Vermont Castings Concord 1660 User manual
Homeowner’s
Installation
and Operating
Manual
For Export Only
30005102 11/09 Rev. 1
1128
Madison
cover
11/00
2
Vermont Castings Concord
30005102
Thank you for choosing a Vermont Castings Concord to meet your heating needs.
We’re confident you will find the Concord to be an effective woodburning heater incorporating
modern, non-catalytic combustion technology with the classic aesthetic appeal of its Vermont
Castings lineage.
The Concord achieves high-efficiency through precisely calibrated delivery of primary and
secondary air into a refractory-insulated firebox. Properly operated and maintained according
to the guidelines in this manual, your Concord will provide safe, dependable, and economical
heating for years to come.
The Concord Model 1660 Series has been tested to ANSI/UL-1482 for the United States and
ULC S627 and CAN/CSA B366.2 for Canada.
The Concord Model 1660 Series is for burning wood fuel only. Do not burn other fuels.
We recommend that you hire a professional, solid-fuel stove technician to install your Concord,
or to advise you on the installation should you attempt to install it yourself. Consult the au-
thority having local jurisdiction (such as a municipal building department, fire department, fire
prevention bureau, etc.) before installation to determine the need for a building permit. Also,
consult your insurance agent to be sure your installation complies with specific requirements
that may vary locally.
In addition to directions on installation and operation, this manual includes directions on main-
tenance and assembly. Please read this entire manual before you install or operate your new
room heater.
#1891 Outside Air Kit
#1892 Bottom Heat Shield Kit
#1893 Rear Heat Shield Kit
Specifications .....................................3
Installation Requirements ...................4
Clearances .........................................12
Assembly ...........................................15
Operation ............................................17
Maintenance .......................................20
Draft Management ..............................22
Parts List ...........................................25
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 Concord
30005102
Range of Heat Output................ 11,300 - 39,700 BTU’s
Maximum heat output ..........................39,700 Btu’s/hr.1
Area heated ......................................Up to 1600 sq. ft.2,
Fuel size/type ...................................18” (457 mm) logs
Loading ...................................................... Front & Side
Chimney connector..................... 6” (152 mm) diameter
Chimney flue size .......................6” (152 mm) minimum
Flue exit position......................................... Top or Rear
Primary air ... Manually set, thermostatically maintained
Ash handling system ..................... Removable ash pan
Glass panel......................... High-temperature Infra-red
Weight .............................................................. 420 lbs.
Width (Left leg - Right leg) ....................... 29” (737 mm)
Depth (Front Plate - Flue Collar) ............. 25” (635 mm)
Height ......................................................28” (711 mm)
1 This value can vary depending on how the stove is op-
erated, the type and moisture content of the fuel used,
as well as the design, construction and climatic location
of your home. Figures shown are based on maximum
fuel consumption obtained under laboratory conditions
and on average efficiencies.
2 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 may
not apply. Since so many variables affect performance,
consult your Vermont Castings authorized dealer to
determine realistic expectations for your home.
Concord dimensions.
Drawings not to scale.
1128
29”
(740mm)
28”
(710mm)
246M”
(630mm)
18”
(470mm)
25"
(635mm)
1128
Madison
dimensions
11/00
4
Vermont Castings Concord
30005102
Your stove must be connected either to a sound
masonry chimney that meets local codes, to a relined
masonry chimney that meets local codes, or to an
approved prefabricated metal chimney. Whichever of
those types you use, the chimney and chimney connec-
tor must be in good condition and kept clean.
If you use an existing masonry chimney, it must be
inspected to ensure safe condition before the stove is
installed. Your local professional chimney sweep, build-
ing inspector, or fire department official will be able to
make the inspection or direct you to someone who can.
The chimney should extend at least 3’ (914 mm) above
the highest point where it passes through a roof, and at
least 2’ (610 mm) higher than any portion of a building
within 10’ (3 m).
To assure proper draft and good performance, any
chimney used with this stove should extend at least 16’
(5m) above the flue collar of the stove.
Before you begin an installation, review your plans to
be certain that:
• Your stove and chimney connector will be far
enough from combustible material to meet all clear-
ance requirements.
• The floor protector is large enough and is construct-
ed properly to meet all requirements.
• You have all necessary permits from local authori-
ties.
Your local building official is the final authority for ap-
proving your installation as safe and determining that it
meets local and state codes.
For any unresolved questions about installation, refer
to the National Fire Protection Association’s publication
ANSI/NFPA 211–1988 Standard for Chimneys, Fire-
places, Vents and Solid Fuel Burning Appliances. In
Canada, the equivalent publication is CSA CAN-B365,
Installation Code for Solid Fuel Burning Appliances and
Equipment. These standards are the bases for many
national codes. They are nationally recognized and are
accepted by most local authorities. Your local dealer
or your local building official may have a copy of these
regulations.
An existing masonry chimney must be inspected to con-
firm that it has a lining. Do not use an unlined chimney.
The chimney also should be examined for cracks, loose
mortar, other signs of deterioration, and blockage. Re-
pair any defects before the chimney is used with your
stove.
2’ Min.
2’ Min.
3’
Min.
0 To 10’
3’
Min.
0 To 10’
AC617
RLTSKC8
2/11/98
The 2’-3’-10’ Chimney Rule.
Reference Point AC617
ST241
chimney types
12/13/99 djt
Standard Chimney Types
A prefabricated double-
wall insulated chimney
A tile-lined
masonry
chimney
ST241
5
Vermont Castings Concord
30005102
• 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 wallpa-
per are a hazard and should be sealed with mortar
or refractory cement. In the event of a chimney
fire, flames and smoke may be forced out of these
unused thimbles.
