Vermont Castings Vigilant II 2310 Mounting instructions

0898
Vigilant
Cover 8/6/01 djt
Vigilant II
Coal Stove
Model #2310
Homeowner’s
Installation and
Operating
Instructions
For Use in North America
Do Not Discard This Manual: Retain for Future Use
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 IN-
STALLATION INSPECTION REQUIREMENTS IN YOUR AREA.
2000898 9/06 Rev. 8

2
Vermont Castings Vigilant
2000898
Welcome
Congratulations on your choice of a Vermont Castings Vigilant II Coal Stove. With this purchase, you have made a
commitment to make the hearth a place of warmth, beauty and comfort in your home. At Vermont Castings, we share
that joy and appreciation for the hearth, and we show it in all our cast-iron stoves and fireplaces.
As you become acquainted with your new stove or fireplace, you will find that its visual appearance is matched by its
functionality, due to cast iron’s unique capability to absorb and radiate heat.
Also, Vermont Castings products are among the cleanest-burning stoves and fireplaces available today. And as an
owner of a Vermont Castings 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 operate
your stove properly.
At Vermont Castings, we are equally committed to your satisfaction as a customer. That is why we maintain an ex-
clusive network of the finest dealers in the industry. These dealers are chosen for their expertise and dedication to
customer service. They are factory-trained to know the most minute detail of every Vermont Castings product. Contact
your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its performance.
Be assured that your cast-iron Vermont Castings stove or fireplace has been made with the utmost care and will pro-
vide you with many years of service.
This manual contains valuable instructions on the installation and operation of your Vermont Castings stove. It also
contains useful information on maintenance and assembly of this product. We urge you to read the manual thoroughly
and to keep this manual as a reference.
Sincerely,
All of us at CFM Corporation
The Vigilant II Coal Stove has been tested and is listed
by Warnock Hersey according to ANSI/UL 1482 for
the United States and AN/ULC S627 for Canada. The
Vigilant II Coal Stove is listed for burning coal. Do not
burn other fuels. The Vigilant II Coal Stove is not listed
for installation in mobile homes.
The Vermont Castings Vigilant II Coal Stove is exempt
from the standards set forth by the Federal Environ-
mental Protection Agency, 40 CFR Part 60.530 (g), as
stated on the permanent label attached to this appli-
ance.
Table of Contents
Specifications ........................................................... 3
Installation ................................................................ 4
Operation ............................................................... 16
Maintenance .......................................................... 19
Warranty ................................................................. 27
Proposition 65 Warning: 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

3
Vermont Castings Vigilant
2000898
Specifications
Vigilant II Coal Stove Model #2310
Coal type ................................ Anthracite or bituminous
Coal size ....................................................... Pea or nut
Maximum heat output .......................... 50,000 Btu’s/hr*
Maximum area heated .................................. 2,000sq.ft.
Fuel Capacity ......................................... 45 lbs. (20 kg)
Fuel Loading .............................................................top
Glass Panel ............................. Hi-temperature ceramic
Weight ................................................. 425 lbs. (212kg)
Flue exit position ..........................................Top or rear
Flue exit size ...............................................6” standard
...................................................................... 8” optional
*This value can vary depending on how the unit is
operated, and the type and moisture content of the fuel
used. Figure shown is based on maximum fuel con-
sumption obtained under laboratory conditions and on
average efficiencies.
**These values are based on operation in building-code
conforming homes under typical winter climate condi-
tions in New England. If your home is of nonstandard
construction (e.g. unusually well insulated, not insu-
lated, built under ground, etc.) or if you live in a more
severe or more temperate climate, these figures amy
not apply. Since so many variables affect performance,
consult your Vermont Castings’ Authorized Dealer to
determine realistic expectations for your home.
VIGILANT
28¹⁄₄" (720mm)
31"
(787mm)
33⁷⁄₈"
(861mm)
30" (762mm)
23" (584mm)
20¹⁄₂" (520mm)
28³⁄₈"
(721mm)
30¹⁄₂"
(775mm)
31³⁄₈"
(797mm)
33¹⁄₂"
(851mm)
20" (510mm)
0898
Vigilant Specs
8/01
7⁷⁄₈" Legs
10" Legs
7⁷⁄₈" Legs
10" Legs
Fig. 1 Vigilant II dimensions.
0898

4
Vermont Castings Vigilant
2000898
Installation
Codes and Listings
Conforming to local building codes will be an important
part of your planning. Local authorities make the final
decision on whether or not an installation will be ap-
proved. They need to know that your installation is safe
and meets local codes.
The metal label permanently attached to every Vermont
Castings stove indicates that the stove has been tested
to current UL and ULC standards, and gives the name
of the testing laboratory. Clearance and installation
information is also printed on the label. In most cases,
local authorities will accept the label as evidence that,
when the stove is installed according to the information
on the label and in this manual, the installation meets
codes and can be approved.
However, codes vary in different areas. Be sure to
review your installation plans with your local authority
before starting the installation. Check with your local
Vermont Castings Authorized Dealer for help in provid-
ing the necessary information to local officials.
This section will answer clearance and construction
questions for almost all installations. Your local Ver-
mont Castings Authorized Dealer will also be able to
help. For questions left unanswered, we recommend
that you refer to the National Fire Protection Association
ANSI/NFPA 211-1988 Standard for Chimneys, Fire-
places, Vents and Solid Fuel Burning Appliances, or in
Canada, CSA B365. These standards are the basis for
many national codes.
Remember, your local building official makes the final
decision on approvals of installations.
CAUTION: Follow all installation and use instructions
exactly. Failure to follow instructions may result in a
dangerous situation, including a chimney or house fire.
Chimneys and Draft
Understanding how your chimney contributes to stove
operation is essential if you are to obtain optimum per-
formance from your Vigilant Coal Stove. The chimney
provides a safe pathway for hot smoke and exhaust
gases to exit from the stove, but in addition, the chim-
ney strongly influences the “draft” necessary for opera-
tion of your stove.
Draft is the force which produces a flow of warm gases
up and out of the chimney, and draws fresh combus-
tion air into the stove. Your Vigilant does not come
equipped with “draft”. Draft is the result of a difference
in weight (due largely to a difference in temperature)
between the gases inside the chimney, and gases out-
side the chimney. Because gas expands when heated,
warm gases inside the chimney weigh less than cool
gases outside. This weight difference creates the pres-
sure necessary to produce and sustain draft.
As the lighter, more buoyant gases rise up the chimney,
draft causes a flow of cooler air into the stove. When
starting a fire in a cold stove on an unheated chimney, it
may be necessary to provide some assistance by ignit-
ing several sheets of crumpled newspaper which have
been placed in the flue collar area.
There are other factors which influence draft, such as
barometric pressure, wind speed and direction, the
height, configuration and size of the chimney, and the
airtightness of the home itself.
Improving Draft With Outside Air
In some modern, super-insulated homes, the air neces-
sary for combustion is inadequate due to restricted air
infiltration into the dwelling. (Infiltrated air is simply
that air which finds its way into a home through various
cracks and openings in the foundation, along windows
and doors, and at other non-weathertight areas.) If the
stove is competing with kitchen or bath exhaust fans for
available air, the situation is aggravated further. Where
poor draft is the result of a low infiltration rate, open-
ing a ground floor window in the vicinity of the stove,
or installing a permanent outside air supply, will often
alleviate the problem.
In some areas, bringing air for combustion from outside
the home directly to the air inlet of the stove is required
for new construction. When the air supply for the fire
is brought directly from the outside, it is not affected by
variations in air pressure within the house. Improved
stove performance often results. An Outside Air Adap-
tor Kit is available from your local Vermont Castings
Authorized Dealer.
How Draft Affects Stove Performance
A strong draft will allow you to successfully fine-tune
the Vigilant’s performance by adjusting the primary air
supply to determine the rate of combustion and heat
output. With a strong draft, you can restrict the primary
air supply and lower the heat output without risk of suf-
focating the fire.
A strong draft will be maintained by operating your
stove so that combustion gases entering the chimney
are hot, and stay hot. Air must not be allowed to enter
the chimney without first having passed through the
stove. Make sure that clean-out doors and thimbles are
sealed tightly, and that the chimney is structurally sound.

