Vermont Castings Encore Flexburn 2040 Mounting instructions

Homeowner’s Installation
and Operating Manual
For use in the
United States and Canada

30005295 12/10 Rev. 5






Nous recommandons que nos appareils de chauffage
au bois soient installés et entretenus apr des
professionnels qui ont été accrédités aux É.-U. par le
National Fireplace Institute® (NFI) comme étant des
spécialistes du NFI en matière d’appareilsde chauffage
au ois, ou qui sont accrédités au Canada
dans le cadre du Programme
de formation technique
en énergie du bois (WETT)




2425
Encore NC Cover
5/05

2
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
This manual describes the installation, operation, and
maintenance of the Vermont Castings Encore Model
2040 Non-Catalytic / Catalytic wood burning heater. This
heater meets the U.S. Environmental Protection Agen-
cy’s emission limits for wood heaters sold on or after July
1, 1990. Under specific test conditions this heater has
been shown to deliver heat at rates ranging from 9,900
to 34,000 Btu/hr.
The Encore Model #2040 has been tested and is listed
by OMNI-Test Laboratories of Portland, Oregon. The test
standards are ANSI/UL-1482 and ANSI/UL-737 for the
United States, and ULC S627 for Canada. The Encore
is listed for burning wood only. Do not burn other fuels.
We recommend that you hire a professional installer
certified by the Wood Heat Education and Research
Foundation (WHERF) or the Wood Energy Technical
Training (WETT) to install your stove, or to advise you on
the installation should you attempt to install it yourself.
Please read this entire manual before you install and use
your new stove. Failure to follow instructions may result
in property damage, bodily injury, or even death.
The Encore 2N1 is approved for use in mobile homes in
the United States and Canada when installed with Ver-
mont Castings Mobile Home Kit. Refer to and follow the
instructions provided with the Mobile Home Kit (#0336_
to ensure safe installation.

Specifications ........................................................3
Installation .............................................................4
Clearance Charts.................................................12
Mobile Home Installation .....................................16
Assembly .............................................................17
Operation .............................................................20
Draft Management ...............................................26
Maintenance ........................................................29
The Catalytic Element .........................................33
Replacement Parts ..............................................35
Warranty ..............................................................39


Congratulations on your choice of a Vermont Castings Encore stove. With this purchase you have made a commit-
ment to make the hearth a place of warmth, beauty and comfort in your home. At MHSC, we share that joy and appre-
ciation for the hearth. We assure you that your cast-iron Vermont Castings stove has been made with the utmost care
and will provide you with many years of service.
As you become acquainted with your new stove, you will find that its appearance is matched by its functionality, due to
cast iron’s unique ability to absorb and radiate heat.
Also, MHSC products are among the cleanest-burning wood stoves and fireplaces available today. As an owner of a
Vermont Castings stove, you make a strong statement for pollution-free energy. However, clean burning depends on
both the manufacturer and the operator. Please read this manual carefully to understand how to properly operate and
maintain your stove.
At MHSC, we are equally committed to your satisfaction as a customer. That is why we maintain an exclusive network
of the finest dealers in the industry. Our dealers are chosen for their expertise and dedication to customer service.
They are factory-trained and knowledgeable about every MHSC product. Feel free to contact your Authorized Vermont
Castings Dealer anytime you have a particular question about your stove or its performance.
This manual contains valuable instructions on the installation and operation of your Vermont Castings Encore. It also
contains useful information on maintenance. Please read the manual thoroughly and keep it as a reference.
Sincerely,
All of Us at MHSC
Warming Shelf
#0200 Classic Black
#0205 Biscuit
#0207 Ebony
#0201 Bordeaux
#0208 Brown Majolica
#3265* Outside Air Kit
#3185 Outside Air Adapter
#0336* Mobile Home Kit
#0127 Firescreen
FK26 Fan Kit
#3190 Connector Pipe Heat Shield
A line of porcelain enamel stove pipe is available in
Biscuit, Bordeaux, Ebony, Brown Majolica colors.
*If you order #3265 or #0336, you must also need
#3185.

 Fuels used in gas, woodburn-
ing or oil fired appliances, and the products of combus-
tion of such fuels, contain chemicals known to the State
of California to cause cancer, birth defects and other
reproductive harm.
California Health & Safety Code Sec. 25249.6

3
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295


EPA Emissions rating - Noncatalytic ................ 1.6 g/hr*
Range of heat output - Noncatalytic .......9,900 - 34,000
EPA Emissions rating - Catalytic .................... 1.1 g/hr*
Range of heat output -
Catalytic .........................11,800 to 30,000 BTU/hr.*
Peak heat output ................................ 65,000 BTU/hr.**
Area heated .........................Up to 1,800 Square feet***
Fuel length ................................................................22”
Fuel capacity .............................. 50 pounds, hardwood
Loading .....................................................Front and top
Chimney Connector:
for 6” flue collar .................... 6” (152 mm) diameter
for 8” oval flue collar ............. 8” (203 mm) diameter
Chimney Flue Size:
with 8” Chimney Connector ..8” (203 mm) minimum
with 6” Chimney Connector ..6” (152 mm) minimum
Flue exit position......................................... Top or Rear
Primary Air ...... Manually Set, Thermostatically Maintained
Secondary Air ...............................Fixed, self-regulating
Ash handling system ..................... Removable ash pan
Glass panels ........................ High-temperature ceramic
Weight ............................................... 475 lbs. (215 kg.)
Width (leg to leg) ..................................... 27” (686 mm)
Depth (leg to leg) ..................................... 15” (381 mm)
Height to top of flue collar ........................ 25” (635 mm)
*Under specific conditions during EPA emissions test-
ing.
** This value can vary depending on how the stove
is operated, the type and moisture content of the fuel
used, as well as the design, construction and climatic
location of your home. Figures shown are based on
maximum fuel consumption rates obtained under labo-
ratory conditions and on average efficiencies.
*** These values are based on operation in building
code-conforming homes under typical winter climate
conditions in New England. If your home is of nonstan-
dard construction (e.g. unusually well insulated, not in-
sulated, built underground, etc.) or if you live in a more
severe or more temperate climate, these figures may
not apply. Since so many variables affect performance
consult your Authorized Dealer to determine realistic
expectations for your home.
 Encore 2040 dimensions.
Drawing Not to Scale
16M"
(44 mm)
25"
(635 mm)
Top exit
flue collar
height
27"
(686 mm)
256M"
(654 mm)
1856O"
(470 mm)
756M"
(184 mm)
27"
(686 mm)
2256M"
(565 mm)
1556O"
(394 mm)
5"
(127 mm)
2(6" (73 mm)
236M"
(603 mm)
15"
(381 mm)
36M"
(95 mm)
226M"
(578 mm)

