Vermont Castings Encore 2040-CAT-C User manual
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 18390-204C
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
WARNING
!
• Do not touch glass until it is cooled
•
• Keep children away
•
• Alert children and adults to hazards of high
temperatures
•
• Keep clothing, furniture, draperies and other
For use in the
Encore®Model 2040-CAT-C
NOTICE: SAVE THESE INSTRUCTIONS
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/232 8390-204C
the utmost 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.
reference.
hand built cast iron appliance.
Agency’s emission limits for wood heaters sold on or after
Please read this entire manual before you operate your new
stove. Failure to follow instructions may result in property
damage, bodily injury, or even death.
Fuels used in gas, wood
burning or oil fired appliances, and the products of
combustion of such fuels, contain chemicals known to
other reproductive harm.
8390-038B
U.S. ENVIRONMENTAL PROTECTION AGENCY Export
Stove. May not be sold or operated within the United States.
MODEL / MAQUETTE / MODELL: “Intrepid®Flexburn”
LISTED SOLID FUEL ROOM HEATER BURNING FIREPLACE STOVE
HOMOLOGUE POELE A COMBUSTIBLE SOLIDES
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.
BARCODE LABEL
BARCODE LABEL
HF
Serial No.
Numéro de série.
Seriennummer.:
Date of Manufacture / Date de fabrication:
Manufactured by / Fabriqué par: Hearth and Home Technologies 352 Mountain House Road, Halifax PA 17032
Europe
Country Standards Approved By Report #
Japan
Europe - French
Europe - Flemmish
Japan
SAMPLE
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
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:
!
........................................................
.............................................
...............................
C. California..................................................................
...........................................
................................................
A. Appliance Controls...................................................8
..........................................
.........................................
.....................................................
............................................................
..........................................
...................................................
...............................................
3 Maintenance
.......................
.................................................
............................................
D. Ash Door Adjustment...............................................
...............................................
..............................................18
..............................................
............................................21
5 Reference Material
..................................... 22
....................................
.................................................
= Contains updated information
Î
Î
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
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:
!$
% ' % # *
$'%!
#!+
%#!%'
-%++'#!
%.+#
WARRANTY PERIOD:
%''#*%''
/'+0"!
#%'12'
!'#
!3/415''''65
'''#!7+
''#
Page 1 of 2
4021-645L 10/20
Component
Parts Labor Gas Pellet Wood Electric Venting Component Parts Covered by this Warranty
XAll parts except as covered by Warranty Conditions,
Warranty Exclusions, and Warranty Limitations listed
XX Igniters, Auger Motors, Electronic Components, and
Glass
X
Electrical components limited to modules, remotes/wall
switches, valves, pilots, blowers, junction boxes, wire
harnesses, transformers and lights (excluding light bulbs)
XX Molded Refractory Panels, Glass Liners
XVent Free Burners, Vent Free Logs
XX Castings, Medallions and Baffles
6 years 3 years XCatalysts
7 years 3 years XX Manifold tubes, HHT Chimney and Terminations
10 years 1 year XBurners, logs and refractory
Limited
Lifetime 3 years XXX Firebox and heat exchanger, FlexBurn®System
(engine, inner cover, access cover and fireback)
1 Year None XXXXX All purchased replacement parts
Warranty Period HHT Manufactured Appliances and Venting
All parts including handles, external enameled
components and other material except as covered by
Warranty Conditions, Warranty Exclusions, and
Warranty Limitations listed
2 years
X1 Year XXX
2 Years
5 years 1 year
Firepots, burnpots, mechanical feeders/auger
assemblies
3 years X
A. Warranty Policy
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
WARRANTY CONDITIONS:
8 9!-"%
'!":!"
!#
8 !%'#
8 !%!"
"#
8 ' % # * '
!"#;$'
%'#
8 <!'##'
'%#$
''#!''%#
WARRANTY EXCLUSIONS:
!%'4
8 '/#;''+
/#!7%#
8 =' /'
+0#
8 >.'%#!
4'$/$'7'?'#
8 @+'#!
%#
8 =' ' 4 6
' ' ' / : 1
':A'':2
'B
:D-'0''
E$F'+:G
/:I
+"!:J/+
"!':BK7
#
8 <F!'.#
8 ;F+'/'#
8 !M'%+M#*
' # '
/''#
This warranty is void if:
8 ! F/ 7 ''
#OF/'/B'
'$'/#
8 !.'#
8 !''