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Vermont Castings Vigilant
2000898
Weak draft situations are characterized by smoking
and odor problems in the house, low heat output, and
difficulty maintaining a fire, especially at low thermostat
settings. The reverse situation, overdraft, is rare, but
can be recognized by short burn time, poor response
when trying to slow down the fire, or by any part of the
stove glowing red.
A more common cause of overdraft is inadequate
maintenance, such as worn gasket allowing uncon-
trolled air to enter the stove. Following recommended
maintenance procedures will ensure consistent stove
performance.
Following the stove manufacturer’s recommendation on
both chimney size and height will also help ensure ad-
equate chimney flow capacity. Flow capacity measures
the ability of the chimney to evacuate combustion gas-
es quickly. Even the strongest draft cannot overcome
an insufficient flow capacity; the result is a back up of
combustion gases in the chimney which forces smoke
out of chimney connector joints or the stove itself. Re-
member, the Vigilant and the chimney must function as
a unit. For optimum performance, they must be sized
properly for each other. Your Vermont Castings Autho-
rized Dealer can help you assess your existing chimney
or plan a new one for best stove operation.
Chimney Guidelines
DO NOT CONNECT TO ANY AIR DISTRIBU-
TION DUCT OR SYSTEM.
New Chimneys
Both masonry and prefabricated metal chimneys work
well.
A new prefabricated metal chimney should be one test-
ed and listed for use with solid-fuel burning appliances
to the High-Temperature (H.T.) Chimney Standard UL-
103-1985 (2100° F.) and have interior walls especially
designed for use with coal-burning stoves. Be sure to
follow the chimney manufacturer’s instructions exactly
when passing the chimney through a combustible wall
or ceiling. Special accessories may be necessary for
this type of installation.
The chimney should extend at least 3 feet above the
highest point where it passes through a roof, and at
least 2 feet higher than any portion of a building within
10 feet.
ST241
chimney types
12/13/99 djt
Prefabricated Double-
wall Insulated Chimney
Tile-lined
Masonry
Chimney
ST241
Fig. 2 Chimney types.
A new masonry chimney should be constructed to con-
form to the standards of your local building code or a
recognized national code. Masonry chimneys must be
lined with code-approved masonry or pre-cast refrac-
tory tiles, stainless steel pipe suitable for use with coal,
or a code-approved poured-in-place liner. The chimney
must have a tight sealing clean-out door.
For proper draft and good performance, any chimney
used with a Vermont Castings wood or coal burning
stove should extend at least 16 feet above the flue col-
lar of the stove.
Existing Chimneys
An existing masonry chimney may work well, but be
sure to have it carefully inspected before using it. De-
fects may have gone unnoticed if the chimney previ-
ously was used only occasionally. Defects must be
repaired before the chimney is used with your stove.
If you are not sure that you can make the inspection
yourself, your local professional chimney sweep, build-
ing inspector, or fire inspector will be able to make the
inspection or direct you to someone who can.
The chimney should be thoroughly cleaned before be-
ing used with your stove.
First, check to see that the chimney has a lining. Do
not use an unlined chimney. Your local Vermont Cast-
ings Authorized Dealer or chimney sweep can help
you with information about approved chimney lining
systems. In addition, look for and repair (if necessary)
these defects: (Fig. 4)
A. Improper chimney height and roof clearance; check
local building codes for proper construction.
B. Chimney cap deterioration; rebuild.
C. Creosote stains indicate flue damage; inspect and
repair.
2' Min.
2' Min.
3'
Min.
0 To 10'
3'
Min.
0 To 10'
AC617
RLTSKC8
2/11/98

Reference
Point AC617
Fig. 3 The 2’-3’-10’ chimney rule.

6
Vermont Castings Vigilant
2000898
A
B
C
E
D
F
G
H
I
J
H
ST562
Chimney hazards
12/14/00 djt
ST562
Fig. 6 Existing chimney.
D. Blockage within flue; remove.
E. Improper clearance between chimney and com-
bustible materials. Generally, a clearance of 2” (50
mm.) is required to all combustible walls and framing
members; check local codes.
F. Improper clearance between smoke chamber and
adjacent framing members; check local codes.
G. Creosote accumulation; chimney needs thorough
cleaning.
H. Structural deterioration of the fireplace; must be
repaired before use.
I. Loose or broken bricks or mortar; replace and
remortar.
J. Loose or broken clean-out door; repair or replace.
Existing masonry chimneys, especially older ones, may
have two or more openings through the chimney walls
to the same flue. The openings were used to connect
stoves in different rooms to the chimney. The unused
openings must be sealed with masonry to the thickness
of the chimney wall. Unused openings sealed with
pie plates or wallpaper are a hazard. In the event of a
chimney fire, flames and smoke may be forced out of
these unused thimbles.
DO NOT CONNECT YOUR STOVE OR INSERT TO A
CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
Chimney Size
When outfitted with the standard 6” (150 mm) flue col-
lar, The Vigilant II Coal Stove is designed to perform
well when vented through flues that have these dimen-
sions:
Prefabricated
Round Liner, I.D. 6” (150 mm)
Masonry
Square Liner 8” x 8” (nominal)
Rectangular Liner 7” x 11” (nominal)
Round Liner 6” (inside dimensions)
A Vigilant II Coal Stove equipped with the optional 8”
(200 mm) flue collar is designed to perform well when
vented through flues that have these dimensions:
Prefabricated
Round Liner 8” (inside dimension)
Masonry
Square Liner 8” x 8” (nominal)
Rectangular Liner 8” x 12” (nominal)
Round Liner 8” (inside dimensions)
CHIMNEYS WITH LINERS LARGER THAN 8” X 12”
MAY EXPERIENCE RAPID COOLING OF COMBUS-
TION GASES AND REDUCTION IN DRAFT, ESPE-
CIALLY IF THEY ARE LOCATED OUTSIDE THE
HOME.
These large chimneys may need to be insulated or the
flues re-lined for good stove performance. Vermont
Castings offers chimney lining accessories to help
make the connection between stainless steel chimney
liners and our stoves and fireplaces.
If you are planning to vent a small stove into a large
flue, particularly an exterior masonry flue, you may find
it necessary to insulate the chimney, reline the chimney,
or operate the stove with the damper open to maintain
high flue temperatures.

