Vermont Castings Dauntless FlexBurn 0002235 User manual
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 13-90-586000C
Owner’s Manual
Operation & Care
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
Contact your dealer with questions on installation, operation, or service.
NOTE
To obtain a French translation of this manual, please
contact your dealer or visit www.vermontcastings.com
Pour obtenir une traduction française de ce manuel, s’il
vous plaît contacter votre revendeur ou visitez www.
vermontcastings.com
If the information in these instructions is not
WARNING
!
and liquids in the vicinity of this or any other appliance.
warranty.
• Comply with all minimum clearances to combustibles
HOT SURFACES!
Glass and other surfaces are hot
during operation AND cool down.
WARNING
!
• Do not touch glass until it is cooled
• NEVER allow children to touch glass
• Keep children away
•
• Alert children and adults to hazards of high
temperatures
•
• Keep clothing, furniture, draperies and other
Dauntless FlexBurn®
Catalytic / Non-Catalytic
Wood Stove
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/232 3-90-586000C
Congratulations on your choice of a Vermont Castings Dauntless FlexBurn®Wood Stove. At Vermont Castings we take
care and will provide you with many years of service.
iron’s unique ability to absorb and radiate heat.
depends on both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate
and maintain your stove.
At Vermont Castings, we are committed to your satisfaction as a customer. That is why we maintain an exclusive network of
contact your Authorized Vermont Castings Dealer anytime you have a particular question about your stove or its performance.
This manual contains valuable instructions on the operation of your Vermont Castings Dauntless FlexBurn®
also contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
This heater meets the U.S. Environmental Protection
Agency’s emission limits for wood heaters sold on or after
May 15, 2020.
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.
BARCODE LABEL
BARCODE LABEL
HF
Serial No.
N
o
de série:
3-90-586190_R2
Date of Manufacture / Date de fabrication:
2021 2022 2023 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Manufactured by / Fabriqué par: Hearth and Home Technologies 352 Mountain House Road, Halifax PA 17032
MODEL / MODÈLE: “Dauntless FlexBurn Catalytic / Non-Catalytic”
LISTED SOLID FUEL ROOM HEATER
HOMOLOGUE POELE A COMBUSTIBLE SOLIDES
SUITABLE FOR MOBILE-HOME INSTALLATION – USA ONLY
Tested and Listed by Omni-Test Laboratories Inc.
Report #/Rapport # 0061WS104E, 0061WS104S
Tested to / Testé à: ASTM E2515, ASTM E3053, UL 1482-2011 (R2015), ULC-S627-00,
CAN/CSA B415.1.
Install and use only in accordance with manufacturer’s installation and operation
inspection in your area. Install only with legs provided in accordance with installation
instructions.
WARNING:
heater.
Fuel: Use with solid wood fuel only. Do not burn other fuels.
open while operating.
Chimney: Use a minimum 6” diameter factory built high temperature (H.T.) chimney
which is listed to UL-103-1985 (2100°F) or 8” X 8” nominal or larger approved masonry
Inspect and Clean Chimney Frequently – Under Certain Conditions of Use, Creosote
Buildup May Occur Rapidly.
Chimney Connector: Use a minimum 6” diameter 24 gauge chimney connector. Install
chimney connector at least 18” from ceiling. Refer to local building codes and Vermont
Castings Install Manual for precautions for passing a chimney or chimney connector
through a combustible wall or ceiling.
Floor Protection U.S.:
protector such as 1/4” non-asbestos mineral board or equivalent or 24 gauge sheet metal. The
may be covered with a noncombustible decorative material if desired.
Floor Protection Canada:
front and 203 mm (8 in.) to the sides and rear.
Optional Components:
Replace glass only with Vermont Castings 5mm ceramic glass.
Do not remove or cover this label. Catalytic Combustor Part No. 8346-006
CAUTION:
the combustor inactive. The combustor is fragile, handle carefully. The durability of the
Danger, Risk of electrical shock. Disconnect power before servicing unit.
Combustion air cannot be obstructed.
Damper must be open before opening doors.
The space heater must be installed with the legs provided, attached as shown in the
installation instructions.
connaître les restrictions et inspections nécessaires. N’installer que les pattes qui sont
incluses, en conformité avec les instructions du fabricant.
Ne pas obstruer l’espace sous le poele.
Attention:
chauffe-eau.
Le registre doit être ouvert avant d’ouvrir les portes.
l’accumulation de créosote peut se produire rapidement.
