Vermont Castings 2040ce User manual
Homeowner’s
Installation and
Operating Manual
30005552 7/11 Rev. 1
For use in Europe
2425
Encore NC Cover
5/05
2
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
This manual describes the installation, operation, and main-
tenance of the Vermont Castings Encore Model 2040CE
Non-Catalytic / Catalytic wood burning heater. This heater
meets the U.S. Environmental Protection Agency’s emis-
sion limits for wood heaters sold on or after July 1, 1990.
Under specic test conditions this heater has been shown
to heat 9.6kW (34,000 Btu/hr).
The Encore Model #2040CE has been tested to current
standards. The test standards are ANSI/UL-1482 and
ANSI/UL-737 for the United States, and EN13240:2001 +
A2:2004 for Europe. The Encore is listed for burning wood
only. Do not burn other fuels.
We recommend that you hire a professional installer to
install your stove, or to advise you on the installation should
you attempt to install it yourself.
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.
Specications ........................................................3
Installation .............................................................4
Assembly .............................................................12
Operation .............................................................15
Maintenance ........................................................18
The Chimney System ..........................................20
The Catalytic Element .........................................22
Replacement Parts ..............................................24
Warranty ..............................................................27
Congratulations on your choice of a Vermont Castings Encore stove. With this purchase you have 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
for the hearth. We assure you that your cast-iron Vermont Castings stove has been made with the utmost care and will
provide you with many years of service.
As you become acquainted with your new stove, you will nd that its appearance is matched by its functionality, due to
cast iron’s unique ability to absorb and radiate heat.
Also, MHSC products are among the cleanest-burning wood stoves and replaces available today. As an owner of a
Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning depends on
both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate and
maintain your stove.
At MHSC, we are equally committed to your satisfaction as a customer. That is why we maintain an exclusive network
of the nest dealers in the industry. Our dealers are chosen for their expertise and dedication to customer service. They
are factory-trained and knowledgeable about every MHSC product. Feel free to contact your Authorized Vermont Cast-
ings Dealer anytime you have a particular question about your stove or its performance.
This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore. It also
contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
Sincerely,
All of Us at MHSC
Warming Shelf
#0200 Classic Black
#0205 Biscuit
#0207 Ebony
#0201 Bordeaux
#0208 Brown Majolica
#3265* Outside Air Kit
#3185 Outside Air Adapter
#0336* Mobile Home Kit
#0127 Firescreen
FK26 Fan Kit
#3190 Connector Pipe Heat Shield
A line of porcelain enamel stove pipe is available in
Biscuit, Bordeaux, Ebony, Brown Majolica colors.
*If you order #3265 or #0336, you must also need
#3185.
3
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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44 mm
(16M”)
635 mm
(25”)
Top exit
flue collar
height
686 mm (27”)
654 mm
(256M”)
470 mm
(1856O”)
184 mm
(756M”)
686 mm (27”)
565 mm
(2256M”)
394 mm
(1556O”)
127 mm
(5”)
73 mm (2(6”)
603 mm
(236M")
381 mm
(15”)
95 mm
(36M”)
578 mm
(226M”)
Encore 2N1
dimensions CE
Encore 2040CE dimensions.
Drawings Not to Scale
Nominal heat out put ........7.8 - 8.0 kW (34,000 BTU/hr)1
Minimum ue draught ........................12 Pa (0.048” WG)
Mean ue gas temp ................................ 339° C (642° F)
Efciency (Space heating) with Catalyst ............... 75.9%
Efciency (Space heating) w/o Catalyst ................ 72.9%
Area heated ..................... Up to 167 sq. m (1800 sq. ft.)1
Fuel size/type .......................457-559 mm (18-22”) wood
Fuel capacity ............................................. 22 kg (50 lbs)
Flue mass gas ow ............................................... 6.6 g/s
CO Emissions (@ 13% O2) ..w/Cat. 0.09% w/o Cat. 0.42
Loading .......................................................Front and top
Chimney connector:
for 8” ue collar ..........................203 mm (8”) diameter
for 6” ue collar ..........................152 mm (6”) diameter
Chimney ue size:
for 8” ue collar ......................... 203 mm (8”) minimum
for 6” ue collar ......................... 152 mm (6”) minimum
Flue exit position...........................Reversible, top or rear
Primary air ..... Manually set, thermostatically maintained
Secondary air .................................Fixed, self-regulating
Ash handling system ....................... Removable ash pan
Glass panel.............................High-temperature ceramic
Weight .................................................. 215 kg (475 lbs.)
Width (leg-to-leg) ........................................685 mm (27”)
Depth (leg-to-leg)........................................380 mm (15”)
Height to top of ue collar ...........................635 mm (25”)
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 efciencies.