7
Vermont Castings Vigilant
2000898
Clearances
Your stove and chimney connector will radiate energy
in all directions when in operation. An important part
of planning a safe installation is to be sure combustible
materials near your stove do not overheat due to inad-
equate clearance.
Clearance is the distance between your stove (or chim-
ney connector) and nearby walls, ceiling, and floors, as
well as other combustible materials. Correct clearance
must also be maintained to moveable items, such as
furniture, newspapers, or clothes left to dry near the
stove. Keep all combustibles a considerable distance
away from the stove; 48” is a good minimum clear-
ance. Installing your Vigilant to the tested clearance
and keeping those clearance areas empty assures that
nearby surfaces will not overheat.
Clearances must be large enough so that furniture and
other combustibles near your stove will not overheat
and catch fire. Wood framing that is part of a wall
or floor will dry as it ages, and its ignition point (the
temperature at which it will start to burn) will be low-
ered. The change may take place slowly over a period
of many years, or more quickly if the wood is near a
source of heat such as a stove.
Your Vermont Castings Vigilant II Coal Stove has been
carefully and thoroughly tested by independent test-
ing laboratories to determine safe clearances. During
testing, heat sensors installed in all surfaces near the
stove and chimney connector, including floors and ceil-
ings, show the temperatures reached during a variety
of combustion situations. Clearance distances are
accepted only when the sensors show the stove is far
enough from nearby surfaces to meet strict UL or ULC
standards.
Using The Clearance Chart
If your stove will be parallel to the wall behind it (parallel
installation), use the columns of the chart labelled “side”
and “rear”. If your stove will be installed in a corner
(corner installation), use the columns labelled “corner”.
Your stove will be in either a parallel or a corner instal-
lation, not both. Use only the part of the chart that ap-
plies to your installation. Note: Side clearances do not
apply to corner installations.
Measure clearance between the edge of the stove’s top
plate and the nearby combustible surface. For most
common installations, when the stove has the proper
clearance from nearby surfaces, the chimney connector
will also have the proper clearance. However, instal-
lations vary. It is important to double check all installa-
tions for proper chimney connector clearance, as well
as stove clearance.
The clearance distance must be empty except for non-
combustible heat shields. Air flowing between the stove
(and/or chimney connector) and nearby shields car-
ries away heat. Do not block the air flow by filling this
empty space with any insulating material.
Clearance Reductions
When no shields are used, empty space alone provides
protection against overheating. When shields are used,
it is usually possible to reduce the required clearance,
as the shields offer additional protection.
Stove shields and connector shields (used only on
single-wall connectors) attach directly to the stove or
connector. Wall shields attach to wall surfaces. Combi-
nations of the these shield types may be used.
When shields are attached to the stove or chimney con-
nector, they are mounted 1” - 2” away from the stove
or connector surface on non-combustible spacers. The
shiny shield surface facing the heat source must be left
unpainted, enabling it to reflect heat back towards the
stove or connector and away from the wall.
The greatest clearance reductions result from using
both stove and chimney connector shields in conjunc-
tion with walls which are protected with wall shields.
Unprotected Walls
Clearances With No Heat Shields
If the Vigilant is installed parallel to the rear wall (paral-
lel installation) and no shields are used, the stove must
be at least 20” (510 mm) from the wall behind it, and at
least 18” (460 mm) from walls beside it.
20" (510mm)
18"
(460mm)
ST683
Vigilant
clearances
parallel,
no heat shield
8/7/01 djt
ST683
Fig. 5 Minimum clearances, parallel installation, no heat
shield.

8
Vermont Castings Vigilant
2000898
If the Vigilant is installed in a corner (corner installation)
and no shields are used, the corners of the stove must
be at least 16” (410 mm) from nearby walls. (Fig. 6)
Measure these distances from the edge of the top plate
of the stove nearest the wall to the combustible part of
the wall.
Unshielded single wall chimney connectors must be a
minimum of 17” (430 mm) from the wall or ceiling.
Clearances With Only the
Stove Rear Heat Shield
If you install a Vigilant with a rear heat shield in a
parallel installation, but use no chimney connector heat
shields, different clearances will be required for top-exit-
ing and rear-exiting stoves.
For top-exiting stoves, clearance to the rear wall is
determined by heat from the unshielded chimney con-
nector, not heat from the stove. Stove placement must
ensure that the unshielded connector cannot overheat
the rear wall. Reminder: Use the Flue Collar Heat
Shield (#140-0924) included with the Rear Heat Shield
#0175 to protect the area directly behind the flue collar.
Rear clearance must be a minimum of 20” (510 mm),
measured from the edge of the stove top to the rear
wall. Side clearance is determined by heat from the
stove. It must be a minimum of 18” (460 mm) , mea-
sured from the edge of the stove top to the combustible
component of the unprotected wall. (Fig. 7)
ST684
Vigilant
clearances
corner,
no heat shield
8/7/01 djt
16" (410mm)
16" 
(410mm)
ST684
Fig. 6 Minimum clearance, corner installation, no heat shield.
20" (510mm)
18"
(460mm)
ST685
Vigilant
clearances
parallel,
rear heat shield
8/7/01 djt
ST685
Fig. 7 Minimum clearance, parallel installation, rear heat
shield.
For rear-exiting stoves, both rear and side clearances
are determined by the heat from the stove (provided
that the connector does not pass near a combustible
surface).
The rear heat shield protects the wall behind the stove
so that clearance may be reduced to 13” (330 mm),
measured from the rear edge of the stove’s top plate
to the combustible part of the wall. Side clearance re-
mains the same — 18”, measured from the edge of the
stove top to the side wall. (Fig. 8)
13" (330mm)
18"
(460mm)
ST686
Vigilant
clearances
parallel, rear exit
rear heat shield
8/7/01 djt
ST686
Fig. 8 Minimum clearance, rear exit, rear heat shield.
For corner instllations, the clearance is 16”, measured
from the corners of the stove perpendicular to the wall.
Clearances With Double-wall Connectors,
Or Single-wall Connectors And Connector
Heat Shields
The Vigilant II Coal Stove listing includes using single-
wall or double-wall chimney connectors. The rows
of the clearance chart labelled “Chimney Connector
Clearance” give clearances measured from the chim-
ney connector to nearby walls and ceilings. (“Ceilings”
is emphasized to remind you that ceiling clearance is
an important clearance that is sometimes overlooked.)
Be sure to double-check chimney connector clearances
before completing your installation.
Reminder: For top-exiting stoves using a rear heat
shield, install the Flue Collar Heat Shield (#140-0924),
included with the Rear Heat Shield #0175, to protect
the area directly behind the flue collar. Instructions are
included with the heat shield package.
When using a chimney connector heat shield on a
single-wall connector, it may only extend 24” (610 mm)
above the flue collar. The shield must come down to
meet the top of the Flue Collar Heat Shield. (Fig. 9)