• The chimney should be thoroughly cleaned before
use.
• A newly-built masonry chimney must conform to the
standards of local building code, or, in the absence
of a local code, to a recognized national code. Ma-
sonry chimneys must be lined, either with code-ap-
proved masonry or precast refractory tiles, stainless
steel pipe, or a code-approved, “poured-in-place”
liner. The chimney clean-out door must seal tightly to
ensure a good draft.
A prefabricated metal chimney must be one that is
tested and for use with solid-fuel burning appliances to
the High-Temperature (H.T.) Chimney Standard UL-
103-1985 (2100° F.) for the United States, and High
Temperature (650°C) Standard ULC S-629 for Canada.
This Concord is approved for venting into a masonry
chimney with a nominal flue size of 8” x 8” (203 x 203
mm), and into a round flue size of 8” (203 mm) or 6”
(152 mm). It may be vented into larger chimneys as
well, however, chimneys with liners larger than 8” x 12”
(203 x 305 mm) may experience rapid cooling of smoke
and reduction in draft, especially if they are located
outside the home. Such large chimneys may need to be
insulated or relined for proper stove performance.
A chimney connector is the double-wall or single-wall
pipe that connects the stove to the chimney. The chim-
ney itself is a masonry or prefabricated structure that
encloses the flue. Chimney connectors are used only
to make the connection from the stove to the chimney.
They are for interior use only.
Double-wall connectors must be tested and for use
with solid-fuel burning appliances. Single-wall con-
nectors should be made of 24 gauge or heavier steel,
and should be 6” (150 mm) in diameter. Do not use
galvanized chimney connector; it cannot withstand the
high temperatures that can be reached by smoke and
exhaust gases, and may release toxic fumes under high
heat.
If possible, do not pass the chimney connector through
a combustible wall or
ceiling. If passage
through a combustible
wall is unavoidable,
refer to the recommen-
dations in the sec-
tion following on Wall
Pass-throughs. Do
not pass the connec-
tor through an attic, a
closet or any similar
concealed space. The
whole chimney con-
nector should be ex-
posed and accessible
for inspection and cleaning.
Install the single wall chimney connector not less than
23” (585 mm) from the ceiling. Keep it as short and
direct as possible, with no more than two 90 degree
turns. If possible, use 45 degree elbows. Slope horizon-
tal runs of connectors upward 1/4” per foot (20 mm per
meter) going from the stove toward the chimney. The
recommended maximum length of a horizontal run is 3
feet (1 meter), and the total length of chimney connec-
tor should be no longer than 8’ (2.5 m).
In cathedral ceiling installations, extend the prefabricat-
ed chimney downward to within 8’ (2.5 m) of the stove.
ST242
Chimney connector
12/13/99 djt
Flue gas
direction
Toward
stove
Chimney connector.
ST242
6
Vermont Castings Concord
30005102
The Concord is approved for installation in the U.S.
and Canada with double-wall chimney connectors that
have been tested and for use with solid-fuel burning
appliances by a recognized testing laboratory.
Follow the instructions for assembling and installing
double-wall connectors provided by the manufacturer
of the double-wall chimney. To ease assembly and
help assure safety, use chimney components manufac-
tured by a single source.
• Beginning at the flue collar of the stove, assemble
the chimney connector. Insert the first crimped end
into the stove’s flue collar, and keep each crimped
end pointing toward the stove. Using the holes in
the flue collar as guides, drill 1/8” (3 mm) holes in
the bottom of the first section of chimney connector
and secure it to the flue collar with three #10 x 1/2”
sheet metal screws.
• Secure each joint between sections of chimney
connector, including telescoping joints, with at least
three sheet metal screws. The predrilled holes in
the top of each section of chimney connector serve
as guides when you drill 1/8” (3 mm) holes in the
bottom of the next section.
• Secure the chimney connector to the chimney. In-
structions for various installations follow.
• Be sure the installed stove and chimney connec-
tor are correct distances from nearby combustible
material.
Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney con-
nector are available to simplify assembly. Slip pipes
eliminate the need to cut individual connector sections.
Consult your local dealer about these special connec-
tor sections.
Follow the installation instructions of the chimney
manufacturer exactly.
Special adapters are available from your local dealer to
make the connection between the prefabricated chim-
ney and the chimney connector. The top of such adapt-
ers attach directly to the chimney or to the chimney’s
ceiling support package. The bottom of the adapter is
secured to the chimney connector.
The adapter forms a union between the chimney and
chimney connector that ensures any soot or creosote
falling from the inner walls of the chimney will stay
inside the chimney connector.
The Concord may be connected to either a freestand-
ing masonry chimney or to a fireplace masonry chim-
ney.
If the chimney connector must pass through a combus-
tible wall to reach the chimney, follow the recommenda-
tions for Wall Pass-Through construction on Pages 7-8.
The opening through the chimney wall to the flue - the
“breech” – must be lined with a ceramic or metal
thimble which is securely cemented in place. (Fig. 5)
A metal pipe section called the “thimble sleeve,” slightly
smaller in diameter than standard connector and the
thimbles, will allow the removal of the chimney connec-
tor system for inspection and cleaning. Thimble sleeves
are available from your local dealer.
To install a thimble sleeve, slide it into the breech until
it is flush with the inner flue wall. Be sure that it does
not extend into the flue passage where it could interfere
with the draft.
The thimble sleeve should protrude 1-2” (25-51 mm)
into the room. Use furnace cement and thin gasketing
to seal the sleeve in place in the thimble. Secure the
chimney connector to the outer end of the sleeve with
sheet metal screws.