Encore 2N1
dimensions

4
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295








Before you begin an installation, be sure that:
• Your stove and chimney connector will be far
enough from combustible material to meet all clear-
ance requirements.
• The floor protector is large enough and is construct-
ed properly to meet all requirements.
• You have all necessary permits from local authori-
ties.

Your local building official is the final authority for ap-
proving your installation as safe and determining that it
meets local and state codes.
The metal label permanently attached to the back of
every Vermont Castings’ stove indicates that the stove
has been tested to current UL and ULC standards, and
gives the name of the testing laboratory. Clearance
and installation information also is printed on the label.
When the stove is installed according to the information
both on the label and in this manual, local authorities
usually will accept the label as evidence that the instal-
lation meets codes and can be approved.
However, codes vary in different areas. Before starting
the installation, review your plans with the local building
authority. Your local dealer can provide any additional
information needed.
For any unresolved installation issues, refer to the
National Fire Protection Association’s publication
ANSI/NFPA 211 Standard for Chimneys, Fireplaces,
Vents and Solid Fuel Burning Appliances. For Canada,
the equivalent publication is CSA CAN-B365 Installation
Code for Solid Fuel Burning Appliances and Equipment.
These standards are the basis for many national codes.
They are nationally recognized and are accepted by
most local authorities. Your local dealer or your local
building official may have a copy of these regulations.






In some modern, super-insulated homes, there may be
inadequate air supply for combustion because of insuf-
ficient air infiltration into the building. Such air enters a
home through unsealed cracks and openings. Exhaust
fans in kitchens or bathrooms can compete with the
stove for available air and compound the problem.
When poor draft is caused by a low infiltration rate,
opening a ground floor window on the windward side of
the house and near the stove will usually alleviate the
problem.
A better solution is to install a permanent outside air
supply to the stove and/or room. In fact, bringing air
for combustion from outside the home directly to the
air inlet of the stove is required for new construction in
some areas.
Pressure variations within the house do not affect a
stove equipped with an outside air supply, and im-
proved stove performance often results. An Outside Air
Kit for the Encore is available from your local dealer.

You must connect the Encore to a code-approved
masonry chimney with a flue liner, to a relined masonry
chimney that meets local codes, or to a prefabricated
metal chimney that complies with the requirements
for Type HT chimneys in the Standard for Chimneys,
Factory-Built, Residential Type and Building Heating
Appliance, UL 103. Figure 2 illustrates the two types.
The chimney and chimney connector must be in good
condition and kept clean.
ST241
chimney types
12/13/99 djt
A prefabricated double-
wall insulated chimney
A tile-lined
masonry
chimney
ST241
 Approved chimney types.

5
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
If you use an existing masonry chimney, it must be
inspected to ensure it is in a safe condition before
the stove is installed. Your local professional chimney
sweep, building inspector, or fire department official will
be able to inspect the chimney or provide a referral to
someone who can.
The chimney must extend at least 3’ (914 mm) above
the highest point where it passes through or near a
roof, and at least 2’ (610 mm) higher than any part of a
building within 10’ (3 m) horizontally. (Fig. 3)
For proper draft and good performance, any chimney
used with a Encore should extend at least 16’ (5 m)
above the flue collar of the stove.
2’ Min.
2’ Min.
3’
Min.
0 To 10’
3’
Min.
0 To 10’
AC617
RLTSKC8
2/11/98
Reference
Point AC617
 The 2’-3’10’ Chimney Rule.

A prefabricated metal chimney must be one tested and
listed for use with solid-fuel burning appliances to the
High-Temperature (H.T.) Chimney Standard UL-103-
1985 (2100°F) for the United States, and High Temper-
ature (650°C) Standard ULC S-629 for Canada.



An Encore with an 8” (203 mm) flue collar is approved
for venting into a masonry chimney with a nominal flue
size of 8” x 8” (203 x 203 mm) or 8” x 12” (203 x 305
mm), and into a round flue with nominal flue size of 8”
(203 mm). An Encore with a 6” (152 mm) flue connector
is approved for venting into a masonry chimney with a
nominal flue size of 8” x 8” (203 x 203 mm), and into a
round flue with nominal flue of 6” (152 mm).



Whatever the flue collar size, an Encore may be vented
into larger chimneys as well. However, chimneys
with liners larger than 8” x 12” (203 x 305 mm) may
experience rapid cooling of smoke and reduction in
draft, especially if the chimneys are located outside the
home. These large chimneys may need to be insulated
or have their flues relined for proper stove performance.
Accessories to help make the connection between
stainless steel chimney liners and your Encore are
available through your local dealer.

A chimney connector is the single-wall pipe that con-
nects the stove to the chimney. The chimney itself is the
masonry or prefabricated structure that encloses the
flue. Chimney connectors are used only to connect the
stove to the chimney.
Single-wall connectors should be made of 24 gauge
or heavier steel. Do not use galvanized connector; it
cannot withstand the high temperatures that can be
reached by smoke and exhaust gases, and may re-
lease toxic fumes under high heat. The connector may
be 6” (152 mm) or 8 “ (203 mm) in diameter.
If possible, do not pass the chimney connector through
a combustible wall or ceiling. If passage through a com-
bustible wall is unavoidable, refer to the section on Wall
Pass-Throughs. Do not pass the connector through an
attic, a closet or similar concealed space. The whole
connector should be exposed and accessible for in-
spection and cleaning.