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Before you begin an installation, be sure that:
• Your stove and chimney connector will be far enough
from combustible materials 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 authori-
ties.
Your local building ofcial is the nal authority for approv-
ing 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. Your local dealer can provide any additional
information needed.
In some modern, super-insulated homes, there is inad-
equate air for combustion because of insufcient air inl-
tration into the building. Such air enters a home through
unsealed cracks and openings. Exhaust fans for kitchen
or bath can compete with the stove for available air and
compound the problem.
When poor draft is caused by a low inltration rate, open-
ing a ground oor window on the windward side of the
house and in the vicinity of the stove will usually alleviate
the problem.
For appliances with power outputs above 5 kW, a perma-
nently open air vent is required by Section 2 of Document
J. Air inlet grilles should be positioned so that they will not
be blocked. Refer to local and national codes for recom-
mended congurations.
Pressure variations within the house do not affect a stove
equipped with an outside air supply, and improved stove
performance often results. An Outside Air Adapter Kit for
the Encore is available from your local Vermont Castings
dealer.
Altitude affects chimney performance. When using a 6”
ue collar on the Encore, refer to Figure 2 for suggested
chimney heights at various altitudes. Chimney height
should be measured from the ue collar to the top of the
chimney. The recommended minimum chimney height is
4.9 m (16’).
30
25
20
15
0 2000 4000 6000 8000 10000 12000
Height
Altitude
ST491
Defiant
chimney height
11/2/00 djt
ST491
Chimney height requirements for Encore when equipped
with a 152 mm (6”) chimney.
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Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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You must connect the Encore 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.
(Fig. 3) The chimney and chimney connector must be in
good condition and kept clean.
ST241
chimney types
12/13/99 djt
ST241
A tile-lined
masonry
chimney
A prefabricated double-
wall insulated chimney
Approved chimney types.
An inspection of the chimney must conrm that it has a lin-
ing. Do not use an unlined chimney. The chimney should
have no cracks, loose mortar, other signs of deterioration,
and blockage. Repair any defects before the chimney is
used with your stove.
Unused openings in an existing masonry chimney must
be sealed with masonry to the thickness of the chimney
wall, and the chimney liner should be repaired. Openings
sealed with pie plates or wallpaper are a hazard and should
be sealed 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 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.
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.
An Encore with an 203 mm (8”) ue collar is approved for
venting into a masonry chimney with a nominal ue size
of 203 x 203 mm (8” x 8”) or 203 x 305 mm ( 8” x 12”), and
into a round ue with nominal ue size of 203 mm (8”).
An Encore with a 152 mm (6”) ue collar is approved for
venting into a masonry chimney with a nominal ue size of
203 x 203 mm (8” x 8”), and into a round ue with nominal
ue of 152 mm (6”).
Whatever the ue collar size, an Encore may be vented
into larger chimneys as well. However, chimneys with
liners larger than 203 x 305 mm (8” x 12”) may experience
rapid cooling of smoke and reduction in draft, especially if
the chimneys are located outside the home. These large
chimneys may need to be insulated or have their ues
relined for proper stove performance.
Accessories to help make the connection between stain-
less steel chimney liners and your Encore are available
through your local dealer.
A chimney connector is the double-wall or single-wall pipe
that connects the stove to the chimney. The chimney itself
is the masonry or prefabricated structure that encloses the
ue. Chimney connectors are used only to connect the
stove to the chimney, as in Figure 5.
Connector pipes should meet the requirements of the build-
ing 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 fluepipes complying with BS 41: 1973
(1998).
If you use an existing masonry chimney, it must be in-
spected to ensure it is in a safe condition before the stove is
installed. Your local professional chimney sweep, building
inspector, or re department ofcial 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 Appli-
ances and Fuel Storage Systems).
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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 ap-
propriate, by packing joint with noncombustible rope and
re cement.
Double-wall connectors must be tested and listed for use
with solid-fuel burning appliances. Single-wall connectors
should be made of 24 gauge or heavier steel. Do not use
galvanized connector; it cannot withstand the high tempera-
tures that can be reached by smoke and exhaust gases,
and may release toxic fumes under high heat. The connec-
tor may be 152 mm (6”) or 203 mm (8”) in diameter.
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 on Wall
Pass-Throughs. Do not pass the connector through an
attic, a closet or similar concealed space. The whole con-
nector should be exposed and accessible for inspection
and cleaning.
In horizontal runs of chimney connector, maintain a dis-
tance of 610 mm (24”) from the ceiling. Keep it as short and
direct as possible, with no more than two 90° turns. Slope
horizontal runs of connector upward 6 mm per metere
(1/4” per foot) going from the stove toward the chimney.
The recommended maximum length of a horizontal run
is 914 mm (36”), and the total length should be no longer
than 2.4 m (8’). In cathedral ceiling installations, extend
the prefabricated chimney downward to within 2.4 m (8’)
of the stove.