ST243
thinble connection
12/13/99 djt
Chimney
Connector
Thimble Sleeve
The thimble, made of either ceramic or metal, must be
cemented securely in place.
Flue
Keep sleeve
end flush with
flue tile
ST243
7
Vermont Castings Concord
30005102
In this installation, the chimney connector enters the
fireplace flue through a thimble located above the
fireplace. (Fig. 6) The liner of the fireplace chimney
should extend at least to the point at which the chimney
connector enters the chimney. Follow all the guidelines
for installing a chimney connector into a freestanding
masonry chimney, and pay special attention to these
additional points:
• The stove and chimney connector clearances to
combustible mantel and trim materials are the same
as clearances to combustible walls. If necessary,
use a combination of mantel, trim, and connector
heat shields to provide the required clearances.
Refer to Page 12.
• Double-check connector clearance to the ceiling.
• The fireplace damper must be closed and sealed to
prevent room air from being drawn up the flue which
could reduce performance. However, it must be
possible to reopen the damper to inspect or clean
the chimney.
• Floor protection requirements also apply to fireplace
installations.
Whenever possible, design the installation so that the
connector does not pass through a combustible wall.
If you must include a wall pass-through in your instal-
lation, check with your building inspector before you
begin. Also check with the chimney connector manu-
facturer for any specific requirements.
Consult with your dealer regarding special connection
components available for use as wall pass-throughs.
Use only parts that have been tested and for use as a
wall pass-through.
The National Fire Protection Association (NFPA) has
established guidelines for use in the United States for
passing chimney connectors through combustible walls.
Many building code inspectors follow these guidelines.
Figure 7 shows one NFPA-approved method. All com-
bustible material in the wall is cut away to provide 12”
(305 mm) clearance to the connector. Brick and mortar
are used to enclose the clearance area.
• Using a section of double-wall chimney with a 9”
(229 mm) clearance to combustibles. (Fig. 8)
• Placing a chimney connector pipe inside a steel
double-wall ventilated thimble, which is then sepa-
rated from combustibles by 6” (152 mm) of fiberglass
insulating material. (Fig. 9)
ST272
masonry wall pass through
w/ single wall
connector
12/99
Min. 2” (51mm) Chimney clear-
ance to brick and combustibles
= Minimum 12” (305 mm) brick con-
struction between liner and combustible
framing materials
Min. 12”
(305 mm)
Fire clay
liner
Chimney Flue
Fire clay
liner
Masonry
Chimney
constructed
to NFPA 211
Masonry Wall Pass-through with single wall
chimney connector.
Chimney
connector
ST272
ST273
nfpa
factory built insulated
chimney section
12/99
Wall Pass-through using factory-built insulated
chimney section.
Min. 9”
(230mm)
Air Space
Min. 9”
230mm
Chimney Flue
Sheet Steel
Supports
Min. 2”
(51mm)
Non-soluble refrac-
tory cement
Solid insulated,
factory-built
chimney length
set flush with
flue
Chimney
Connector
Masonry
Chimney
constructed to
NFPA 211
24 ga.Sheet
Steel Sup-
ports
ST273
ST244a
Madison
fplc over mantel
12/00
If the clearance between the chimney connector and
either the ceiling or the mantel is inadequate, a protective
heat shield is required.
Mantel
Chimney Connector
Heat Shield
ST244a
8
Vermont Castings Concord
30005102
A tremendous amount of heat radiates from the bottom
plate of your Concord. The floor area directly under and
around the stove will require protection from radiant
heat as well as from stray sparks or embers that may
escape the firebox.
Heat protection is provided through the use of a Ver-
mont Castings Bottom Heat Shield #1892. Spark and
ember protection must be provided by a floor protector
constructed with noncombustible material as specified.
Most installations will require that the bottom heat shield
be attached. Only when the stove is placed on a complete-
ly noncombustible surface such as unpainted concrete over
earth may it be used without the heat shield.
Even when the bottom heat shield is installed, you must
provide special protection to the floor beneath. For
installations with the heat shield attached, use a non-
combustible floor protector such as 1/4” non-asbestos
mineral board or equivalent, or 24 gauge sheet metal.
The floor protector may be covered with a noncombus-
tible decorative material if desired. Do not obstruct the
space under the heater.
Protection requirements vary somewhat between the
United States and Canada as follows:
the floor protector is required
under the stove and must extend at least 18” from the
front of the stove (“D”, Fig. 12), at least 4” from the right
side and rear (“C”, Fig. 12) and 16” from the left side
(“E”, Fig. 12). It must also extend under the chimney
connector and 2” to either side (“F”, Fig. 12).
To meet these requirements, a floor protector must be
at least 48” wide (“A”,Fig. 12) and 48” deep (“B”,Fig. 12)
, a noncombustible floor protector is required
under the heater also. The floor protector must extend
18” (457 mm) to the front (D), and 8” (203 mm) from the
right side (C) and rear (C) and 18” (457 mm) from left
side (E).
ST274
single wall
w/ventilated thimble
12/99
Wall Pass-through using single wall chimney
connector with a ventilated steel thimble.
Min. 6”
(152mm)
Chimney clearance to sheet steel
supports and combustibles 2” (51mm) Min.