An inspection of the chimney must confirm that it has
a lining. Do not use an unlined chimney. The chimney
should have no cracks, loose mortar, other signs of
deterioration, and blockage. Repair any defects before
the chimney is used with your stove.
Unused openings in an existing masonry chimney must
be sealed with masonry to the thickness of the chimney
wall, and the chimney liner should be repaired. Open-
ings sealed with pie plates or wallpaper are a hazard
and should be sealed with mortar or refractory cement.
In the event of a chimney fire, flames and smoke may
be forced out of these unused thimbles.
The chimney should be thoroughly cleaned before use.
A newly-built masonry chimney must conform to the
standards of your local building code or, in the absence
of a local code, to a recognized national code. Masonry
chimneys must be lined, either with code-approved
masonry or pre-cast refractory tiles, stainless steel
pipe, or a code-approved, “poured-in-place” liner. The
chimney’s clean-out door must seal tightly. A loose or
leaky clean-out door can weaken chimney draft, caus-
ing performance problems.

6
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295


Follow the installation instructions of the chimney
manufacturer exactly as you install the chimney. The
manufacturer of the chimney will supply the acces-
sories to support the chimney, either from the roof of
the house, at the ceiling of the room where the stove is
installed, or from an exterior wall.
Special adapters are available from your local dealer
to make the connection between the prefabricated
chimney and the chimney connector. The top of such
adapters attaches directly to the chimney or to the
chimney’s ceiling support package, while the bottom of
the adapter is screwed to the chimney connector.
These adapters are designed so the top end will fit out-
side the inner wall of the chimney, and the bottom end
will fit inside the first section of chimney connector.


Both freestanding masonry chimneys and fireplace ma-
sonry chimneys may be used for your installation.

If the chimney connector must pass through a combus-
tible wall to reach the chimney, follow the recommen-
dations in the Wall Pass-Through section that follows.
The opening through the chimney wall to the flue
(the “breech”) must be lined with either a ceramic or
metal cylinder, called the “thimble”, which is cemented
securely in place. Most chimney breeches incorporate
In horizontal runs of un shielded chimney connector,
maintain a distance of 30” (762 mm) from the ceiling.
Keep it as short and direct as possible, with no more
than two 90° turns. Slope horizontal runs of connector
upward 1/4” per foot (6mm per meter) going from the
stove toward the chimney. The recommended maxi-
mum length of a horizontal run is 3’ (1 m), and the total
length should be no longer than 8’ (2.4 m). In cathedral
ceiling installations, extend the prefabricated chimney
downward to within 8’ (2.4 m) of the stove. This will help
maintain a good draft by keeping the smoke warm, so
that it rises readily.
Wear gloves and protective eyewear when drilling, cut-
ting or joining sections of chimney connector.

• Begin assembly at
the flue collar of the
stove. Insert the
first crimped end
into the stove’s flue
collar, and keep
each crimped end
pointing toward
the stove. (Fig. 4)
Using the holes in
the flue collar as
guides, drill 1/8” (3
mm) holes in the
bottom of the first
section of chimney connector and secure it to the
flue collar with three #10 x 1/2” sheet metal screws.
Lift off the griddle, and shield the stove’s surface
between the griddle opening and the front of the flue
collar to protect the finish when you drill the front
hole.
• Fasten each joint between sections of chimney
connector, including telescoping joints, with at least
three (3) sheet metal screws. The pre-drilled holes in
the top of each section of chimney connector serve
as guides when you drill 1/8” (3 mm) holes in the
bottom of the next section.
• Fasten the chimney connector to the chimney.
Instructions for various installations follow. Figure 5
illustrates the general layout of chimney connector
parts.
• Be sure the installed stove and chimney connector
are correct distances from nearby combustible mate-
rials.
 Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney con-
nector are available to simplify installations. They often
eliminate the need to cut individual connector sections.
Consult your local dealer about these special pieces.
ST492
Defiant
freestanding
installation
11/00
Chimney
Elbow
Slip Pipe
Standard
Connector
Oval to
Round Adapter
Flue Collar
Thimble
Flue In-
ner
Flue
ST492
 An exploded view of the chimney connection in a free-
standing masonry installation.
ST242
Chimney connector
12/13/99 djt
Flue Gas
Direction
Toward
Stove
ST242
 Chimney connector.

7
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
ST244
Plymouth
fplc over mantel
12/99
*
*
Check These
Clearances
Mantel
ST244
 In this installation, the chimney connector attaches to
the chimney above the fireplace opening.
Seal
This Off
ST243
thinble connection
12/13/99 djt
Thimble Sleeve
Chimney Connector
Flue
Keep
sleeve
end flush
with flue
tile
ST243
 The thimble, made of either ceramic or metal, must be
cemented securely in place.
thimbles, but the fit must be snug and the joint between
the thimble and the chimney wall must be cemented
firmly.
A special piece called the “thimble sleeve,” slightly
smaller in diameter than standard connectors and
most thimbles, will facilitate the removal of the chimney
connector system for inspection and cleaning. (Fig. 6)
Thimble sleeves are available from your local dealer.
To install a thimble sleeve, slide it into the breech until
it is flush with the inner flue wall. Do not extend it into
the actual flue passage, as this could interfere with the
draft.
• Check the clearance between the mantel and the
chimney connector, and any combustible trim or the
mantel.
• Check the clearance between the chimney connec-
tor and the ceiling. The clearance should be at least
30” (762 mm) with unshielded connectors. Consult
the clearance charts for other installation options.
• The fireplace damper must be sealed to prevent
room air from escaping up the flue. However, it
must be possible to re-open the damper to inspect
or clean the chimney.