Information on assembling and installing double-wall con-
nectors 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 chimneys and connectors from the
same manufacturer makes the assembly and installation
straightforward.
For installations using double-wall connectors,
minimum clearances must conform to the listed clearances
in the clearance chart on Page 14.
If the Encore is equipped with the 203 mm (8”) ue collar,
an oval-to-round adapter will be needed. Double-wall oval-
to-round adapters are available from some manufacturers.
Your local dealer can help you select the right connector.
• Begin assembly at the ue collar of the stove. Insert the
rst crimped end into the stove’s ue collar, and keep
each crimped end pointing toward the stove. (Fig. 4)
Using the holes in the ue 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 con-
nector, including telescoping
joints, with at least three (3)
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 connec-
tor to the chimney. Instruc-
tions for various installations
follow.
• Be sure the installed stove
and chimney connector are
correct distances from nearby combustible materials.
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.
Follow the installation instructions of the chimney manufac-
turer exactly as you install the chimney. The manufacturer
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 chimney
and the chimney connector. The top of such adapters
attaches directly to the chimney or to the chimney’s ceil-
ing support package, while the bottom of the adapter 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 as-
sembled in this way, any soot or creosote falling from the
inner walls of the chimney will stay inside the chimney
connector.
ST242
Chimney connector
12/13/99 djt
the crimped end
of the connector points
toward stove.
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Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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ST492
Defiant
freestanding
installation
11/00
Chimney
Elbow
Slip Pipe
Standard
Connector
Oval to
Round Adapter
Flue Collar
Thimble
Flue Liner
Flue
ST492
Chimney connection in a freestanding masonry instal-
lation.
Both freestanding masonry chimneys and replace masonry
chimneys may be used for your installation.
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
“breech”) must be lined with either a ceramic or metal
cylinder, called the “thimble”, which is cemented securely
in place. Most chimney breeches incorporate thimbles, but
the t must be snug and the joint between the thimble and
the chimney wall must be cemented rmly.
A special piece called the “thimble sleeve,” slightly smaller
in diameter than standard connectors 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.
To install a thimble sleeve, slide it into the breech 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 1-2” (25-50mm) into
the room. (Fig. 6) Use furnace cement and thin gasket-
ing to seal the sleeve in place in the thimble. Secure the
chimney connector to the outer end of the sleeve with sheet
metal screws.
ST243
thinble connection
12/13/99 djt
Thimble Sleeve
Chimney Connector Flue
Keep
sleeve
end ush
with ue
tile
ST243
The thimble, made of either ceramic or metal, must be
cemented securely in place.
Without a thimble, a suitable length of chimney connector
can be extended through the breech to the inner face of
the ue liner, and cemented securely in place. Additional
pieces of connector are then attached with sheet metal
screws.
The chimney connector may be connected to the chimney
above the replace opening or through the replace.
The Encore may be connected to a chimney above a
replace opening. (Fig. 7) 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. 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 men-
tioned 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 connec-
tor heat shields to achieve the required clearances.
• Check the clearance between the chimney connector
and the ceiling. If no heat shields are used, the clear-
ance should be at least 610 mm (24”).
• 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.
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Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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* Check These
Clearances
If your replace opening height is at least 737 mm (29"), you
may install an Encore through the opening using a “positive
connection” kit, available from your local dealer. These posi-
tive connection kits ensure a tight t between the stove ue
collar and the chimney ue. (Fig. 8)
Fireplace installations, whether connected to the ue above
or through the replace opening, have special clearance
requirements to adjacent trim and the mantel. You’ll nd the
required safe clearances for Encore replace installations
on Page 11.
Floor protection requirements also apply to replace instal-
lations. This information is on Page 9.
Whenever possible, design your installation so the connec-
tor 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 specic
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.
ST245
fireplace
flex connector
12/99
Flexible Connector
Mantel Shield
Fireplace Adapter
Kit “Positive Con-
nection”
ST245
In this installation, the chimney connector enters the
repalce opening and then connects to the chimney.
Figure 9 shows one method of passing a connector through
a wall. All combustible material in the wall is cut away to
provide the required 457 mm (18”) clearance for the con-
nector. 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.
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.
T
ST494
steel
wall pass thru
11/00
457 mm (18”) clear
space all around the
pipe
ST494
An approved wall pass-through.
ST244
Plymouth
fplc over mantel
12/99
DEFIANT
*
*
Check These
Clearances
Mantel
ST244a
In this installation, the chimney connector attaches to
the chimney above the replace opening.
Seal
This Off
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Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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Do not assume that your replace hearth is completely
noncombustible.
Many replace hearths do not meet the “completely non-
combustible” requirement because the brick or concrete in
front of the replace opening is supported by heavy wood
framing. (Fig. 11) 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.
