Vermont Castings Encore Flexburn 2040 Mounting instructions
Homeowner’s Installation
and Operating Manual
For use in the
United States and Canada
30005295 8/13 Rev. 18
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®FlexBurn™ 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 Agency’s
emission limits for wood heaters sold on or after July 1,
1990. Under specic 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 certi-
ed 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 Flexburn 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.
Specications ........................................................3
Installation .............................................................4
Clearance Charts.................................................12
Mobile Home Installation .....................................16
Assembly .............................................................17
Operation .............................................................20
Draft Management ...............................................26
Maintenance ........................................................28
The Catalytic Element .........................................32
Replacement Parts ..............................................34
Warranty ..............................................................39
Congratulations on your choice of a Vermont Castings Encore stove. With this purchase you have made a commitment
to make the hearth a place of warmth, beauty and comfort in your home. At Vermont Castings Group, we share that
joy and appreciation 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 nd that its appearance is matched by its functionality, due to
cast iron’s unique ability to absorb and radiate heat.
Also, Vermont Castings Group products are among the cleanest-burning wood stoves and replaces 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 Vermont Castings Group, we are equally committed to your satisfaction as a customer. That is why we maintain
an exclusive network of the nest dealers in the industry. Our dealers are chosen for their expertise and dedication to
customer service. They are factory-trained and knowledgeable about every Vermont Castings Group 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 Vermont Castings Group
Warming Shelf 8” Flue Collar
#0200 Classic Black #0555 Classic Black
#0205 Biscuit #0556 Biscuit
#0207 Ebony #0557 Brown Majolica
#0199 Bordeaux #0560 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 red 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®FlexBurn™ 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” ue collar 6” (152 mm) diameter
for 8” oval ue 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 ue collar 25” (635 mm)
*Under specic conditions during EPA emissions testing.
** 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 laboratory conditions
and on average efciencies.
*** These values are based on operation in building code-
conforming homes under typical winter climate conditions
in New England. If your home is of nonstandard construc-
tion (e.g. unusually well insulated, not insulated, built
underground, etc.) or if you live in a more severe or more
temperate climate, these gures 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
16M"
(44 mm)
25"
(635 mm)
Top exit
flue collar
height
27"
(686 mm)
256M"
(654 mm)
1856O"
(470 mm)
756M"
(184 mm)
27"
(686 mm)
2256M"
(565 mm)
1556O"
(394 mm)
5"
(127 mm)
2(6" (73 mm)
236M"
(603 mm)
15"
(381 mm)
36M"
(95 mm)
226M"
(578 mm)
Encore 2N1
dimensions
4
Encore®FlexBurn™ 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 clearance require-
ments.
• The oor protector is large enough and is constructed
properly to meet all requirements.
• You have all necessary permits from local authorities.
Your local building ofcial is the nal authority for approv-
ing 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 installation 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 publica-
tion 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 ofcial may have a
copy of these regulations.
In some modern, super-insulated homes, there may be
inadequate air supply for combustion because of insuf-
cient air inltration 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 inltration rate, opening
a ground oor 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 improved 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 ue 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®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
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If you use an existing masonry chimney, it must be in-
spected to ensure it is in a safe condition before the stove
is installed. Your local professional chimney sweep, building
inspector, or re department ofcial 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
ue 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 Temperature
(650°C) Standard ULC S-629 for Canada.
An Encore with an 8” (203 mm) ue collar is approved for
venting into a masonry chimney with a nominal ue size
of 8” x 8” (203 x 203 mm) or 8” x 12” (203 x 305 mm), and
into a round ue with nominal ue size of 8” (203 mm). An
Encore with a 6” (152 mm) ue connector is approved for
venting into a masonry chimney with a nominal ue size of
8” x 8” (203 x 203 mm), and into a round ue with nominal
ue of 6” (152 mm).
Whatever the ue 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 ues
relined for proper stove performance.
