Vermont Castings The Intrepid II 1990 Installation instructions

130003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
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.
For use in Europe
0966
Intrepid Cover
11/00
Intrepid®II Wood Burning Stove
Model 1990
NOTICE: SAVE THESE INSTRUCTIONS
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.
• Donotstoreorusegasolineorotherammablevapors
andliquidsinthevicinityofthisoranyotherappliance.
• Donotoverre-Ifanyexternalpartstartstoglow,you
areoverring.Closeaircontrols.Overringwillvoid
yourwarranty.
• Complywithallminimumclearancestocombustibles
asspecied.Failuretocomplymaycauseahousere.
WARNING
!
Save These Instructions For Future Reference
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.
Testedandapprovedforusewithdry,seasonedcordwood
only.DoNotBurnWetorGreenWood.Burninganyother
typeoffuelwillvoidyourwarranty.
CAUTION
!

230003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Welcome
CongratulationsonyourchoiceofaVermontCastingsIntrepidII.Withthispurchase,youmadeacommitmenttomakethe
hearthaplaceofwarmth,beautyandcomfortinyourhome.AtVermontCastingsGroup,wesharethatjoyandappreciation
ofthehearth,andweshowitinallourcastironstovesandreplaces.
Asyoubecomeacquaintedwithyournewstove,youwillndtheaestheticappealofcastironismatchedonlybyitssuperb
capacitytoabsorbandradiateheat.
Also,VermontCastingsGroupproductsareamongthecleanestburningwoodstovesandreplacesavailabletoday.Asan
ownerofaVermontCastingsGroupstove,youaremakingastrongstatementforpollution-freeenergy.Butcleanburning
dependsonboththemanufacturerandtheoperator.Pleasereadthismanualcarefullytounderstandhowtoproperlyoperate
yourstove.
AtVermontCastingsGroup,weareequallycommittedtoyoursatisfactionasacustomerandthatiswhywemaintainan
exclusivenetworkofthenestdealersintheindustry.Chosenfortheirexpertiseanddedicationtocustomerservice,our
dealersarefactory-trainedandknoweachVermontCastingsGroupproductindetail.FeelfreetocontactyourAuthorized
VermontCastingsDealeranytimeyouhaveaquestionaboutyourstoveoritsperformance.
WehavebuiltyourVermontCastingsIntrepidIIwiththeutmostcare.Withnormaluseandpropercare,itwillprovideyou
withmanyyearsofservice.
ThismanualcontainsvaluableinstructionsontheinstallationandoperationofyourVermontCastingsstove.Youwillalso
ndusefulinformationonassemblyandmaintenanceprocedures.Weurgeyoutoreadthemanualthoroughlyandtokeep
itasareference.
Specications................................................... 3
Installation........................................................ 4
Clearances....................................................... 9
Assembly........................................................ 11
Operation........................................................ 12
DraftManagement.......................................... 18
Maintenance................................................... 19
CatalyticCombustor....................................... 21
ServicePartsList............................................ 26
Warranty......................................................... 31
Table of Contents AskyourVermontCastingsdealerhowtheseinstallation
accessoriescanenhancetheversatility,appearance,and
safetyofyourIntrepidStove.
Chimneyconnectorheatshields
Heavy-gaugeenamelpipetomatchthestove’scolor
Warmingshelves:
0098 ClassicBlack 1380 Bordeaux
1373 BrownMajolica 1376 Biscuit
3258 Outsideairkit
0136 Sparkscreenforopen-replaceuse
StoveSerialNo._____________________
Dealer____________________________
__________________________________________
__________________________________________
Phone_____________________________
DatePurchased_____________________
Installer___________________________
__________________________________________
__________________________________________
Phone_____________________________
DateInstalled_______________________
Please record the following information
for future reference.
= Contains updated information


330003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Specications
Intrepid II, Model 1990CE
TestedbyCTIF:4418b
Nominalheatoutput.................4.9kW(21,100BTU/hr)1
Minimumuedraught........................12Pa(0.048"WG)
Meanuegastemp................................337°C(639°F)
Efciency(spaceheating)........................................75%
Areaheated..................... Upto112sq.m(1200sq.ft.)1
Fuelsize/type...................................410mm(16")wood
Fluemassgasow............................................... 5.6g/s
COEmissions(@13%O2)....................................0.09%
Loading......................................................... Front or top
Chimneyconnector....................... 152mm(6")diameter
Chimneyuesize.........................152mm(6")minimum
Flueexitposition.......................... Reversible,toporrear
Primaryair........Manualset,thermostaticallymaintained
Secondaryair...........................................Self-regulating
Ashhandlingsystem.......................Removableashpan
Glasspanels.......................... Hightemperatureceramic
545 mm
(21¹⁄₂")
510 mm (20")
640 mm
(25¹⁄₄")
Top exit
flue collar
height
540 mm (21¹⁄₄")
610 mm
(24")
180 mm
(7¹⁄₈")
545 mm (21¹⁄₂")
C
L
540 mm (21¹⁄₄")
460 mm (18")
31 mm
(1¹⁄₄")
520 mm
(20¹⁄₂")
350 mm (13³⁄₄")
3840
Intrepid EU
specifications
7/06
DRAWINGS NOT TO SCALE
Figure 1-IntrepidII1990CEdimensions.
Weight................................................ 101kg(233lbs.)
Width(leg-to-leg)............................... 545mm(21-1/2")
Depth(leg-to-leg)............................... 350mm(13-3/4")
Heighttotopofuecollar:
 withregularlegs.......................635mm(25")topexit
............................................... 610mm(24")rearexit
 withoptionalshortlegs.............535mm(21")topexit
......................................... 500mm(19-3/4")rearexit
1. This value can vary depending on how the stoveis
operated,thetypeandmoisturecontentofthefuelused,
aswellasthedesign,constructionandclimaticlocation
ofyourhome.Figuresshownarebasedonnominalfuel
consumption obtained under laboratory conditions and
onaverageefciencies.

430003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Installation
SAFETY NOTICE: IF YOUR STOVE IS NOT PROPERLY
INSTALLED, A HOUSE FIRE MAY RESULT. TO REDUCE
THE RISK OF FIRE, FOLLOW THE INSTALLATION
INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE
OFFICIALSABOUT RESTRICTIONSAND INSTALLATION
INSPECTION REQUIREMENTS IN YOUR AREA.
Beforeyoubeginaninstallation,reviewyourplanstoseethat:
• Yourstoveandchimneyconnectorwillbefarenough
from combustible material to meet all clearance
requirements.
• Theoorprotectorislargeenoughandisconstructed
properlytomeetallrequirements.
• Youhaveallnecessarypermitsfromlocalauthorities.
Yourlocalbuildingofcialisthenalauthorityforapproving
yourinstallationassafeanddeterminingthatitmeetslocal
andstatecodes.
Themetallabelpermanentlyattachedtothebackofevery
VermontCastingsstoveindicatesthestovehasbeentested
tocurrentstandards.TheteststandardisEN13240:2001+
A2:2004forEurope.Clearanceandinstallationinformation
also is printed on the label. When the stove is installed
according to the information both on the label and in this
manual,localauthoritiesinmostcaseswillacceptthelabel
asevidencethat the installationmeetscodes and canbe
approved.
However,codesvaryindifferentcountries.Beforestartingthe
installation,reviewyourplanswiththelocalbuildingauthority.
You local dealer can provide any additional information
needed.
IMPORTANT: Failure to follow these installation
instructions may result in a dangerous situation, including
a chimney or house re. Follow all instructions exactly,
and do not allow makeshift compromises to endanger
property and personal safety.
All local regulations, including those referring to national
and European standards, need to be complied with when
installing this stove.
Outside Air
Insomemodern,super-insulatedhomes,thereisnotenough
airforcombustionbecauseofinsufcientairinltrationinto
thebuilding.Suchairentersahomethroughunsealedcracks
andopenings.Kitchen or bathexhaustfans can compete
withthestoveforavailableairandcompoundtheproblem.
ST241
chimney types
12/13/99 djt
Aprefabricateddouble-
wallinsulatedchimney
Atile-lined
masonrychimney
Figure 2-Standardchimneytypes.
Ifyouuseanexistingmasonrychimney,itmustbeinspected
toensuresafeconditionbeforethestoveisinstalled.Your
localprofessionalchimneysweep,buildinginspector,orre
department ofcial will be able to inspect the chimney or
provideareferraltosomeonewhocan.
TheueandchimneydesignmustmeetrequirementJ2,Part
Jofthebuildingregulations2000(CombustionAppliances
andFuelStorageSystems).
Whenpoordraftiscausedbyalowinltrationrate,openinga
groundoorwindowonthewindwardsideofthehouseand
inthevicinityofthestovewillusuallyalleviatetheproblem.
Anothersolutionistoinstallapermanentoutsideairsupply
tothestoveand/orroom.Insomeareas,infact,bringingair
forcombustionfromoutsidethehomedirectlytotheairinlet
ofthestoveisrequiredfornewconstruction.
Anoutsideairsupplyisnotaffectedbypressurevariations
within the house, and improved stove performance often
results.An OutsideAirAdaptor Kit for the Intrepid II is
availablefromyourlocalVermontCastingsdealer.
What Kind of Chimney to Use
Your Intrepid II must be connected to a code-approved
masonry chimney with a ue liner, to a relined masonry
chimneythatmeetslocalcodes,ortoaprefabricatedmetal
chimney.Whateverkindyouuse,thechimneyandchimney
connectormustbeingoodconditionandkeptclean.Figure
2showsthetwochimneytypes.