Combustible: N’utiliser que du bois comme combustible. Ne pas utiliser d’autres types
de combustible. Inspecter et nettoyer la cheminée fréquemment - Sous certainesusages,
l’accumulation de créosote peu se produire rapidement. Garder les portes toutes fermées
ou toutes ouvertes durant l’opération.
Faire le feu directement sur la grille prévue à cet effet. Laisser les portes du poêle soit
complètement ouverts ou complètement fermées lors de l’utilisation. Ne pasraccorder le
conduit de cheminée du poêle à une cheminée servant à d’autres appareils. N’utiliser que
les vitres de céramique Vermont Castings en cas de remplacement de celles-ci.
Protection de plancher Canada: Lorsqu’il est installé sur un plancher de combustible, un
protecteur de plancher non combustible est requis sous le chauffe-eau. Le protecteur de
plancher doit s’étendre sur 460 mm (18 po) vers l’avant et 200 mm (8 po) vers les côtés et
l’arrière.
Catalyseur pièce no. 8346-006
Replacer uniquement qu’avec une glace 5mm Vermont Castings.
Attention:
inactif.
Attention: Le catalyseur est fragile, manipulaer avec soin.
US ENVIRONMENTAL PROTECTION AGENCY
wood at 1.1 g/hr (without catalyst) and 1.2 g/hr (catalytic). This wood
heater contains a catalytic combustor which needs periodic inspection and
replacement for proper operation. Consult the Owner’s Manual for further
information. It is against Federal Regulations to operate this wood heater in
a manner inconsistent with operating instructions in the Owner’s Manual.
Made in U.S.A. of US and imported parts. / Fabriqué aux États-Unis-
d’Amérique par des pièces d’origine américaine et pièces importées.
CAUTION:
HOTWHILEINOPERATION-DONOTTOUCH-KEEPCHILDREN
AND CLOTHING AWAY- CONTACT MAY CAUSE SKIN BURNS- SEE NAMEPLATE
AND INSTRUCTIONS. KEEP FURNISHINGS AND OTHER COMBUSTIBLE
MATERIALS A CONSIDERABLE DISTANCE AWAY FROM THE APPLIANCE.
ATTENTION:
CHAUD LORS DU FONCTIONNEMENT- NE TOUCHEZ PAS L’APPAREIL-
GARDEZ LES ENFANTS ET LES VÊTEMENTS ÉLOIGNÉS- TOUT CONTACT PEUT ENTRAÎNER
DES BRÛLURES DE LA PEAU. RÉFÉREZ-VOUS À LA PLAQUE SIGNALÉTIQUE ET AU MODE
D’EMPLOI. GARDEZ LE MOBILIER ET LES AUTRES MATÉRIAUX COMBUSTIBLES BIEN À
L’ÉCART DE L’APPAREIL.
A= Unit to Sidewall 14”
B= Unit to Backwall 14”
C= Chimney Connector to Sidewall 23.5”
D= Chimney Connector to Backwall 15”
E= Unit to Adjacent Wall 15”
F= Sides (Floor Protection) 6”
G= Front to Glass (Floor Protection) 16”
H= Rear (Floor Protection) 6”
I= Top of Stove to Ceiling 57.5”
J= Chimney Connector to Ceiling 18”
A= Entre le mur lateral et l’appareil 357 mm
B= Entre le mur arriereet l’appareil 357 mm
C= Entre le tuyau et le mur lateral 597 mm
D= Entre le tuyau et le mur arriere 381 mm
E= Entre le mur adjacent et l’appareil 381 mm
F= Côtes (la protection de plancher) 152 mm
G= Devant, par rapport au verr 457 mm
H= Arrière (la protection de plancher) 152 mm
I= du haut du poêle au plafond 1461 mm
J= raccord de cheminée au plafond 457 mm
Minimum Clearances to combustible Construction /
Minimum De Degagement Jusqu’a la construction combustible
The clearances shown belolw are for use with single wall connector pipe
C
D
B
A
E
E
I
J
Appliance to
Ceiling Clearance
Minimum Floor
Protection
G
F
F
H
Serial No.
SAMPLE
Model Name
Mfg. Date
Note: Cast iron is an artisan crafted material, which is
process, part to part variation is normal and adds to the
character of a hand built cast iron appliance
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 33-90-586000C
TABLE OF CONTENTS
Safety Alert Key:
• DANGER! will result in death or serious injury.
• WARNING!could result in death or serious injury.
• CAUTION! could result in minor or moderate injury.
• NOTICE:
!
