Vermont Castings The Intrepid II 1990 Mounting instructions

Homeowner’s
Installation and
Operating Manual
For use in the
United States and Canada
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2000966 9/10 Rev. 30
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0966
Intrepid Cover
11/00

2
Intrepid®II Woodburning Stove
2000966

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 MHSC, we share that joy and appreciation of the
hearth, and we show it in all our cast iron stoves and fireplaces.
As you become acquainted with your new stove, you will find the aesthetic appeal of cast iron is matched only by its
superb capacity to absorb and radiate heat.
Also, MHSC products are among the cleanest burning wood stoves and fireplaces available today. As an owner of a MHSC
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 MHSC, we are equally committed to your satisfaction as a customer and that is why we maintain an exclusive net-
work of the finest dealers in the industry. Chosen for their expertise and dedication to customer service, our dealers are
factory-trained and know each MHSC 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 find useful information on assembly and maintenance procedures. We urge you to read the manual thoroughly and
to keep it as a reference.
Sincerely,
All of us at MHSC
This manual describes the installation, operation, and maintenance of the Vermont Castings Intrepid II Model 1990
catalytic-equipped wood burning heater. This heater meets the U.S. Environmental Protection Agency’s emission limits
for wood heaters sold on or after July 1, 1990. Under specific test conditions this heater has been shown to deliver heat
at rates ranging from 8,200 to 26,700 Btu/hr.
The Intrepid II Model 1990 has been tested and is listed by Canadian Standards Association (CSA). The test standards
are ANSI/UL-1482 and ANSI/UL-737 for the United States, and ULC S627 and CAN/CSA-B366.2 for Canada. The Intrepid
II is listed for burning wood only. Do not burn other fuels. The Intrepid II is approved for use in manufactured (mobile)
homes only in the United States, and only when installed with Vermont Castings Mobile Home Kit No. 3248.
Installation or service of this woodburning stove should only be completed by a qualified installer, preferably NFI or
WETT (Canada) certified.
Please read this entire manual before you install and use your new stove. Failure to follow instructions may result in
property damage, bodily injury, or even death.


3
Intrepid®II Woodburning Stove
2000966
Ask your Vermont Castings dealer how these instal-
lation accessories can enhance the versatility, ap-
pearance, and safety of your Intrepid Stove.
0307 Bottom Heat Shield
0172 Rear Heat Shield
Chimney connector heat shields
Heavy-gauge enamel pipe to match the stove’s
color
Warming shelves
0098 Classic Black 1375 Suede Brown
1362 Sand 1376 Biscuit
1365 Green 1377 Chestnut Brown
1371 Bordeaux 1378 Ebony
1372 Midnight Blue 1379 Vt. Classic Green
1373 Brown Majolica
0136 Spark screen for open-fireplace use
Short Legs
0868 Classic Black 1525 Suede Brown
1512 Sand 1527 Biscuit
1510 Green 1530 Chestnut Brown
1515 Bordeaux 1535 Ebony
1520 Midnight Blue 1537 Vt. Classic Green
3258 Outside air kit
3248 Mobile-home kit.
 Fuels used in gas, wood-
burning or oil fired appliances, and the products of
combustion of such fuels, contain chemicals known
to the State of California to cause cancer, birth de-
fects and other reproductive harm.
California Health & Safety Code Sec. 25249.6
Specifications ....................................... 4
Installation ............................................ 5
Clearances ......................................... 15
Assembly ............................................19
Operation ............................................20
Draft Management ..............................26
Maintenance .......................................28
Catalytic Combustor ...........................34
Parts List .............................................35
Warranty ............................................39
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4
Intrepid®II Woodburning Stove
2000966
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2156O"
(545 mm)
20"
(510 mm)
2556M"
(640 mm)
Top exit
flue collar
height
2156M"
(540 mm)
24"
(610 mm)
756"
(180 mm)
2156O"
(545 mm)
C
L
2156M"
(540 mm)
18"
(460 mm)
156M"
(31 mm)
2056O"
(520 mm)
136M"
(350mm)
0966
Intrepid II
specifications
11/00
0966
DRAWINGS NOT TO SCALE
 Intrepid II 1990 dimensions.
Range of heat output .................8,260-26,740 Btu’s/Hr3
Maximum heat output .......................... 27,000 Btu’s/Hr1
Area heated .................. Up to 1200 sq. ft. (112 sq. m.)2
Fuel size/type ...................................16” (410 mm) logs
EPA emissions rating (g/h, catalytic) .......................2.13
Loading ....................................................... Front or top
Chimney connector..................... 6” (152 mm) diameter
Chimney flue size .......................6” (152 mm) 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
Weight ................................................. 223 lbs. (101kg)
Width (leg-to-leg) .................................. 21¹⁄₂” (545 mm)
Depth (leg-to-leg).................................. 13³⁄₄” (350 mm)
Height to top of flue collar:
with regular legs .......................25” (635 mm) top exit
............................................... 24” (610 mm) rear exit
with optional short legs .............21” (535 mm) top exit
............................................ 19³⁄₄” (500 mm) 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 maximum fuel consumption obtained
under laboratory conditions and on average efficien-
cies.
2. These values are based on operation in building
code-conforming homes under typical winter climate
conditions in New England. If your home is of non-
standard construction (e.g., unusually well insulated,
not insulated, built underground, etc.) or if you live in
a more severe or more temperate climate, these fig-
ures may not apply. Since so many variables affect
performance, consult your Vermont Castings Autho-
rized Dealer to determine realistic expectations for
your home.
3. Under specific conditions used during EPA emis-
sions testing.