Accessories to help make the connection between stain-
less 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 ue.
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 release 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 con-
nector should be exposed and accessible for inspection
and cleaning.
An inspection of the chimney must conrm that it has a lin-
ing. 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. Openings
sealed with pie plates or wallpaper are a hazard and should
be sealed with mortar or refractory cement. In the event
of a chimney re, ames 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 stan-
dards of your local building code or, in the absence of a
local code, to a recognized national code. Masonry chim-
neys must be lined, either with code-approved masonry or
pre-cast refractory tiles, stainless steel pipe, or a code-ap-
proved, “poured-in-place” liner. The chimney’s clean-out
door must seal tightly. A loose or leaky clean-out door can
weaken chimney draft, causing performance problems.
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Encore®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
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Follow the installation instructions of the chimney manufac-
turer exactly as you install the chimney. The manufacturer
of the chimney will supply the accessories 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 ceil-
ing support package, while the bottom of the adapter is
screwed to the chimney connector.
These adapters are designed so the top end will t outside
the inner wall of the chimney, and the bottom end will t
inside the rst section of chimney connector.
Both freestanding masonry chimneys and replace ma-
sonry chimneys may be used for your installation.
If the chimney connector must pass through a combustible
wall to reach the chimney, follow the recommendations in
the Wall Pass-Through section that follows. The opening
through the chimney wall to the ue (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 thimbles, but the t must be
In horizontal runs of unshielded chimney connector, main-
tain 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 chim-
ney. The recommended maximum 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, cutting
or joining sections of chimney connector.
• Begin assembly at the ue collar of the stove. Insert
the first crimped
end into the stove’s
ue collar, and keep
each crimped end
pointing toward the
stove. (Fig. 4) Using
the holes in the ue
collar as guides, drill
1/8” (3 mm) holes
in the bottom of the
rst section of chim-
ney connector and
secure it to the ue
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 ue collar to protect the nish when you
drill the front hole.
• Fasten each joint between sections of chimney con-
nector, 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. Instruc-
tions 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 materials.
Special slip pipes and thimble sleeves that form
telescoping joints between sections of chimney connector
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.
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Encore®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
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ST244
Plymouth
fplc over mantel
12/99
*
*
Check These
Clearances
Mantel
ST244
In this installation, the chimney connector attaches to
the chimney above the replace opening.
Seal
This Off
ST243
thinble connection
12/13/99 djt
Thimble Sleeve
Chimney Connector
Flue
Keep
sleeve
end ush
with ue
tile
ST243
The thimble, made of either ceramic or metal, must be
cemented securely in place.
snug and the joint between the thimble and the chimney
wall must be cemented rmly.
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.
• Check the clearance between the chimney connector
and the ceiling. The clearance should be at least 30”
(762 mm) with unshielded connectors. Consult the
clearance charts for other installation options.
• The replace damper must be sealed to prevent room
air from escaping up the ue. However, it must be
possible to re-open the damper to inspect or clean the
chimney.
If your replace 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 dealer. Positive
connection kits ensure a tight t between the stove ue
collar and the chimney ue. (Fig. 8)
Fireplace installations, whether connected to the ue above
or through the replace opening, have special clearance
requirements to adjacent trim and the mantel. You’ll nd
the required safe clearances for Encore replace installa-
tions on Page 12.
Floor protection requirements also apply to replace instal-
lations. This information is on Page 9.
Whenever possible, design your installation so the connec-
tor 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 specic
requirements.
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.
To install a thimble sleeve, slide it into the breech until it is
ush with the inner ue wall. Do not extend it into the actual
ue passage, as this could interfere with the draft.
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 connector
can be extended through the breech to the inner face of
the ue 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 chim-
ney above the replace opening or through the replace.
