Vermont Castings Dauntless FlexBurn User manual

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/2113-90-586000i
Installation Manual
Installation & Appliance Set-Up
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
NOTICE: DO NOT DISCARD THIS MANUAL
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
followed exactly, a re may result causing
property damage, personal injury, or death.
WARNING
!
• Donotstoreorusegasolineorotherammablevapors
and liquids in the vicinity of this or any other appliance.
• Donotoverre-Ifapplianceorchimneyconnector
glows, you are over ring. Over ring will void your
warranty.
• Comply with all minimum clearances to combustibles
asspecied.Failuretocomplymaycausehousere.
Installationandserviceofthisapplianceshouldbeperformedby
qualiedpersonnel.Hearth&HomeTechnologiesrecommends
HHTFactoryTrainedorNFIcertiedprofessionals.
HOT SURFACES!
Glass and other surfaces are hot
duringoperationANDcooldown.
Hot glass will cause burns.
WARNING
!
• Do not touch glass until it is cooled
• NEVERallowchildrentotouchglass
• Keep children away
• CAREFULLYSUPERVISEchildreninsameroomas
replace.
• Alert children and adults to hazards of high
temperatures
• High temperatures may ignite clothing or other
ammable materials.
• Keep clothing, furniture, draperies and other
ammablematerialsaway.
Dauntless FlexBurn®
Catalytic / Non-Catalytic
Wood Stove

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/21 23-90-586000i
TABLE OF CONTENTS
Safety Alert Key:
• DANGER! Indicatesahazardoussituationwhich,ifnotavoidedwill result in death or serious injury.
• WARNING!Indicatesahazardoussituationwhich,ifnotavoidedcould result in death or serious injury.
• CAUTION! Indicatesahazardoussituationwhich,ifnotavoided,could result in minor or moderate injury.
• NOTICE:Indicatespracticeswhichmaycausedamagetotheapplianceortoproperty.
!
1 Product Listing and Important Safety Information
A. ApplianceCertication ............................................. 3
B. BTU&E󰀩ciencySpecications............................... 3
C. MobileHomeApproved(USAONLY) ...................... 3
D. GlassSpecications ................................................ 3
E. Non-CombustibleMaterials ..................................... 4
F. Combustible Materials ............................................. 4
G. California.................................................................. 4
2 Getting Started
A. DesignandInstallationConsiderations ................... 5
B. FireSafety ............................................................... 5
C. NegativePressure ................................................... 5
D. ToolsAndSuppliesNeeded..................................... 6
E. InspectApplianceandComponents ........................ 6
F. InstallChecklist........................................................ 7
3 Dimensions and Clearances
A. Appliance Dimensions ............................................. 8
B. HearthProtectionRequirements ............................. 9
C. Clearances to Combustibles.................................... 10
D. FireplaceInstallation................................................ 11
E. LocatingYourAppliance&Chimney........................ 12
F. ChimneyTerminationRequirements........................ 12
G. ChimneyLocation(2-10-3Rule).............................. 13
4 Chimney Systems
A. Venting&DraftManagement................................... 14
B. VentingComponents .............................................. 15
C. ChimneySystems.................................................... 15
D. InstallingChimneyComponents .............................. 17
5 Appliance Set-Up
A. RemovingUnitFromSkid........................................ 18
B. Assembly ................................................................. 18
C. SmokeandCODetectors&SafetyTips.................. 19
D. ReversibleFlueCollar ............................................. 19
E. OutsideAirInstallation ............................................. 20
6 Mobile Home Installation......................................... 21
= Contains updated information




Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/2133-90-586000i
A. Appliance Certication
MODEL: Dauntless FlexBurn®WoodStove
LABORATORY: TestedandListedbyOMNITest
Laboratories,Inc
REPORT NO. 0061WS104E,0061WS104S
TYPE: SolidFuelTypeRoomHeaters
STANDARD(s): ASTME2515,ASTME3053,
UL-1482(R2015),ULC-S627-00,B415.1
Fire Risk.