If your fireplace opening height is at least 29" (737 mm),
you may install a Encore through the opening using a
“positive connection” kit, available from your local deal-
er. Positive connection kits ensure a tight fit between
the stove flue collar and the chimney flue. (Fig. 8)
Fireplace installations, whether connected to the flue
above or through the fireplace opening, have special
clearance requirements to adjacent trim and the man-
tel. You’ll find the required safe clearances for Encore
fireplace installations on Page 12.
Floor protection requirements also apply to fireplace
installations. This information is on Page 9.

Whenever possible, design your installation so the con-
nector does not pass through a combustible wall. If you
are considering a wall pass-through in your installation,
check with your building inspector before you begin.
Also, check with the chimney connector manufacturer
for any specific requirements.
The thimble sleeve should protrude 1-2” (25-50 mm)
into the room. Use furnace cement and thin gasketing
to seal the sleeve in place in the thimble. Secure the
chimney connector to the outer end of the sleeve with
sheet metal screws.
Without a thimble, a suitable length of chimney con-
nector can be extended through the breech to the inner
face of the flue liner, and cemented securely in place.
Additional pieces of connector are then attached with
sheet metal screws.

The chimney connector may be connected to the
chimney above the fireplace opening or through the
fireplace.

The Encore may be connected to a chimney above
a fireplace opening. (Fig. 7) In such installations, the
stove is positioned on the hearth in front of the fireplace
and the chimney connector rises from the stove top and
then angles ninety degrees back into the chimney. The
chimney liner should extend to the point at which the
chimney connector enters the chimney.
If the chimney connector in your installation enters the
chimney above a fireplace, follow all the guidelines
mentioned above for freestanding installations. In addi-
tion, give special consideration to the following points:

8
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
ST245
fireplace
flex connector
12/99
Flexible
Connector
Mantel Shield
Fireplace Adapter Kit
“Positive Connection”
ST245
 Through the fireplace installation.
DEF
IA
N
ST493
Brick pass thru
11/00
Wall Stud
Chimney
Connector
Floor Protec-
tion
12” of
Noncombustible
Material
ST493
 An approved wall pass-through for the United States.
Accessories are available for use as wall pass-
throughs. If using one of these, make sure it has been
tested and listed for use as a wall pass-through.
In the United States, the National Fire Protection As-
sociation (NFPA) has established guidelines for passing
chimney connectors through combustible walls. Many
building code inspectors follow these guidelines when
approving installations.
Figure 9 shows one NFPA-recommended method. All
combustible material in the wall is cut away from the
single-wall connector to provide the required 12” (305
mm) clearance. Any material used to close up the open-
ing must be noncombustible.
Three other methods are also approved by the NFPA:
• Placing a section of chimney connector inside a
ventilated thimble, which in turn is separated from
combustibles by 6” (152 mm) of fiberglass insulat-
ing material.
• Placing a section of chimney connector inside a
section of 9” (230 mm) diameter, solid-insulated,
factory-built chimney, with 2” (51 mm) of air space
between the chimney section and combustibles.
• Using a section of solid-insulated double-wall high
temperature chimney, with an inside diameter the
same as the chimney connector, at least one inch
of solid insulation, and a minimum of 9” (229 mm)
air space between the outer wall of the chimney
section and combustibles.
In Canada, The Canadian Standards Association has
established different guidelines for wall pass-throughs.
Figure 10 shows one method, in which all combustible
material in the wall is cut away to provide the required
18” (457 mm) clearance for the connector. The resulting
space must remain empty. A flush-mounted sheet metal
cover may be used on one side only. If covers must be
used on both sides, each cover must be mounted on
noncombustible spacers at least 1” (25 mm) clear of the
wall.
DEF
IA
N
T
ST494
steel
wall pass thru
11/00
18” (460mm) clear-
ance between pipe and
sides/top/bottom of
opening
ST494
 An approved wall pass-through for Canada.
Your local dealer or your local building inspector can
provide details for other approved methods of passing
a chimney connector through a combustible wall in your
area. In Canada, this type of installation must conform
to CAN/CSA-B365, Installation Code for Solid Fuel
Burning Appliances and Equipment.
 Do not vent your Encore into a factory-built
(zero-clearance) fireplace. These appliances and their
chimneys are specifically designed as a unit for use as
fireplaces. It may void the listing or be hazardous to
adapt them for any other use.



9
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

A tremendous amount of heat radiates from the bottom
plate of your stove. The floor area directly under and
around the stove will require protection from radiant
heat as well as from stray sparks or embers that may
escape the firebox.
Heat protection is provided with the use of the Bottom
Heat Shield supplied with the stove.
Most installations will require the bottom heat shield
to be attached. Only when the stove is placed on a
completely noncombustible surface such as unpainted
concrete over earth may it be used without the heat
shield.
Even when the bottom heat shield are installed, most
installations require special thermal protection (insula-
tion) for the floor beneath. Use an approved 1” (25 mm)
noncombustible hearth pad with k = 0.84 BTU/in ft2 hr
°F or an equivalent material with an R-value of at least
1.18. (Refer to “How to Determine if Alternate Floor
Protection Materials are Acceptable” section.) The floor
protector may be covered with a decorative noncom-
bustible material if desired. Do not obstruct the space
under the heater.
When using a fire screen with doors open, UL737,
Standard for Fireplace Stoves, use an approved 1” (25
mm) noncombustible hearth pad with k = 0.84 Btu/in
ft2 hr °F or an equivalent material with an R-value of
at least 1.18. (Refer to “How to Determine if alternate
Floor Protection Materials are Acceptable” section.)
The floor protector may be covered with a decorative
noncombustible material if desired. Do not obstruct the
space under the heater. An 8” chimney and chimney
connector is required an the bypass damper must be in
the fully open position.