530003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Connecting Flue Pipes
Connectorpipesshouldmeettherequirementsofthebuilding
regulations. This can be achieved by the use connecting
uepipesincludedinthefollowingcategories:
a)VitreousenamelledsteelpipecomplyingwithBS6999:
1989(1996);
b)PipesmadefromstainlesssteelasdescirbedinBSEN
1008-1:1995 grades 1.4401, 1.4404, 1.4432 or 1.4436
withuewallthicknessofatleast1mm;
c)MildsteeluepipescomplyingwithBS1449:Part1:1991,
withauewallthicknessofatleast3mm;
d)CastironuepipescomplyingwithBS41:1973(1998).
Flue Pipes with a spigot and socket joint should be tted
withthesocketfacingupwards,tocontaincondensatesand
moisture within the ue. Joints should be made gas tight
usingproprietaryjointingaccessories,or,whereappropriate,
bypackingjointwithnoncombustibleropeandrecement.
Double-wallchimneyconnectorsmustbetestedandlistedfor
usewithsolid-fuelburningappliances.Single-wallchimney
connectorsshouldbemadeof24gaugeorheaviersteel,and
shouldbe150mm(6")indiameter.Donotusegalvanized
connector; it cannot withstand the high temperatures that
canbereachedbysmokeandgases,andmayreleasetoxic
fumesunderhighheat.
Ifpossible, donot pass the chimney connector through a
combustiblewallorceiling.Ifpassagethroughacombustible
wall is unavoidable, refer to the section following on Wall
Pass-Throughs.Donotpassthechimneyconnectorthrough
anattic,acloset,oranysimilarconcealedspace.Thewhole
connectorshouldbeexposedandaccessibleforinspection
andcleaning.
Inhorizontalrunsofsingle-wallchimneyconnectorwithout
protectiveshields,maintainaclearanceofatleast660mm
(26")fromtheceiling.
Keepthehorizontalrunofchimneyconnectorasshortand
directaspossible,withnomorethantwo90°turns.Slope
horizontal runs of connector upward 20 mm per m (1/4"
per foot) going from the stove toward the chimney. The
recommendedmaximumlengthofahorizontalrunis914mm
(36").Therecommendedtotallengthofchimneyconnector
is2.4m(8’).
In cathedral ceiling installations, extend the prefabricated
chimneydowntowithin2.4m(8’)ofthestove.
SAFETY NOTE: ALWAYS WEAR GLOVES AND
PROTECTIVE EYEWEAR WHEN DRILLING, CUTTING OR
JOINING SECTIONS OF CHIMNEY CONNECTOR.
Masonry Chimneys
Aninspectionofthechimneymustconrmthatithasalining.
Donotuseanunlinedchimney.Thechimneyshouldhaveno
cracks,loosemortar,othersignsofdeterioration,orblockage.
Repairanydefectsbeforeusingthechimneywithyourstove.
Sealanyunusedopeningsinanexistingmasonrychimney
with masonry to the thickness of the chimney wall, and
repairthechimneyliner.Openingssealedwithpieplatesor
wallpaperareahazard;sealthemwithmortarorrefractory
cement.Intheeventofachimneyre,amesandsmoke
maybeforcedoutoftheseunusedthimbles.
Thechimneyshouldbethoroughlycleanedbeforeuse.
A newly-built masonry chimney must conform to the
standardsofyourlocalbuildingcodeor,intheabsenceofa
localcode,toarecognizednationalcode.Masonrychimneys
mustbelined,eitherwithcode-approvedmasonryorpre-cast
refractory tiles, stainless steel pipe, or a code-approved,
“poured-in-place”liner.Thechimney’sclean-outdoormust
sealtightly.
Prefabricated Chimneys
Theseshouldbeaninternaldiameterof150mm(6")andbe
ofthetwinwallinsulatedconstructionthathasbeenapproved
forsolidfueluse(e.g.RiteVentICSofICIDLiteChimney
Systems).Diametersover200mm(8")arenotrecommended
duetothelargecross-sectioncausingexcessivecoolingof
theuegases.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE
SERVING ANOTHER APPLIANCE.
Chimney Size
AnIntrepidIIisapprovedforventingintoamasonrychimney
withamaximumuesizeof200x200mm(8"x8"),andinto
arounduesizeof150mm(6").
It may not be vented into larger chimneys without a liner
toreducethe effectiveue size to150mm (6") diameter.
Larger chimneys must have their ues relined for proper
stoveperformance.
Accessoriestomaketheconnectionbetweenstainlesssteel
chimneylinersandyourIntrepidIIareavailablethroughyour
localdealer.
Chimney Connector Guidelines
Chimney connector is the double-wall or single-wall pipe
thatconnectsthestovetothechimney.Thechimneyisa
masonryor prefabricatedstructure thatencloses the ue.
Chimneyconnectorsareusedonlytomaketheconnection
fromthestovetothechimney.

630003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Double-wall Chimney Connector
Information on assembling and installing double-wall
connector is provided by the manufacturer of the double-
wall pipe. Follow the manufacturer’s instructions exactly
asyouassemble the connectorand attach it tothestove
and chimney.  Using connectors and chimneys from the
same manufacturer makes the assembly and installation
straightforward.
NOTE: For installations using double-wall connectors,
minimum clearances must conform to the listed
clearances on Page 9.
Single-wall Chimney Connector
•  Beginning at the ue collar
of the stove, assemble the
chimney connector. Insert
therstcrimpedendintothe
stove’s ue collar, and keep
each crimped end pointing
toward the stove. Using the
holes in the flue collar as
guides, drill 3 mm (1/8")
holesinthebottomoftherst
sectionofchimneyconnector
andsecureittotheuecollar
with three #10 x 1/2" sheet
metalscrews.
• Secure each joint between
sectionsofchimneyconnector,includingtelscopingjoints,
with at least three sheet metal screws.  The pre-drilled
holesinthetopofeachsectionofchimneyconnectorserve
asguideswhenyoudrill3mm(1/8")holesinthebottom
ofthenextsection.
•  Securethechimneyconnectortothechimney.Instructions
forvariousinstallationsfollow.
•  Besuretheinstalledstoveandchimneyconnectorare
correctdistancesfromnearbycombustiblematerial.
NOTE: Special slip pipes and thimble sleeves that form
telescopingjointsbetween sections ofchimneyconnector
areavailabletosimplifyinstallations.Theyofteneliminate
theneedtocutindividualconnectorsections.Consultyour
localdealeraboutthesespecialpieces.
Securing the Single-wall Connector to a Prefabricated
Chimney
Forprefabricatedchimneys,followtheinstallationinstructions
ofthechimneymakerexactlyasyouinstallthechimney.The
makerofthechimneywillsupplytheaccessoriestosupport
thechimney,eitherfromtheroofofthehouse,attheceilingof
theroomwherethestoveisinstalled,orfromanexteriorwall.
ST492a
Intrepid II
freestanding
installation
11/00
I
N
T
R
E
P
I
D
I
I
Chimney
Elbow
SlipPipe
Standard
Chimney
Connector
FlueCollar
Flue
FlueLiner
Thimble
Figure 4-Chimneyconnectioninafreestandinginstallation.
ST242
Chimney connector
12/13/99 djt
Figure 3 - The crimped
endoftheconnectorpoints
towardstove.
Special adapters are available from your local dealer to
maketheconnectionbetweentheprefabricatedchimneyand
thechimneyconnector.Thetopofsuchadaptersattaches
directlytothechimneyortothechimney’sceilingsupport
package,whilethebottomoftheadaptorisscrewedtothe
chimneyconnector.
Theseadaptersaredesignedsothetopendwilltoutside
theinnerwallofthechimney,andthebottomendwilltinside
therstsectionofchimneyconnector.Whenassembledin
thisway,anysootorcreosotefallingfromtheinnerwallsof
thechimneywillstayinsidethechimneyconnector.
Securing the Single-wall Connector to a Masonry Chimney
For masonry chimneys, both freestanding and replace
chimneysmaybeusedforinstallationofyourIntrepidII.
Freestanding Chimney Installations
Ifthechimneyconnectormustpassthroughacombustible
walltoreachthechimney,followtherecommendationsin
theWallPass-throughsectionthatfollows.
Theopeningthroughthechimneywalltotheue(the“breach”)
mustbelinedwitheitheraceramicormetalcylinder,called
the“thimble,”whichiscementedrmlyinplace.Thetmust
besnugandthejointbetweenthethimbleandthechimney
wallmustbecemented.(Figure4)