Keep in mind, also, that many raised hearths will extend
less than the required clearance from the front of the heater
when it is installed. In such cases, sufcient 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.
ST247
Rear exit floor dgrm
12/14/99 djt
Wood framing requires protec-
tion from radiant heat ST247e
Combustible supporting timbers may lie beneath re-
place hearths, requiring additional oor protection.
Hearth rugs do not satisfy the requirements for oor pro-
tection.
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 (mea-
sured from the bottom edge of the stove’s top plate) or
chimney connector, and nearby walls, oors, the ceiling,
and any other xed combustible surface. Your stove has
special clearance requirements that have been established
after careful research and testing to both US and European
standards. These clearance requirements must be strictly
observed.
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 sec-
tion 2 of approved document ‘J’. The size and clearances
of the hearth are as follows:
The constructed hearth should be constructed in ac-
cordance 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).
Unless the stove hearth is completely noncombustible,
the bottom heat shield
should be installed to
provide radiant protec-
tion for framing which
may be below the
hearth. (Fig. 11)
Costructional Hearth
Dimensions as below
At least
300 mm
At least 150 mm
or to a suitable
heat resistant wall
At least
150 mm
Hearth Surface
Free of Com-
bustible Material
Perimeter should be
clearly marked e.g.
edge of superimposed
hearth
Perimeter should be
clearly marked e.g.
edge of superimposed
hearth
Appliance
Doors
Appliance
Doors
ST912
Noncombustible hearth surface dimensions.
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Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
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In addition, furnishings and other combustible materials
must be kept away from the stove as well. In general, a
distance of 1219 mm (48”) must be maintained between
the stove and moveable combustible items such as dry-
ing clothes, furniture, newspapers, rewood, etc. Keeping
those clearance areas empty assures that nearby surfaces
and objects will not overheat.
Clearances to timber framed (studded) walls are included
below. There are no specic minimum clearances to solid
noncombustible surfaces (e.g. the sides and rear of Ingle-
nook 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.
The minimum thickness of solid noncombustible
materials is specied in section 2 of Document ‘J’, in rela-
tion 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.
ST486a
Defiant EU
Clearance
Diagrams
10/06
A
B
ST486a
Minimum clearances.
Single wall connecting uepipes can reach extremely high
temperatures; therefore, clearances from the connecting
uepipe (chimney connector) must comply with the require-
ments of Part J of Building Regulations 2000 (Combus-
tion Appliances and Fuel Storage Systems). This can be
achieved by following the recommendations of Approved
Document ‘J’. These are as shown in Figure 13.
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34
FLUEPIPECLEARANCES
D
at least
3 x D
at least
3 x D
at least
1.5 x D
at least 1.5
x D
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
ST911
Connecting uepipe clearances.
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Cast iron stoves are heavy, and it will take two to four people
to move your Encore into position.
Wipe the protective
coating of oil from the
griddle with a clean
dry rag or a paper
towel.
Install the handle on
the griddle. First,
place the griddle up-
side down at the edge
of a at surface and
assemble the handle as shown.
With the handle pointing 45° from its nal position, tighten
the nut as far as possible with the pliers. Move the handle to
its nal position while still holding the nut with the pliers.
Use the removable handle to open or close the doors. After
using it, remove the handle so it will not get hot. Store the
handle in the handle holder installed behind the right front
leg. (Fig. 15)
ST516
Attach
griddle handle
11/17/00 djt
ST516
Attach the griddle handle.
ST564
handle holder
12/13/00
Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer ST564
Handle holder and heat shield positions.
The Bottom Heat Shield is required in most in-
stallations. Refer to Floor Protection, Page 9, for further
details.
1. Loosen the four 1/4-20 hex head bolts from the corners
of the ash drop on the stove bottom.
2. Align the bottom heat shield holes with the four bolts.
The outside air cutout hole should be toward the rear
of the stove. The unpainted side must face up towards
the stove.
3. Pass all four bolts through the large end of the keyholes
and then pulling the shield forward to engage the smaller
ends of the keyhole slots. (Fig. 16)
4. Attach the heat shield sides by passing the slots over
the bolt heads. Tighten the hex head bolts.
ST857
abottom heat shield
12/05
1/10
ST857a
Attach the bottom heat shield.
Bottom Heat Shield
Lift the stove slightly so there is no weight on the leg
while making the adjustment.
Reverse the ue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket around
the ue collar opening is in position when you screw the
collar back onto the stove.
If you have the optional fan kit, you may decide to adjust the
air deector to blow heat across the top of your stove. (Fig.
17) Loosen the two (2) screws on each side and raise or
lower the deector. After adjustment, tighten the screws.