Hearth & Home Technologies disclaims any
responsibility for, and the warranty will be voided
by, the following actions:
WARNING
!
• Installationanduseofanydamagedappliance.
• Modicationoftheappliance.
• InstallationotherthanasinstructedbyHearth&Home
Technologies.
• Installation and/or use of any component part not
approvedbyHearth&HomeTechnologies.
• Operating appliance without fully assembling all
components.
• Operatingappliancewithoutlegsattached(ifsupplied
withit).
• DoNOTOverre-Ifapplianceorchimneyconnector
glows,youareoverring.
Anysuchactionthatmaycausearehazard.
11 Product Listing and Important Safety Information
B. BTU & E󰀩ciency Specications
TheVermontCastingsDauntlessFlexBurn®
WoodAppliancemeetstheU.S.Environmental
ProtectionAgencyCertiedtocomplywiththe
2020 particulate emission standards using
cord wood.
EPA Report #: 240-19(without catalyst)
246-19(catalytic)
EPA Certied Emissions: 1.1g/hr(withoutcatalyst)
1.2g/hr(catalytic)
*LHV Tested E󰀩ciency: 81.6% (withoutcatalyst)
82.6% (catalytic)
**HHV Tested E󰀩ciency: 76.9% (withoutcatalyst)
77.9% (catalytic)
***EPA BTU Output:
12,250-49,430
(withoutcatalyst)
14,520-41,940
(catalytic)
****Peak BTU/Hour Output: 45,500
Vent Size: 6Inch(152mm)
Firebox Size: 1.8 cu. ft.
Outside Air Size: 3Inch
Recommended Length: 16Inch
Max. Wood Length: 18Inch
Fuel Orientation: East,West
Fuel SeasonedCordwood
(20%moistureorless)
*Weighted average LHV e󰀩ciency using Douglas Fir
dimensional lumber and data collected during EPA
emissions test.
**Weighted average HHV e󰀩ciency using Douglas
Fir dimensional lumber and data collected during EPA
emissions test.
***E󰀩cienciesarebasedontestresultscalculatedusing
B415; these calculated e󰀩ciencies are then used to
calculateoutputBTU’s.
****ApeakBTUoutoftheappliancecalculatedusingthe
maximumrsthourburnratefromtheHighEPATestand
theBTUcontentofcordwood(8600)timesthee󰀩ciency.
This wood appliance needs periodic inspection and repair for
properoperation.Itisagainstfederalregulationstooperate
this wood appliance in a manner inconsistent with operating
instructions in this manual.
C. 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 installed.
• Thestructuralintegrityofthemobilehomeoor,ceiling,
and walls must be maintained.
• Theunitmust beboltedtothe oor.Thiscanbedone
using an appropriate fastener for the application.
• The appliance must be properly grounded to the frame
of the mobile home with #8 copper ground wire, and
chimneymustbelistedtoUL103HToralistedUL-1777
fulllengthsix”(152mm)diameterlinermustbeused.
• Mobile Home Brackets must be installed in a mobile
home installation, supplied with stove.
D. Glass Specications
This appliance is equipped with 5mm ceramic glass.
Replaceglassonlywith5mmceramicglass.Pleasecontact
your dealer for replacement glass.

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/2143-90-586000i
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
Forassistanceoradditionalinformation,consultaqualied
installer, service agency or your dealer.
Hearth & Home Technologies WILL NOT warranty
appliancesthatexhibitevidenceofover-ring.Evidenceof
over-ringincludes,butisnotlimitedto:
• Warped Damper
• Deteriorated refractory
• Deteriorated interior components
E. Non-Combustible Materials
Material which will not ignite and burn, composed of any
combination of the following:
 -Steel   -Plaster
 -Brick   -Iron
 -Concrete  -Tile
 -Glass   -Slate
Materials reported as passing ASTM E 136, Standard
Test Method for Behavior of Metals, in a Vertical Tube
Furnace of 750° C.