Protection requirements vary somewhat between the
Untied States and Canada as follows:
 the floor protector is required
under the stove and must extend at least 16” (not
including the ash lip) from the front of the stove (“F”,
Fig. 11), and at least 6” from the sides and rear. (“D”
and “E”, Fig. 11)
In rear venting configurations, floor protection must also
extend under the chimney connector and 2” to either
side. (“C”, Fig. 11) For the 8” (203 mm) connector, the
protector must be a minimum of 12” (305 mm) wide.
For the 6” (152 mm) connector, the protector must be
10” (254 mm) wide. The protector must be centered
under the connector.
To meet these requirements, a floor protector must be
at least 39” wide and 45” deep.
 A noncombustible floor protector is required
under the stove as well. The floor protector must
extend 18” (457 mm) to the front (“F”, Fig. 11), and 8”
(203 mm) from the sides and rear. (“D” and “E”, Fig. 11)
To meet these requirements, a floor protector must be
at least 43” (1092 mm) wide and 49” (1245 mm) deep.


All floor protection must be noncombustible (i.e. met-
als, brick, stone, mineral fiber boards, etc.). Any organic
materials (i.e. plastics, wood paper products, etc.) are
combustible and must not be used. The floor protection
specified includes some form of thermal designation
such as R-value (thermal resistance) or k-factor (ther-
mal conductivity).

1. Convert specifications to R-value:
i. R-value given - no conversion needed.
ii. k-factor is given with a required thickness (T) in
inches:
iii. K-factor is given with a required thickness (T) in
inches:
iv. r-factor is given with a required thickness (T) in
inches: R = r x T
2. Determine the R-value of the proposed alternate
floor protector:
i. Use the formula in Step 1 to convert values not
expressed as R.
ii. For multiple layers, add R-values of each layer to
determine overall R-value.
D
E
A
B
A
E
C
ST500
Defiant
floor protection
1/31/02 djt
E
F
E
F
 
A. 39” 43” (1092 mm)
B. 45” 49” (1245 mm)
C. 12” 12” (305 mm) 8” Connector
10” 10” (250 mm) 6” Connector
D. 6” 8” (203 mm)
E. 6” 8” (203 mm)
F. 16” 18” (460 mm) ST500
 Required floor protection dimensions.
R = x T
1
k
R = x T
1
K x 12

10
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
R = x T = x 0.5 = 0.59
1
k
1
0.84
1
0.29
3. If the overall R-value of the system is greater than
the R-value of the specified floor protector, the alter-
nate is acceptable.
 The specified floor protector should be 1/2-
inch thick material with k-factor of 0.84. The proposed
alternate is 4” brick with an r-factor of 0.2 over 1/8”
mineral board with a k-factor of 0.29
Step a: Use formula above to convert specification to
R-value:
Step b: Calculate R of proposed system.
4” brick of r = 0.2, therefore:
Rbrick = 0.2 x 4 = 0.8
1/8” mineral board of k = 0.29, therefore
Rmineralboard = x 0.125 = 0.431
Rtotal = Rbrick + Rmineralboard = 0.8 + 0.431 = 1.231
Step c: Compare proposed system Rtotal of 1.231 to
specified R of 0.59. Since proposed system Rtotal is
greater than required, the system is acceptable.
Definitions
r = =
(ft2)(hr)(°F)
(Btu)(in)
1
k
(Btu)(ft)
(ft2)(hr)(°F)
K =
k = = K x 12
(Btu)(in)
(ft2)(hr)(°F)
R = (ft2)(hr)(°F)
Btu

Do not assume that your fireplace hearth is completely
noncombustible. Many fireplace hearths do not satisfy
the “completely noncombustible” requirement because
the brick or concrete in front of the fireplace opening
is supported by heavy wood framing. Because heat
passes readily through brick or concrete, it can easily
pass through to the wood. As a result, such fireplace
hearths can be a fire hazard and are considered a com-
bustible floor.
For all fireplace installations, follow the floor protection
guidelines described above, including the need for a
bottom shield. Keep in mind that many raised hearths
will extend less than the required clearance from the
front of the heater. In such cases, sufficient floor protec-
tion as described above must be added in front of the
hearth to satisfy the minimum floor protector require-
ment from the front of the stove: 16” (410 mm) in the
United States and 18” (460 mm) in Canada. Hearth
rugs do not satisfy the requirement for floor protection
as they are not fire proof.
Fireplace installations also have special clearance
requirements to the side walls, side decorative trim and
fireplace mantel. Refer to the information on fireplace
and mantel trim shields in this section.


Both a stove and its chimney connector radiate heat in
all directions when operating, and nearby combustible
materials can overheat dangerously if they are too close
to the heat source. A safe installation requires that ad-
equate clearance be maintained between the hot stove
and its connector and nearby combustibles.
Clearance is the distance between either your stove or
chimney connector, and nearby walls, floors, the ceiling,
and any other fixed combustible surface. The Encore
has specific clearance requirements that have been
established after careful research and testing. These
clearance requirements must be strictly observed.
In addition, keep furnishings and other combustible
materials away from the stove. In general, a distance
of 48” (1219 mm) must be maintained between the
stove and moveable combustible items such as drying
clothes, furniture, newspapers, firewood, etc. Keep-
ing those clearance areas empty assures that nearby
surfaces and objects will not overheat.

Clearance requirements are established to meet every
installation possibility, and they involve the combination
of these variables:
• When the stove pipe has no listed heat shield
mounted on it.
• When the wall has no heat shield mounted on it.
• When the wall has a heat shield mounted on it.
• When the wall and stove pipe have heat shields.
In general, the greatest clearance is required when you
place a stove and its connector near a wall with no heat
shield.
For example, when the Encore is installed using 6” con-
nector pipe parallel to the rear wall and no connector
shield is used, it must be at least 15” (381 mm) from the
wall behind it and at least 19” (483 mm) from walls on
either side. These dimensions are measured from the
back of the rear shroud and the side edge of the cast
iron top to the combustible wall.
If the Encore is installed in a corner and no shield is
used, the corners of the stove top must be at least 18Z\x”
(470 mm) from nearby walls.
Clearances may be reduced only by means approved
by the regulatory authority, and in accordance with the
clearances listed in this manual. Refer to Page 12 for
approved clearance reduction specifications.