730003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST243
thinble connection
12/13/99 djt
ThimbleSleeve
Chimney
Connector
Flue
Keepsleeveend
ushwithuetile
Figure 5-Thethimble,madeofeitherceramicormetal,mustbe
cementedsecurelyinplace.
ST244
Plymouth
fplc over mantel
12/99
Chimney
ConnectorShields
*CheckThese
Clearances
*
*
Mantel
Seal the
Damper
Figure 6-Chimneyconnectorenterschimneyabovethereplace.
• Thereplacedampermustbesealedtopreventroomair
fromescapinguptheue.However,itmustbepossible
tore-openthedampertoinspectorcleanthechimney.
Fireplace Chimney Installations - Through a Fireplace
Ifyourreplaceheightisatleast635mm(25"),youmay
installanIntrepidIIwithstandardlegsthroughthereplace
opening using a “positive connection” kit available from
yourlocaldealer.Thesepositiveconnectionkitsensurea
tighttbetweenthestoveuecollarandthechimneyue.
(Figure7)Fireplaceinstallations,whetherconnectedtothe
ue above or through the replace opening, have special
clearancerequirementstoadjacenttrimandthemantel.You
willndtherequiredclearancesfortheIntrepidIIreplace
installationsonPage9.
Floor protection requirements also apply to fireplace
installations.FloorprotectioninformationisonPage8.
Wall Pass-Throughs
Wheneverpossible,designyourinstallationsotheconnector
does not pass through a combustible wall.  If you are
consideringawallpass-throughinyourinstallation,check
withyourbuildinginspectorbeforeyoubegin.Also,check
with the chimney connector manufacturer for any specic
requirements.
Toinstallathimblesleeve,slideitintothebreachuntilitis
ushwiththeinneruewall.Donotextenditintotheactual
uepassage,asthiscouldinterferewiththedraft.
Thethimblesleeveshouldprotrude25-50mm(1-2")into
theroom.Usefurnacecementandthingasketingtosealthe
sleeveinplaceinthethimble.Securethechimneyconnector
totheouterendofthesleevewithsheetmetalscrews.
Withoutathimble,asuitablelengthofchimneyconnectorcan
beextendedthroughthebreachtotheinnerfaceoftheue
liner,andcementedsecurelyinplace.Additionalpiecesof
connectorarethenattachedwithsheetmetalscrews.
Fireplace Chimney Installations - Above a Fireplace
TheIntrepidIImaybeconnectedtoachimneyaboveareplace
openingalso.Insuchinstallations,thestoveispositionedon
thehearthinfrontofthereplaceandthechimneyconnector
risesfromthestovetopandthenanglesninetydegreesback
intothechimney.(Figure6)
Thechimneylinershouldextendtothepointatwhichthe
chimneyconnectorentersthechimney.
If the chimney connector from your installation enters the
chimneyaboveareplace,followalltheguidelinesmentioned
aboveforfreestandinginstallations.Inaddition,givespecial
considerationtothefollowingpoints:
• Checktheclearancebetweenthestoveandthechimney
connector,andanycombustibletrimorthemantel.Use
thenecessarycombinationofmantel,trim,andconnector
heatshieldstoachievetherequiredclearances.
• Check the clearance between the chimney connector
andtheceiling.Ifnoheatshieldsareused,theclearance
shouldbeatleast660mm(26").Tondouthowmuch
thisclearancemaybereducedwithheatshields,seethe
clearancechartonPage14.
Aspecialpiececalledthe“thimblesleeve,”slightlysmaller
indiameterthanstandardconnectorandmostthimbles,will
facilitatetheremovalofthechimneyconnectorsystemfor
inspectionandcleaning.Thimblesleevesshouldbeavailable
fromyourlocaldealer.(Figure5)

830003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
T
ST494
steel
wall pass thru
11/00
INT
I
P
D
RE
I
I
460mm(18")clearance
all around the pipe
FlushMounted
SheetMetalCover
Figure 8-Anapprovedwallpass-through.
ST245
fireplace
flex connector
12/99
FlexibleConnector
MantelShield
FireplaceAdaptorKit
Figure 7-Chimneyconnectorenterschimneythroughthereplace
opening.
ST247
Rear exit floor dgrm
12/14/99 djt
Woodframingrequires
protectionfromradiantheat
Figure 9-Supportingtimbersunderreplacehearthareconsidered
tobecombustible.
Keepinmindthatmanyraisedhearthswillextendlessthan
the required clearance from the front of the heater when
it is installed. In such cases, sufcient oor protection as
described above must be added in front of the hearth to
satisfy the minimum oor protector requirement from the
front of the stove: 406 mm (16") from the front. Fireplace
hearthsmustalsooffertherequiredprotectionof152mm
(6")oneitherside.
Yourlocaldealeroryourlocalbuildinginspectorcanprovide
details for other approved methods of passing a chimney
connectorthroughacombustiblewallinyourarea.
DO NOT CONNECT AN INTREPID II TO ANY AIR
DISTRIBUTION DUCT OR SYSTEM.
Hearths
This appliance must be installed on to hearth that meets
therequirementsofPartJoftheBuildingRegulations2000
(CombustionAppliancesandFuelStorageSystems).This
canbeachievedbyensuringthatthehearthisconstructed
and sized in accordance with the guidelines included in
section2ofapproveddocument‘J’.Thesizeandclearances
ofthehearthareasfollows:
Theconstructedhearthshouldbeconstructedinaccordance
withtherecommendationsindocumentJ,andshouldbeof
minimumwidth840mmandminimumdepth840mm(ifa
freestandinghearthb)above)oraminimumprojectionof
150mmfromthejamb(ifarecessedheartha)above).
Floor Protection for Fireplace Installations
Do not assume your fireplace hearth is completely
noncombustible.
Many fireplace hearths do not satisfy the “completely
noncombustible”requirementbecausethebrickorconcrete
infrontofthereplaceopeningissupportedbyheavywood
framingasinFigure9.Becauseheatpassesthroughbrick
orconcretereadily,itcaneasilypassthroughtothewood.
Asaresult,suchreplacehearthscanbearehazardand
areconsideredacombustibleoor.
The following illustration shows one method of passing a
connectorthroughawall.Allcombustiblematerialinthewall
iscutawaytoprovidetherequired460mm( 18")clearance
fortheconnector.Theresultingspacemustremainempty.
Aush-mountedsheetmetalcovermaybeusedononeside
only.Ifcoversmustbeusedonbothsides,eachcovermust
bemountedonnoncombustiblespacersatleast25mm(1")
clearofthewall.
Accessoriesareavailableforuseaswallpass-throughs.If
usingoneofthese,makesureithasbeentestedandlisted
foruseasawallpass-through.