5
Intrepid®II Woodburning Stove
2000966
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
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 floor protector is large enough and is con-
structed properly to meet all requirements.
• You have all necessary permits from local author-
ities.
Your local building official is the final authority for ap-
proving 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 ULC standards, by Canadian
Standards Association (CSA). The test standards are
ANSI/UL-1482 and ANSI/UL-737 for the United States
and ULCS627 and CAN/CSA-B366.2 for Canada.
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 areas. Before starting
the installation, review your plans with the local building
authority. You local dealer can provide any additional
information needed.
For any unresolved installation issues, refer to CSA
CAN-B365 Installation Code for Solid Fuel Burning Ap-
pliances and Equipment. These standards are the basis
for many national codes. They are nationally recog-
nized and are accepted by most local authorities. Your
local dealer or your local building official may have a
copy of these regulations.
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
In some modern, super-insulated homes, there is not
enough air for combustion because of insufficient air
infiltration 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.
When poor draft is caused by a low infiltration rate,
opening a ground floor 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 varia-
tions within the house, and improved stove perfor-
mance often results. An Outside Air Adaptor Kit for the
Intrepid II is available from your local Vermont Castings
dealer.

Your Intrepid II must be connected to a code-approved
masonry chimney with a flue liner, to a relined masonry
chimney that meets local codes, or to a prefabricated
metal chimney that complies with the requirements
for Type HT chimneys in the Standard for Chimneys,
Factory-Built, Residential Type and Building Heating
Appliance, UL 103, or the High Temperature (650°C)
Standard ULC S-629 for Canada. Whatever kind you
use, the chimney and chimney connector must be in
good condition and kept clean. Figure 2 shows the two
chimney types.
ST241
chimney types
12/13/99 djt
A prefabricated
double-wall insu-
lated chimney
A tile-lined ma-
sonry chimney
ST241
 Standard chimney types.

6
Intrepid®II Woodburning Stove
2000966
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, build-
ing inspector, or fire department official will be able to
inspect the chimney or provide a referral to someone
who can.
The chimney must extend at least 3’ (914mm) above
the highest point where it passes through a roof, and at
least 2’ (610mm) higher than any portion of a building
within 10’ (3m). (Fig. 3)
For proper draft and good performance, any chimney
used with an Intrepid II should extend at least 16’ (5m)
above the flue collar of the stove.
2’ Min.
2’ Min.
3’
Min.
0 To 10’
3’
Min.
0 To 10’
AC617
RLTSKC8
2/11/98
AC617
 The 2’-3’-10’ Chimney Rule.
Reference Point

An inspection of the chimney must confirm 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 chim-
ney 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 fire,
flames 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 ma-
sonry 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.

A prefabricated metal chimney must be one tested and
listed for use with solid-fuel burning appliances to the
High Temperature (650°C) Standard ULC S-629 for
Canada.



An Intrepid II is approved for venting into a masonry
chimney with a maximum flue size of 8” x 8” (203 x
203 mm), and into a round flue size of 6” (150 mm).
It may not be vented into larger chimneys without a liner
to reduce the effective flue size to 6”(150 mm) diam-
eter. Larger chimneys must have their flues 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 is the double-wall or single-wall
pipe that connects the stove to the chimney. The chim-
ney is a masonry or prefabricated structure that enclos-
es the flue. Chimney connectors are used only to make
the connection from the stove to the chimney.
Double-wall chimney connectors must be tested and
listed for use with solid-fuel burning appliances. Sin-
gle-wall chimney connectors should be made of 24
gauge or heavier steel, and should be 6” (150 mm) 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 com-
bustible wall is unavoidable, refer to the section follow-
ing on Wall Pass-Throughs. Do not pass the chimney
connector through an attic, a closet, or any similar con-
cealed 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 26” (660 mm) from the ceiling. For information on
reduced clearances using shields on single-wall chim-
ney connector or using double-wall connectors, see the
clearance chart on Page 11.