'#
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
4021-645L 10/20
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
1
1
• This appliance is approved for mobile home installations
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
•
installation.
your dealer for replacement glass.
!WARNING
This product and the fuels used to operate this product
to cause birth defects or other reproductive harm. For
C. California
standards using cord wood.
Catalytic Information
**Actual tested HHV:
***EPA BTU Output:
****Peak BTU/Hour Output:
Other Important Information
Vent Size:
Firebox Size:
Fuel
LABORATORY:
REPORT NO.
TYPE:
ELECTRICAL
RATING:
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
appliance, reserves the right to alter its products, their
maintenance can cause injury or property damage.
installer, service agency or your dealer.
heaterin a manner inconsistent with the operating instructions
in this manual.
Technologies.
components.
Fire Risk.
responsibility for, and the warranty will be voided
WARNING
!
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/238 8390-204C
2
2
A. Appliance Controls
primary air control
damper
and deactivate the combustion system, Figure 2.1.
directions are facing the stove.
conveniently located and easy to operate.
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.
travels through the secondary combustion system where
it can be further burned, before passing up the chimney,
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.
Primary Air
Ashdoor
Andirons
Low Heat
The handle may be positioned anywhere between the
Closed
intermediate positions.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
sharp blow from a hammer or from the thermal shock of
it 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:
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
cracked until the kindling ignites, then close the doors.
and unburned wood against the rear wall. Add several
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 rear wall and on top of the coals. Close the doors and
bypass immediately after loading the stove.
primary air setting.
To open the front doors, insert the handle into the door latch
handle in the right door to the left and up (to the open
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.
holder behind the left front leg of the stove.
WARNING
!
operated only with doors fully open or doors fully
Clockwise to
Counterclockwise
to Close
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
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.
This may result in continuous very high temperatures in the
secondary combustion area and damage the combustor.
these may poison the catalyst and prevent it from operating
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.
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.
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
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
stove temperatures.
combustor installed creates optimum conditions for
of each load of wood.
with the catalytic material. The element sits at the bottom
and particulates that are not fully combusted during the
secondary combustion process pass through the catalyst,
lower emissions.
Thecatalyst will initiatecombustion of smokeandparticulates
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.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 118390-204C
WARNING
!
OR LOSS OF LIFE.
Andirons Help Protect the Glass
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.
designed.
has not been properly seasoned. (Note: Properly seasoned
and metals that can damage the inside surfaces of the
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.
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.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/2312 8390-204C
Surface Thermometer is a Valuable Guide to Operation
An optional surface thermometer tells you when to adjust
the air control, and when to refuel, Figure 2.8.
in the middle of the griddle.
stove is hot enough and it may be time to close the damper
that the stove will warm up much sooner than the chimney,
rate or to reload the stove. A temperature reading over
burn rate.
low to medium heat output.
heat output.
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.
chimney.
smoke leaking into the room through the stove or chimney
connector joints or low heat output.
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
combustion air, especially if adequate draft is available.
heater by altering the air control adjustment range outlined
in these directions.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
LIFE.
before it reaches the top of the ash pan. Check the level at
through the grate slots.
IMPORTANT: Check the level of ash in the ash pan before
down into the ash pan.
• Close the griddle or doors, and unlatch the ash door,
stove.
counterclockwise to close.
Close
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.
and close and latch the ash door.
the ash pan.
CAUTION
!
of the ash properly.
days. The frequency will vary depending on how you operate
at higher heat outputs.
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.
WARNING
!
the stove, void the warranty, or even lead to a house
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
This is the measure of how cleanly your appliance is burning.
an object is totally obscured by the smoke column from a
be seen. As you become familiar with your appliance, you
should periodically check the opacity. This will allow you to
odor from the appliance resulting from the curing of paint
• dors may be irritating to sensitive individuals.
•
CAUTION
!
Fire Risk
•
WARNING
!
•
•
than wood.
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.
lower levels of the house.
Causes include:
• Combustion air requirements for furnaces, water
appliances and other combustion appliances
• Clothes dryers
prevailing winds during the heating season
all combustion appliances
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
• Appliance needs to draft properly for safety.
WARNING
!
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
An easy way to test your chimney draft is to
stabilize, then see whether you can vary the strength of the
yet to let you close the damper, and you’ll need to open it for
rewarded with 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
combinationofinstallationfeaturesandoperational 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
as part of their building codes.