930003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Perimeter should be
clearly marked e.g. edge
of supermiposed hearth
Perimeter should be
clearly marked e.g. edge
of supermiposed hearth
Doors
Doors
Appliance
Appliance Constructional
Hearth Dimensions
as below
Construction-
al Hearth
Dimensions
as below
Hearth
Surface Free
of Combustible
Material
At least
150 mm
At least 150 mm
or to a suitable
heat resistant wall
At least
300 mm
At least
300 mm
Free Standing
Fireplace Recess
Figure 10-Noncombustiblehearthsurfacedimensions.
Clearances
As with any solid fuel heating stove, extremely high
surface temperatures can occur, particularly in the
event of uncontrolled operation, e.g. if the doors are
inadvertently left open. It is crucial that sufficient
clearances are allowed to any combustible surfaces, e.g.
wooden mantels or lintels, and to timber framed (studded)
walls even if they are faced with noncombustible board.
Detailed information on replace and hearth construction
is provided in section 2 of Document J, all installations
must comply with these requirements or with the relevant
National or local building standards.
Clearancestotimber framed (studded)wallsare included
below.There arenospecicminimumclearancestosolid
noncombustible surfaces (e.g. the sides and rear of
Inglenook re openings constructed from solid masonry)
otherthantoallowsafeaccesstothecontrolsofthestove.
Forthisreasonminimumsideclearancesof125mm,anda
minimumrearclearanceof50mmarerecommended.
Summary of Clearances
Minimum recommended side clearances to
noncombustible surfaces 125 mm (5").
Minimum recommended rear clearance to noncombustible
surfaces 50 mm (2").
NOTE: The minimum thickness of solid noncombustible
materialsisspeciedinsection2ofDocument‘J’,inrelation
to the clearance of the appliance from the surface.As a
generalrule,thethicknessofsolidnoncombustiblematerial
formingtherecessofareplaceisaminimumof200mm.
Minimum rear clearance from combustible walls (e.g.
timber framed or studded walls) 760 mm (30") measured
from the rear edge of the stove top. (Figure 11, B)
Minimum side clearance from combustible walls 610
mm (24") measured from the side edge of the stove top.
(Figure 11, A)
Minimum distance from stove to movable combustible
materials (e.g. furniture, drying clothes, etc.) 760 mm
(30").
Optional76mm(3")shortlegsmaybeusedonlyonsuch
hearthsthatmeetthewidthanddepthrequirementsoutlined
previouslyunder“oorprotection.”
Hearth rugs do not satisfy the requirements for floor
protection.
Fireplace installations also have special clearance
requirements to the side walls, side decorative trim, and
replacemantle.Refertotheinformationonreplaceand
manteltrimshieldsinthissection.
Keep the Stove a Safe Distance from Surrounding
Materials
Bothastoveanditschimneyconnectorradiateheatinall
directions when operating, and dangerous overheating of
nearbycombustiblematerialscanoccuriftheyaretoocloseto
theheat.Asafeinstallationrequiresthatadequateclearance
bemaintainedbetweenthehotstoveanditsconnectorand
nearbycombustibles.
Clearance is the distance between either your stove
(measuredfromthebackedgeofthestove’stopplate)or
chimneyconnector,andnearbywalls,oors,theceiling,and
anyotherxedcombustiblesurfaces.Inaddition,furnishings
andothercombustiblematerialsmustbekeptawayfromthe
stoveaswell.Ingeneral,adistanceof1220mm(48")must
bemaintainedbetweenthestoveandmoveablecombustible
itemssuchasdryingclothes,furniture,newspapers,rewood,
etc. Keeping those clearance areas empty assures that
nearbysurfacesandobjectswillnotoverheat.

10 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST486a
Defiant EU
Clearance
Diagrams
10/06
A
B
Figure 11-Minimumclearances.
ST911
fluepipe clearances
10/06
D
at least
3xD
Elevation
Without Shield Elevation
With Shield
at least
3xD
at least
1.5xD
at least
1.5xD
Plan Without Shield
Plan With Shield
Airspaceofatleast12mm
betweennoncombustibleshield
andcombustiblematerial
Fluepipe at least
1.5xD
at least
1.5xD
atleast3xD Dat least
1.5xD
Figure 12-Connectinguepipeclearances.
Connecting Flue Pipe - Clearances
Singlewallconnectinguepipescanreachextremelyhigh
temperatures; therefore, clearances from the connecting
fluepipe (chimney connector) must comply with the
requirements of Part J of Building Regulations 2000
(CombustionAppliancesandFuelStorageSystems).This
can be achieved by following the recommendations of
ApprovedDocument‘J’.TheseareasshowninFigure12.

11 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Assembly
ST513
Remove leg bolts
11/00
Slotted
Screws
Figure 13-Removetheslottedscrewsfromthestovebottom.
ST514
Bottom heat shield
& clips
11/00
Door Handle Holder
BottomHeatShield
Bracket
WingBolt
Figure 15-Handleholderandheatshieldpositions.
Figure 14-Attachbottomheatshield.
ST512
Attach
bottom heat
sh i el d
11/00
10-3/4”
9-3/4”
Reversing the Flue Collar
Youcanreversetheuecollarbyremovingthetwoscrews
thatattachthecollartothebackofthestove.(Figure16)Be
surethegasketaroundtheuecollaropeningisinposition
whenyouscrewthecollarbackontothestove.
Storing the Handle
Usetheremovablehandletoopenorclosethefrontdoors,or
tochangethepositionofthedamper.Afterusingit,removeit
soitwon’tgethot,andstoreitinthehandleholderinstalled
behindtherightfrontleg.(Figure15)
Install the Bottom Heat Shield
Abottomheatshieldmustbeusedunless the stove is to
be situated on a completely noncombustible hearth, such
asunpaintedconcreteoverearth.Toinstallthebottomheat
shield,loosenthelegbolts,andslipthebottomheatshield
C-clipsontothebolts.Attachthebottomheatshieldtothe
C-clipswiththewingnuts,andtightenthelegbolts.Alignthe
shieldasshowninFigure14.
Clean the Griddle Before Use
Atthefactorythegriddleiscoatedwithvegetableoiltoprevent
rustingwhilethestoveisintransitandstorage.Removethe
oilwithadryragorpapertowelbeforeyouusethestove.
Set Up the Stove
Remove any loose parts from inside the stove.  Place a
protectivepadontheoor,arrangesomesectionsof4x4
lumberonthe pad forsupport, and carefullytipthe stove
ontothem,onitsback.
Removeanddiscardthefourlargeslot-headscrewsfromthe
stovebottom(Figure13)andinstallthestovelegs,usingthe
hexheadboltsfromthepartsbag.Use3/8"washerswith
threeofthelegs;thedoor/damperhandleholderinstallsin
placeofawasherontherightfrontleg.Positiontheholder
sotheholetoacceptthehandlenubfacesoutfromtheright
sideofthestove.Tightentheboltsrmly.

12 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST515
reverse
ue collar
11/17/00 djt
FlueCollarScrews
Figure 16-Reversingtheuecollar.
ST516
Attach
griddle handle
11/17/00 djt
Figure 17-Attachingthegriddlehandle.
Operation
Your Intrepid II’s Controls and What They Do
Thestovehastwocontrolstoregulateperformance:aprimary
air control supplies oxygen for the re, and a damper
directsairowwithinthestovetoactivateanddeactivate
thecatalyticcombustor.
Additional air for catalytic combustion is regulated
automatically,anddoesnotrequireoperatorcontrol.
Symbols cast into the stove are reminders of the correct
directions for opening and closing the controls. In these
directions,‘left’ and‘right’assumethatyouare facing the
frontofthestove.
A Single Air Control Regulates the Amount of Heat the
Fire Will Produce and How Long it Will Burn
The primary air control lever,locatedattherightrearcorner
ofthestove,controlstheamountofincomingairforstarting,
maintaining,andrevivingare.Moreairenteringthestove
makesthereburnhotterandfaster,whilelessairprolongs
theburnatalowerheatlevel.
Forthegreatestairsupplyandmaximumheatoutput(but
theshortestburntime),movethelevertotheleft.Forare
thatwilllastlongerwithlessheat,movethelevertotheright.
Youcansettheleveranywhereinbetweentheleftandright
extremes.(Figure19)
TheIntrepidIIfeaturesanautomaticthermostattoensurean
evenheatoutputatanysettingyouselect.Thethermostat
senses the heating and cooling of the stove surface and
adjuststheairshutteraccordingly.
ST518
Intrepid II
controls
11/20/00 djt
AirControlLever
Griddle
Handle
DamperHandle
Door Handle
Door Handle
Holder
(BehindLeg)
AshPan
Andiron
Figure 18-TheIntrepidIIcontrols.
ST517
Intrepid II
Thermostat
positions
11/17/00 djt
High Heat
Low Heat
Figure 19-Thethermostathandlemaybepositionedanywhere
betweenthetwoextremesfordifferentheatlevels.
Rear View
Attach the Griddle Handle
Installthehandle on thegriddle.Place the griddleupside
downattheedgeofaatsurfaceandassemblethehandle
asshown.(Figure17)
Withthehandlepointing45°fromitsnalposition,tighten
thenutasfaraspossiblewithpliers.Movethehandletoits
nalpositionwhilestillholdingthenutwiththepliers.Take
carenottoovertighten,astabmaysnap.