Glass Fiber
Insulation
Chimney Connector
Chimney Flue
with two 1”
(25mm) Ventilated
Channels
Masonry Chimney construct-
ed to NFPA 211
24 ga.Sheet
Steel Supports
ST274
• Placing a chimney connector pipe inside a section of
9” (230 mm) diameter, solid-insulated, factory-built
chimney, with two inches of air space between the
chimney section and combustibles. (Fig. 10)
In Canada, the Canadian Standards Association has
established specific guidelines regarding wall pass-
though design. Figure 11 shows one approved method
in which all combustible material in the wall is cut away
to provide the required 18” (45mm) clearance around
the connector. The resulting space must remain empty.
A flush-mounted sheet metal cover may be used on
one side only. If covers must be used on both sides,
each cover must be mounted on noncombustible
spacers at least 1” (2mm) clear of the wall. Your local
dealer or your local building inspector can provide de-
tails of other approved methods of passing a chimney
connector through a combustible wall.
In Canada, this type of installation must conform to
CAN/CSA-B365, Installation Code for Solid Fuel Burn-
ing Appliances and Equipment.
ST276
CSA approved wall
pass-through
12/99
CSA approved Wall Pass-through.
24 ga.Sheet
Steel Support
24 ga. Sheet
Steel Support
(one side only)
Min. 18”
(460mm)
Chimney clearance to sheet steel
supports and combustibles 2” (51mm)
Min.
Chimney Flue
Chimney
Connector
Masonry Chimney con-
structed to CAN/CSA-B365
Min. 18”
(460mm)
ST276
ST275
wall with
ventilated
steel thimble
Wall Pass-through with ventilated steel thimble.
24 ga. Sheet
Steel Supports
24 ga. Sheet
Steel Supports
2” (51mm) Min.
Chimney clearance to sheet steel
supports and combustibles
2” (51mm)
Min.
Chimney Flue
2” (51mm) Min.
air space
Prefab Chim-
ney
Section
Prefab
Chimney
Section
Chimney Con-
nector
Masonry Chimney construct-
ed to NFPA 211
ST275
9
Vermont Castings Concord
30005102
To meet these requirements, a floor protector must be
at least 54” (1372 mm) wide (“A”,Fig. 12) and 52” (1320
mm) deep (“B”, Fig. 12).
Do not assume that your fireplace hearth is completely
noncombustible. Many fireplace hearths do not satisfy
the “completely noncombustible” requirement because
the brick or concrete in front of the fireplace opening is
supported by heavy wood framing. (Fig. 13) Because
heat is readily conducted by brick or concrete, it can
easily pass through to the wood. As a result, such fire-
place hearths can be a fire hazard and are considered
a combustible floor.
For all fireplace installations, follow the floor protection
guidelines described above.
Keep in mind that many raised hearths will extend
less than the required clearance from the front of the
heater when it is installed. In such cases, sufficient
floor protection as described above must be added in
front of the hearth to satisfy the minimum floor protector
requirement from the front of the stove: 18” (460 mm)
from the front in the United States and 18” (460 mm)
from the front in Canada.
Hearth rugs do not satisfy the requirements for floor
protection as they are only fire-retardant, not fire proof.
ST247a
Rear exit floor dgrm
12/14/99 djt
Supporting timbers under fireplace hearths are
considered to be combustible.
Wood framing
requires protection
from radiant heat ST247a
When the stove is operating, both the stoveplate and
the chimney connector radiate heat in all directions. A
safe installation requires that adequate clearance be
maintained between the stove and nearby combustible
materials to ensure that those materials do not over-
heat.
Clearance is the distance between either your stove
or chimney connector, and nearby walls, floors, the
ceiling, and any other fixed combustible surface.
In general, a distance of 48”
(1219 mm) must be maintained between the stove and
moveable combustible items such as drying clothes,
furniture, newspapers, firewood, etc. Keep this area
empty of any combustible material.
The Concord clearance requirements, and diagramed
on Pages 12-13, have been established through testing
to UL and ULC standards to meet most installation con-
figurations. These involve four basic variables:
• When neither the chimney connector nor the wall
has a heat shield installed.
• When only the chimney connector has a heat
shield installed.
• When only the wall has a heat shield mounted on
it.
• When a heat shield is installed on both the chim-
ney connector and wall.
In general, the greatest clearance is required when the
stove will be positioned with no heat shield near a wall
with no heat shield. The least clearance is required
when both the stove and the wall have heat shields.
Reducing a stove clearance may require installation of
a heat shield on the chimney connector as well.
Clearances may be reduced only by means approved
by the regulatory authority, or in accordance with the
clearances in this manual.
D
A
B
A
D
C
C E C
E
C
Top Vent
Rear Vent
F
St500a
Madison
floor protection
7/26/01 djt
These dimensions are minimum requirements only.
Use greater dimensions whenever possible.
A: 48” 54” (1372 mm)
B: 48” 52” (1321 mm)
C: 4” 8” (203 mm)
D: 18” 18” (457 mm)
E: 16” 18” (457 mm)
F: 10” 10” (254 mm)
ST500a
10
Vermont Castings Concord
30005102
Wall shields should be constructed of 24 gauge or
heavier sheet metal, or another noncombustible mate-
rial such as 1/2” (13 mm) insulation board (Fig. 14) or
common brick “laid on flat,” with the 3¹⁄₂" (89 mm) side
down.
Shields must be spaced out from the combustible
surface 1" (25 mm) on noncombustible spacers. The
spacers should not be directly behind the stove or
chimney connector.
Air must be able to flow between the wall and the
shield. At least 50% of the bottom 1" (25 mm) of the
shield should be open and the shield must be open at
the top.
The following examples of wall shield construction illus-
trate common designs used to safely achieve reduced
clearances to combustible wall materials.
Fig. 15: Reduced clearances for
both rear and side walls. Wall shields may meet at
corner if desired. Shielding for connector is centered
behind connector.
