL VIA
AN HORIZONTAL COLLAR THROUGH A CLOSURE PLATE INTO A BRICK OR
STONE BUILT CHIMNEY WITH OR WITHOUT INTEGRAL CHIMNEY LINER.
MAXIMUM
150MM
HORIZONTAL
FLUE LENGTH
MINIMUM EFFECTIVE
FLUE HEIGHT
2.5 METRES INTEGRAL CHIMNEY LINER
MINIMUM 125MM (5”)
DIAMETER
FLUE SYSTEM TO
TERMINATE WITH A
CHIMNEY POT OR A
FLUE TERMINAL
COMPLYING WITH BS
5440 : PART 1
DEBRIS / REGISTER PLATE TO
BE SEALED TO THE
CHIMNEY WITH SUITABLE
TAPE.
CLOSURE PLATE TO BE SEALED TO
WALL WITH TAPE ETC WITH AN
ADHESIVE STRENGTH OF 100 DEG / C.
VOID VOLUME TO BE A
MINIMUM OF 12 dm3. MAXIMUM
VOLUME AS PER INFORMATION
ON PAGE 17.
MINIMUM CLEARANCE OF
100mm.
50mm
MINIMUM
MINIMUM
2.5 METRES

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2.8 DIRECTLY HORIZONTAL INSTALLATION OF STOVE INTO A PROPERTY BUILT
WITHOUT CHIMNEY LINER, UTILISING A METAL FLUE PIPE.
If you require to fit the Intrepid II gas stove into a property without a stone or brick built
chimney, you will need to fit sufficient length of flue pipe for clearance of the combustion
products. This must be a minimum of 2.5 meters effective flue height / length. The flue
pipe must also be a minimum of 5” (125mm) in diameter.
Any flue pipe fitted should be secured to the building in line with current building
regulations.
The flue pipe can be purchased either from the manufacturer or from an external supplier
of flue pipes. Any pipe used should conform to the requirements of BS 715.
A minimum effective flue height of 2.5m from the centre of the flue outlet spigot is
required, and a flue terminal conforming to the requirements of BS 5440 : Part 1 will
need to be fitted.
The flue spigot outlet has been fitted to the appliance from the factory in the vertical
position, if you require to fit the flue pipe in the horizontal position, you must rotate the flue
outlet spigot as shown on page 20 & 21.
The flue will need to be tested for positive up-draught, as described on page 5, when the
flue pipe is in place, before the stove is attached to it.
Once this is complete, proceed with the connection of the gas supply, fuelbed layout and
commisioning of the stove.
On the following pages, diagrams are shown to illustrate a installation in the horizontal
(page 18) and vertical spigot position (page 19)
See page 31 for flue pipe/elbow options.

19
INSTALLATION OF AN INTREPID II GAS STOVE DIRECTLY VERTICAL VIA,
A HORIZONTAL COLLAR FITTED WITH MINIMUM 5” (125mm) DIAMETER FLUE
PIPE.
FLUE SYSTEM TO
TERMINATE WITH A
CHIMNEY POT OR A FLUE
TERMINAL COMPLYING
WITH BS 5440 : PART 1
FLUE PIPE OF
MINIMUM 5” (125mm)
DIAMETER OR
EQUIVALENT
CROSS-SECTIONAL
AREA COMPLYING
WITH BS 715.
MINIMUM
EFFECTIVE FLUE
HEIGHT
2.5 METRES
MAXIMUM 150MM
HORIZONTAL FLUE
LENGTH
ENSURE THAT CLEARANCES (NORMALLY
50MM) FOR COMBUSTIBLE MATERIALS
COMPLY WITH YOUR LOCAL AND
NATIONAL BUILDING REGULATIONS
MINIMUM 50mm
CLEARANCE

20
INSTALLATION OF AN INTREPID II GAS STOVE DIRECTLY VERTICAL, FITTED
WITH MINIMUM 5” (125mm) DIAMETER FLUE PIPE
FLUE PIPE OF
MINIMUM 5”
(125MM) DIAMETER
OR EQUIVALENT
CROSS SECTIONAL
AREA COMPLYING
WITH BS
715
FLUE SYSTEM TO
TERMINATE WITH A
CHIMNEY POT OR A FLUE
TERMINAL COMPLYING
WITH BS 5440 : PART 1
MINIMUM
EFFECTIVE
FLUE HEIGHT
2.5 METRES
ENSURE THAT CLEARANCES (NORMALLY 50MM) TO COMBUSTIBLE
MATERIALS COMPLY WITH LOCAL AND NATIONAL
BUILDING REGULATIONS
MINIMUM 50MM
CLEARANCE