13 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST519
Intrepid II
damper
11/20/00 djt
Open
(UpdraftMode)
Closed
(CatalyticMode)
Figure 20 - The damper is either open or closed.There are no
intermediatepositions.
Side View
ST520
Intrepid
andirons
11/20/00 djt
Figure 21-Removetheandironsforfrontloading.
INTREPID II
ST521
Intrepid
loading
11/00
Figure 22-Toploadingisthebestwaytoaddfuelduringregular
use.Frontloadingisusefulforkindlingare.
Two Ways to Add Fuel
TheIntrepidII’sgriddleliftsforconvenienttop-loadingoflogs,
andistheeasiestwayofregularlyaddingfuel.However,the
frontdoorsopenaswellforaddinganoccasionallogtoa
re.(Figure22)
Youcanopen(orevenremove)thefrontdoorsandplace
theoptionalIntrepidIIsparkscreeninthefrontopeningfor
open-reviewing.
Andirons
Yourstovehasandironstokeeplogsawayfromtheglass
panels. The andirons are important to maintain clear
reviewing and should be removed only while reloading
throughthefrontdoors.
Wearheavystovegloveswhenremovingtheandirons,and
placethemonanoncombustiblesurfaceuntilyoureplacethem
inthestove.Moststoveownerswillprefertheconvenience
oftoploadingthroughthegriddle,andwillleavetheandirons
inplacepermanently.
Glass Door Panels
Theglasspanelsinthedoorshaveaheat-reectivecoating
ontheoutsidesurface.Heatreectedbacktotheinsideofthe
glasshelpskeeptheinnersurfaceatahighertemperature
than the outside. In combination with pre-heated primary
combustionair‘washing’overtheinsideoftheglass,this
helpsprovideclearre-viewingatmostoperatinglevels.
A Damper Directs Air Flow Within the Stove
The damper handleopensandclosesthedampertodirect
airowwithinthestove,andisnextto,andtotherightof,
theprimaryaircontrolleverontherightsideofthestove.
(Figure20)
When the handle points to the oor, the damper is open,
letting smoke pass directly into the chimney. The damper
mustbeopenwhenstartingorrevivingare,andwhenever
thegriddleordoorsareopened.
Whenthehandlepointstothefront,thedamperisclosed.
Smokefromtheretravelsthroughthecatalyticcombustion
systemwhereitcanburnfurtherforgreaterefciency,before
passingupthechimney.
Thedamperhasnointermediatepositions.Figure28shows
thehandle’sopenandclosedpositions.
When closing the damper, push rmly and snap it into
the locked position to ensure that the stove remains in
the catalytic mode.

14 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST522
Intrepid
close doors
11/00
Open
Position
Closed
Position
Figure 23-Toopenthefrontdoors,turnhandleclockwise.
ST523
Intrepid
temp readings
11/00
Figure 24 - Take temperature readings with a thermometer
locatedinthemiddleofthegriddle.
Whenthermometerreadingsdropbelow175°C(350°F)
it’stimetoadjusttheaircontrolforahigherburnrateorto
reloadthestove.
• Atemperaturereadingover400°C(750°F)isasignto
cutbackontheairsupplytoslowtheburnrate.
• Readingsinthe150-200°C(300-400°F)rangeindicate
lowtomediumheatoutput.
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woodshouldbe410mm(16")
inlength.Do not burn construction materials;theyoften
containchemicalsandmetalsthatcandamagethecatalytic
combustororpollutetheair.Donotburnoceandriftwood;
whenitburns,thesaltitabsorbswillattackthecastiron.
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,r,andredwood.Thesetooshouldbe
properlydried.
Storerewoodundercovertokeepitdry.Dry,well-seasoned
woodisbest for heatingandre-viewing. However, avoid
wood dried more than two years. This wood burns very
quickly,reducingburntime.
Evenforshort-termstorage,keepwoodasafedistancefrom
theheaterandkeepitoutoftheareasaroundtheheater
usedforrefuelingandashremoval.
A Surface Thermometer is a Valuable Guide to Operation
Anoptional surfacethermometer tellsyou whento adjust
theaircontrol,whentorefuel,andhelpstotellwhenyour
catalystisoperatingproperly.
Forexample,whenthethermometerregistersatleast230°
C(450°F)afterstart-upyouknowthestoveishotenough
tobegin catalytic combustionandit may betimeto close
thedamper.
Place the thermometer in the center of the griddle, as in
Figure24,andusethefollowingtemperaturerangesasa
guidetooperation:
Burn Only High-Quality Wood
TheIntrepidIIisdesignedtoburnnaturalwoodonly;donot
burnfuelsotherthanthatforwhichitwasdesigned.
IMPORTANT: Do not burn any type of articial or
synthetic materials such as re starter logs (containing
wax) in this appliance. Never burn liquid-based fuels
such as kerosene, gasoline or alcohol.
Burning any materials not allowed in these instructions,
or over-ring the stove, may void the warranty
Toopenthefrontdoors,insertthehandleintothedoorlatch
stubandturnittotheleftandup.Toclosethem,alwaysclose
theleftdoorrst.Turnthehandleintherightdoortotheleft
andup(totheopenposition)andclosethedoor.Pushon
thedoorasyouturnthehandletotherightanddown.The
doorswilldrawinslightly,andthehandleshouldoffersome
resistanceasyouturnittotheclosedposition.(Figure23)
Avoidstrikingtheglassorslammingthedoorstoreducethe
riskofbreakingtheglass.
Whenyou’renotusingthedoorhandle,storeitintheholder
behindtherightfrontlegofthestove.
For safety and greatest efciency, operate your stove
only with all doors/griddles fully closed. The test
standard for your stove when it is operated in this
mode is UL 1482.
Your stove may be used as a replace with the front
doors open or removed only when the spark screen is
placed correctly in the opening to protect against the
possibility of sparks and embers leaving your stove.
The test standard for your stove when it is operated
in this mode is UL 737.
Use only the Intrepid II spark screen, part #0136, with
your Intrepid II. Intrepid II spark screens are available
from your Vermont Castings’ Authorized Dealer.
WARNING
!