Fig. 16: Reduced clearances for both
rear and side walls. Wall shields may meet at corner if
desired. Shielding for connector is centered behind con-
nector. Wall pass-through must comply with codes.
Fig. 17: Reduced side clearances. Wall
shields MUST meet at corner.
Fig. 18: Reduced clear-
ances for rear wall. Shielding for connector is centered
behind connector. Wall pass-through must comply with
codes.
Parallel installation, vertical chimney connector, two
wall shields.
C
C
C
BAB
ST550
Madison
wall shield
11/00
A
C
ST550
A = 48” (1219 mm)
B = Max. - C
C = 1” (25 mm)
Parallel installation with rear wall pass-through, two
wall shields.
A
B
C
B
A
C
ST551
Madison
Wall shield
BB
11/00
ST551
A = 48” (1219 mm)
B = 48” (1219 mm)
C = 1” (25 mm)
Corner installation, vertical chimney connector, two
wall shields.
B
B
CC
A
A
ST552
Madison
Wall shield
cc
11/00
C
C
ST552
A = 48” (1219 mm)
B = Max. - C
C = 1” (25 mm)
C
A
B
ST564Madison
wall shield
11/00
A = 48” (1219 mm)
B = 48” (1219 mm)
C = 1” (25 mm)
ST564
Parallel installation, rear wall pass through, rear wall
shield.
ST248a
wall shield construction
12/14/99 djt
Approved Wall shield construction
Air flow
Wall shield
Air flow
Stud wall
framing
Noncombustible
spacers and
fasteners
Drywall
Metal Spacer
Shield
ST248a
11
Vermont Castings Concord
30005102
Because of their restricted air flow and heat retention
characteristics, specific construction requirements and
special clearances apply to installations into alcoves.
No stove or chimney connector heat shields are used in
alcove installations.
The following illustrations show noncombustible ceiling
framing and maximum and minimum permitted dimen-
sions for alcove construction.
36"
Max.
48" Min.
ST502
Intrepid
Alcove floor plan
11/10/00 djt
Use recommended
floor protection
7/16” Durock®
(or equivalent)
spaced 1” off
wood studs on
noncombustible
spacers
ST502
Alcove floor plan. Sheetrock on front face butts to Du-
rock® (or equivalent) alcove lining.
ST503
Alcove side view
11/10/00 djt
Metal
Stud
Combustible
facing may
overlap metal
studs by only
1”
1” air gap top
and bottom,
on both
sides and
back wall
7/16” Durock® (or
equivalent)
Joist Shield
(Supplied
by Chimney
Manufacturer)
ST503
Alcove side section.
65" 62" Min.
to Alcove
Ceiling
ST506
Alcove front view
11/00
Ceiling sup-
port package
extends 2”
below Durock®
(or equivalent)
ceiling
1” air gap,
top, bottom,
on both
sides and
back wall
ST506
Front view: 65” minimum clearance from hearth to
combustibles on front face. Combustible facing may overlap
metal studs by only 1”. It should not extend below the height of
the noncombustible ceiling.
From 62” to
65” must be
covered by
a noncom-
bustible
material.
St504
Alcove cutaway
11/00
ST504
Cutaway perspective of alcove installation.
24"
1456M"
48" Min.
11"
Min.
36"
Min.
ST505
Alcove Ceiling plan
11/00
Existing Combustible
Framing
Metal studs
support 7/16”
Durock® (or
equivalent)
ceiling
ST505
Reflected ceiling plan.
12
Vermont Castings Concord
30005102
Use the chart below together with the diagrams on the next page to determine the minimum clearance required for
your particular installation. In any case, it is always advisable to locate the stove as far away from walls as possible
in order to take full advantage of the radiant properties of cast iron.
Stove clearances are measured between the cast iron Top Plate of the stove and the combustible surface. Note
that the cast iron back on the Concord protrudes 5” (127 mm) out from the stovetop, and will therefore be closer to
the wall than the top of the stove.
Chimney Connector clearances are measured between the connector surface and the combustible surface. For
Double-wall Chimney Connector, use the manufacturer’s clearance specification.
Use NFPA 211 default clearance or manufacturer’s installation specifications for those configurations not tested.
Top exit, no heat shields
Top exit, heat shields on stove,
no shields on single wall con-
nector
Top exit, heat shield on stove,
heat shield on single wall con-
nector
Top exit, heat shield on stove,
double wall chimney connector
Rear exit, no heat shields
Rear exit, heat shields
Without Connector Heat
Shields
With Connector Heat Shields
* A distance of 48” (1220 mm) must be maintained between the stove and moveable combustible items such
as drying clothes, furniture, firewood, etc.
48” (1220 mm)
Single-wall Connector
21”
(533 mm)
24”
(610 mm)
21”
(533 mm)
21”
(533 mm)
22”
(559 mm) 18”
(457 mm)
12”
(305 mm)
14”
(356 mm) 10”
(250 mm)
19” (483 mm) 13” (330 mm)
23” (584 mm) 23” (584 mm)
21”
(533 mm) 24”
(610 mm)
21”
(533 mm)
12”
(305 mm) 14”
(356 mm)
10”
(250 mm)
12”
(305 mm) 8”
(203 mm)
14”
(356 mm)
12”
(305 mm)
16”
(406 mm)
11”
(279 mm)
18”
(457 mm)
8”
(203 mm)
12”
(305 mm)
20”
(508 mm)
18”
(457 mm)
15”
(381 mm)
12”
(305 mm)
18”
(457 mm)
16”
(406 mm)
12”
(305 mm)
12”
(305 mm)
13
Vermont Castings Concord
30005102
F
F
C
C
A
B
D
E
J
KL
L
G
H
ST553
Madison Clearance
Diagrams
11/00
P
Q
M
N
I
I
O
O
R
R
V
W
S
T
U
U
X
X
Top Exit Installations, no heat shields
Top Exit Installations, heat shield on stove, no shields on single-wall connector
Top Exit Installations, heat shield on stove, heat shields on single-wall connector
Top Exit Installations, heat shield on stove, double-wall chimney connector
Top Exit, Bottom Heat Shield always used, floor protection,
minimum 18” (457 mm) in front.