7
Intrepid®II Woodburning Stove
2000966
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 1/4” per foot
(20 mm per m) going from the stove toward the chim-
ney. The recommended maximum length of a horizontal
run is 3’ (914 mm). The recommended total length of
chimney connector is 8’ (2.4 m).
In cathedral ceiling installations, extend the prefabri-
cated chimney down to within 8’ (2.4 m) of the stove.




The listing for the Intrepid II for the U.S. and Canada
includes use of double-wall chimney connectors that
have been tested and listed for use with solid-fuel burn-
ing appliances by a recognized testing laboratory.
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 chim-
neys from the same manufacturer makes the assembly
and installation straightforward.




• Beginning at the flue collar of the stove, assemble the
chimney connector. Insert the first crimped end into the
stove’s flue collar, and keep each crimped end pointing
toward the stove. Using the holes in the flue collar as
guides, drill 1/8” (3 mm) holes in the bottom of the first
section of chimney connector and secure it to the flue
collar with three #10 x 1/2”
sheet metal screws.
• Secure each joint be-
tween sections of chimney
connector, including tele-
scoping 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 1/8”
(3 mm) holes in the bottom
of the next section.
• Secure the chimney
connector to the chimney.
Instructions for various
installations follow.
ST242
Chimney connector
12/13/99 djt
 The crimped end of
the connector points toward
stove.
• Be sure the installed stove and chimney connector
are correct distances from nearby combustible material.
 Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney con-
nector are available to simplify installations. They often
eliminate the need to cut individual connector sections.
Consult your local dealer about these special pieces.


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.
Special adapters are available from your local dealer to
make the connection between the prefabricated chim-
ney and the chimney connector. The top of such adapt-
ers attaches directly to the chimney or to the chimney’s
ceiling support package, while the bottom of the adap-
tor is screwed to the chimney connector.
These adapters are designed so the top end will fit
outside the inner wall of the chimney, and the bottom
end will fit inside the first section of chimney connector.
When assembled in this way, any soot or creosote fall-
ing from the inner walls of the chimney will stay inside
the chimney connector.


For masonry chimneys, both freestanding and fireplace
chimneys may be used for installation of your Intrepid II.
ST243
thinble connection
12/13/99 djt
Thimble Sleeve
Chimney
Connector
Flue
Keep
sleeve
end
flush
with flue
tile
ST243
 The thimble, made of either ceramic or metal, must be
cemented securely in place.

If the chimney connector must pass through a combus-
tible wall to reach the chimney, follow the recommenda-
tions in the Wall Pass-through section that follows.

8
Intrepid®II Woodburning Stove
2000966
The opening through the chimney wall to the flue (the
“breach”) must be lined with either a ceramic or metal
cylinder, called the “thimble”, which is cemented firmly
in place. The fit must be snug and the joint between the
thimble and the chimney wall must be cemented. (Fig.
6)
A special piece called the “thimble sleeve,” slightly
smaller in diameter than standard connector and most
thimbles, will facilitate the removal of the chimney con-
nector system for inspection and cleaning. Thimble
sleeves should be available from your local dealer. (Fig.
5)
To install a thimble sleeve, slide it into the breach until
it is flush with the inner flue wall. Do not extend it into
the actual flue passage, as this could interfere with the
draft.
The thimble sleeve should protrude 1-2” (25-50 mm)
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 con-
nector can be extended through the breach to the inner
face of the flue liner, and cemented securely in place.
Additional pieces of connector are then attached with
sheet metal screws.


The Intrepid II may be connected to a chimney above a
fireplace opening also. In such installations, the stove is
positioned on the hearth in front of the fireplace and the
chimney connector rises from the stove top and then
angles ninety degrees back into the chimney. (Fig. 7)
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 fireplace, follow all the guidelines
mentioned above for freestanding installations. In addi-
tion, 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 re-
quired clearances.
• Check the clearance between the chimney connec-
tor and the ceiling. If no heat shields are used, the
clearance should be at least 26” (660 mm). To find
out how much this clearance may be reduced with
heat shields, see the clearance chart on Page 14.
• The fireplace damper must be sealed to prevent
room air from escaping up the flue. However, it must
be possible to re-open the damper to inspect or
clean the chimney.
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
ST492a
 Chimney connection in a freestanding installation.
ST244
Plymouth
fplc over mantel
12/99
Chimney Connector
Shields
* Check
These Clear-
ances
*
*
Mantel
Seal the
Damper
ST244
 Chimney connector enters chimney above the firep.
lace.