A. Warranty Policy........................................................ 4
............................................. 6
............................... 6
C. California.................................................................. 6
...................... 6
................................................ 6
A. The Dauntless FlexBurn®Controls .......................... 8
B. Conditioning Your Stove .......................................... 9
......................................... 9
D. Ways to Add Fuel..................................................... 9
E. Ash Disposal............................................................ 12
.......................................... 13
G. Negative Pressure ................................................... 13
............................................... 14
3 Maintenance
A. Cleaning the and Replacement of Glass ................. 15
B. Damper Adjustment ................................................. 16
C. Door Latch Adjustment ............................................ 16
D. Gasket Replacement ............................................... 16
E. The Chimney System ..............................................17
F. Maintenance Schedule ............................................ 18
The Stove ................................................................ 18
The Chimney Connector.......................................... 18
G. The Catalytic Element..............................................18
............................................ 20
5 Reference Material
A. Maintenance Log ..................................................... 21
B. Service Parts List..................................................... 22
................................................. 28
Î= Contains updated information
Î
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/234 3-90-586000C
Hearth & Home Technologies LLC
LIMITED LIFETIME WARRANTY
Hearth & Home Technologies LLC (“HHT”) extends the following warranty for HHT gas, wood, pellet and electric hearth appliances
!"#
WARRANTY COVERAGE:
!$
% ' % # *
$'%!
#!+
%#!%'
-%++'#!
%.+#
WARRANTY PERIOD:
%''#*%''
/'+0"!
#%' 12'
!'#
!3/415''''65
'''7'''
''#!8+'
'#
Page 1 of 2
4021-645M 9/21
Component
Parts Labor Gas Pellet Wood Electric Venting Component Parts Covered by this Warranty
XAll parts except as covered by Warranty Conditions,
Warranty Exclusions, and Warranty Limitations listed
XX Igniters, Auger Motors, Electronic Components, and
Glass
X
Electrical components limited to modules, remotes/wall
switches, valves, pilots, blowers, junction boxes, wire
harnesses, transformers and lights (excluding light bulbs)
XX Molded Refractory Panels, Glass Liners
X
Burners and logs for standalone gas log sets
(Vented and Vent Free gas log sets not sold as
components of the fireplace or stove)
XVent Free Burners and Vent Free Log components of
HHT manufactured fireplaces or stoves
XX Castings, Medallions and Baffles
6 years 3 years XCatalysts
7 years 3 years XX Manifold tubes, HHT Chimney and Terminations
10 years 1 year XBurners, logs and refractory components of HHT
manufactured fire
p
laces or stoves
Limited
Lifetime 3 years XXX Firebox and heat exchanger, FlexBurn®System
(engine, inner cover, access cover and fireback)
1 Year None XXXXX All purchased replacement parts
Warranty Period HHT Manufactured Appliances and Venting
All parts including handles, external enameled
components and other material except as covered by
Warranty Conditions, Warranty Exclusions, and
Warranty Limitations listed
2 years
X
1 Year XXX
2 Years
5 years 1 year
Firepots, burnpots, mechanical feeders/auger
assemblies
3 years X
5 years
A. Warranty Policy
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 53-90-586000C
WARRANTY CONDITIONS:
9 :!-"%
'!";!"
!#
9 !%'#
9 !%!"
"#
9 ' % # * '
!"#<$'
%'#
9 =!'##'
'%#$
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WARRANTY EXCLUSIONS:
!%'4
9 '/#<''+
/#!8%#
9 >' /'
+0#
9 ?.'%#!
4'$/$'8'@'#
9 A+'#!
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/''#
This warranty is void if:
9 ! F/ 8 ''
#OF/'/D'
'$'/#
9 !.'#
9 !''
'#
LIMITATIONS OF REMEDIES AND LIABILITY:
• EXCEPT TO THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY SPECIFIED
limited to replacement of the Component Part(s), repair of the Component Part(s), or refund of the original purchase price of the
other rights which vary from State to State. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF THE
Page 2 of 2
4021-645M 9/21
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 63-90-586000C
1
1
D. Mobile Home Approved (USA ONLY)
• This appliance is approved for mobile home installations
in the USA when not installed in a sleeping room and
when an outside combustion air inlet is provided.
•
and walls must be maintained.
• The appliance must be properly grounded to the frame
of the mobile home with #8 copper ground wire, and
•
This appliance is equipped with 5mm ceramic glass.
Replace glass only with 5mm ceramic glass. Please contact
your dealer for replacement glass.
MODEL: Dauntless FlexBurn®Wood Stove
LABORATORY:
REPORT NO. 0061WS104E, 0061WS104S
TYPE:
STANDARD(s): ASTM E2515, ASTM E3053,
!