ST553
14
Vermont Castings Concord
30005102
Rear Exit Installations, Bottom Heat Shield, floor protec-
tion, minimum 18” (457mm) in front.
Y
Z
AA
BB
EE
FF
CC
DD
ST563
Madison Clearance
Diagrams - REAR
12/00
N / A N / A
Rear Exit Installations, no heat shields
Rear Exit Installations, heat shields
ST563
15
Vermont Castings Concord
30005102
ST465
Seville
Install
bottom heat shield
You will need the following tools to assemble the Con-
cord:
• 9/16” open end wrench • safety glasses & gloves
• flat head screwdriver • power drill w/ 1/8” (3 mm) bit
• stub handle phillips screwdriver
1. Remove the shipping straps and plastic wrap.
2. Inspect the stove and contents for shipping damage
or missing parts. Immediately notify your dealer of
any damage. Do not install this stove if any damage
is evident or any parts are missing.
• Stove Legs, 4
• 3/8-16 x 1¹⁄₄” hex head Leg Bolts with washers, 4
• Touch-up Paint (Porcelain enamel stoves only)
Remove and discard the four large slot-head screws
from the stove bottom. Install the stove legs using the
hex head bolts from the parts bag. Use 3/8” washers
with all four legs; the door handle holder installs on the
right front leg. Position the holder so the hole to ac-
cept the handle hub faces out from the right side of the
stove. Tighten the bolts firmly. Overtighten-
ing can strip tapped threads.
The #1892 Bottom Heat Shield must be used in the
U.S. and Canada in any installation on a floor that is not
comprised of unpainted cement on earth.
1. Remove the 1/4-20x 1/2” phillips screw from the cen-
tral mounting boss in the stove bottom. (Fig. 25)
2. Mount the bottom heat shield to the stove bottom
Attach the Bottom Heat Shield to the boss in the
center of the stove bottom.
1/4-20 x 1/2” Pan Head Screw
ST465
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. 25a)
using the same phillips head screw previously removed.
The corners of the shield will butt against the cast leg
locators at each corner of the stove bottom.
Models 1660, 1661.
Remove and retain the factory installed flue collar heat
shield. Loosen two phillips screws, on either side of
the flue collar, approximately one turn each. Slide heat
shield away from the flue collar, then push flue collar
forward and retighten phillips screws.
ST564
handle holder
12/13/00
Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer
ST564
Handle holder and heat shield positions.
ST466
Seville
Attach legs
Attach the stove legs with leg levellers.
Leg Bolt and
Washer
Leg Leveller ST466
16
Vermont Castings Concord
30005102
Insert the crimped end of the first section of chimney
connector into the flue collar. Using the holes in the
collar as guides, drill 1/8” (3 mm) holes through the
connector pipe. Use the three #10 x 1/2” sheet metal
screws provided to secure the chimney connection to
the flue collar.
If applicable, attach Chimney Connector Heat Shields
following the instructions included with those parts.
The optional #1891 Outside Air Adapter provides a
collar to which a 3” diameter air duct may be attached
directly to the air inlet area at the back of the stove.
This option can be installed in two different configura-
tions, with Rear Heat Shield #1893 and without the heat
shield.
1. Engage the Adapter against the Air inlet opening in
the Rear Heat Shield. Align clearance holes in the
adapter with pilot holes in the Rear Heat Shield as
shown at the bottom of Figure 26.
2. Use two sheet metal screws provided in the kit to
attach the Adapter to the Rear Heat Shield at the
aligned holes.
1. Facing the rear of the stove, loosen the pan head
screw located a the upper left hand corner of the
primary air inlet two revolutions. Position the Adapter
over the air inlet opening in the rear of the stove with
the pan head screw passing through the slotted tab
in the Standoff. Make certain that the damper tab is
located between the stove and the standoff and is
oriented as it was before the screw was loosened.
Tighten the pan head screw using the access hole
in the standoff. The Thermostat and Primary Air Flap
should operate freely.
2. Engage the Adapter against the air inlet opening in
the Outside Air Standoff. Align clearance holes in the
adapter with pilot holes in the Standoff as shown at
the top of Figure 26.
3. Use two sheet metal screws provided in the kit to
attach the Adapter to the Outside Air Standoff at the
aligned holes.
ST562
Madison
outside air adapter
12/00
Stove Back
Outside Air
Standoff
Outside Air
Adapter
Primary Air Flap
Rear Heat
Shield
Oustide Air Adapter
ST462
Outside Air Adapter options.
17
Vermont Castings Concord
30005102
Combustion control is achieved in the Concord through
two separate air delivery systems.
The , located at the left rear
corner of the stove, controls the amount of incoming pri-
mary air for starting, maintaining, and reviving the fire.
More air entering the stove makes the fire burn hotter
and faster, while less air prolongs the burn at a lower
heat level.
For the greatest air supply and maximum heat output
(but the shortest burn time), move the lever to the left
most position. For a fire that will last longer with less
heat, move the lever to the right. You can set the lever
anywhere in between the upper and lower extremes.