9
Intrepid®II Woodburning Stove
2000966


If your fireplace height is at least 25” (635 mm), you
may install an Intrepid II with standard legs through
the fireplace opening using a “positive connection” kit
available from your local dealer. These positive connec-
tion kits ensure a tight fit between the stove flue collar
and the chimney flue. (Fig. 8) Fireplace installations,
whether connected to the flue above or through the
fireplace opening, have special clearance requirements
to adjacent trim and the mantel. You’ll find the required
clearances for the Intrepid II fireplace installations on
Page 14.
Floor protection requirements also apply to fireplace
installations. Floor protection information is on Page 9.
ST245
fireplace
flex connector
12/99
Flexible Connector
Mantel Shield
Fireplace Adaptor Kit
ST245
 Chimney connector enters chimney through the fire-
place opening.

Whenever possible, design your installation so the con-
nector 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 specific requirements.
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.
 the National Fire Protection As-
sociation (NFPA) has established guidelines for passing
chimney 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
single-wall connector to provide the required 12” (305
mm) clearance. Any material used to close up the open-
ing must be noncombustible.
Three other methods are also recommended by NFPA:
• Using a section of double-wall chimney with a 9”
(230 mm) clearance to combustibles.
• Placing a section of chimney connector inside a
ventilated thimble, which in turn is separated from
combustibles by 6” (150 mm) of fiberglass insulating
material.
• Placing a section of chimney connector inside a sec-
tion of 9” (230 mm) diameter, solid-insulated, factory-
built chimney, with 2” (50 mm) of air space between
the chimney section and combustibles.
T
ST493a
Brick pass thru
11/00
INT
I
P
D
RE
I
I
Wall Stud
Chimney
Connector
Floor
Protection
12” of
Noncombustible
Material
ST493a
 An approved wall pass-through for the United States.
 The Canadian Standards Association has
established installation guidelines. The following il-
lustration shows one method, in which all combustible
material in the wall is cut away to provide the required
18” (460 mm) clearance for the connector. The resulting
space must remain empty. A flush-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 1” (25 mm) clear of the
wall.

10
Intrepid®II Woodburning Stove
2000966
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. In Canada, this type of installation must conform
to CAN/CSA-B365, Installation Code for Solid Fuel
Burning Appliances and Equipment.
T
ST494
steel
wall pass thru
11/00
INT
I
P
D
RE
I
I
18” (460mm) clearance all
around the pipe
Flush Mounted
Sheet Metal
Cover
ST494a
 An approved wall pass-through for Canada.
Do not vent your Intrepid II into a factory-built
(zero-clearance) fireplace. These appliances and their
chimneys are specifically designed as a unit for use as
fireplaces. It may void the listing or be hazardous to
adapt them for any other use.



A tremendous amount of heat radiates from the bottom
plate of an Intrepid II, and the floor beneath requires
two kinds of special protection.
Heat protection is provided by a Bottom Heat Shield,
part #0307.
Spark and ember protection is provided by a floor pro-
tector, which may be any noncombustible material.
For a new hearth, we recommend a noncombustible
floor protector such as 1/4” non-asbestos mineral board
or its equivalent, or 24 gauge sheet metal. If carpeting
is present, it must be removed before installation of the
floor protector. The floor protector may be covered with
a noncombustible decorative material if desired. When
using brick, tile, or stone, individual pieces must be
mortared so sparks cannot fall through.





Even with the bottom heat shield installed, you must
also use a floor protector.
 the floor protector required under
the stove must extend at least 16” from the front of the
stove - not from the ashlip - (Labeled ‘E’ in Fig. 11), and
at least 6” from the sides and rear (‘D’, Fig. 11).
To meet the requirement in the United States, a floor
protector must be at least 34” wide and 40” deep.
 the floor protector required under the stove
must extend 18” (460 mm) to the front (labeled ‘E’, Fig.
11), and 8” (203 mm) from the sides and rear. (‘D’ ,Fig.
11)
To meet Canadian requirements, a floor protector must
be at least 38” (965 mm) wide and 44” (1118 mm) deep.
Floor protection also must extend under the chimney
connector and 2” (51 mm) to either side. (‘C’, Fig. 11)
For 6” (152 mm) connector used with the Intrepid II, the
protector must be a minimum of 10” (254 mm) wide,
centered under the connector.
D
E
DD
A
B
D
D
A
E
D
C
ST500
intrepid
floor protection
11/10/00
 
A. 34” 38” (965 mm)
B. 40” 44” (1118 mm)
C. 10” 10” (254 mm)
D. 6” 8” (203 mm)
E. 16” 18” (457 mm)
 
ST500
 Required floor protector dimensions.