F. Combustible Materials
Materialmadeof/orsurfacedwithanyofthefollowing
materials:
 -Wood  -CompressedPaper
 -PlantFibers  -Plastic
 -Plywood/OSB  -SheetRock(drywall)
Anymaterialthatcanigniteandburn:ameproofedornot,
plasteredornon-plastered.
NOTE:Thisinstallationmustconformwithlocalcodes.
Intheabsenceoflocalcodesyoumustcomplywiththe
UL1482-11,UL737-11,(UM)84-HUDandNPFA211in
theU.S.A.andtheULC S627-00andCAN/CSA-B365
Installation Codes in Canada. NOT APPROVED FOR
MOBILE HOME INSTALLATIONS IN CANADA!
NOTE:Hearth&HomeTechnologies,manufacturerofthis
appliance, reserves the right to alter its products, their
specicationsand/orpricewithoutnotice.
!WARNING
This product and the fuels used to operate this product
(wood),andtheproductsofcombustionofsuchfuels,can
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
G. California

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/21 53-90-586000i
A. Design and Installation Considerations
Consideration must be given to:
 • Safety
• Convenience
 • Tra󰀩cow
• Chimney and chimney connector required
Itisagoodideatoplanyourinstallationonpaper,usingexact
measurementsforclearancesandoor protection,before
actuallybeginningtheinstallation.If youarenotusingan
existing chimney, place the appliance where there will be a
clearpassageforafactory-builtlistedchimneythroughthe
ceiling and roof.
Werecommendthataqualiedbuildinginspectorandyour
insurance company representative review your plans before
and after installation.
Ifthisapplianceisinanareawherechildrenmaybenear
it is recommended that you purchase a decorative barrier
to go in front of the appliance. Remembertoalwayskeep
children away while it is operating and do not let anyone
operate this appliance unless they are familiar with these
operating instructions.
C. Negative Pressure
Negativepressureresultsfromtheimbalanceofairavailable
fortheappliancetooperateproperly.Itcanbestrongestin
lower levels of the house.
Causes include:
• Exhaustfans(kitchen,bath,etc.)
• Rangehoods
• Combustion air requirements for furnaces, water
appliances and other combustion appliances
• Clothes dryers
• Locationofreturn-airventstofurnaceorairconditioning
• ImbalancesoftheHVACairhandlingsystem
• Upperlevelairleakssuchas:
- Recessedlighting
- Attichatch
- Ductleaks
B. Fire Safety
To provide reasonable re safety, the following should be
given serious consideration:
1. Install at least one smoke detector on each oor of
your home to ensure your safety. They should be
located away from the heating appliance and close
to the sleeping areas. Follow the smoke detector
manufacturer’s placement and installation instructions,
and be sure to maintain regularly.
22 Getting Started
Checkbuildingcodespriortoinstallation.
• InstallationMUSTcomplywithlocal,regional,stateand
national codes and regulations.
• Consult insurance carrier, local building, re o󰀩cials
or authorities having jurisdiction about restrictions,
installation inspection, and permits.
CAUTION
!
Asphyxiation Risk
• DONOTCONNECTTHISAPPLIANCETO
ACHIMNEYFLUESERVICINGANOTHER
APPLIANCE.
WARNING
!
• DONOTCONNECTTOANYAIRDISTRIBUTION
DUCTORSYSTEM.
Mayallowuegasestoenterthehouse.
2. AconvenientlylocatedClassAreextinguishertocontend
withsmallresresultingfromburningembers.
3. ACOdetectorshouldbeinstalledintheroomwiththe
appliance.
4. A practiced evacuation plan, consisting of at least two
escape routes.