The ue collar heat shield must be attached
to the Encore stove. Use four #10 sheet metal screws
supplied to secure the ue collar heat shield to the rear of
the stove. (Fig. 17)
Use the 1/4” -20 x 3” screw to attach the damper handle
to the damper stub on the left side.
The primary air thermostat handle is the smaller of the
two black handles. Secure the handle to the stub on the
right side of the stove with an 8-32 x 2” slot head machine
screw. (Fig. 18)
13
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
ST1180
flue collar heat shield
Sheet
Metal
Screws
Sheet
Metal
Screws
Flue Collar
Heat Shield
ST1180
Install ue collar heat shield.
Air Deector
Air Deector
The ue collar heat shield must be installed
in all vertical installations. The ue collar heat shield is
not used when the ue collar is in the rear exit position.
The ceramic removable insert handle opens and closes
the front doors. Remove after each use, and store it in
the handle holder behind the right front leg. Assemble
the handle by passing the 3³⁄₈" screw through the ceramic
shaft and into the bright metal nub. (Fig. 19) Tighten care-
fully until snug.
ST540
Assembly
handle
11/00
ST540
Assemble the front door handle.
ST635
Encore
Install thermostat
handle
2/01
ST635
Attach the thermostat handle.
1. Attach the fan assembly at the bottom edge of the in-
ner back with two (2) 1/4-20 x 3/4” hex head screws.
2. Attach snapstat to the mounting holes on the underside
of the bottom with two (2) 1/4-20 pan head screws.
3. Attach the rheostat holder (provided with the stove)
under the right front wing of the bottom heat shield with
two (2) #10 sheet metal screws.
4. Attach the rheostat to its holder by inserting the rheo-
stat control shaft through the holder hole. Install the
retaining ring and rheostat knob onto the shaft.
5. Secure the rheostat cable to the underside of the bot-
tom heat shield using the wire tie provided and the
hole at the right rear edge of the heat shield.
6. Fan will not operate until stove reaches approximately
43° C (109° F).
7. Plug blower cord into a grounded outlet. Do not re-
move ground prong from plug. Route power cord to
avoid heat from the stove or other damage. Do not
route cord under or in front of appliance.
Fan installation (Kit # 2767).
34
FANINSTALL
Rheostat
Knob
Rheostat Snapstat Screws ST848
Hole for Wire
Tie to Secure
Cable
Rheostat
Holder
14
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
1. Remove the access cover by gently lifting up and pull-
ing out from the bottom edge. (Fig. 21)
2. Remove the inner cover by pulling it straight out. (Fig.
22)
3. Remove the catalyst by gently pulling it straight out.
(Fig. 23) Place the catalyst where the catalyst’s ce-
ramic components will not be damaged.
ST1187
remove access cover
Access
Cover
ST1187
Remove access cover.
ST1188
remove inner cover
Inner Cover
ST1188
Remove inner cover.
ST1189
remove catalyst
Remove Catalyst ST1189
Remove catalyst.
15
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
Two controls regulate the performance of the Encore: a
supplies oxygen for the re, and a
directs air ow within the stove to activate and
deactivate the catalytic combustor.
Symbols cast into the stove are reminders of the correct
directions for opening and closing the controls. The sym-
bols assume that you are facing the front of the stove.
ST633
Encore
controls
2/01
Griddle Handle
Damper Handle
Air Control
Lever
Door Handle
Holder (Be-
hind leg)
Ashdoor
Handle
Andirons ST636
The Encore controls are conveniently located and
easy to operate.
Door Handle
The , located on the right side 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.
High and low settings appear in Figure 25.
For the greatest air supply and maximum heat output (but
the shortest burn time), move the lever toward the front
of the stove. For a re that will last longer with less heat,
move the lever toward the rear of the stove.
The Encore’s air control system also features an automatic
thermostat to ensure an even heat output at whatever
manual setting you select. The thermostat senses the
heating and cooling of the stove surface and adjusts the
air shutter accordingly.
The on the left side of the stove operates
the damper to direct air ow within the stove.
The damper is when the handle points to the ,
enabling smoke to pass directly into the chimney. The
ST637
encore
Air control
2/01
ST637
The handle may be positioned anywhere between the
two extremes for different heat levels.
damper must be open when starting or reviving a re, and
whenever the griddle or doors are opened.
The damper is when the handle points
Smoke travels through the non-catalytic combustion sys-
tem where it can be further burned, before passing up the
chimney. (Fig. 26)
ST638
Encore
damper control
2/01
Open
(Updraft Mode)
Closed
(High Efciency
Mode)
ST638
The damper is either open or closed. There are no
intermediate positions.
An Encore leaves the factory with the combustor packaged
separately.
In the United States, it is against the law to operate this
wood heater in a manner inconsistent with operating in-
structions in this manual. The components of the catalytic
16
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
combustion system in your Encore work together to pro-
duce optimum conditions for secondary combustion.