15 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Intrepid II Control Settings
Burn Rate Primary Air Control
 Low Fromfarrightto1/3thedistancetoleft
 Medium From1/3to2/3thedistancetoleft
 High From2/3thedistancetolefttofarleft
Before you start using the stove, please read the Draft
Management section starting on Page 18 to see how the
featuresofyourinstallationwillaffectthestove’sperformance.
Youandthestovearepartsofasystem,andotherpartsof
thesystemhaveastrongeffectonoperation;youmayneed
tovaryyourringtechniquetogettheperformanceyouwant.
How to Build a Wood Fire and Keep it Going
AnIntrepidIIleavesthefactorywiththecombustorinstalled.
IntheUnitedStates,itisagainstthelawtooperatethiswood
heaterinamannerinconsistentwithoperatinginstructions
inthismanual,orifthecatalyticcombustorisdeactivated
orremoved.
High-Efciency Wood Burning with Catalytic Combustion
ThecatalyticcombustionsysteminyourIntrepidIIproduces
thebestconditionsforsecondarycombustion.
Whenthestovedamperisclosed,smokegoesthroughthe
catalytic element, burning at temperatures of 260-315°
C(500-600°F), half the temperaturenormallyneeded for
unaidedsecondarycombustion.
The catalytic element is a ceramic “honeycomb” coated
withanoblemetal,usuallyplatinum.Theelementisinthe
secondary combustion chamber,madeofaspecialhigh-
temperature insulating refractorymaterial.Thechamber
providesthecorrectenvironmentnecessaryforsecondary
combustionofthefuel(smoke).
Closingthedampermayalsoreducedraft.Closingthedamper
toosoonmayputoutthereordeactivatethecombustor.
Closethedamperonlywhenthereiswellestablished.When
startingare,waituntilthereisanemberbedofatleast76
-102mm(3-4")beforeclosingthedamper.
Neverkindlearewithcoloredpaperorpaperthathascolored
inkoraglossysurface,andneverburntreatedwood,garbage,
solvents,ortrash.Allofthesemaypoisonthecatalystand
preventitfromoperatingproperly.Neverburncardboardor
loosepaperexceptforkindlingpurposes.Neverburncoal;
doingsocanproducesootorlargeakesofcharoryash
thatcancoatthecombustorandcausesmoketospillinto
theroom.Coalsmokealsocanpoisonthecatalystsothatit
won’toperateproperly.
• Readingsof260-340°C(500-650°F)indicatehighheat
output.OperatingyourIntrepidIIcontinuouslyatgriddle
temperaturesof400°C(750°F)orhighermaydamage
innerpartsortheenamelnish.
Use the Air Control Settings that Work Best for You
Nosingleaircontrolsettingwillteverysituation.Settings
willdifferdependingonthequalityofthefuel,theamountof
heatdesired,andhowlongyouwishthere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
IntrepidII,andcouldevendamagethecombustor.Onthe
otherhand,toolittledraftcancausebackpufng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uncontrollableburn
or a glowing-red stove part.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insufcient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outdoorstothestove.Infact,insome
areasprovisionsforoutsidecombustionairarerequiredin
allnewconstruction.
Your Intrepid II will accept a duct carrying outside air for
combustion.
Whenrstusingthestove,keeptrackoftheaircontrolsettings.
You will quickly nd that a specic setting will give you a
xedamountofheat.Itmaytakesometimetodetermine
theamountofheatandthelengthofburnyoushouldexpect
fromvarioussettings. Please readtheDraft Management
sectionbeginningonPage18formoreinformationonhow
installationfeaturesaffectdraft.
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 ring of
your heater by altering the air control adjustment range
outlined in these directions.
Usethefollowingaircontrolsettingsasastartingpointto
helpdeterminethebestsettingsforyourinstallation.Each
isdescribedasafractionofthetotaldistancethelevermay
bemovedfromrighttoleft.

16 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST263
starting a re
12/99
Figure 25-Starttherewithnewspaperanddrykindling.
3. Lightthenewspaperandclosethedoor.Graduallybuild
uptherebyaddingafew76-127mm(3-5")diameter
splits. If this is one of the rst few “break-in” res, let
the re burn brightly, and then let it die out.
Duringthebreak-inres,don’tletthestovegethotterthan
260° C (500° F) as measured on an optional stove-top
thermometer.Adjust the air control lever as necessary to
controlthere.Someodorfromthestove’shotmetal,the
paint,andthecementisnormalfortherstfewres.
NOTE:Somechimneysneedtobe“primed,”orwarmedup,
beforetheywilldrawsufcientlytostartare.Tocorrectthis
situation,rollupacouplepiecesofnewspaper,placethem
ontopofthekindlingandtowardthebackofthestove,light
them,and close the doors.This should heat the chimney
enoughtoinitiateadraft.
Oncethedraftisestablished,openthefrontdoorandlight
therestofthefuelfromthebottom.Donotlightthemain
bed of fuel until the chimney begins drawing, and repeat
theprocedureasoftenasnecessaryiftheinitialattemptis
unsuccessful.
4. If your Intrepid II has been broken-in previously using
Steps1-3,continuetobuildtheregradually.Addlarger
woodwithadiameterof76-102mm(3-4").(Figure26)
 Continue adding split logs of this size to the briskly-
burningreuntilthereisaglowingemberbedatleast76
mm(3")deep.Agoodemberbedisnecessaryforproper
functioningofthecatalyticsystemandmaytakeanhour
ormoretoestablish.
5. Closethedamperwhenthegriddletemperaturereaches
230°C(450°F).
6. Adjusttheaircontrolforyourdesiredheatoutput.
Ingeneral,theremustbesufcientlywell-establishedto
ensurecatalyticactivityisinitiated.Whenrststartingare,
maintaina medium-to high-ring ratefor at least twenty
minutes.Thisensuresthestove,catalyst,andfuelareall
stabilizedattheproperoperatingtemperatures.Thismaybe
longenoughtowarmthechimneywellenoughtosupporta
gooddraft;someinstallationsmayneedmoretime.Please
readtheDraftManagementinformationstartingonPage23
toseeifyourinstallationhasfeaturesthatmayrequiremore
timetowarmup.
Eventhoughitispossiblefortheretogetquitehotwithina
fewminutes,thecombustormaystopworkingortheremay
gooutifthereisallowedtodiedownimmediatelyasaresult
ofclosingthedamper.Oncethecombustorstartsworking,
heatgeneratedbyburningthesmokewillkeepitworking.
Todeterminewhetherthecombustorisoperating,observe
theamountofsmokeleavingthechimneywhenthedamper
isactivatedandwhenitisnot.Thisprocedureisdescribed
onPage27.
Conditioning Your Stove
Castironisextremelystrong,butitcanbebrokenwithasharp
blowfromahammerorfromthethermalshockofrapidand
extremetemperaturechange.
The cast plates expand and contract with changes in
temperature. When you rst begin using your Intrepid II,
minimize thermal stress by allowing the plates to adjust
graduallyduringthreeorfourinitialbreak-inresfollowing
Steps 1-3below.
Starting and Maintaining a Wood Fire
BurnsolidwoodfuelonlyintheIntrepidII,andburnitdirectly
onthegrate.Donot elevatethefuel.Donotburncoalor
otherfuels.
The damper must be open when starting a re or when
refueling.
1. Openthestovedamper,andopentheprimaryaircontrol
fully.
2. Placeseveralsheetsofcrumplednewspaperinthestove.
Do NOTuseglossyadvertisementsorcoloredpaper,as
theycanpoisonthecatalyst.Placeonthepapersixor
eight pieces of dry kindling split to a nger-width size,
andonthekindlinglaytwoorthreelargersticksofsplit
drywoodapproximately25-50mm(1-2")indiameter.
(Figure25)
DO NOT USE CHEMICALS OR FLUIDS TO START THE
FIRE. DO NOT BURN GARBAGE OR FLAMMABLE FLUIDS
SUCH AS GASOLINE, NAPHTHA, OR ENGINE OIL. Also,
never use gasoline-type lantern fuel, kerosene, charcoal
lighter uid, or similar liquids to start or “freshen up” a
re. Keep all such liquids well away from the Intrepid II
while it is in use.