11
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
ST248
wall shield construction
12/14/99 djt
Stud Wall
Framing
Wall Shield
Noncombus-
tible Spacers
and Fasteners
Drywall
Air Flow
Air Flow
Screen
Shield
Metal
Spacer
ST248
 Approved wall shield construction.
Noncombustible shields
installed 1” (25 mm) away from
the combustible surface on
noncombustible spacers, called
ventilated shields, may be used
to reduce clearances.
To protect a mantel from the
heat of a stove in a fireplace
installation, use a custom-
made ventilated mantel shield
that is at least 48” (1220 mm)
long, centered over the stove.
(Fig. 13) Ventilated shields for
side trim must extend the full
length of the trim.
An unprotected mantel (“A”, Fig. 14) cannot be more than
9” (230 mm) deep and must have a minimum clearance of
28” (711 mm), measured from the stove’s top plate. With
a ventilated shield, this clearance may be reduced safely
to 15” (381 mm).
Unprotected top trim (B) protruding 3/4” (19 mm) or less
from the face of the fireplace must be a minimum of 25”
(635 mm) from the stove’s top surface. With a ventilated
trim shield, this clearance may not be reduced safely.
Unprotected side trim (C) that protrudes 3/4” (19 mm) or
less from the face of a fireplace must have a minimum
clearance of 22” (554 mm), measured from the stove’s top
side edge. If the trim extends more than 3/4” (19 mm), it
is subject to the requirements for wall clearance.
The charts and sample installations that follow list all
the clearances required for the various installation
configurations of the Encore.
1" (25mm)
1/4" (6mm)
ST501
mantel and
trim shield
11/10/00 djt
ST501
 A custom-formed
mantel shield.

One way to reduce clearances is with a wall shield con-
structed of 24 gauge or heavier sheet metal, or of another
noncombustible material such as 1/2” (13 mm) insulation
board such as Durock® or Wonderboard®, or common brick
“laid on flat,” with the 3Z\x" (90 mm) side down.
Shields must be spaced out from the combustible surface
1" (25 mm) on noncombustible spacers, as in Figure 12.
The spacers should not be directly behind the stove or
chimney connector.
Air must be able to flow between the wall and the shield.
At least 50% of the bottom 1" (25 mm) of the shield must
be open, and the shield must be open at the top. Metal
screening across the top will keep small stray objects from
being trapped behind the shield. (Fig. 12)
The shield must be a minimum of 48" (1219 mm) tall, and
must extend at least 19" (483 mm) higher than the top
of the stove, whichever is higher. The shield behind the
chimney connector must be 30" (760 mm) wide, centered
behind the pipe; for installations that use an approved
prefabricated chimney to pass through the ceiling, the
shield behind the chimney connector must stop 1" (25
mm) below the ceiling.
With 8” connections and chimneys, because of potentially
higher pipe temperatures, the shield must extend the full
height of the wall (up to 9’ (2.7 m)) and stop 1” (25 mm)
below the ceiling.

A fireplace installation requires special clearance between
the side of the stove and the right and left walls, between
the side of the stove and the decorative side trim on the
fireplace face, and between the top of the stove and the
mantel.
ST253b
Encore
trim clearances
02/01 djt
CC
AB
D
 
A. Mantel 28” (711 mm) 15” (281 mm)
B. Top Trim 25” (635 mm) 15” (281 mm)
C. Side Trim 22” (554 mm) 11” (280 mm)
D. Side Wall 22” (559 mm) 11” (280 mm)

ST253b
 Maintain clearances to combustible components of
the mantelpiece.
Side
Wall

12
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
(A) 19” (B) 20” (C) 18Z\x” (D) 5” (E) 7” (F) 12”
(483 mm) (508 mm) (470 mm) (127 mm) (178 mm) (305 mm)
(G) 19” (H) 10” (I) 18Z\x” (J) 6” (K) 6” (L) 12”
(483 mm) (254 mm) (470 mm) (152 mm) (152 mm) (305 mm)
(M) 22” (N) 12” (P) 11” (Q) 12”
(559 mm) (305 mm) n/a (279 mm) (305 mm) n/a
(G) 18” (H) 7” (I) 12” (J) 4” (K) 5” (L) 5”
(457 mm) (178 mm) (305 mm) (102 mm) (127 mm) (127 mm)

 

For use with either 6” or 8” flue collar/chimney connection
    
    
     
     
Top Exit, 8” single
wall connector without
shields, vertical flue col-
lar heat shield installed
 single-wall
chimney connector heat
shield2, vertical flue col-
lar h.s. installed

No flue collar heat
shield
 double-wall
chimney connector3,
vertical flue collar heat
shield installed

All Installations (S) 48” (1219 mm)
The provided rear shroud must be used in all installations. The flue collar heat shield must be used in all vertical
installations.
1. A ceiling heat shield 24” (610 mm) in diameter and suspended 1” (25 mm) from the ceiling must surround the
pipe in installations where chimney penetrates the ceiling.
2. The connector pipe heat shield must extend 36” (914 mm) above flue collar.
3. Using listed double wall oval to round adapter when installing optional 8” oval flue collar.
, single wall
6” connector without
shields, vertical flue col-
lar heat shield installed
(A) 19” (B) 15” (C) 18Z\x” (D) 5” (E) 7” (F) 12”
(483 mm) (381 mm) (470 mm) (127 mm) (178 mm) (305 mm)


13
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295




 
 
, No Stove Heat Shields, collar heat shield installed.
D
E
F
F
C
C
A
B
J
K
L
L
I
I
G
H
ST628
Encore Clearance
Diagrams
02/01
P
Q
M
N
N/A N/A
, vertical collar heat shield, and chimney connector heat shields or double-wall connector.
.

For use with either 6” or 8” flue collar/chimney connector

14
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

The information on this page is helpful in planning stove placement for top-exiting installations, particularly those in-
stallations with chimneys that pass through the ceiling. However, this is not a clearance chart. Final stove clearances
must adhere to the guidelines stated in the clearance chart on Page 13.
Dimensions indicated are valid for installations with either 6” or 8” flue collars.