9
Vermont Castings Vigilant
2000898
VIGILANT
24" 
(610mm)
Max.
ST687
chimney connector
8/7/01 djt
Prefabricated
Chimney
Single-wall
Chimney Connector
Chimney
Connector
Heat Shield
Bottom
Heat
Shield
ST687
Fig. 9 Chimney connector heat shields may be used to re-
duce clearances when single-wall connectors are used.
Clearances With Double Wall Chimney
Connectors And Rear Stove Heat Shields
When a rear heat shield is used on the stove and a
double wall chimney connector is used, the rear clear-
ance is 15¹⁄₂" (395 mm) and the chimney connector
clearance is 12" (300 mm).
Clearances With Single-wall Chimney
Connectors, Connector Shields And Rear
Stove Heat Shields
Use of both stove and chimney connector heat shields,
on single-wall connectors, in top-exiting installations
reduces the required clearance. (Fig. 10)
13" (330mm)
18"
(460mm)
ST688
Vigilant
clearances
parallel,
rear heat shield,
chimney connector
heat shield
8/7/01 djt
ST688
Fig. 10 Minimum clearance, chimney connector heat shield,
rear heat shield.
Protected Walls
A properly constructed wall shield may be used to
change an unprotected wall to a protected wall, allow-
ing the clearances given in the right half of the Clear-
ance Chart.
Wall shields should be
constructed of 24 gauge
or heavier sheetmetal,
1/2” noncombustible insu-
lation board, or common
brick laid on flat (3¹⁄₂" side
down). Shields must be
spaced out from the com-
bustible wall or ceiling 1"
on noncombustible spac-
ers. The spacers should
not be directly behind the
stove or chimney connec-
tor.
Air must be able to flow
between the wall and the
shield. At least one-half
(50%) of the bottom 1"
of the shield should be
open and the shield must
stop 1" from the ceiling.
Protect the top opening
with metal screening to
prevent objects from fall-
ing behind the shield.
Rear wall shields must extend 18" above the top of the
stove or to within 1" of the ceiling, must be centered
behind the stove, and must be a minimum of 48" (1220
mm) wide by 48" high.
Side wall shields must be 48" (1220 mm) wide by 44"
high, and must extend 15" (380 mm) beyond the front
of the stove as measured from a point on the wall that
is on the same plane as the door glass.
ST248
wall shield construction
12/14/99 djt
Air Flow
Wall Shield
Noncom-
bustible
Spacer and
Fasteners
Drywall
Stud Wall Fram-
ing
Air Flow
ST248
Fig. 11 Wall shield con-
struction.

10
Vermont Castings Vigilant
2000898
Vigilant II Clearance Chart
Unprotected Surfaces
Side Rear Corners Side Rear Corners
Stove in Corner
Stove Installed Par-
allel to Wall
Stove in Corner
Stove Installed Par-
allel to Wall
Stove Clearance
Protected Surfaces
Chimney Connector Clearance
Single-wall
connector
No heat shields
Single-wall connector
Rear exit,
Rear heat shield
Double-wall connector
Top exit
Rear heat shield
Single-wall connector
Top exit
Rear and chimney
connector heat
shields 1
Single-wall connector
No connector heat
shields
Single-wall connector
Connector heat
shields installed
Double-wall
connector
All Installations
48” (1219 mm)
Clearance to Combustibles in Front of Stove
1. A ceiling heat shield, 24” (610 mm) in diameter and suspended 1” (25 mm) from the ceiling, must surround the chimney con-
nector in installations in which the chimney connector penetrates the ceiling. The chimney connector shield extends only to
24” (610 mm) above the flue colllar.
2. The ceiling heat shield required when the chimney connector shields are used should meet the wall protector. This will require
trimming the ceiling shield along the line of intersection with the wall protector.
All Installations
All Installations
18”
(457 mm)
20”
(508 mm)
16”
(406 mm)
7”
(178 mm)
13”
(330 mm)
9”
(229 mm)
18”
(457 mm)
13”
(330 mm)
16”
(406 mm)
7”
(178 mm)
11”
(279 mm)
9”
(229 mm)
18”
(457 mm)
13”
(330 mm) N/A 7” (178 mm)
11”
(279 mm) N/A
15¹⁄₂”
(394 mm)
13”
(330 mm)
16”
(457 mm)
7”
(178 mm)
10¹⁄₂”
(267 mm)
9”
(229 mm)
17” (432 mm)
11” (279 mm)
12” (305 mm)
9” (229 mm)
9” (229 mm)2
7” (178 mm)

11
Vermont Castings Vigilant
2000898
Floor Protection
Freestanding Installations
A tremendous amount of heat radiates from the bottom
plate of a Vigilant Coal Stove, and the floor beneath re-
quires special protection. A Vigilant Coal Stove Bottom
Heat Shield (be sure to install the included shield insert
when the shorter 7⁷⁄₈ (197 mm) legs are used) provides
heat protection. A floor protector provides spark and
ember protection.
Most installations will require the bottom heat shield
together with its shield insert or “double bottom” and a
floor protector be used. Only when the stove is placed
on a completely non-combustible surface such as
unpainted concrete over earth may it be used without
either. In Canada, the double bottom heat shield is
always required.
When using the standard 10” (250 mm) legs on the
stove over a combustible floor, a single bottom heat
shield must be used in conjunction with a floor protec-
tor that consists of a minimum of one layer of 24 guage
galvanized sheet metal or .25” thick mineral board or
the equivalent. The floor protector must be at least
45” (1140 mm) wide x 48” (1220 mm) deep and must
extend under the full length of any horizontal run of
chimney connector. For the 6” (150 mm) connector that
is standard with the Vigilant Coal Stove, the protector
must be a minimum of 10” (250 mm) wide, centered
under the connector. When the optional 8” (200 mm)
connector is used, the protector must be a minimum of
12” (300 mm) wide and centered under the connector.
When the shorter 7⁷⁄₈" (197 mm) legs are used on the
stove over a combustible floor, the double bottom heat
shield must be used as well as a floor protector. The
E
C
A
B
E
A
C
F
ST689
Vigilant
floor protection
8/7/01
DD
A. 45” (1143 mm)
B. 48” (1219 mm)
C. 8” (203 mm)
D. 16” (406 mm)
E. 12” (305 mm)
F. 2” (51 mm) to either side of connector
Fig. 12 Minimum floor protection requirements.
ST689
floor protector must meet the same requirements as for
standard legs.
Floor Protection for Fireplace Installations
In many fireplaces the brick or concrete hearth in front
of the fireplace opening is supported by heavy wooden
framing. Bricks and concrete are not good insulators,
so heat radiated to the hearth under the stove will pass
through the hearth directly to the wooden framing.
Such fireplace hearths must be protected like any other
combustible floor. If a bottom heat shield and regular
legs are used, the existing fireplace hearth may provide
adequate spark and falling ember protections if it meets
the necessary size requirement of 45” x 48”. Without
a bottom heat shield (regular legs), or with the double
bottom heat shield (short legs), the hearth construction
must meet the requirements given in the previous sec-
tion.
We recommend always using a bottom heat shield
when using regular legs, so that your hearth/floor pro-
tector may reflect your personal design preference.
Fireplace Mantel and Trim Clearance
If your installation will utilize an existing fireplace and
its masonry chimney built to code, you must check your
fireplace mantel and trim clearances.
Ventilated shields (noncombustible shields installed on
non-combustible spac-
ers 1” away from the
combustible surface)
may be used to reduce
clearances. (Fig. 14)
Mantel and top trim
shields for the Vigilant
Coal Stove must be at
least 48” long, centered
over the stove; side trim
shields must extend the
full length of the trim.
ST690
Vigilant
Rear exit floor dgrm
8/7/01 djt
VIGILANT�
Heavy
Wooden Framing ST690
Fig. 13 Additional protection may be required when the
hearth is built over wooden framing.
1" (25mm)
1/4" (6mm)
ST501
mantel and
trim shield
11/10/00 djt
Mantel
Spacer
Custom-
formed
Mantel
Shield
ST501
Fig. 14 A custom formed man-
tel shield.