The Encore may be connected to a chimney above a
replace opening. (Fig. 7) In such installations, the stove
is positioned on the hearth in front of the replace 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 replace, follow all the guidelines men-
tioned above for freestanding installations. In addition, give
special consideration to the following points:
• Check the clearance between the mantel and the
chimney connector, and any combustible trim or the
mantel.
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Encore®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
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ST245
fireplace
flex connector
12/99
Flexible
Connector
Mantel Shield
Fireplace Adapter Kit
“Positive Connection”
ST245
Through the replace 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.
In the United States, the National Fire Protection Associa-
tion (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 opening 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 berglass insulating
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 es-
tablished 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 ush-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) replace. These appliances and their chimneys
are specically designed as a unit for use as replaces.
It may void the listing or be hazardous to adapt them for
any other use.
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A tremendous amount of heat radiates from the bottom
plate of your stove. The oor 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 rebox.
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 instal-
lations require special thermal protection (insulation) for the
oor 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 oor protector may be covered
with a decorative noncombustible material if desired. Do
not obstruct the space under the heater.
When using a re screen with doors open, UL737, Stan-
dard 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 oor 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 Un-
tied States and Canada as follows:
the oor 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 congurations, oor 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 oor protector must be at
least 39” wide and 45” deep.
A noncombustible oor protector is required
under the stove as well. The oor 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 oor protector must be at
least 43” (1092 mm) wide and 49” (1245 mm) deep.
All oor protection must be noncombustible (i.e. metals,
brick, stone, mineral ber boards, etc.). Any organic materi-
als (i.e. plastics, wood paper products, etc.) are combus-
tible and must not be used. The oor protection specied
includes some form of thermal designation such as R-value
(thermal resistance) or k-factor (thermal conductivity).
1. Convert specications 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 oor
protector:
i. Use the formula in Step 1 to convert values not ex-
pressed as R.
ii. For multiple layers, add R-values of each layer to
determine overall R-value.
3. If the overall R-value of the system is greater than the
R-value of the specied oor protector, the alternate
is acceptable.
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 oor protection dimensions.
R = x T
1
k
R = x T
1
K x 12
10
Encore®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
The specied oor 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 specication 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 speci-
ed R of 0.59. Since proposed system Rtotal is greater
than required, the system is acceptable.
Denitions
R = x T = x 1.00 = 1.18
1
k
1
0.84
1
0.29
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 replace hearth is completely
noncombustible. Many replace hearths do not satisfy the
“completely noncombustible” requirement because the brick
or concrete in front of the replace 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 replace hearths can be a re hazard and
are considered a combustible oor.
For all replace installations, follow the oor 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, sufcient oor protection as described
above must be added in front of the hearth to satisfy the
minimum oor protector requirement 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
oor protection as they are not re proof.
Fireplace installations also have special clearance require-
ments to the side walls, side decorative trim and replace
mantel. Refer to the information on replace and mantel
trim shields in this section.
Both a stove and its chimney connector radiate heat in all
directions when operating, and nearby combustible materi-
als can overheat dangerously if they are too close to the
heat source. A safe installation requires that adequate
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, oors, the ceiling,
and any other xed combustible surface. The Encore has
specic clearance requirements that have been established
after careful research and testing. These clearance require-
ments must be strictly observed.
In addition, keep furnishings and other combustible ma-
terials 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, furni-
ture, newspapers, rewood, etc. Keeping 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 clear-
ances listed in this manual. Refer to Page 12 for approved
clearance reduction specications.
11
Encore®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
ST248
wall shield construction
12/14/99 djt
Stud Wall
Framing
Wall Shield
Noncombustible
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 replace
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 replace 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 replace 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
congurations 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 at,” 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 ow 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 replace 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
replace 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®FlexBurn™ 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” ue collar/chimney connection
Top Exit, 8” single
wall connector without
shields, vertical ue col-
lar heat shield installed
single-wall
chimney connector heat
shield2, vertical ue col-
lar h.s. installed
No ue collar heat
shield
double-wall
chimney connector3,
vertical ue collar heat
shield installed
All Installations (S) 48” (1219 mm)
The provided rear shroud must be used in all installations. The ue 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 ue collar.