17 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
ST264
good re
12/99
Figure 26-Addlargerpiecesofwoodastherebeginstoburnwell.
ST264a
add wood re
11/00
Figure 27-Addfullsizelogswhentheemberbedis3"(75mm)
deep.
Ash Disposal
Removeashbeforeitreachesthetopoftheashpan.Check
thelevelatleastonceaday,andbeforeeachre-fueling.If
theashisclosetothetopedgeofthepan,emptyitaccording
tothisprocedure:
1. Openthedamper.
2. Openthefrontdoorsfully.
3. Usingstovegloves,pulltheashpanoutofthestoveby
itshandle.
4. Removetheashpanandproperlydisposeoftheashes.
Besuretokeepthepanlevelduringdisposal.
5. Returntheashpantothestove.
Empty the ash pan regularly, typically every one to three
days.Thefrequencywillvarydependingonhowyouoperate
yourIntrepidII;ifyouburnmorewoodathigherheatoutput
settings,ashwillaccumulaterapidly.
Remove ash frequently and place it outdoors in a metal
containerwithatight-ttinglid.Puttheclosedcontainerofash
onanoncombustibleoororontheground,wellawayfrom
allcombustiblematerials,pendingnaldisposal.Iftheash
isdisposedofbyburialinsoilorotherwiselocallydispersed,
keepitintheclosedcontaineruntilallcindershavethoroughly
cooled.Youcanusewoodashasagardenfertilizer.
Refuel While the Embers are Still Hot
ReloadtheIntrepidIIwhileitisstillhotandthereareplenty
ofglowingemberstore-kindlethere.Includesomesmaller
piecesofwoodinthenewloadoffueltohelpthestoverebuild
itsoperatingtemperaturequickly.
Wear stove gloves, and follow this procedure when you
reloadyourstove:
1. Openthethermostatlever.
2. Openthedamper.
3. Checktheashlevelintheashpan;empty,ifnecessary,
andreplacethepan.
4. Openthegriddle.
5. Positionthecharcoalinthemiddleoftherebox(Figure
41)thenloadwood—smaller,splitpiecesrst.Increase
theamountoffuelyouloadintothestoveasyoubecome
familiar with your stove and the heating needs of your
home.
NOTE:Iftheremainingcharcoalbedisrelativelythickand
ifyourfueliswellseasoned,itispossibletoaddfreshfuel
(smallerpiecesrst),closethedooranddamper,andreset
theprimaryairthermostatforthedesiredheatoutput.
Donotbreakthecharcoalintoverysmallpiecesorpoundor
compressthecharcoalbed.
Itisimportantthataircancirculateunderthewoodforthe
retobequicklyrevived.
DO NOT OVERFIRE THIS HEATER. Overringmaycause
ahousere,orcanresultinpermanentdamagetothestove
andtothecatalyticcombustor.IfanypartoftheIntrepidII
glows,youareoverring.
CAUTION
!
The Intrepid II will be hot while in operation. Keep
children, clothing and furniture away. Contact may
cause skin burns.
WARNING
!
Operate your Intrepid II only with the doors either fully
open or fully closed.
CAUTION
!
Never use your household or shop vacuum cleaner to
removeashfromthestove;alwaysremoveanddispose
oftheashproperly.

18 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Draft Management
Flue sizing
Theinsidesizeofachimneyforan‘airtight’stoveshouldmatch
thesizeofthestove’sueoutlet.Whenachimneyservesan
airtight,moreisnotbetter;infact,itcanbeadisadvantage.
Hotgasescooloffthroughexpansion;ifweventastovewith
a152mm(6")uecollar{181sq.cm(28sq.in.)area}into
a254x254mm(10"x10")ue,thegasesexpandtoover
threetimestheiroriginalsize.Thiscoolsthegases,which
weakensdraftstrength.Ifanoversizedueisalsooutside
thehouse,theheatitabsorbsgetstransferredtotheoutdoor
airandtheueusuallystayscool.
It’scommonfor amasonry ue,especially one built for a
replace,tobeoversizedforanairtightstove. It can take
quiteawhiletowarmupsuchaue,andtheresultscanbe
disappointing.Thebestsolutiontoanoversizedueisan
insulatedsteelchimneyliner,thesamediameterasthestove
orinsert’sueoutlet;thelinerkeepsthesmokeatitsoriginal
volume,andtheresultisastrongerdraft.Anuninsulatedliner
isasecondchoice-thelinerkeepsthesmokerestrictedtoits
originalsize,butthesmokestillmustwarmuptheairaround
theliner.Thismakesthewarm-upprocesstakelonger.
Pipe & Chimney Layout
Everyturnthesmokemusttakeinitstravelfromthestoveto
thechimneytopwillslowitdown.Theidealpipeandchimney
layoutisstraightupfromthestove,toacompletelystraight
chimney. If you’re starting from scratch, use this layout if
possible.If the stovepipe must elbow to enter a chimney,
locatethethimbleaboutmidwaybetweenthestovetopandthe
ceiling.Thisachievesseveralgoals:itletsthesmokespeed
upbeforeitmustturn,itleavessomepipeintheroomfor
heattransfer,anditgivesyoulong-termexibilityforinstalling
atallerstovewithoutrelocatingthethimble.
Thereshouldbenomorethaneightfeetofsingle-wallstove
pipebetweenthestoveandachimney;longerrunscancool
thesmokeenoughtocausedraftandcreosoteproblems.
Usedouble-wallstovepipeforlongruns.
Single Venting
Each‘airtight’stoverequiresitsownue.Ifanairtightstove
isventedtoauethatalsoservesanopenreplace,ora
leakierstove,it’seasierforthechimneydrafttopullairin
throughthosechannelsthanitistopullairthroughtheairtight,
andperformancesuffers.Imagineavacuumcleanerwitha
holeinthehosetoseetheeffecthere.Insomecasesthe
otherappliancecanevencauseanegativedraftthroughthe
airtight,andresultinadangerousdraftreversal.
A stove is part of a system, which includes the chimney,
theoperator,thefuel,andthehome.Theotherpartsofthe
systemwillaffecthowwellthestoveworks.Whenthereis
agoodmatchbetweenalltheparts,thesystemworkswell.
Woodstoveoperationdependsonnatural(unforced)draft.
Naturaldraftoccurswhenthesmokeishotter(andtherefore
lighter)thantheoutdoorairatthetopofthechimney.The
biggerthetemperaturedifference,thestrongerthedraft.As
thesmokerisesfromthechimneyitprovidessuctionor‘draw’
thatpullsairintothestoveforcombustion.Aslow,lazyre
withthestove’sairinletfullyopenindicatesaweakdraft.A
briskre,supportedonlybyairenteringthestovethrough
thenormalinlet,indicatesagooddraft.Thestove’sairinlet
ispassive;itregulateshowmuchaircanenterthestove,but
itdoesn’tmoveairintoit.
Depending on the features of your installation - steel or
masonrychimney,insideoroutsidethehouse,matchedto
thestove’soutletoroversized-yoursystemmaywarmup
quickly,oritmaytakeawhiletowarmupandoperatewell.
Withan‘airtight’stove,onewhichrestrictstheamountofair
gettingintotherebox,thechimneymustkeepthesmoke
warmallthewaytotheoutdoors.Somechimneysdothis
betterthanothers.Here’salistoffeaturesandtheireffects.
Masonry Chimney
Masonry is a traditional material for chimneys, but it can
performpoorlywhenitservesan‘airtight’stove.Masonryis
averyeffective‘heatsink’-itabsorbsalotofheat.Itcancool
thesmokeenoughtodiminishdraft.Thebiggerthechimney,
thelongerittakestowarmup.It’softenverydifculttowarm
up an outdoor masonry chimney, especially an oversized
one,andkeepitwarmenoughtomaintainanadequatedraft.
Steel Chimney
Mostfactory-madesteelchimneyshavealayerofinsulation
aroundtheinnerue.Thisinsulationkeepsthesmokewarm.
Theinsulationislessdensethanmasonry,sotheinnersteel
linerwarmsupmorequicklythanamasonrychimney.Steel
doesn’t have the good looks of masonry, but it performs
muchbetter.
Indoor/Outdoor location
Becausethechimneymustkeepthesmokewarm,it’sbestto
locateitinsidethehouse.Thisusesthehouseasinsulation
fortheueandallowsalittleheatreleaseintothehome.An
indoorchimneywon’tloseitsheattotheoutdoors,soittakes
lessheatfromthestovetogetitwarmandkeepitwarm.