Fuel:
the wood. This reduces the amount of heat that reaches your
home and can contribute to a creosote problem. There are
and often cracks. The more weathered and cracked a piece
is, the drier it is.
and combustible gases can ‘gas out’ from the wood quickly
the wood moisture is not too low.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
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
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.
than a single heavy one.
Care of the Porcelain Enamel Surface
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 with water or a cleaner made especially for
surfaces of the stove.
• Dry the glass completely.
Replace Broken Glass Immediately
Donot operate your stove if the glass in the doors is damaged.
use substitutes.
3
3 Maintenance
the door bottom slightly outward and pull down to release
the upper hinge pin. Place the doors face down on a
doors.
place, and remove the clips.
resilient so that the glass will seal properly against the door.
1. Center the glass on the gasket.
properly. Adjust as necessary.
Glass Panel
Gasket
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
E. Gasket Replacement
particularly on moving parts, gaskets can become brittle and
will need periodic replacement.
The sizes of replaceable gasket are listed below, along with
their applications.
each other.
follow the standard safety procedure for working with dusty
The procedure for replacing gaskets is the same, regardless
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 load doors are factory adjusted for clearance, proper
sometimes shift in transit or from use and may need to be
adjust and align the doors.
Just like the load doors, the ash door is factory adjusted for
adjustment to minimize sagging at the latch side, a simple
Note: For video instruction please refer to www.
adjustable to compensate for compression of the gasket that
clockwise with an Allen wrench provided with your stove.
Pressure Adjusting
Damper
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 188390-204C
Cement
Stove Gasket
gasket in place.
F. The Chimney System
Creosote
inspection and maintenance must still be performed. For
safety, good stove performance, and to protect your chimney
and chimney connector, inspect your chimney and chimney
connector on a regular schedule. Clean the system if
necessary.Failure to keep the chimney and connector system
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
let the cement that holds the new gasket dry thoroughly.
it may need tightening to compensate for compression of
the new gasket.
All Gasketed Construction Gaskets
but these are not subject to the same wear and deterioration
need to replace these gaskets unless the involved parts are
• All connections between the stove plates.
the channel of any remaining cement or bits of gasket.
cutting surface, and cut it at the marked spot with a utility
knife.
Twist the ends slightly to keep the gasket from unraveling.
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,
being sure to secure the joints between individual sections
with sheet metal screws.
sweep.
WARNING
!
certain conditions of use, creosote buildup may occur
rapidly.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
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
connector.
a masonry chimney should be made by a professional
chimney sweep can help determine when replacement
is necessary.
• Thoroughly clean the chimney.
G. The Catalytic Element
Maintenance ScheduleThe Stove
• 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.
necessary.
• Check gasketing for wear, and replace if necessary.
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
CAUTION
!
COAL, PLASTIC, GARBAGE, SULPHUR, OR OIL, MAY
Thiswoodheater contains a catalytic combustor, which needs
heaterin a manner inconsistent with the operating instructions
in this manual.
the combustor periodically to ensure that it is functioning
properly, as well as to determine when it needs to be replaced.
damage two to three times per year. Clean the combustor
as needed.
The refractory package that houses the catalytic combustor
combustor.
Clean out any
ash build up
components
combustion system.
Vermont Castings • Encore Model 2040-CAT-C Owner’s Manual_R13 • 2019 - ___ • 06/23 8390-204C
When to Suspect a Combustor Problem
The best way to evaluate the performance of your appliance’s
combustor is to observe the amount of smoke leaving the
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.
smoke does not.
as well, such as the weather or a change in the quality of
are a good solution under these conditions.
poorer performance than burning properly seasoned fuel.
catalyst, resulting in cracking, or the eventual fallout, of the
using green or wet wood.
Also, consider any changes in your operating routine.
decline in performance, inspect and clean the combustor if
the stove parts aside.
Also, consider any changes in your operating routine.
decline in performance, inspect and clean the combustor if
the stove parts aside.
NOTE
in poorer performance than burning properly seasoned
the catalyst, resulting in cracking, or the eventual fallout, of
using green or wet wood.
Catalyst
Access Door
To assure a long life for the combustor, it is recommended
to service the combustor on a regular basis based on the
necessary.
outside and clean it by blowing air gently through it. Do
ceramic base, shortening the catalyst’s life and reducing
broken in pieces or has sections missing, it should be
Dealer for a replacement element.
access door.
inspectingthe chimney and the chimney connector frequently
during this period.
the chimney system for a few weeks to ensure that proper
performance continues.
the catalytic element will need to be replaced. Contact your
about a replacement element.
NOTE:
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3
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