When the damper is closed, smoke travels through the cat-
alytic element, which causes ignition of smoke at tempera-
tures of 260°-315°C (500°-600° F), half the temperature
normally required for unaided secondary combustion.
The catalytic element is a ceramic “honeycomb” coated
with the catalytic material. The element is located in the
secondary combustion chamber, molded from a special
high-temperature insulating refractory material. The
chamber provides the correct environment necessary for
secondary combustion of the fuel (smoke).
Closing the damper exposes the smoke to the combustor.
If the combustor is at least 315°C (600°F), it will begin to
burn the smoke.
Closing the stove damper may also reduce the draft, so
to avoid putting out the re or deactivating the combustor,
close the damper only when a re is well-established and
the chimney is thoroughly warmed. When starting a re,
wait until the re is well established and there is an ember
bed of at least 75 - 100 mm (3-4 inches) 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.
In general, the re must be sufciently well-established to
ensure that catalytic activity is initiated. When rst starting a
re, a medium- to high- ring rate must be maintained until
the stove, catalyst, and fuel are all stabilized at the proper
operating temperatures, and the chimney is warmed.
Even though it is possible for the re to get quite hot within
a few minutes after a re is started, the combustor may
stop working or the re may go out if the re dies down
immediately as a result of the damper being closed. 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 22.
Avoid using a full load of very dry wood in the rebox. This
may result in continuous very high temperatures in the
secondary combustion area and damage the combustor.
Wood which has been split, and stored under cover for
more than 18 months may be considered very dry. If you
must burn extra-dry wood, mix it with greener wood for a
longer re and less stress on the combustor. Also, do not
use a full load of dry slab wood or scrap wood. For long
burns, use a mix of dry and moderately dry wood.
The Encore’s griddle lifts for convenient top-loading of logs,
and is the easiest way to add fuel. (Fig. 27)
However, the front doors open as well for adding an oc-
casional log to a re. If the stove is equipped with 8” (203
mm) stove pipe, the front doors may be opened (or even
removed) and the optional Encore spark screen placed
in the opening for open-re viewing.
Defiant
ST521
Intrepid
loading
11/00
ST521
Top loading is the best way to add fuel during regular
use. Front loading is useful for kindling a re.
To open the front doors, insert the handle into the door latch
stub and turn it to the left and up. (Fig. 28)
To close them, always close the left door rst. Turn the
handle in the right door to the left and up (to the open po-
sition) and close it. Finally, 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.
To reduce the risk of breaking the glass, avoid striking the
glass or slamming the doors.
When you are not using the door handle, store it in the
holder behind the right front leg of the stove. Be careful to
not drop the handle, since it is breakable.
ST544
door open
11/00
Clockwise to
Open
Counter-
clockwise
to Close
ST544
To open the front doors, turn the handle clockwise.
17
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
Overring may
cause a house re, or can result in permanent dam-
age to the stove and to the catalytic combustor. If any
part of the Encore glows, you are overring.
You should remove ash before it reaches the top of the ash
pan. Check the level at least once a day. Every few days,
clear any ash from the outer edges of the rebox. Most of
the ash will fall through the grate. Slice or stir the ash with
a shovel or poker so that it falls through the grate slots.
Check the level of ash in the ash pan before
reloading the stove. If the ash level is close to the top edge
of the pan, empty the pan according to this procedure:
• Open the damper.
• Open the griddle or front doors, and use a shovel or
poker to stir excess ash through the ash slots in the
grate down into the ash pan.
• Close the griddle or doors, and unlatch the ash door. It
will pivot, swinging the ash pan out of the stove.
• Slide the cover onto the pan, making sure it is securely
closed. (Fig. 29)
ST566
Remove
Ashpan
12/00
ST566
Be sure the cover is securely attached before remov-
ing the ash pan.
• Remove the ash pan, making sure to keep it level.
• To keep the cover from sliding off and to keep ash from
falling on the oor, do not tilt the ash pan forward.
If the stove is in operation, close the ash door while
disposing of the ash.
• Properly dispose of the ash in a metal container with a
tight-tting lid. Store the container outdoors away from
all combustible material.
• Return the ash pan to its original position in the stove,
and close and latch the ash door.
• Do not operate the stove with the ash door open. This
will result in over-ring, and could cause damage to the
stove, void the warranty, or even lead to a house re.
Empty the ash pan regularly, typically every one to three
days. The frequency will vary depending on how you op-
erate your Encore: ash will accumulate faster at higher
heat outputs.
Remove ash frequently and place it outdoors in a metal
container with a tight-tting lid. Place 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, it should be kept in the closed container until all
cinders have thoroughly cooled.
You can use wood ash as a garden fertilizer.