19 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Draft Testing
Aneasywaytotestyourchimneydraftistoclosethestove’s
damper,waitafewminutestolettheairowstabilize,thensee
whetheryoucanvarythestrengthoftherebyswingingthe
aircontrolopenandclosed.Resultsarenotalwaysinstant;
you may need to wait a few minutes for a change in the
aircontrolsettingtohaveaneffectonthere.Ifthere’sno
change,thenthedraftisn’tstrongenoughyettoletyouclose
thedamper,andyou’llneedtoopenitforawhilelongerand
managetherewiththeairinletuntilthedraftstrengthens.
Ifyoukeeptrackofyourburninghabitsandrelatethemto
theireffectsonthestove’soperation,you’llberewardedwith
goodperformanceandasafesystem.
Negative Pressure
Gooddraftalsodependsonasupplyofairtothestove;a
chimneycan’tpullinmoreairthanisavailabletoit.Sluggish
draft results when a house is tight enough to prevent the
readyowofairtothestove,orbycompetitionbetweenthe
stoveandotherequipmentthatsendsindoorairoutside-
especiallypower-drivenequipmentlikerangehoods,clothes
dryers,etc.Ifthechimneydrawswellwithallotherequipment
turnedoff(orsealed,inthecaseofreplacesand/orother
stoves),thenyousimplyneedtobecarefulwithtimingthe
useoftheotherequipment.Ifyouneedtocrackanearby
windowordoortoenablethechimneytodrawwell,that’s
asignthatyoushouldinstallanoutside-airintaketobring
combustionairdirectlytothestove.VermontCastingsdealers
carryadapterstoattachtothestovetoconnectanairduct
foroutdoorcombustionair.
Inmanycases,localornationalcodesrequiretheinstallationof
permanentlyopenairvents,particularlywithlargerappliances
(i.e.above5kW).Refertothesecodestodeterminespecic
requirementsforyourinstallation.
Conclusion
Wood-burningisanartratherthanascience.Oncethestove
andchimneysystemareinplace,thestoveusercanonly
varytechnique,mostlyyourtiming,toachievegoodresults.
Ifyoukeeptrackofyourburninghabitsandrelatethemto
theireffectsonthestove’soperation,you’llberewardedwith
goodperformanceandasafesystem.
Creosote
Creosoteisaby-productofslowwood-burning.It’sanorganic
tarthatcancondenseintheueifit’sdenseinthesmoke,
andslow-moving,andcoolsofftolessthan130°C(290°F).
Condensedcreosoteisvolatile,andcangeneratechimney
resifitgetshotenough.Allthefeaturesthataffectchimney
draftalsoaffect creosotecondensation-sousewhatever
combinationofinstallationfeaturesandoperationalstepsthat
willencouragegooddraftandminimizecreosoteproduction.
Becauselettingthesmokecool offandslowdown is one
ofthekeystocreosoteproduction,itmakessensetolinea
chimneytomatchthestove’soutletsize,forsafetyreasonsas
wellasperformance.Consultaqualiedinstallerandcheck
localandnationalcodesforrecommendedchimneysize.
Fuel
Even the best stove installation will not perform well with
poorfuel.Thebestfuelishardwoodthathasair-dried12-
18months.Softwoodburns,butnotaslongashardwood.
Fairly‘green’woodhasagoodamountofmoistureinit;it
willburn,butsomeoftheheatpotentialisusedtodrivethe
remainingmoistureoffthewood.Thisreducestheamount
thatreaches yourhome andcan contribute to a creosote
problem.Therearemoisturemetersavailableforrewood;
youcanalsojudgeyourwoodbyitsappearanceandweight.
Ifyougetitgreen,liftapieceandgetasenseofitsweight;
itcanloseathirdormoreofitsweightasitdries.Alsolook
attheendsofalog;asitdriesitshrinksandoftencracks.
Themoreweatheredandcrackedapieceis,thedrieritis.
Drywoodburnsreadilywithagoodchimneydraft.Butwith
modernstoves,especiallycatalyticones,thewoodcanbe
too dry. While extra-dry wood has little creosote in it, the
remaindercan‘gasout’fromthewoodquicklyanddensely
enoughtooverloadthecatalyticburner.Ifyouheararumbling
orroaringnoise,likeapropanetorch,fromthestove,thatisa
signthatthecatalystisseriouslyoverring.Thecatalystisa
platinumlmonaceramicbase;themetalcangettohigher
temperaturesthantheceramiccantake,andoverringthe
catalystcanbreakit.Drywoodcanalsoburnoutfasterthan
youwant.Ifyourdrywoodburnsouttooquicklyoroverloads
thecatalystyoucanmixingreenerwoodtoslowtheredown.
Back-pufng
Back-pufngresultswhenthereproducesvolatilegases
fasterthanthechimneydraftpullsthemoutoftherebox.
Thegasesbackupinthereboxtillthey’redenseenough
andhotenoughtoignite.Ifyourstoveback-puffs,youshould
openupthedampertoletthesmokerisetotheuemore
quickly,letmoreairintotherebox,andavoidbigloadsof
rewood. Run your stove with enough primary air so that
youalwaysseelively,dancingamesintherebox;alazy,
smokyreisinefcientandcancontributetocreosotebuildup
inthechimney.

20 30003840Vermont Castings • Intrepid II 1990 UE Installation Manual_R22 • 07/19
Maintenance
Letthereinthestovegooutandallowthestovetocool
completelybeforebeginninganymaintenanceprocedure.
Care of the Cast Iron Surface
Anoccasionaldustingwithadryragwillkeepthepainted
castironofyourIntrepidlookingnew.
Thestove’spaintcanbetouchedupasneeded.First,clean
theareastobepaintedwithawirebrush.Then,touchup
thestovewithhightemperaturestovepaint.Applythepaint
sparingly,andkeepinmindthattwolightcoatsofpaintare
betterthanasingleheavyone.
Care of Porcelain Enamel Finish
Useadryorslightlydampragorasoftbrushtoremovespills
orstains.Fordifcultjobsthatrequireacleaningagent,use
onlyakitchenappliancecleanerorpolishrecommendedfor
useonenamelsurfaces.
Cleaning the Glass
Mostofthecarbondepositsontheglasswillburnoffduring
hotres.However,theashresiduethataccumulatesonthe
glasssurfaceshouldberemovedregularlytopreventetching.
Followthisproceduretocleantheglass:
• Besuretheglassiscompletelycool.
• Cleantheglasswithwateroracleanermadeespecially
forthispurpose.Donotuseabrasivecleaners.
• Rinsetheglassthoroughly.
• Drytheglasscompletely.
Glass Replacement
Replace glass only with Part no. 140-1156 right side and
140-1157leftsideglasspanels.Theglasspanelrestsona
cushionprovidedbyaropegasketpartno1203556,andis
heldinplacebyclips.(Figure28)TheglassisIRcoatedon
onesidewhichismarked“THISSIDEOUT”.
1. Removethedoorfromthestoveandplaceitonasturdy,
levelworksurface.Useatoweltoprotecttheporcelain
enamelnish.
2. Removetheretainerclips.(Twophillipsheadscrewson
eachclip.)
3. Inspect the gasket. If the window gasket is in good
condition,youcanleaveitinplace.Ifyoureplaceit,use
onlyPartNo.1203556.Besurethechannelaroundthe
windowopeningisclean,andfreeofdust.
4. Installtheglass.Laytheglassontheinnergasketwiththe
coatedsidedown(towardtheoutsideofthedoor).Tighten
thescrewssnugly,butlooseenoughtoallowforalittle
movementoftheglasswhenthestoveisinoperation.
Overtighteningcancracktheglassimmediatelyorcause
ittocrackifitisunabletoexpandwhenhot.
KT160
Intrepid
glass replacement
addendum
11/00
Rope
Gasket
Figure 28-Doorglassinstallation.
Check the Operation of the Primary Air Shutter
Theprimaryairshutterisvisiblefromthebackofthestove.
Theshuttermustopenandclosefreelywhenyoumovethe
thermostatlever.Ifitdoesnot,checkforanyobstruction,or
foraboundorstretchedchainneedingadjustment.(Figure
29)
Onacoldstovetheshuttershouldbeopennomorethan1/8
(3mm)whentheprimaryaircontrolleverispushedcompletely
totheleft(closed),asseenfromthebackofthestove.When
theleverispushedcompletelytotheright(open),theshutter
shouldbeopentoanangleofapproximately70°fromthe
stoveback.
The ball chain should measure 216 mm (81⁄2") from
connectiontothethermostatcoiltoconnectionontheprimary
airap.
If setting is incorrect, the thermostat coil may be bent or
broken.CallyourVermontCastingsDealerforassistance.
How to Adjust the Door Latch
Overtime,thegasketingaroundthedoorswillcompress,and
thelatchmayneedadjustment.Toadjustthelatch,loosen
thesmalllockingnut,extendthestrikerscrewoneturnwhile
keeping the striker screw from turning. (Figure 30) Keep
makingadjustmentsalittleatatimeuntilthesettingisright.
Thefrontdoorsofthestoveshouldclosesecurelyandtightly,
whenthehandleisintheclosedposition.Whenthelatchis
properlyadjustedthereshouldbeaslightresistanceasthe
doorsaremovedtothecompletelyclosedposition.