This product and the fuels used to operate this product
expose you to chemicals including carbon black, which
is known to the State of California to cause cancer, and
carbon monoxide, which is know to the State of California
to cause birth defects or other reproductive harm. For
more information go to: www.P65Warnings.ca.gov
C. California
Technologies.
components.
Fire Risk.
responsibility for, and the warranty will be voided
by, the following actions:
WARNING
!
The Vermont Castings Dauntless FlexBurn®
WoodAppliance meets the U.S. Environmental
2020 particulate emission standards using
cord wood.
EPA Report #: without catalyst
catalytic
81.6%
82.6%
76.9%
77.9%
***EPA BTU Output:
****Peak BTU/Hour Output: 45,500
Vent Size:
Firebox Size: 1.8 cu. ft.
Outside Air Size:
Fuel Orientation: East, West
Fuel Seasoned Cordwood
dimensional lumber and data collected during EPA
emissions test.
**
Fir dimensional lumber and data collected during EPA
emissions test.
***
calculate output BTU’s.
****A peak BTU out of the appliance calculated using the
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 73-90-586000C
NOTE:
this appliance, reserves the right to alter its products, their
maintenance can cause injury or property damage.
installer, service agency or your dealer.
heater in a manner inconsistent with the operating instructions
in this manual.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/238 3-90-586000C
2
2
A. The Dauntless FlexBurn®Controls
Two controls regulate the performance of the Dauntless
FlexBurn®: a primary air control
and a damper
deactivate the combustion system, Figure 2.1.
Symbols on the stove are reminders of the correct directions
for using the controls. The words ‘Left’ and ‘Right’ in these
directions are facing the stove.
®controls are conveniently
located and easy to operate.
Damper
Air
Control
Lever
Ashdoor
Low Heat
The handle may be positioned anywhere between the
Damper Positions
intermediate positions.
A Damper Directs Air Flow Within the Stove
The damper handle on the left side of the stove operates
The damper is open when the handle points to the rear,
enabling smoke to pass directly into the chimney. The damper
the griddle or doors are opened.
The damper is closed when the handle points down. Smoke
travels through the secondary combustion system where
it can be further burned, before passing up the chimney,
Figure 2.3.
The damper should always be either fully open or fully
closed. There are no intermediate positions. When
the handle into the locked position.
regulations to alter this setting or otherwise operate this
wood heater in a manner inconsistent with operating
instructions in this manual.
WARNING
!
The primary air control lever, on the right of the stove,
controls the amount of incoming air for starting, maintaining,
automatically maintains the heat output at a constant level
for a more even heat over the life of the burn.
faster, while less air prolongs the burn at a lower heat output
level.
the lever toward the rear of the unit, Figure 2.2.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 93-90-586000C
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
FlexBurn®, minimize thermal stress by letting the plates
Burn only solid wood in the Dauntless FlexBurn®Wood
Stove, and burn it directly on the grate. Do not elevate the
is against the law to operate this wood heater in a manner
inconsistent with operating instructions in this manual.
start or “freshen up”
The following procedures are important for reliable, clean
Cold start:
When starting your stove at room temperature and when no
burning coals are present the following kindling procedure
has been found to be the most reliable.
wall. Place a small amount of newspaper on top of this
pile with one or two small pieces of kindling on top. This
is referred to as a top down method and while providing a
slower start, also serves to preheat the combustion properly
resulting in a reliable start., Figure 2.4.
and unburned wood against the rear wall. Add several
pieces of larger split wood between 2 to 3 inches in diameter
kindling coals. Close the doors and bypass to engage the
combustion system. The air should remain on high for up
to one hour or until the wood is mostly converted to coals.
After a hot bed of coals is produced, open the door and
bypass damper and push the remaining coals again toward
the rear wall. Add large pieces of wood starting against the
bypass immediately after loading the stove.
should burn for at least 30 minutes prior to reducing the
primary air setting.
D. Ways to Add Fuel
easiest way to add fuel, Figure 2.5.
®Wood Stove is not
approved for operation with the front doors open.
With the bypass damper open and the primary air set to its
highest position, light the newspaper. Leave the front door
cracked until the kindling ignites, then close the doors.
To open the front doors, insert the handle into the door latch
stub and turn it clockwise, Figure 2.6.
the handle counterclockwise. The doors will draw in slightly,
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.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/2310 3-90-586000C
The catalyst will initiate combustion of smoke and particulates
the startup operation steps in the previous section the stove
the combustor starts working, heat generated by burning
the smoke will keep it working.