The Concord features an automatic thermostat to
ensure an even heat output at any manual setting
you select. As the fuel burns, the thermostat reacts to
the heat radiating from the stove surface and, conse-
quently, adjusts the air shutter attached to it. As the fire
intensity (and heat output) builds, the thermostat slowly
closes the air shutter, thereby restricting incoming com-
bustion air. As the fire intensity then wanes (and heat
output lessens), the thermostat responds and gradually
opens the air shutter which allows more combustion air
to again enliven the fire. This ebb and flow action func-
tions continuously to prolong the burn cycle until the
fuelbed is exhausted.
Another separate supply of oxygen is delivered to the
upper area of the firebox to support combustion of
gases released from the main fuel bed. This
enters the stove through two, unrestricted inlets
and is heated while passing through separate channels
before being delivered through three stainless steel
multi-ported tubes located at the top of the firebox.
You will enjoy the best results when burning wood that
has been adequately air-dried. Avoid burning “green”
wood that has not been properly seasoned. The wood
should be no longer than 18” (457 mm) in length, how-
ever, you will find that shorter wood lengths ease refuel-
ing and promote the most efficient combustion.
The best hardwood fuels include oak, maple, beech,
ash, and hickory that has been split, stacked, and air-
dried outside under cover for at least one year.
For areas that do not have a supply of hardwood, com-
monly burned softwoods include tamarack, yellow pine,
white pine, Eastern red cedar, fir, and redwood. These
too should be properly dried.
Keep wood a safe distance from the heater and keep
it out of the areas around the heater used for refueling
and ash removal.
No single air control setting will be appropriate for every
situation. Settings will differ depending on the quality of
the fuel, the amount of heat desired, and how long you
wish the fire to burn.
The control setting also depends on your particular
installation’s “draft,” or the force that moves air from the
stove up through the chimney. Draft is affected by such
things as the length, type, and location of the chimney,
local geography, nearby obstructions, and other factors.
Too much draft may cause excessive temperatures in
the Concord, and could even damage it. On the other
hand, too little draft can cause backpuffing into the
room and/or the “plugging” of the chimney.
How do you know if your draft is excessively high or
low? Symptoms of too much draft include an uncontrol-
lable burn or a glowing-red stove part. A sign of inad-
equate draft is smoke leaking into the room through the
stove or chimney connector joints, low heat, and dirty
glass.
18
Vermont Castings Concord
30005102
ST263
starting a fire
12/99
Start a fire with small, dry kindling.
ST263
ST264
good fire
12/99
Gradually add larger pieces of wood until all the wood
is burning well.
ST264
In newer homes that are well-insulated and weather-
tight, poor draft may result from insufficient air in the
house. In such cases, a slightly opened window near
the stove on the windward side of the house will provide
the fresh air needed.
A more effective option for delivering ample combustion
air to the stove is to duct air directly from outdoors to
the stove. In fact, in some areas, provisions for outside
combustion air are required in all new construction. The
optional Concord Outside Air Adapter is available from
your dealer.
When you first begin using the stove, pay attention
to the air control settings. You will quickly find that a
specific setting will give you a fixed amount of heat. It
may take some time to determine the amount of heat
and the length of burn you should expect from various
settings.
Use the following air control settings as a starting point
to help determine the best settings for your installation.
High Left most position Fully Open
Medium Half Open
Low Right most position Fully Closed
Before you begin using the stove, please read the Ap-
pendix on Draft Management, starting on Page 22, to
learn how the characteristics of your particular instal-
lation will affect your stove’s performance. You and the
stove are parts of a system; other parts of the system
have a strong effect on performance. You may need to
vary your firing technique to get the results you desire.
Cast iron is extremely strong, but it can be broken with
a sharp blow from a hammer or from the thermal shock
of rapid and extreme temperature change.
The cast plates expand and contract with changes in
temperature. When you first begin using your Concord,
minimize thermal stress by allowing the plates to adjust
gradually during three or four initial break-in fires follow-
ing .
Step 1. Open the primary air control fully. (Lever at left
most position)
Step 2. Place several sheets of crumpled newspaper
in the stove. Avoid using glossy or colored paper, as
these burn poorly. At the front of the firebox, place on
the paper six or eight pieces of dry kindling split to a
finger-width size, and on the kindling lay two or three
larger sticks of split dry wood approximately 1-2” (25-
51mm) in diameter. (Fig. 27)
Step 3. Light the newspaper and close the doors.
Gradually build up the fire by adding a few 3-5” (80-
120 mm) diameter splits. (Fig. 28) If this is one of
the first few “break-in” fires, let the fire burn brightly,
and then let it die out.
• During the break-in fires, don’t let the stove get
hotter than 500°F. (260°C) as measured on an op-
tional stove-top thermometer. Adjust the air control
lever as necessary to control the fire.
• Some odor from the stove’s hot metal, the paint,
and the cement is normal for the first few fires.
19
Vermont Castings Concord
30005102
Some chimneys need to be “primed,” or
warmed up, before they will draw sufficiently to sus-
tain a fire. To correct this situation, roll up a couple
pieces of newspaper, place them on top of the
kindling and toward the back of the stove, light them,
and close the doors. This should heat the chimney
enough to initiate strong draft.
Once the draft is established, open the front doors
and light the rest of the fuel bed at the bottom. Do
not light the main bed of fuel until the chimney be-
gins drawing.
Step 4. After the stove has been broken-in using Steps
1-3, continue to build the fire gradually. Add larger
wood with a diameter of 3-4” (75-100 mm).