12
Vermont Castings Vigilant
2000898
An unprotected mantel must have a minimum clear-
ance of 36”, measured from the stove’s top plate; with a
ventilated shield the clearance may safely be reduced
to 18”.
Unprotected top trim must be a minimum of 36” from
the stove’s top surface; with a ventilated trim shield the
clearance may be safely reduced to 18”.
Unprotected side trim which protrudes 2” or more from
the face of the fireplace must have a minimum 36” of
clearance, measured from the stove’s top side edge;
with a ventilated trim shield, the clearance may be
safely reduced to 18”.
Unprotected side trim which protrudes less than 2” from
the fireplace face must have a minimum clearance of
18”; with a ventilated trim shield, this may be safely
reduced to 12”. (Fig. 15)
ST691
Vigilant
trim clearances
8/7/01 djt
C C
AB
Unprotected Protected
A. Mantel .... 36” (910mm) 18” (460mm)
B. Top Trim . 36” (910mm) 18” (460mm)
C. Side Trim
.......Over 2” 36” (910mm) 18” (460mm)
.....Under 2” 18” (460mm) 12” (300mm)
ST691
Fig. 15 Maintain clearances to combustible mantel compo-
nents.
Wall Pass-Throughs
Whenever possible, design your installation so that the
chimney connector does not pass through a combus-
tible wall. If you are considering a wall-pass through in
your installation, be sure you check with your building
inspector before you begin. Also check with the chim-
ney connector manufacturer for any specific require-
ments.
Accessories are available on the market which have
been tested and listed specifically for use as wall pass-
throughs. Use only these tested and listed accessories
for wall pass-throughs.
The National Fire Protection Association (NFPA) has
established guidelines for passing chimney connectors
through combustible walls. Many building code inspec-
tors follow these guidelines when approving installa-
tions.
The illustration below shows one NFPA recommended
method, in which all combustible material in the wall
is cut away from the single wall connector a sufficient
distance to provide the required 12” clearance for the
connector. Any material used to close up the opening
must be noncombustible.
DEF
IA
N
T
ST493
Brick pass thru
11/00
Wall Stud
Chimney Con-
nector
Floor Pro-
tection
12”
Noncombustible
Naterial
ST493
Fig. 16 An approved wall pass-through method.
Three other methods are also approved by the NFPA.
•Using a section of double-wall chimney with a nine-
inch clearance to combustibles
•Placing a chimney connector pipe inside a ventilated
thimble, which is then separated from combustibles by
six inches of fiberglass insulating material
•Placing a chimney connector pipe inside a section of
eight-inch diameter solid insulated factory-built chim-
ney, with two inches of airspace between the chimney
section and combustibles.
Chimney Connectors
The chimney connector should be made of 24 gauge
or heavier sheetmetal. Galvanized chimney connector
should not be used, as it may release toxic fumes when
exposed to high temperatures.
The chimney connector should be as short and direct
as possible, with no more than two 90 degree turns.

13
Vermont Castings Vigilant
2000898
Horizontal runs of chimney connectors should slope
upward 1/4” per foot going from the stove toward the
chimney. The recommended maximum length of a
horizontal run is 3 feet. The total length of chimney
connector should be no longer than 8 feet to prevent
the cooling of flue gases.
In cathedral ceiling installations, a prefabricated
chimney should be brought down to within 8 feet of
the stove. The whole chimney connector should be
exposed and accessible for inspection and cleaning.
Never pass a chimney connector through a combustible
ceiling.
Installation Procedures
Setting Up the Stove
Our stoves are heavy and require at least two people
to move and set them up. To make the job a bit easier,
you may lift off the loading doors and remove the grid-
dle, grates, and ashpan. Do not try to move the stove
alone as the stove can be damaged by mishandling.
Place the stove close to its final position before install-
ing the stove legs.
The griddle has not been painted in order to allow
cooking directly on its surface. In order to protect the
surface from rust during shipping, a coating of oil has
been applied. Be sure to wash the griddle thoroughly
with soap and water. As the stove is used, the griddle
will gradually darken to match the color of the stove.
Your Vigilant Coal Stove arrives completely assembled
except for the installation of the legs and handle holder,
and the assembly of the removable handle. The only
tool needed are a 9/16” wrench, used to tighten the leg
bolts.
So that you can easily secure the first section of chim-
ney connector pipe to the stove, three holes have been
drilled in the flue collar and three sheetmetal screws are
included in the hardware package.
If you have ordered any accessories such as heat
shields, they will come with their own installation
instructions. Generally speaking, nothing more compli-
cated than a screwdriver is involved in the installation of
accessories.
The Removable Handle
The removable handle is inserted into the front door
stub or the damper handle stub when you want to open
or close the doors, or change the position of the damp-
er. The handle is removed when not being used so it
will not get hot, and stored in the handle holder installed
on one of the front legs.
To assemble the handle, pass the long threaded screw
through the ceramic shaft and into the bright metal
insert. Tighten until snug; do not overtighten.
Chimney Connector Dampers
Because of the draft requirements of our stoves, we do
not recommend the use of an in-flue damper. Not only
is this an unnecessary restriction in the flue, but it is an
additional surface directly in the path of the flue gases
upon which deposits can form, creating a potential haz-
ard. Combustion air entering your Vigilant Coal stove
is controlled effectively by the thermostat, so no flue
damper is required.
The Chimney Connector
Assembly
• Assemble the chimney connector beginning at the
flue collar of the stove, keeping the crimped ends
towards the stove. Using the holes in the flue collar
as guides, drill 1/8” holes in the bottom of the first
section of chimney connector, and secure it to the
flue collar with #10 x 1/2” sheetmetal screws.
• Align the seams of the individual sections. Secure
each joint between sections of chimney connector,
including telescoping joints, with at least three sheet-
metal screws.
• Secure the chimney connector to the chimney. In-
structions for various installations follow.
• Be sure the installed stove and chimney connector are
correct distances from nearby combustible material.
Your dealer may offer a variety of specialty pipe pieces
to simplify the installation, including slip pipes and
thimble sleeves that can be used to form telescoping
joints between sections of chimney connector. Tele-
scoping joints may eliminate the need to cut individual
sections of connector.
ST693
Vigilant
freestanding
installation
8/01
Chimney
Elbow
Slip Pipe
Standard
Connector
Oval to Round
Connector
Flue Collar
Thimble
Flue
Liner
Flue
ST693
Fig. 17 An exploded view of the chimney connection in a
freestanding masonry installation.