To determine whether the combustor is operating, refer to
the temperature probe which shows the operating range of
the catalytic combustor. This is located on the back of the
stove and is viewed from the top.
NOTE:
damper for the temperature probe to fully adjust to the new
catalyst range, add fuel or open the bypass damper to allow
the catalytic combustor is running too hot and may be
reduce the catalyst temperature and adding less wood with
each loading can also help if overheating is persistent. Do
not add wood to the stove if the probe reads above the
operate catalyst range.
as dry slab wood or wood with below 14% moisture content.
This may result in continuous very high temperatures in the
secondary combustion area and damage the combustor.
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
combustor and cause smoke to spill into the room. Coal
smoke can also poison the catalyst so that it won’t operate
properly.
NOTE: The catalytic combustor is fragile and will crack if
subjected to thermal shock. Thermal shock can occur when
refueling with wet wood or closing the bypass damper too
early after refueling.
gloves to protect your hands and forearms.
loading doors. Stir the hot coals to allow ash to fall through
wall and leveled depending on the amount of coals. Add
fresh wood and close the loading door and bypass damper.
control to any setting immediately after loading the stove.
and either the top or front loading door. Stir the coals to
allow ash to fall through the grate. Push the remaining coals
and set the primary air to the highest position. Allow the
A proper bed of coals is critical to the performance of the
Dauntless stove. The rear refractory wall of the stove should
be almost entirely white in color with proper operation. This
indicates the combustion system is running at a proper
or develops a dark brown color, it is likely that the coal bed
above instructions and adjust the amount of kindling or time
at high air settings to get the system hotter. Wood size or
excessive moisture may also cause lower than desirable
stove temperatures.
While not required, operating your stove with the catalytic
combustor installed creates optimum conditions for
to 15% on low burn, making sure you get the most heat out
of each load of wood.
the catalytic material. The element sits at the bottom
of the secondary combustion chamber. Smoke, gases
and particulates that are not fully combusted during the
secondary combustion process pass through the catalyst,
lower emissions.
WARNING
!
DO NOT OPERATE THE STOVE WITH THE ASH
DOOR OPEN. OPERATION WITH THE ASH DOOR
OR LOSS OF LIFE.
Counterclockwise
to Close
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 113-90-586000C
Your stove has andirons to keep logs away from the glass
viewing, and should be left in place. Since the andirons may
slightly hinder refueling through the front doors, most stove
owners will prefer the convenience of top loading through
the griddle. Do not place fuel between the andirons and the
doors.
The Dauntless FlexBurn®is designed to burn natural wood
only; do not burn fuels other than that for which it was
designed.
Burning any materials not allowed in these instructions, or
You’ll enjoy the best results when burning wood that has
Note: Properly seasoned
burn construction materials; they often contain chemicals
and metals that can damage the inside surfaces of the
stove and pollute the air. Do not burn ocean driftwood; when
it burns, the salt it contains will attack the cast iron.
The best hardwood fuels include oak, maple, beech, ash,
outside under cover for at least one year.
include tamarack, yellow pine, white pine, Eastern red cedar,
term storage, be sure to keep wood a safe distance from the
stove and keep it out of the areas around the stove used for
refueling and ash removal.
An optional surface thermometer tells you when to adjust
the air control, and when to refuel, Figure 2.7.
in the middle of the griddle.
For example, when the thermometer registers at least
stove is hot enough and it may be time to close the damper
that the stove will warm up much sooner than the chimney,
operation. When thermometer readings drop below 350°F.
rate or to reload the stove. A temperature reading over
burn rate.
Use the following temperature ranges as a guide:
low to medium heat output.
heat output.
®continuously
draft.
The control setting also depends on your particular
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
Dauntless FlexBurn®, and could even damage the stove.
Symptoms of too much draft include an uncontrollable
smoke leaking into the room through the stove or chimney
connector joints or low heat output.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/2312 3-90-586000C
stove on the windward side of the house can provide the
combustion air supply needed.
Another option for getting more combustion air to the stove
areas provisions for outside combustion air are required in
all new construction.
determine the amount of heat and the length of burn you
should expect from various settings.
Most installations do not require a large amount of
combustion air, especially if adequate draft is available.
heater by altering the air control adjustment range outlined
in these directions.
E. Ash Disposal
DO NOT OPERATE THE STOVE WITH THE ASH DOOR
OPEN. OPERATION WITH THE ASH DOOR OPEN CAN
LIFE.