5. Aplantodealwithachimneyreasfollows:
In the event of a chimney re:
a. Evacuatethehouseimmediately
b. Notifyredepartment.
Notice: Hearth & Home Technologies assumes no
responsibility for the improper performance of the
appliance system caused by:
• Inadequatedraftduetoenvironmentalconditions
• Down drafts
• Tight sealing construction of the structure
• Mechanical exhausting devices
• Overdraftingcausedbyexcessivechimneyheights
• Idealperformanceiswithheightofchimneybetween16
feet(4.88m)measuredfromthebaseoftheappliance.
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 Installation Manual_R8 • 2020 - ___ • 11/2163-90-586000i
D. Tools And Supplies Needed
Before beginning the installation be sure the following tools
and building supplies are available:
E. Inspect Appliance and Components
• Removeapplianceandcomponentsfrompackagingand
inspect for damage.
• Reporttoyourdealeranypartsdamagedinshipment.
• Read all the instructions before starting the installation.
Follow these instructions carefully during the
installation to ensure maximum safety and benet.
Tominimizethee󰀨ectsofnegativeairpressure:
• Install outside air to the stove with the intake facing
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
• Recessedlightingshouldbea“sealedcan”design
• Attic hatches weather stripped or sealed
• Atticmountedductworkandairhandlerjointsandseams
taped or sealed
• Basement installations should be avoided
•Reciprocatingsaw •Framingmaterial
• Pliers • Hightempcaulkingmaterial
•Hammer •Gloves
• Phillips screwdriver • Framing square
•Flatbladescrewdriver •Electricdrillandbits
•Plumbline •Safetyglasses
•Level •Tapemeasure
• Misc. screws and nails
•1/2-3/4in.length,#6or#8self-drillingscrews
• Installationanduseofanydamagedappliance.
• Modicationoftheappliance.
• InstallationotherthanasinstructedbyHearth&Home
Technologies.
• Installation and/or use of any component part not
approvedbyHearth&HomeTechnologies.
• Operating appliance without fully assembling all
components.
• Operatingappliancewithoutlegsattached(ifsupplied
withappliance).
• DoNOTOverre-Ifapplianceorchimneyconnector
glows,youareoverring.
Any such action that may cause a re hazard.
Fire Risk.
Hearth&HomeTechnologiesdisclaimsany
responsibility for, and the warranty will be
voided by, the following actions:
WARNING
!
Fire Risk
Inspectapplianceandcomponentsfor
damage. Damaged parts may impair safe
operation.
• DoNOTinstalldamagedcomponents.
• DoNOTinstallincompletecomponents.
• DoNOTinstallsubstitutecomponents.
Reportdamagedpartstodealer.
WARNING
!

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/21 73-90-586000i
ATTENTION INSTALLER:
Follow this Standard Work Checklist
Thisstandardworkchecklististobeusedbytheinstallerinconjunctionwith,notinsteadof,theinstructionscontainedinthisinstallationmanual
Customer:
DateInstalled:
Lot/Address:
LocationofAppliance:
Installer:
Dealer/DistributorPhone#:
Serial#:
Model :
WARNING! Risk of Fire or Explosion! Failure to install appliance according to these instructions can lead to a fi re or explosion.
Appliance Install YES IF NO, WHY?
Veriedclearancetocombustibles.
Appliance is leveled and connector is secured to appliance.
Hearthextensionsize/heightdecided.
OutsideAirInstalled.
Floor protection requirements have been met.
Ifapplianceisconnectedtoamasonrychimney,itshouldbecleanedand
inspectedbyaprofessional.Ifinstalledtoafactorybuiltmetalchimney,
the chimney must be installed according to the manufacturer’s instructions
and clearances.
Chimney
Chimneycongurationcomplieswithdiagrams.
Chimneyinstalled,lockedandsecuredinplacewithproperclearance.
Chimneymeetsrecommendedheightrequirements(Minimum16Feet).
Roofashinginstalledandsealed.