Continue adding split logs of this size to the briskly-
burning fire until there is a glowing ember bed at
least 2” (50 mm) deep. A good ember bed is neces-
sary for proper functioning and may take up to an
hour to establish.
Step 5. Adjust the thermostatic air control for the de-
sired heat output.
Reload the Concord while it is still hot and there are
plenty of glowing embers to re-kindle the fire. Include
some smaller pieces of wood in the new load of fuel
to help the stove return to its operating temperature
quickly. Wear stove gloves, and follow this procedure
when you reload your stove:
Step 1. Open the thermostat lever.
Step 2. Open the doors and check the ash level in the
ash pan. If necessary, dispose of the ashes and
replace the pan.
Step 3. Use a fireplace tool to break up the charcoal
and direct ash through the grate. Pull the charcoal
from the back to the front.
Step 4. Load wood — smaller, split pieces first. Close
the doors. Ideal performance will be achieved by
operating with the air control set in the maximum
(HIGH) positon for several minutes after refueling.
Reset the primary air control for the desired heat
output after the fire is re-established.
Remove ash before it reaches the top of the ash pan.
Check the level at least once a day, and before each re-
fueling. Using stove gloves, pull the ash pan out of the
stove by its handle. Remove the ash pan and properly
dispose of the ashes. Be sure to keep the pan level dur-
ing disposal.
Empty the ash pan regularly, typically every one to
three days. The frequency will vary depending on how
you operate your Concord; if you burn more wood at
higher heat output settings, ash will accumulate rapidly.
Dispose of ashes into a metal container with a tight-fit-
ting lid, kept outdoors. Put the closed container of ash
on a noncombustible floor or on the ground, well away
from all combustible materials, pending final disposal.
If the ash is disposed of by burial in soil or otherwise
locally dispersed, keep it in the closed container until all
cinders have thoroughly cooled. You can use wood ash
as a garden fertilizer.
The use of smoke detectors throughout the home is
strongly advised, if not required by building codes or in-
surance regulations. It is a good idea to install a smoke
detector in the living areas and each bedroom.
You may not, however, wish to install a detector in the
immediate vicinity of the stove. Depending on the sensi-
tivity of the unit, the alarm can be set off while you are
tending the fire or emptying the ashes. If you install a
detector in the same room, locate it as far away from
the stove as possible.
20
Vermont Castings Concord
30005102
Let the fire in the stove go out and allow the stove to
cool completely before beginning any maintenance
procedure.
An occasional dusting with a dry rag will keep the
painted cast iron of your Concord looking new.
The stove’s paint can be touched up as needed. First,
clean the areas to be painted with a wire brush. Then,
touch up the stove with Vermont Castings high tem-
perature stove paint. Apply the paint sparingly, and
keep in mind that two light coats of paint are better than
a single heavy one.
Use a dry or slightly damp rag or a soft brush to remove
spills or stains. For difficult jobs that require a cleaning
agent, use only a kitchen appliance cleaner or polish
recommended for use on enamel surfaces.
Most of the carbon deposits on the glass will burn off
during hot fires. However, the ash residue that accumu-
lates on the glass surface should be removed regularly
to prevent etching. Follow this procedure to clean the
glass:
• Be sure the glass is completely cool.
• Clean the glass with water or a cleaner made espe-
cially for this purpose. Do not use abrasive cleaners.
• Rinse the glass thoroughly.
• Dry the glass completely.
Replace glass only with Vermont Castings glass pan-
els. The glass panel rests on a cushion provided by a
gasket, and is held in place by two clips. The glass is
coated on one side which is slightly colored. Remove
the door from the stove and place it on a sturdy, level
work surface. Use a towel to protect the porcelain
enamel finish.
(Two phillips head
screws on each clip).
If the window gasket is in good
condition, you can leave it in place. If you replace it,
use only Vermont Castings gasket 1203556. Be sure
the channel around the window opening is clean,
and free of dust.
Place the gasket into the panel inset.
Lay the glass on the inner gasket
with the coated side down, marked “This Side Out”
(toward the outside of the door). Tighten the screws
snugly, but loose enough to allow for a little move-
ment of the glass when the stove is in operation.
Overtightening can crack the glass immediately or
cause it to crack if it is unable to expand when hot.
Your Concord uses rope-type fiberglass gaskets to
make a tight seal between some parts. With use, par-
ticularly on those parts that move, gaskets can become
brittle and compressed and can begin to lose their ef-
fectiveness. These will need periodic replacement.
The sizes of replaceable gasket are below, along with
their applications.
Gasket Size
3/8” Fiberglass Door Gasket - 1203589
Wait until the fire 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.
Remove the existing gasket by grasping an
end and pulling firmly.
Use a wire brush or 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.
Determine the correct length of the appropri-
ate-sized gasket by laying it out in the channel. Allow
an extra 1-2” (25-50 mm), and mark the spot to be cut.
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 discourage the gasket from
unraveling.
Lay an unbroken 1/8” (3 mm) bead of gasket
cement in the newly-cleaned channel.
Starting at one end, press the gasket into the
channel.
Ensure a good joint where the gasket meets before
trimming any excess. Do not overlap the gasket ends
or leave ends with ragged edges.
Press the gasketed part firmly against its
normal mating surface to seat the gasket evenly in its
channel. Close and latch the door to do this; close the
door on a piece of waxed paper to keep the cement
from migrating onto the non-gasketed part, or mask
other parts
Clean excess cement from around the chan-
nel. Let the cement that holds the new gasket dry
thoroughly.
This manual suits for next models
1
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