Routine ash removal is important for ease of maintenance,
and is important for the stove’s durability. 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
the grate. Stir the ash with a shovel or poker so that it falls
through the grate slots.
IMPORTANT: Check the level of ash in the ash pan before
of the pan, empty the pan according to this procedure:
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,
stove.
counterclockwise to close.
Close
• Slide the cover onto the pan, making sure it is securely
closed, Figure 2.9.
the ash pan.
• Remove the ash pan, making sure to keep it level.
disposing of the ash. You may need to lift the latch end
of the door slightly to align the latch with the mating part
on the stove bottom.
• Properly dispose of the ash in a metal container with a
all combustible material.
• Return the ash pan to its original position in the stove,
and close and latch the ash door.
WARNING
!
Do not operate the stove with the ash door open. This
the stove, void the warranty, or even lead to a house
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 133-90-586000C
CAUTION
!
Never use your household or shop vacuum cleaner to
remove ash from the stove; always remove and dispose
of the ash properly.
Empty the ash pan regularly, typically every one to three
days. The frequency will vary depending on how you
operate your Dauntless FlexBurn®: ash will accumulate
faster at higher heat outputs.
Removed ash should be placed outdoors in a metal
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.
F. Opacity (Visible Smoke)
This is the measure of how cleanly your appliance is burning.
an object is totally obscured by the smoke column from a
chimney, and 0% opacity means that no smoke column can
be seen. As you become familiar with your appliance, you
should periodically check the opacity. This will allow you to
and odor from the appliance resulting from the curing
of paint and burning off of any oils remaining from
manufacturing.
DISSIPATE SMOKE AND ODORS!
• dors may be irritating to sensitive individuals.
• Smoke detectors may activate.
CAUTION
!
Fire Risk
•
WARNING
!
•
•May generate carbon monoxide if burn material other
than wood.
May result in illness or possible death.
Fire Risk
Keep combustible materials, gasoline and other
WARNING
!
• Combustible materials may ignite.
vicinity.
• Keep all such liquids well away from the appliance
while it is in use.
Negative pressure results from the imbalance of air available
lower levels of the house.
Causes include:
• Range hoods
• Combustion air requirements for furnaces, water
appliances and other combustion appliances
• Clothes dryers
• Upper level air leaks such as:
prevailing winds during the heating season
• Ensure adequate outdoor air for all combustion appliances
and exhaust equipment
• Ensure furnace and air conditioning return vents are not
located in the immediate vicinity of the appliance
• Avoid installing the appliance near doors, walkways or
small isolated spaces
• Attic hatches weather stripped or sealed
• Attic mounted duct work and air handler joints and seams
taped or sealed
Asphyxiation Risk
• Negative pressure can cause spillage of
combustion fumes, soot and carbon monoxide.
• Appliance needs to draft properly for safety.
WARNING
!
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/2314 3-90-586000C
An easy way to test your chimney draft is to close the stove’s
air control open and closed. Results are not always instant;
you may need to wait a few minutes for a change in the
change, then the draft isn’t strong enough yet to let you close
the damper, and you’ll need to open it for awhile longer and
good performance and a safe system.
Conclusion:
only vary your technique, mostly your timing, to achieve good
with good performance and years of reliable heating.
H. Important Information
Creosote
Condensed creosote is volatile, and can generate chimney
combination of installation features and operational steps that
will encourage good draft and minimize creosote production.
the keys to creosote accumulation, it makes sense to line a
chimney to match the stove’s outlet size, for safety reasons
as well as performance. Canadian law requires a matching
chimney; in the US, the National Fire Protection Association
stove or insert. Some localities enforce the NFPA guidelines
as part of their building codes.
Fuel: Even the best stove installation will not perform well
‘Green’ wood contains a lot of moisture; it will burn, but some
of the heat potential is used to boil the extra moisture from
the wood. This reduces the amount of heat that reaches your
home and can contribute to a creosote problem. There are
a sense of its weight; it can lose a third or more of its weight
as it dries. Also look at the ends of a log; as it dries it shrinks
and often cracks. The more weathered and cracked a piece
is, the drier it is.
Dry wood burns readily with a good chimney draft. But with
modern stoves, wood can be too dry and too volatile. Smoke
and combustible gases can ‘gas out’ from the wood quickly
the stove needs to cool down. You should open the damper
the wood moisture is not too low.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 153-90-586000C
completely before beginning any maintenance procedure.
This wood appliance needs periodic inspection and repair for
this wood appliance in a manner inconsistent with operating
instructions in this manual.