Terminations installed and sealed.
Clearances
Combustiblematerialsnotinstalledonnon-combustibleareas.
Veriedallclearancesmeetinstallationmanualrequirements.
Mantels and wall projections comply with installation manual requirements.
Protective hearth strips and hearth extensions installed per manual
requirements.
Appliance Setup
Allpackagingandprotectivematerialsremoved.
Firebrick/Refractory,baffleandceramicblanket(ifapplicable)installedcorrectly
All labels have been removed from the door.
Allpackagingmaterialsareremovedfrominside/undertheappliance.
Manual bag and all of its contents are removed from inside/under the
appliance and given to the party responsible for use and operation.
Hearth & Home Technologies recommends the following:
• Photographingtheinstallationandcopyingthischecklistforyourle.
• Thatthischecklistremainvisibleatalltimesontheapplianceuntiltheinstallationiscomplete.
Comments:Furtherdescriptionoftheissues,whoisresponsible(Installer/Builder/OtherTrades,etc.)andcorrectiveactionneeded:
Comments communicated to party responsible by on
(Builder/Gen.Contractor) (Installer) (Date)
F. Install Checklist

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/2183-90-586000i
33 Dimensions and Clearances
A. Appliance Dimensions NOTE:FlueCollarsizeis6”(152mm)diameter(ID)
Figure 3.1-FrontView
4” / 102 mm
From Glass
Flue Centerline
to glass surface
Door opening
width
24-5/8”
625 mm
17-1/2”
445 mm
16-3/8”
416 mm
18-7/16”
479 mm
23-1/16”
586 mm
25-3/4”
654 mm
25-5/8”
651 mm
25-3/4”
654 mm
13-3/8”
340 mm
27”
686 mm
22-5/8”
575 mm
Figure 3.2 -TopView
4” / 102 mm
From Glass
Flue Centerline
to glass surface
Door opening
width
24-5/8”
625 mm
17-1/2”
445 mm
16-3/8”
416 mm
18-7/16”
479 mm
23-1/16”
586 mm
25-3/4”
654 mm
25-5/8”
651 mm
25-3/4”
654 mm
13-3/8”
340 mm
27”
686 mm
22-5/8”
575 mm
Figure 3.2-SideView-TopVent
4” / 102 mm
From Glass
Flue Centerline
to glass surface
Door opening
width
24-5/8”
625 mm
17-1/2”
445 mm
16-3/8”
416 mm
18-7/16”
479 mm
23-1/16”
586 mm
25-3/4”
654 mm
25-5/8”
651 mm
25-3/4”
654 mm
13-3/8”
340 mm
27”
686 mm
22-5/8”
575 mm
Figure 3.4-SideView-RearVent
4” / 102 mm
From Glass
Flue Centerline
to glass surface
Door opening
width
24-5/8”
625 mm
17-1/2”
445 mm
16-3/8”
416 mm
18-7/16”
479 mm
23-1/16”
586 mm
25-3/4”
654 mm
25-5/8”
651 mm
25-3/4”
654 mm
13-3/8”
340 mm
27”
686 mm
22-5/8”
575 mm

Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/21 93-90-586000i
B. Hearth Protection Requirements
FLOOR PROTECTION: It is necessary to install a Type I
oor protector. (Spark & Ember protection ONLY)
Floorprotectormustbenon-combustiblematerialextending
undertheappliancetoaminimumof16”(406mm)infrontof
glass,and8”(203mm)tobothsidesofthefuelloadingdoor.
Openthedoorandmeasure8”(203mm)fromthesideedge
oftheopeninginthefaceoftheappliance.*Seeexception.
In Canada,similaroorprotectionmustbeprovided18”(457
mm)infrontand8”(203mm)fromthesidesandrearofthe
appliance, Figure 3.8
*EXCEPTION: Non-combustible floor protections must
extendbeneaththeuepipewheninstalledwithhorizontal
ventingandextend2”(51mm)beyondeachside,Figure3.7.