14
Vermont Castings Vigilant
2000898
Securing the Connector to
a Prefabricated Chimney
Follow the installation instructions of the chimney
manufacturer exactly as you install the chimney. The
manufacturer of the chimney will supply the accesso-
ries to support the chimney, either from the roof of the
house or at the ceiling of the room where the stove is
installed.
Again, your dealer can supply a variety of specialty
pieces to simplify the installation. Some adaptors, for
example, enable you to make an attachment directly
to the chimney or to the chimney’s ceiling support
package. The bottom of the adaptor is screwed to the
chimney connector. (Fig. 18)
Some pieces 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. In this
way, any soot or creosote falling from the inner walls of
the chimney will stay inside the chimney connector.
NOTE: For double-wall chimneys with an outside
dimension greater than 10¹⁄₄", or with triple-wall chim-
neys, check with the manufacturer of the chimney for
the right trim collar to finish the installation.
ST694
Prefab
chimney connector
8/7/01 djt
ST693
Prefab
chimney connector
8/7/01 djt
Prefabricated
Chimney
Prefab Con-
nector
Collar
Roof Support
Package
ST693
ST694
Prefabricat-
ed Chimney
Prefab Con-
nector
Chimney
Support
Package
Fig. 18 Special pre-fab chimney connectors may be available
from the chimney manufacturer.
Securing the Connector to
a Masonry Chimney
Both freestanding masonry chimneys and fireplace
masonry chimneys may be used for installation of your
Vigilant II Coal Stove.
Freestanding: If the chimney connector must pass
through a combustible wall to reach the chimney, follow
the recommendations in the Wall Pass-Through sec-
tion.
ST243
thinble connection
12/13/99 djt
Thimble Sleeve
Chimney Connector Flue
Keep sleeve
end flush
with flue tile
ST243
Fig. 19 The thimble, made of either ceramic or metal, must
be cemented securely in place.
The opening through the chimney wall to the flue (the
“breech”) must be lined with either a ceramic or metal
cylinder, called the “thimble”, which is securely cement-
ed in place. Most chimney breeches incorporate thim-
bles, but check to be sure the fit is snug and the joint
between thimble and chimney wall firmly cemented.
A thimble sleeve, available from your local dealer, will
facilitate the removal of the chimney connector for
inspection and cleaning. The thimble sleeve is slightly
smaller in diameter than standard connector pipe and
most thimbles.
It is installed by sliding it into the breech until it is flush
with the inner wall. It should not extend into the actual
flue passage, however, since this could interfere with
the draft.
The thimble sleeve should protrude 1-2” (25-50 mm)
into the room, and should be sealed in place with fur-
nace cement and thin gasketing.
Once it the thimble sleeve is installed, the chimney con-
nector should be attached to it with sheet metal screws.
Lacking a thimble, a suitable length of chimney con-
nector can be extended through the breech to the inner
face of the flue liner, and securely cemented in place.
Additional pieces of connector are then attached with
sheetmetal screws.
Above a fireplace
In this installation, the chimney connector goes up from
the stove, turns 90 degrees, and goes back into the
fireplace chimney. The liner of the fireplace chimney
should extend at least to the point at which the chimney

15
Vermont Castings Vigilant
2000898
connector enters the chimney. Follow all the guidelines
for installing a chimney connector into a freestanding
masonry chimney, and watch these additional points:
ST695
Vigilant
above fireplace
8/8/01
VIGILANT�
Thimble Sleeve
Mantel
Bottom Heat
Shield
Damper - closed
and locked
ST695
Fig. 20 In this installation the chimney connector is attached
to the chimney above the fireplace.
• If there is a combustible mantel or trim, check the
stove and chimney connector clearances in the
Clearance Chart. Use the necessary combination of
mantel, trim, and connector heat shields to provide
the required clearances.
• Double check connector clearance from the ceiling.
• The fireplace damper must be closed and sealed
to prevent room air from being drawn up the flue,
reducing the draft. However, it must be possible to
re-open the damper to inspect or clean the chimney.
Through a fireplace
When installed through a fireplace opening, the chim-
ney connector goes back from the stove, enters the
fireplace cavity, turns upward, and passes through the
fireplace damper opening and smoke chamber, and
finally to the chimney flue. Watch these points:
• If there is a combustible mantel or trim, check the
stove and chimney connector clearances in the
Clearance Chart. Use the necessary combination of
mantel, trim, and connector heat shields to provide
the required clearances.
• When passing the chimney connector through the
damper opening it may be necessary to “ovalize” the
ST696
fireplace
flex connector
8/8/01
VIGILANT�
Flex Connector
Mantel Shield
Fireplace Adapter
Bottom
Heat
Shield
ST696
Fig. 21 In this installation, the chimney connector enters the
fireplace opening and then connects to chimney.
connector pipe. Do not make the narrowest width
less than 5¹⁄₂".
• The damper should be removed if possible, or
sealed in the open position if removal is impossible.
• A seal must be provided so that room air is not
drawn into the fireplace and up the chimney, reduc-
ing draft. The Vermont Castings Flex Connector
System provides a convenient method for making
the required seal and offers a flexible stainless steel
chimney connector which can be bent to allow pas-
sage through most narrow damper openings.
NOTE: Do not vent your Vermont Castings stove
into a factory-built (zero-clearance) fireplace. Zero-
clearance fireplaces and their chimneys are specifi-
cally designed as a unit for use as fireplaces. It may
void the listing or be hazardous to adapt them for
any other use.