 
   
    
Side (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)
32Z\x” 13Z\₄” 22Z\x” 19Z\x” 9Z\₄” 18Z\x”
(826 mm) (337 mm) (572 mm) (495 mm) (235 mm) (470 mm)
**To locate center of flue collar for corner installation, add 6Z\x” (165 mm) to the clearance distance from stove corner to wall.
Mark off the resulting distance from the corner along both walls. Next, measure the same distance from these two points out
from the walls. These last two measurements will meet at a point representing the center of the flue collar. Refer to the dia-
grams above.
ST632a
ST632a
Encore
flue centerline
Diagrams
02/01
ABCDEF

 
   
    
Side (A) Rear (B) Side (A) Side (D) Rear (E) Corner (F)
32Z\x” 23Z\₄” 22Z\x” 18Z\x” 10Z\₄” 18Z\x”
(826 mm) (591 mm) (572 mm) (470 mm) (260 mm) (470 mm)
* This distance, from the center of the flue collar to the front edge of the hearth, is the same for all installations on this page:
35Z\₄” in the United States and 37Z\₄” (946 mm) in Canada.
ST632
ST632
Encore
flue centerline
Diagrams
2/01
*
ABC
*
DEF

15
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
48"
(1220 mm)
ST498
Defiant
Wall shield B
11/00
 Parallel installation with rear wall pass-through, two
wall shields. Reduced clearances to both rear and side walls.
Wall shields may meet at corner if desired. Wall pass-through
must comply with codes.
Refer to “Special Installations.”
ST498
48"
(1220 mm)
ST497
Defiant
wall shield A
11/00
48"
(1220 mm)
 Parallel installation, vertical chimney connector, two
wall shields. Reduced clearances for both rear and side walls.
Wall shields may meet at corner if desired. Shielding for con-
nector is centered behind connector.
ST497
48"
(1220 mm)
48"
(1220 mm)
ST499
Defiant
Wall Shield C
11/00
ST499
 Corner installation, vertical chimney connector, two
wall shields. Reduced side clearances. Wall shield MUST
meet at corner.

16
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

You must use an MHSC Vermont Castings Kit #0336 for
installation into a mobile home.
1. An outside air inlet must be provided for combus-
tion and must remain clear of leaves, debris, ice
and/or snow. It must be unrestricted while stove
is in use to prevent room air starvation which can
cause smoke spillage and an inability to maintain a
fire. Smoke spillage can also set off smoke alarms.
2. Stove must be secured to the mobile home struc-
ture using the fasteners provided in the Mobile
Home Kit.
3. Stove must be grounded with #8 solid copper
grounding wire or equivalent and terminated at
each end with N.E.C. approved grounding device.
4. Stove must be installed with an approved UL103
HT ventilated chimney connector, UL103 HT chim-
ney and terminal cap with spark arrestor. Never
use a single wall connector (stove pipe) in a mobile
home installation. Use only double-wall connector
pipe, Dura-Vent DVL, Selkirk metalbestos DS, Se-
curity DL double wall connector or any listed double
wall pipe connector.
5. Refer to Pages 12, 13 and 14 of this manual or the
serial number label on the back of the stove for
clearances to combustibles.
6. Floor protection requirements on Page 9 must be
followed precisely.
7. In Canada, this appliance must be connected to a
6 inch (152 mm) factory-built chimney conforming
to CAN/ULC 629M, STANDARD FOR FACTORY
BUILT CHIMNEYS. Floor protection referenced on
Page 10 must be followed.
8. Use silicone to create an effective vapor barrier at
the location where the chimney or other component
penetrates to the exterior of the structure.
9. Follow the chimney and chimney connector man-
ufacturer’s instructions when installing the flue
system for use in a mobile home.
 Offsets from the vertical, not exceeding 45°, are
allowed per Section 905(a) of the Uniform Me-
chanical Code (UMC). Offsets greater than 45° are
considered horizontal and are also allowed, provid-
ing the horizontal run does not exceed 75% of the
vertical height of the vent. Construction, clearance
and termination must be in compliance with the
UMC Table 9C. This installation also complies with
NFPA 211.
 Top sections of the chimney must be removable
to allow maximum clearance of 13.5 ft. (411 cm)
from ground level for transportation purposes.
10. Burn wood only. Other types of fuels may generate
poisonous gases (e.g. carbon monoxide).
11. If unit burns poorly while exhaust blower is on in
home, (i.e. kitchen range hood) increase combus-
tion air.
    
 


    






ST1190
mobile home install
Spark
Arrestor
Cap
Roof
Flashing
Storm Collar
Joint
Shield/
Firestop Listed Chimney
Connector
Floor
Protection
Outside Air Kit
Connector
Outside Air Floor Vent KT1190
 Mobile home installation.

17
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

Cast iron stoves are heavy, and it will take two to four
people to move your Encore into position.
Wipe the protective coating of oil from the griddle with a
clean dry rag or a paper towel.
Install the handle on the griddle. First, place the griddle
upside down at the edge of a flat surface and assemble
the handle as shown.
With the handle pointing 45° from its final position,
tighten the nut as
far as possible with
the pliers. Move the
handle to its final
position while still
holding the nut with
the pliers.


The stove is shipped with the legs attached. In some
instances, the legs may have been removed. Fol-
low these instructions to reattach the legs. Install the
stove legs (Fig. 20) using the hex head bolts from the
parts bag. Use 3/8” washers with all four legs; the door
handle holder installs on the right front leg. Position the
holder so the hole to accept the handle hub faces out
from the right side of the stove. Tighten the bolts firmly.
Overtightening can strip tapped threads.
 When moving the stove, lift the stove to take
weight off the legs whenever possible. Dragging or
sliding the stove, especially across rough surfaces can
cause the legs to loosen or even break.
34
ATTACHLEGS

Leg Bolt and
Washer
ST858
 Attach the stove legs.
ST564
handle holder
12/13/00
Bottom Heat Shield
Door Handle Holder
Leg Bolt and Washer ST564
 Handle holder and heat shield positions.