Care of the Cast Iron Surface
An occasional dusting with a dry rag will keep the painted
cast iron of your Dauntless FlexBurn®looking new.
The stove’s paint can be touched up as needed. First, mask
the areas, such as enameled parts, glass, or handles, around
the spot to be painted. Clean the spot with a wire brush.
brush, or steel wool.
Then, touch up the stove with high temperature stove paint.
Apply the paint sparingly; two light coats of paint are better
than a single heavy one.
Care of the Porcelain Enamel Surface
Use a dry or slightly damp rag or soft brush to remove spills
only a kitchen appliance cleaner or polish recommended for
use on enamel surfaces.
Allow to dry completely before operating stove.
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
surfaces of the stove.
• Rinse the glass thoroughly.
• Dry the glass completely.
Do not operate your stove if the glass in the doors is damaged.
5 mm ceramic glass supplied by Vermont Castings. Do not
use substitutes.
3
3 Maintenance
Glass Panel
Gasket
Right Door
2. Place the doors face down on a padded work surface. Be
especially careful with enameled doors.
3. Remove the screws that hold the glass retainer clips in
place, and remove the clips.
4. 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, Figure 3.2.
3. Replace the doors on the stove.
properly. Adjust as necessary.
Bolts
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/2316 3-90-586000C
Adjusting Screw Lock Nut Damper
Roller
Lock Nut
Set Screw
Shoulder Screw
Flat Washer
(as needed)
Your Dauntless FlexBurn®
make a tight seal between some parts. With use, particularly
on moving parts, gaskets can become brittle and compressed
periodic replacement.
The sizes of replaceable gasket are listed below, along with
their applications.
each other.
replacement from your Vermont Castings’ Authorized Dealer.
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, regardless
of the gasket location. Follow these steps:
1. Remove the existing gasket by grasping an end and pulling
A handle on the left side of the stove controls the damper.
The handle attaches to the damper rod with a set screw.
Periodically 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
positioned vertically when the door is closed.
compress and the latch may need adjustment. To adjust the
handle, follow this procedure:
3.4.
3. Rotate the pawl 180°. Replace the lock nut. Tighten the
set screw, Figure 3.4.
pawl rotation.
Test the door seal. Close the door on a dollar bill and attempt
gasket isn’t snug enough at that spot. Continue to make
small adjustments until the setting is right.
area. Pack more cement or a smaller diameter gasket into the
channel beneath the gasket so the main gasket is raised and
replacement are given later in this section.
(as Needed)
The tension on the Dauntless FlexBurn’s damper is adjustable
to compensate for compression of the gasket that seals the
1. Remove the griddle. Loosen the lock nut at the center of
the damper, Figure 3.3.
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
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 173-90-586000C
Cement
Stove Gasket
gasket in place.
E. The Chimney System
Creosote
Your Dauntless FlexBurn®is designed to reduce creosote
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
6. Starting at one end, press the gasket into the channel,
Figure 3.6. Ensure a good joint where the gasket meets
before trimming any excess. Do not overlap the gasket
ends or leave ends with ragged edges.
surface to seat the gasket evenly in its channel. Close
and latch the door to do this, or tap other parts with the
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
latch to accommodate the new gasket; after a few weeks,
it may need tightening to compensate for compression of
the new gasket.
but these are not subject to the same wear and deterioration
need to replace these gaskets unless the involved parts are
Refer to the service parts list for gasket replacement.
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, Figure 3.5.
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 unraveling.
When wood is burned slowly, it produces tar, organic vapors
and moisture that combine to form creosote. The creosote
and have a clearly understood plan on how to handle one.
• Close the damper and air control lever.
• Get everyone out of the house.
• Call the Fire Department.
season as part of a regular maintenance schedule. To inspect
the chimney, let the stove cool completely. Then, using a
fashion, the stove must be disconnected to provide better
viewing access.
Clean the chimney using a brush the same size and shape
brush up and down the liner, causing any deposits to fall
to the bottom of the chimney where they can be removed
Clean the chimney connector by disconnecting the sections,
wire brush. Reinstall the connector sections after cleaning,
being sure to secure the joints between individual sections
with sheet metal screws.
your local Vermont Castings dealer or a professional chimney
sweep.
WARNING
!
certain conditions of use, creosote buildup may occur
rapidly.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 183-90-586000C
The Chimney Connector
Two Weeks:
necessary.
Two Months:
attention to the horizontal runs of chimney connector, and
the elbows. Clean the system if necessary.