16
Vermont Castings Vigilant
2000898
Operation
The Vigilant Controls
The Thermostat Lever
Adjust the thermostat lever to control the heat level.
Move the thermostat lever to the left to make the fire
burn hotter. Move it to the right for less heat.
The thermostat regulates the heat level when the stove
is operating by controlling the amount of combustion
air entering the stove. The heat level is based on the
setting of the thermostat lever and the strength of your
chimney’s draft. (Refer to Page 4 for more information
on draft.)
ST697
Damper controls
8/8/01 djt
Rear View
Less Heat More Heat
Thermostat
Lever
Thermostat
Air Inlet Flap
Air Inlet
ST697
Fig. 22 The components that regulate incoming air.
The Damper
Use the internal damper to control the direction of ex-
haust flow within the stove.
When the damper is open, smoke goes directly to the
chimney. The resulting heat warms the chimney and
helps develop and maintain the strongest draft.
When the damper is closed, smoke —and heat— is
held in the stove longer. This results in more heat radi-
ated into the room and less heat going up the chimney.
The Vigilant II Coal Stove may be set for a long burn
with the damper either open or closed. However, some
chimneys may require the extra heat provided when the
damper is open for best operation.
The thermostat lever will continue to control the amount
of combustion air entering the stove to ensure a steady
heat output.
Fuel
High quality fuel gives best results
Pea or nut-sized coal, either anthracite or bituminous,
may be burned. Anthracite coal that has a low ash
content will provide more heat with less ash than most
other types of coal. Your fuel dealer may be able to
provide you with information about the ash content of
the coal he sells.
The Vigilant II Coal Stove is designed to burn anthracite
(hard coal) or bituminous coal (soft coal). Do not burn
other fuels. As shipped from the factory it is set up to
burn bituminous coal.
If you wish to burn anthracite, call your Vermont Cast-
ings Authorized Dealer, and request that your stove be
modified to burn anthracite. The dealer will make the
modification and attach a label to the top of the ash
door stating that the stove has been modified to burn
anthracite, and warning against burning bituminous
coal in the modified stove. If your stove has the label
attached to the top of the ash door, it has already been
modified.
Do not burn bituminous coal in a stove which has been
modified to burn anthracite. Burning bituminous coal
in a stove which has been modified to burn anthracite
could cause very high temperatures and create a haz-
ardous condition.
Coal should be stored under cover to maintain dryness.
Even for short term storage, keep coal a safe distance
from the heater and keep containers of coal out of the
areas around the heater used for refueling and ash
removal.
Starting a Coal Fire
The most important step to a successful coal fire is
to build a thick bed of hardwood or charcoal briquette
coals on the grates. Coal requires a high ignition
temperature compared to wood, and a concentrated
ember bed is necessary to get a coal fire going. In ad-
dition, the heat produced during this step is necessary
to warm the flue and establish a strong draft.
Follow this procedure to start a coal fire:
1. Cover the grates with crumpled newspaper. Add a
layer of short, finger-sized kindling wood, preferably
hardwood. NOTE: Do not build the fire close to
the glass. Open the damper, close the griddle, and
move the thermostat lever to the left.
2. Light the paper, and once the kindling is burning
briskly, add a layer of larger wood or untreated
charcoal.

17
Vermont Castings Vigilant
2000898
3. Continue building up the fire until there is a thick bed
of hot embers on the grates.
IMPORTANT: Don’t hurry this part of the burn. Inad-
equate preheating of the chimney system is the most
common cause of poor coal stove performance.
NOTE: The cast iron plates in your Vigilant will “sea-
son” as they heat and cool over a period of time. The
thermal shock of very rapid temperature changes can
cause the cast iron to crack. NEVER build a roaring fire
in a cold stove.
4. Add a moderate layer (1” - 2” ) of coal. When this
is burning well, indicated by a blue flame just above
the first layer, you may add coal layer by layer. Be
sure each new layer is burning well before adding
the next layer.
CAUTION: Hot while in operation. Keep children,
clothing, and furniture away. Contact may cause
skin burns.
5. Coal may be loaded to the top of the front grill, and
to within one inch of the exhaust ports in the top of
the left and right side plates. Keep the coal level at
least an inch below the exhaust ports.
SAFETY NOTE: Do not burn garbage or flammable
fluids such as gasoline, naphtha, or engine oil. Do
not use charcoal lighter fluid or any flammable liq-
uid to kindle or re-establish a fire in your coal burn-
ing stove. Also, never use self-starting charcoal
briquettes. The volatile gases given off by these
materials when heated may explode if ignited.
CAUTION: Follow these instructions carefully to get the
safest, most efficient results with your stove. Failure
to follow these instructions may result in a dangerous
chimney or house fire.
Daily Operation
Surface Thermometer
Use a surface thermometer to monitor stove perfor-
mance.
The Vigilant’s surface temperature, determined by plac-
ing a stove thermometer in the middle of the griddle,
can provide helpful information about how the stove is
performing.
ST698
Vigilant
surface therm
08/01
Surface Thermometer
ST698
Fig. 23 A stove thermometer can provide helpful information
about how the stove is performing.
The normal range of operating temperatures is between
400° and 700° F, although temperatures slightly outside
of this range may be expected. However, if tempera-
tures go above 700° F for extended periods, decrease
the air supply (move the thermostat lever to the right)
and slow the fire to avoid overfiring.
When starting a new fire, or after re-loading the stove,
leave the damper open until the surface temperature
reaches at least 500° F. Do not close the damper on a
fire before it is well-established.
If the surface temperature drops below 400° F, revive
the fire by one of the following:
• Increase the air supply by moving the thermo
stat lever to the left.
• Open the damper.
• Clear ash from the grates and empty the ash
pan.
• Re-load the stove.
• Add a layer of untreated charcoal or NON-
SELF-STARTING charcoal briquettes.
• If the coal needs to be re-ignited, try placing a
small amount of very dry, finely split kindling
on top of the coal bed. The heat produced
by the burning kindling will increase the draft,
and the improved draft will increase the air flow
through the coal bed to create better conditions
for ignition.
Internal Damper
The internal damper provides operating flexibility
Operate the Vigilant with the damper open when start-
ing the fire, when re-building the fire after a long burn,
or when burning a small fire with moderate heat output.
Close the damper only after establishing a strong fire
and a good draft by burning the stove with the damper
open.
Because installation characteristics vary, the time nec-
essary to establish a good draft may also vary, from ap-
proximately 5 to 30 minutes or more. Exterior chimneys
are generally more difficult to heat up, and may require
the longest period of time.
On large and/or outside chimneys, the damper may
always need to be open for the flue to be sufficiently
warmed so that it will support an adequate draft. Even
if this is necessary, the Vigilant will operate effectively.
Be sure to open the damper and run the stove for a few
minutes before opening either the griddle or the front
doors. This will direct extra heat to the flue to increase
the draft, and will clear exhaust gases from the baffle
system. Do not leave doors and griddle open simulta-
neously to avoid having gases escape.

18
Vermont Castings Vigilant
2000898
Reloading the Stove
Put on a small layer of fresh coal and allow it to catch
before clearing the grates of ash. Once the new coal is
ignited, shake the grates with full, steady strokes of the
shaker handle. Stop shaking when red coals cover the
ashpan or when you feel resistance. Using the slicer,
clear ash from between the bars of the front grill. Also,
clear ash from along the sides and the back of the grate
area. Leave a bed of hot coals on the grates to ignite
new fuel.
If the fire has burned very low before reloading, add just
a small amount of fuel at a time and leave the damper
open while the fire is regaining strength. Once the fire
is burning briskly again, you may add coal layer by
layer until you have re-built a full bed.
The new fuel must be burning briskly before you reduce
the air supply or close the damper.
Important Warm-weather Considerations
Draft strength depends on the temperature difference
between the outside air and flue gases. When the
outside temperature rises, this temperature difference
becomes smaller and draft problems can result.
Avoid draft problems when the outside temperature
is 35°F. or higher, by operating your stove with the
damper open to keep flue temperatures high.
If draft problems occur when the wind is blowing, install
a chimney cap designed to stabilize draft under windy
conditions.
Remove Ash Regularly
To avoid blocking incoming air, empty the ash pan be-
fore the ash reaches the top of the pan.
Empty the ash pan before shaking the grates so you do
not have to handle an ashpan that is full of hot embers.
Use care when handling and disposing of ash, particu-
larly if there are hot embers.
To empty the ash pan, open the ash door and remove
the pan from the stove. Carry the pan to your ash dis-
posal container.
Check that there is no accumulation of ash in the bot-
tom of the stove, and remove any that is found before
replacing the ashpan.
Dispose of Ash Safely
A container for ash disposal must be made of metal and
must have a tight fitting lid. It must be located outdoors
away from all combustible material. Ash taken from an
operating stove may continue to burn and to generate
heat and gases for many days.
Dispose of ash properly. Coal ash should not be used
in the garden, as it may contain unacceptable levels of
toxic heavy metals.