Use the removable handle to open or close the doors.
After using it, remove the handle so it will not get hot.
Store the handle in the handle holder installed behind
the right front leg. (Fig. 21)

The Bottom Heat Shield is required in most in-
stallations. Refer to Floor Protection, Page 9, for further
details.
1. Loosen the four 1/4-20 hex head bolts from the cor-
ners of the ash drop on the stove bottom.
2. Align the bottom heat shield holes with the four
bolts. The outside air cutout hole should be toward
the rear of the stove. The unpainted side must face
up towards the stove.
3. Pass all four bolts through the large end of the key-
holes and then pulling the shield forward to engage
the smaller ends of the keyhole slots. (Fig. 22)
4. Attach the heat shield sides by passing the slots
over the bolt heads. Tighten the hex head bolts.
ST857
abottom heat shield
12/05
1/10
ST857a
 Attach the bottom heat shield.
Bottom Heat Shield
ST516
Attach
griddle handle
11/17/00 djt
ST516
 Attach the griddle handle.

18
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

Lift the stove slightly so there is no weight on the leg
while making the adjustment.

Reverse the flue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket
around the flue collar opening is in position when you
screw the collar back onto the stove.

 The flue collar heat shield must be at-
tached to the Encore stove. Use four #10 sheet metal
screws supplied to secure the flue collar heat shield to
the rear of the stove. (Fig. 23)
ST540
Assembly
handle
11/00
ST540
 Assemble the front door handle.
ST635
Encore
Install thermostat
handle
2/01
ST635
 Attach the thermostat handle.
ST1180
flue collar heat shield
Sheet
Metal
Screws
Sheet
Metal
Screws
Flue Collar
Heat Shield
ST1180
 Install flue collar heat shield.
 The flue collar heat shield must be installed
in all vertical installations. The flue collar heat shield is
not used when the flue collar is in the rear exit position.

Use the 1/4” -20 x 3” screw to attach the damper handle
to the damper stub on the left side.

The primary air thermostat handle is the smaller of the
two black handles. Secure the handle to the stub on
the right side of the stove with an 8-32 x 2” slot head
machine screw. (Fig. 24)

The ceramic removable insert handle opens and closes
the front doors. Remove after each use, and store it in
the handle holder behind the right front leg. Assemble
the handle by passing the 3³\₈" screw through the
ceramic shaft and into the bright metal nub. (Fig. 25)
Tighten carefully until snug.

19
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

1. Attach the fan assembly at the bottom edge of the in-
ner back with two (2) 1/4-20 x 3/4” hex head screws.
2. Attach snapstat to the mounting holes on the un-
derside of the bottom with two (2) 1/4-20 pan head
screws.
3. Attach the rheostat holder (provided with the stove)
under the right front wing of the bottom heat shield
with two (2) #10 sheet metal screws.
4. Attach the rheostat to its holder by inserting the rheo-
stat control shaft through the holder hole. Install the
retaining ring and rheostat knob onto the shaft.
5. Secure the rheostat cable to the underside of the
bottom heat shield using the wire tie provided and
the hole at the right rear edge of the heat shield.
6. Fan will not operate until stove reaches approximate-
ly 109°F.
7. Plug blower cord into a grounded outlet. Do not
remove ground prong from plug. Route power cord
to avoid heat from the stove or other damage. Do not
route cord under or in front of appliance.
 Fan installation (Kit # 2767).
34
FANINSTALL

Rheostat
Knob
Rheostat Snapstat Screws ST848
Hole for Wire
Tie to Secure
Cable
Rheostat
Holder

1. Remove the access cover by gently lifting up and
pulling out from the bottom edge. (Fig. 27)
2. Remove the inner cover by pulling it straight out.
(Fig. 28)
3. Remove the catalyst by gently pulling it straight out.
(Fig. 29) Place the catalyst where the catalyst’s
ceramic components will not be damaged.
ST1187
remove access cover
Access
Cover
ST1187
 Remove access cover.
ST1188
remove inner cover
Inner Cover
ST1188
 Remove inner cover.
ST1189
remove catalyst
Remove Catalyst ST1189
 Remove catalyst.

20
Encore®2040 Non-Catalytic / Catalytic Woodburning Stove
30005295

Two controls regulate the performance of the Encore: a
supplies oxygen for the fire, and a
 directs air flow within the stove to activate and
deactivate the combustion system. (Fig. 30)
Symbols cast into the stove are reminders of the correct
directions for using the controls. The words ‘Left’ and
‘right’ in these directions are facingthestove.



The , on the right side of the
stove, controls the amount of incoming air for starting,
maintaining, and reviving a fire.
More air entering the stove makes the fire burn hotter
and faster, while less air prolongs the burn at a lower
heat output level. (Fig. 31)
For the greatest air supply and maximum heat output
(but the shortest burn time), move the lever toward the
front of the stove. For a fire that will last longer with
less heat, move the lever toward the rear of the stove.


The  on the left side of the stove oper-
ates the damper to direct air flow within the stove.
The damper is  when the handle points to the
, enabling smoke to pass directly into the chimney.
The damper must be open when starting or reviving a
fire, and whenever the griddle or doors are opened.
The damper is  when the handle points 
Smoke travels through the non-catalytic combustion
system where it can be further burned, before passing
up the chimney. (Fig. 32)




ST633
Encore
controls
2/01
Griddle Handle
Damper Handle
Air Control
Lever
Door Handle
Holder (Be-
hind leg)
Ashdoor
Handle
Andirons ST636
 The Encore controls are conveniently located and
easy to operate.
Door Handle
ST637
encore
Air control
2/01


ST637
 The handle may be positioned anywhere between the
two extremes for different heat levels.
ST638
Encore
damper control
2/01

Open
(Updraft Mode)
Closed
(High Efficiency
Mode)
ST638
 The damper is either open or closed. There are no
intermediate positions.


A Encore leaves the factory with the combustor pack-
aged separately.
In the United States, it is against the law to operate this
wood heater in a manner inconsistent with operating
instructions in this manual. The components of the cata-
lytic combustion system in your Encore work together to
produce optimum conditions for secondary combustion.