Never use your household or shop vacuum
cleaner to remove ash from the stove; always remove and
dispose of the ash properly.
ST545
ashdoor
11/00
ST545
Turn the handle to the ash pan compartment clock-
wise to open and counterclockwise to close.
Open
Close
18
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
Let the re in the stove go out and allow the stove to cool
completely before beginning any maintenance proce-
dure.
An occasional dusting with a dry rag will keep the painted
cast iron of your Encore looking new.
The stove’s paint can be touched up as needed. First, mask
the areas, such as enamelled parts, glass, or handles,
around the spot to be painted. Clean the spot with a wire
brush. Remove the griddle and set it aside. It is normal
for the griddle to darken after use. You can clean it with a
ne-bristle wire brush, or steel wool.
Then, touch up the stove with Vermont Castings’ high
temperature stove paint. Apply the paint sparingly; two light
coats of paint are better than a single heavy one.
Use a dry or slightly damp rag or soft brush to remove spills
or stains. For difcult jobs that require a cleaning agent, use
only a kitchen appliance cleaner or polish recommended
for use on enamel surfaces.
If porcelain enamel becomes chipped or scratched during
use, apply “enamel epoxy” to the damaged area and allow
to dry. Once the epoxy has dried, sand the area to blend
with surrounding area and apply appropriate color touch-up
paint. Allow to dry completely before operating stove.
Most of the carbon deposits on the glass will burn off dur-
ing hot res.
However, the ash residue that accumulates on the glass
surface should be removed regularly to prevent etching.
To clean the glass, follow this procedure:
• 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. Use
cleaning agents sparingly and be sure to keep them off
the outer surfaces of the stove.
• Rinse the glass thoroughly.
• Dry the glass completely.
Do not operate your stove if the glass in the doors is dam-
aged.
If you need to replace the glass, use only the high tempera-
ture 5 mm ceramic glass supplied by Vermont Castings.
Do not use substitutes.
1. Remove the right and left door assemblies by raising
the door until the lower hinge pin clears its hole; then,
angle the door bottom slightly outward and pull down to
release the upper hinge pin. Place the doors face down
on a padded work surface. Be especially careful with
enamelled doors.
2. Remove the screws that hold the glass retainer clips in
place, and remove the clips.
3. Carefully lift the broken glass panel from the door.
Check the gasket around the window; it should be soft
and resilient so that the glass will seal properly against
the door. Replace the gasket if it has hardened or if it is
compressed.
1. Center the glass on the gasket.
2. Secure the glass on both doors with the retainer clips.
Tighten all screws. (Fig. 31)
3. Replace the doors on the stove.
4. Open and close the doors to check that they t and work
properly. Adjust as necessary.
Retainer
Clips (4)
Glass Panel
Gasket
Exploded view of the glass assembly for the right door.
Right Door
ST854
ST854
glass xview
7/05
19
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
The tension on the Encore’s damper is adjustable to com-
pensate for compression of the gasket that seals the damper
to the upper reback. To adjust the damper:
1. Remove the griddle. Loosen the lock nut at the center
of the damper. (Fig. 32)
2. Turn the pressure screw approximately one half turn
clockwise with an Allen wrench provided with your
stove.
3. Tighten the lock nut. Prevent the pressure screw from
turning as you tighten the nut. Re-test the damper.
ST554
Damper adjustment
11/00
Pressure Ad-
justing Screw
Allen
Wrench
Lock Nut
Damper
ST554
Adjust the damper with the Allen wrench.
A handle on the left side of the stove controls the damper.
The handle attaches to the damper rod with a set screw. Pe-
riodically check the set screw and tighten as necessary.
The front door of the stove should close securely to prevent
accidental opening and should close tightly to prevent air
from leaking into the re chamber. The door handle will be
positioned vertically when the door is closed.
Over a period of time, the gasket around the door will
compress and the latch may need adjustment. To adjust
the handle, follow this procedure:
1. Remove and retain the lock nut with a 9/16” wrench.
(Fig. 33)
2. Loosen the set screw with a 1/8” Allen wrench.
3. Rotate the pawl 180°. Replace the lock nut. Tighten the
set screw.
4. Additional adjustment can be made by removing the at
washer. Or any combination of washer removal and/or
pawl rotation.
Test the door seal. Close the door on a dollar bill and at-
tempt to pull it free. If the bill is freed with little resistance,
the gasket isn’t snug enough at that spot. Continue to make
small adjustments until the setting is right.
If additional adjusting of the latch does not enable the door
to seal sufciently in one area, try “adjusting” the gasket in
that area. Pack more cement or a smaller diameter gasket
into the channel beneath the gasket so the main gasket
is raised and makes contact with the door frame. If this
procedure doesn’t solve the problem, replace the gasket.