19
Vermont Castings Vigilant
2000898
Maintenance
The fire must be out and the stove no longer hot before
you work on the stove. We suggest you wear gloves
and safety goggles when working on your stove.
Cleaning Cast Iron
An occasional dusting with a dry rag is usually all that is
necessary to keep your Vigilant looking new. From time
to time, you may wish to go over the cast iron surface
with a damp cloth; do this while the stove is cool, and
make sure no water remains on the stove surface.
If your stove’s paint needs retouching, allow the stove
to cool completely. Brush any areas needing atten-
tion with a wire brush, and make sure the entire stove
is clean and dry. Remove the griddle and set it aside.
Touch up the stove with Vermont Castings High Tem-
perature Stove Paint. Apply the paint sparingly. Two
light coats are better than one heavy one.
Cleaning Porcelain Enamel
Use a dry rag or soft brush as necessary. Do not use
water or other liquids on your stove. Fingerprints usu-
ally can be buffed off porcelain enamel with a dry, soft
rag. If marks remain, allow the stove to cool com-
pletely, then buff with a slightly damp, soft rag. Dry
completely before starting a fire to avoid streaking.
Never use abrasives or harsh chemical cleaners on the
porcelain finish.
If you must remove spills or stains from porcelain
surfaces, make sure the fire is out and the stove is
completely cold before cleaning. Use ONLY a kitchen
appliance cleaner and polish especially formulated for
enamel surfaces. Apply cleaner sparingly with a soft
rag, and buff away ALL traces of the cleaner.
Adjusting The Door Latch
The front doors should be securely closed when the
handle is pointing down. If the doors are loose when
closed, adjust the latch by loosening the small locking
nut, extending the striker screw one turn, and re-tight-
ening the small locking nut. Keep making adjustments
slowly until the setting is right. The handle should resist
slightly as it is turned to the closed position, and the
doors should pull in slightly.
ST531
Door Pawl
11/00
Pawl
SmallLocking Nut
Large
Locking Nut
Set Screw
Handle Stub
Striker Screw
ST531
Fig. 24 Turn the door latch striker screw in or out to tighten or
loosen the door latch.
Check the Air Inlet Shutter
The air inlet shutter must open and close freely. If it
doesn’t, check to be sure the shutter or shutter pin is
not bent.
Be sure the gaskets are in good condition
The gaskets used in the assembly of your Vigilant Coal
Stove play an important part in ensuring consistent,
reliable performance. Inspection of the gaskets and
replacement when necessary is an important part of
routine maintenance. Gasketing is used to guarantee
that the incoming air and outgoing combustion gases
flow through the stove along the proper pathways. All
the gaskets in your Vigilant are fiberglass, secured with
Vermont Castings High Temperature Stove Gasket Ce-
ment.
Light colored streaks on the inside of the stove near the
door or griddle openings may indicate air leaks due to
worn or damaged gasketing. You may also check for
leaks by shining a strong light along gasketed seams
to see if light leaks through. While minor leaks may be
repaired by building up the gasketing in just the area of
the leak, it is usually better to replace the gasketing in
the door or griddle.
Anytime you remove or replace parts is a good time to
examine the exposed gasketing. Replace any gasket
which appears frayed or worn. Pay particular attention
to any point where a continuous gasket meets itself.
Follow this procedure to replace worn gaskets:
• Remove the old gasketing.
• Clean the gasket channel or groove with a wire
brush. Remove stubborn deposits of cement with a
cold chisel if necessary.
• Clean all parts to be gasketed. Place on a level
clean surface.

20
Vermont Castings Vigilant
2000898
• Select the appropriate gasket. Your Vermont Cast-
ings Authorized Dealer carries a complete line of
gaskets. Cut to the recommended length plus a 1”
- 2” excess.
• Place an unbroken 1/8” bead of gasket cement in
the channel or groove.
• Starting at one end, press the gasket into the chan-
nel. Where ends of the gasket meet, insure a good
joint before trimming any excess. Do not overlap or
leave ragged edges.
• If possible, place the gasketed part firmly against its
normal mating surface to seat the gasket evenly in
its channel or groove. Remove the gasketed part
and clean away any excess gasket cement before
placing the part aside to dry.
Clean-Out Access Covers
Remove the three clean-out access covers to clean
behind the lower fireback, and the left and right side
plates.
Slide the cover in the left side plate toward the back of
the stove and pull it to the inside of the stove. Slide the
cover in the lower fireback to the right, and the cover
in the right side plate toward the front of the stove and
then pull them into the stove.
Use a shop vac, or an old household vacuum (it will get
dirty) to clean out the areas on the bottom of the stove
behind the side plates, and the lower fireback.
The three covers are identical. Always put the end
of the cover with the longer offset into the clean-out
opening first, then slide it so the end with the shorter
offset end catches behind the cast iron. Put the longer
end of the cover into the access opening in the left side
plate and then slide it toward the front of the stove so
the end with the shorter offset will be behind the iron.
The cover in the lower fireback will be inserted into the
opening and pushed to the left, and the cover in the
right side plate will be inserted and pushed toward the
back of the stove.
The Interior Parts
On occasion you may wish to remove the interior parts
to clean unburned coal from the firebox, or to inspect or
replace worn parts.
• Lift the Front Grilel straight up so that you may direct
the tabs on either side of the top of the grille into
the exhaust ports at the top of the side plates. Slide
the tabs of the grille backward and lift the grille to a
horizontal position.
• Move one end of the grille forward and the other end
backward so the tabs may be disengaged from the
exhaust ports. Then lift the grille out through the
griddle opening.
ST699
Vigilant
interior
8/9/01 djt
Exhaust
Port
Fire-
brick
Front Grille
Grates
ST699
Fig. 25 Interior parts of the Vigilant II.
• Lift the Ash Fettle straight up and out of the stove.
• To remove or replace the Low Grates, pull the
shaker handle away from the stove. The Grates
may now be removed or replaced on the grate sup-
ports. To remove or replace the High Grates, push
the shaker handle toward the stove. The Grates
may now be removed or replaced on the grate sup-
ports. High Grates may be interchanged with each
other, and Low Grates may be exchanged with each
other also. If one grate shows excessive wear, swap
it with another of the same kind.
ST700
Vigilant
low grate
8/14/01 djt
Grate
Grate Support
ST700/701
Fig. 26 Placing low grates on grate support.
ST701
Vigilant
High grate
8/14/01 djt
Grate
Grate Sup-
port
Low Grates
High Grates