Fire Risk
Hearth pads must be installed exactly as
specied. High temperatures or hot embers
may ignite concealed combustibles.
WARNING
!
35-3/8 in.
minimum
39-3/8 in.
minimum
16 in
(FRONT DOOR OPENING)
8
in
USA
Figure 3.5 Figure 3.6
61-3/8 in.
30-1/2 in.
36-5/8 in.
56-3/8 in.
16 in.
(front door opening)
USA
Corner hearth pad dimensions with single wall pipe
1600mm
810mm
931mm
1467mm
457mm
(front door opening)
CANADA
Figure 3.7
457MM
(FRONT DOOR OPENING)
203MM
1114mm
minimum
1254mm
minimum
203MM
Must extend 51mm
beyond each side
of pipe (shaded area)
CANADA
50 in.
22-1/2 in.
36-5/8 in.
48-3/8 in.
16 in.
(front door opening)
USA
Figure 3.8
Corner hearth pad dimensions with double wall pipe
1321MM
605MM
930MM
1265MM
457mm
(front door opening)
CANADA
CAUTION
HearthandHomeTechnologiesdoesnotrecommendadhesive
based vinyl ooring due to thermal expansion. Floating-style
ooring(LVP-luxuryvinylplankorLVT–luxuryvinyltile)canbe
used, but it will reach temperatures up to 110 °F in a room with
ambienttemperatureof70°F.Consultooringspecicationsto
ensure compatibility.
WhenusingLVP/LVTooring,woodstoveandinsertsrequire
57inches ofalternativeooring infrontofthestove orinsert
beforeusing LVP/LVT. Whetherthe stoveorinsert sitsush
on the oor or is elevated on a raised hearth, 57 inches of
alternativeooringisrequiredinfrontofthestoveorinsert.
Forallotherooring,continuetofollowclearancetocombustible
requirements in the installation manual.
NOTICE: Clearances that do not meet the minimum guidelines
could result in damage or buckling to the vinyl ooring and is
done at the installer’s risk.


Vermont Castings • Dauntless FlexBurn Installation Manual_R8 • 2020 - ___ • 11/2110 3-90-586000i
C. Clearances to Combustibles
Minimum Clearances to Combustible Materials
Note:A,CandFDimensionsaretothecenteroftheuecollar
Installation: Full Vertical
A B C D E F G H*
SingleWallPipe 18” 14” 26-1/2” 14” 15” 19-1/2” 57-1/2” 18”
Double Wall Pipe 16” 12” 24-1/2” 12” 7” 12” 57-1/2” 18”
Installation: 90 Degree Elbow o󰀨 Top of Appliance through back wall
SingleWallPipe 16” 12” 24-1/2” 12” 15” 19-1/2” 57-1/2” 18”
Installation: Horizontal Through the Wall
SingleWallPipe 10” 26-1/2” 14”
ForFactoryAlcove:6”diameterlistedDoublewallairinsulatedconnectorpipewithUL103HTlistedfactorybuiltClassA
ChimneyorMasonrychimney.MaximumdepthAlcoveshallbenomorethan48”(1219mm)andthereferencedAlcove
clearances.CanadamustcomplywithCAN/ULC-S269M87forthe650°factorybuiltchimney.
*Follow pipe manufacturers clearances as required.
Fire Risk
• Comply with all minimum clearances to
combustiblesasspecied.
• Failuretocomplymaycausehousere.
WARNING
!
G
A
Alcove Side View
C
B
A
D
Back wall/Sidewall
C
Alcove Top View
F
E
Corner Installation
Figure 3.9
10”
254 mm
Mantal
12” Max
52-1/2”
1334 mm
26-1/2”
673 mm
Horizontal Through Wall
Top and Side View
G
H*
Appliance to
Ceiling Clearance
Figure 3.10