Instructions for gasket replacement are given later in this
section.
Your Encore uses berglass rope gaskets to make a tight
seal between some parts. With use, particularly on moving
parts, gaskets can become brittle and compressed and can
begin to lose their effectiveness. These will need periodic
replacement.
The sizes of replaceable gasket are listed below, along
with their applications.
5/16” The griddle to the stove top
(wire reinforced gasket)
5/16” The damper to the upper reback
3/8” the front doors to the stove front; and
the doors to each other.
3/8” The ash door to the front of the bottom
panel
3/16” The outer glass panes to the door
If you need to change a gasket, rst obtain an appropri-
ate replacement from your Vermont Castings’ Authorized
Dealer.
Wait until the re is out and the stove has cooled. Be sure
to follow the standard safety procedure for working with
dusty materials: wear safety goggles and a dust mask.
The procedure for replacing gaskets is the same, regard-
less of the gasket location. Follow these steps:
1. Remove the existing gasket by grasping an end and
pulling rmly. (Fig. 34)
2. Use a wire brush or the tip of a screwdriver to clean
the channel of any remaining cement or bits of gasket.
Remove stubborn deposits of cement with a cold chisel if
necessary. (Fig. 34)
ST1154
door pawl
Roller
Lock Nut
Set Screw
Shoulder Screw
Handle Stub ST1154
Rotate pawl and/or remove at washer to adjust latch.
Flat Washer
20
Encore®2040CE Non-Catalytic / Catalytic Woodburning Stove
30005552
6. Starting at one end, press the gasket into the channel.
(Fig. 35) Ensure a good joint where the gasket meets before
trimming any excess. Do not overlap the gasket ends or
leave ends with ragged edges.
7. Press the gasketed part rmly against its normal mating
surface to seat the gasket evenly in its channel. Close and
latch the door to do this, or tap other parts with the rubber
mallet (or hammer/block of wood).
8. Clean any excess cement from around the channel, then
let the cement that holds the new gasket dry thoroughly.
9. The stove’s doors may need adjustment after you have
regasketed them. Initially, it may require loosening the
latch to accommodate the new gasket; after a few weeks,
it may need tightening to compensate for compression of
the new gasket. The directions for adjusting the latches
are on Page 19.
ST559
Remove
gasket
11/30/00 djt
Remove gasket then clean channel with wire brush.
ST560
ST559
Remove
gasket
11/30/00 djt
Cement
Stove Gasket
ST561
Lay a bead of gasket silicone or cement then press
gasket in place.
3. Determine the correct length of the appropriate-sized
gasket by laying it out in the channel. Allow an extra 1-2”
(25-50 mm), and mark the spot to be cut.
4. Remove the gasket from the channel, place it on a
wood cutting surface, and cut it at the marked spot with a
utility knife.
Twist the ends slightly to keep the gasket from unravel-
ing.
5. Lay an unbroken 1/8” (3 mm) bead of silicone or cement
in the newly-cleaned channel. (Fig. 35)
Other gaskets form seals between all other non-moving
parts, but these are not subject to the same wear and
deterioration as gaskets on moving parts. It is unlikely
that you will ever need to replace these gaskets unless
the involved parts are disassembled and then put back
together. If this is the case, the job should be done only
by a qualied service technician.
5/16” diameter gasket seals the following parts:
• The lower reback to the back panel
• The left and right air plates (inner sides)
• All connections between the stove plates.
Your Encore is designed to reduce creosote build-up
signicantly. However, regular chimney inspection and
maintenance must still be performed. For safety, good stove
performance, and to protect your chimney and chimney
connector, inspect your chimney and chimney connector
on a regular schedule. Clean the system if necessary.
Failure to keep the chimney and connector system clean
can result in a serious chimney re.
When wood is burned slowly, it produces tar, organic vapors
and moisture that combine to form creosote. The creosote
vapors condense in the relatively cool chimney ue of a
slow-burning re. As a result, creosote residue accumulates
on the ue lining. When ignited, this creosote makes an
extremely hot re within the ue system that can damage
the chimney and overheat adjacent combustible material.
If a signicant layer of creosote has accumulated —1/8”
(3 mm) or more — it should be removed to reduce the risk
of a chimney re.
You can never be too safe. Contact your local re author-
ity for information on what to do in the event of a chimney
re, and have a clearly understood plan on how to handle
one.
If you do experience a chimney re, act promptly to:
• Close the damper and air control lever.
• Get everyone out of the house.
• Call the Fire Department.
Inspect the system every two weeks during the heating
season as part of a regular maintenance schedule. To
inspect the chimney, let the stove cool completely. Then,
using a mirror and a strong light, sight up through the ue
collar into the chimney ue. If you cannot inspect the ue
system in this fashion, the stove must be disconnected to
provide better viewing access.
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