3. Using listed double wall oval to round adapter when installing optional 8” oval ue collar.
, single wall
6” connector without
shields, vertical ue 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®FlexBurn™ 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” ue collar/chimney connector
14
Encore®FlexBurn™ 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” ue 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 ue 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 ue 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 ue 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®FlexBurn™ 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 connector 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®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
You must use an Vermont Castings Group Vermont Cast-
ings Kit #0336 for installation into a mobile home.
1. An outside air inlet must be provided for combustion
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 re. Smoke
spillage can also set off smoke alarms.
2. Stove must be secured to the mobile home structure
using the fasteners provided in the Mobile Home Kit.
3. Stove must be grounded with #8 solid copper ground-
ing 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 chimney and
terminal cap with spark arrestor. Never use a single
wall connector (stove pipe) in a mobile home installa-
tion. Use only double-wall connector pipe, Dura-Vent
DVL, Selkirk metalbestos DS, Security 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 clear-
ances to combustibles.
6. Floor protection requirements on Page 9 must be fol-
lowed 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 pen-
etrates to the exterior of the structure.
9. Follow the chimney and chimney connector manufac-
turer’s instructions when installing the ue system for
use in a mobile home.
Offsets from the vertical, not exceeding 45°, are
allowed per Section 905(a) of the Uniform Mechanical
Code (UMC). Offsets greater than 45° are considered
horizontal and are also allowed, providing the hori-
zontal 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 combustion
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®FlexBurn™ 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 at surface and assemble
the handle as shown.
With the handle pointing 45° from its nal position, tighten
the nut as far as pos-
sible with the pliers.
Move the handle to its
nal position while still
holding the nut with
the pliers.
The stove is shipped with the legs attached. In some in-
stances, the legs may have been removed. Follow 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 rmly.
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
ATTACHLEGS
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 corners
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 keyholes
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®FlexBurn™ 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 ue collar by removing the two screws that
attach it to the back of the stove. Be sure the gasket around
the ue collar opening is in position when you screw the
collar back onto the stove.
The ue collar heat shield must be attached
to the Encore stove. Use four #10 sheet metal screws
supplied to secure the ue 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.
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)
ST1180
flue collar heat shield
Sheet
Metal
Screws
Sheet
Metal
Screws
Flue Collar
Heat Shield
ST1180
Install ue collar heat shield.
The ue collar heat shield must be installed
in all vertical installations. The ue collar heat shield is not
used when the ue collar is in the rear exit position.
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 care-
fully until snug.
19
Encore®FlexBurn™ 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 underside
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 bot-
tom 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 approximately
109°F.
7. Plug blower cord into a grounded outlet. Do not re-
move 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
FANINSTALL
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 pull-
ing 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 ce-
ramic 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®FlexBurn™ 2040 Non-Catalytic / Catalytic Woodburning Stove
30005295
Two controls regulate the performance of the Encore: a
supplies oxygen for the re, and a
directs air ow 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 facingthestove.
The , on the right side of the
stove, controls the amount of incoming air for starting,
maintaining, and reviving a re.
More air entering the stove makes the re 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 re that will last longer with less heat,
move the lever toward the rear of the stove.
The on the left side of the stove operates
the damper to direct air ow 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 re, and
whenever the griddle or doors are opened.
The damper is when the handle points
Smoke travels through the non-catalytic combustion sys-
tem 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 Efciency
Mode)
ST638
The damper is either open or closed. There are no
intermediate positions.
A Encore leaves the factory with the combustor packaged
separately.
In the United States, it is against the law to operate this
wood heater in a manner inconsistent with operating in-
structions in this manual. The components of the catalytic
combustion system in your Encore work together to pro-
duce optimum conditions for secondary combustion.
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