• Disassemble the chimney connector and take it outdoors
for inspection and cleaning. Replace weak sections of
connector.
a masonry chimney should be made by a professional
mason. Replace damaged sections of prefabricated
chimney. Your local Vermont Castings dealer or a
chimney sweep can help determine when replacement
is necessary.
• Thoroughly clean the chimney.
F. Maintenance Schedule
The Stove
• Check damper ramp adjustment and damper tightness.
When closing the damper, there should be a distinct stop
handle does not click over into the closed position or if
the damper falls open on its own after manually closing
the damper, the damper ramp needs to be tightened to
ensure damper sealing and positive engagement of the
damper system. Refer to page 16 for instructions on how
to adjust the damper ramp.
Daily:
• Ashes should be removed before they reach the top of
the ash pan. Check accumulation at least once a day.
• Keep the area around the stove clear of any combustible
materials such as wood, furniture or clothing.
Two Months:
• Check door handle to be sure it is working properly.
Gasketing becomes compressed after a period of time.
Adjust handle tightness if necessary.
• Check leg bolts and heat shield screws; tighten if
necessary.
• If installed:
and physical damage. Clean the combustor as needed.
• Check gasketing for wear, and replace if necessary.
• Remove ashes from the ash pan and replace with a
the interior of the stove dry.
• Clean the dust from the inner sides of bottom, rear or pipe
heat shields if your stove is equipped with them. Clean
• Touch up the black paint.
package. This should be done in conjunction with annual
inserted in the passage, Figure 3.7.
combustion system.
Clean out any
ash build up
Remove
Access Cover
CAUTION
!
BURN UNTREATED WOOD ONLY. OTHER MATERIALS
SUCH AS WOOD PRESERVATIVES, METALS, FOILS,
The Dauntless FlexBurn®is designed to burn equally well
with the catalyst. The following section only applies if the
and installed. The Dauntless FlexBurn®is designed and
either be replaced or removed completely.
sluggishly and produce noticeable smoke at the outlet of
the venting system. The simplest situation in that case is to
catalytic. The catalyst can then be replaced as time allows
without producing a smoky burn or low heat output.
Under normal operating conditions, the catalytic combustor
the combustor periodically to ensure that it is functioning
properly, as well as to determine when it needs to be replaced.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 193-90-586000C
When to Suspect a Combustor Problem
The best way to evaluate the performance of your Dauntless
FlexBurn’s combustor is to observe the amount of smoke
the damper closed to route smoke through it as described
smoke leaving the chimney.
• Then, open the stove damper and once again check the
smoke leaving the chimney.
damper is open and exhaust does not pass through the
steam from wet wood. Steam dissipates in the air quickly;
established coal bed is required for catalytic combustion to
occur.
as well, such as the weather or a change in the quality of
are a good solution under these conditions.
Catalyst
Access Door
Also, consider any changes in your operating routine.
decline in performance, inspect and clean the combustor if
necessary. Be sure to protect any surface you use for setting
the stove parts aside.
combustor by lifting up and pulling towards you, Figure 3.8.
NOTE
in poorer performance than burning properly seasoned
fuel. Reloading with green wood can also thermal shock
the catalyst, resulting in cracking, or the eventual fallout,
of the honeycomb substrate. You may have to run your
using green or wet wood.
outside and clean it by blowing air gently through it. Do
not push anything through the honeycomb; the combustor
should be cleaned by forcing air through the combustor
air.
broken in pieces or has sections missing, it should be
removed or replaced. Call your local Vermont Castings
Authorized Dealer for a replacement catalyst.
in the stove and replace the refractory access door.
Vermont Castings • Dauntless FlexBurn Owner’s Manual_R17 • 2020 - ___ • 09/23 203-90-586000C
4
4
and the corrective action to be taken.
Contact your dealer for additional information regarding operation and troubleshooting.
Visit www.vermontcastings.com to locate a dealer.
Start Fire Problems Possible Cause Solution
• Excessive smoke spillage
• Burns too slowly
• Not enough heat output
Use dry kindling, more paper. Arrange
Check for restricted termination cap
Refer to Negative Pressure section
Wood condition is too wet, too large
Bed of coals not established before
adding wood
Flue blockage such as birds’ nests or
leaves in termination cap
sweep.
Down draft or negative pressure
Competition with exhaust devices
Fire burns too fast
Extremely dry or soft wood
Mix in hardwood.
established.
Check for correct vent height; too much
vertical height creates overdrafting.
Check location of vent termination
Coal Bed too small
bed and move coals to the rear of the
Excessive Coal Bed Reduce burn rate and allow coals to
burn down before reloading.
This manual suits for next models
3
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