Vermont Castings The Intrepid II 1990 User manual
Homeowner’s
Installation and
Operating Manual
For use in the
United States and Canada
2000966 7/13 Rev. 34
0966
Intrepid Cover
11/00
2
Intrepid®II Woodburning Stove
2000966
Congratulations on your choice of a Vermont Castings Intrepid II. With this purchase, you 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 ap-
preciation of the hearth, and we show it in all our cast iron stoves and replaces.
As you become acquainted with your new stove, you will nd the aesthetic appeal of cast iron is matched only by its
superb capacity 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 Group stove, you are making a strong statement for pollution-free energy. But clean
burning depends on both the manufacturer and the operator. Please read this manual carefully to understand how to
properly operate your stove.
At Vermont Castings Group, we are equally committed to your satisfaction as a customer and that is why we maintain an
exclusive network of the nest dealers in the industry. Chosen for their expertise and dedication to customer service, our
dealers are factory-trained and know each Vermont Castings Group product in detail. Feel free to contact your Authorized
Vermont Castings Dealer anytime you have a question about your stove or its performance.
We have built your Vermont Castings Intrepid II with the utmost care. With normal use and proper care, it will provide
you with many years of service.
This manual contains valuable instructions on the installation and operation of your Vermont Castings stove. You will
also nd useful information on assembly and maintenance procedures. We urge you to read the manual thoroughly and
to keep it as a reference.
Sincerely,
All of us at Vermont Castings Group
This manual describes the installation, operation, and maintenance of the Vermont Castings Intrepid II Model 1990
catalytic-equipped 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 8,200 to 26,700 Btu/hr.
The Intrepid II Model 1990 has been tested and is listed by Canadian Standards Association (CSA). The test standards
are ANSI/UL-1482 and ANSI/UL-737 for the United States, and ULC S627 and CAN/CSA-B366.2 for Canada. The Intrepid
II is listed for burning wood only. Do not burn other fuels. The Intrepid II is approved for use in manufactured (mobile)
homes only in the United States, and only when installed with Vermont Castings Mobile Home Kit No. 3248.
Installation or service of this woodburning stove should only be completed by a qualied installer, preferably NFI or
WETT (Canada) certied.
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.
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Intrepid®II Woodburning Stove
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Ask your Vermont Castings dealer how these instal-
lation accessories can enhance the versatility, ap-
pearance, and safety of your Intrepid Stove.
0307 Bottom Heat Shield
0172 Rear Heat Shield
Chimney connector heat shields
Heavy-gauge enamel pipe to match the stove’s color
Warming shelves
0098 Classic Black 1377 Chestnut Brown
1372 Midnight Blue 1378 Ebony
1373 Brown Majolica 1379 Vt. Classic Green
1376 Biscuit 1380 Bordeaux
0136 Spark screen for open-replace use
Short Legs
0868 Classic Black 1530 Chestnut Brown
1515 Bordeaux 1535 Ebony
1525 Suede Brown 1537 Vt. Classic Green
1527 Biscuit
3258 Outside air kit
3248 Mobile-home kit.
Fuels used in gas, wood-
burning or oil red appliances, and the products of
combustion of such fuels, contain chemicals known
to the State of California to cause cancer, birth de-
fects and other reproductive harm.
California Health & Safety Code Sec. 25249.6
Specications ....................................... 4
Installation ............................................ 5
Clearances ......................................... 14
Assembly ............................................18
Operation ............................................19
Draft Management ..............................24
Maintenance .......................................26
Catalytic Combustor ...........................32
Replacement Parts .............................33
Warranty ............................................39
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Intrepid®II Woodburning Stove
2000966
2156O"
(545 mm)
20"
(510 mm)
2556M"
(640 mm)
Top exit
flue collar
height
2156M"
(540 mm)
24"
(610 mm)
756"
(180 mm)
2156O"
(545 mm)
C
L
2156M"
(540 mm)
18"
(460 mm)
156M"
(31 mm)
2056O"
(520 mm)
136M"
(350mm)
0966
Intrepid II
specifications
11/00
0966
DRAWINGS NOT TO SCALE
Intrepid II 1990 dimensions.
Range of heat output ................... 8,260-26,740 Btu’s/Hr3
Maximum heat output .............................27,000 Btu’s/Hr1
Area heated ..................... Up to 1200 sq. ft. (112 sq. m.)2
Fuel size/type ..................................... 16” (410 mm) logs
EPA emissions rating (g/h, catalytic) ......................... 2.13
Loading ..........................................................Front or top
Chimney connector........................6” (152 mm) diameter
Chimney ue size ......................... 6” (152 mm) minimum
Flue exit position...........................Reversible, top or rear
Primary air ........ Manual set, thermostatically maintained
Secondary air ........................................... Self-regulating
Ash handling system ........................Removable ash pan
Glass panels ........................... High temperature ceramic
Weight ....................................................223 lbs. (101kg)
Width (leg-to-leg) .....................................21¹⁄₂” (545 mm)
Depth (leg-to-leg).....................................13³⁄₄” (350 mm)
Height to top of ue collar:
with regular legs ......................... 25” (635 mm) top exit
..................................................24” (610 mm) rear exit
with optional short legs ............... 21” (535 mm) top exit
...............................................19³⁄₄” (500 mm) rear exit
1. This value can vary depending on how the stove is oper-
ated, 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 obtained under laboratory conditions and
on average efciencies.
2. These values are based on operation in building code-
conforming homes under typical winter climate condi-
tions in New England. If your home is of nonstandard
construction (e.g., unusually well insulated, not insu-
lated, 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 Vermont Castings Authorized Dealer to
determine realistic expectations for your home.
3. Under specic conditions used during EPA emissions
testing.
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Intrepid®II Woodburning Stove
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Before you begin an installation, review your plans to see
that:
• Your stove and chimney connector will be far enough
from combustible material to meet all clearance
requirements.
• The oor protector is large enough and is constructed
properly to meet all requirements.
• You have all necessary permits from local authori-
ties.
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 ev-
ery Vermont Castings stove indicates the stove has been
tested to current ULC standards, by Canadian Standards
Association (CSA). The test standards are ANSI/UL-1482
and ANSI/UL-737 for the United States and ULCS627 and
CAN/CSA-B366.2 for Canada. 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 in most cases 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. You local dealer can provide any additional in-
formation needed.
For any unresolved installation issues, refer to 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 is not enough
air for combustion because of insufcient air inltration into
the building. Such air enters a home through unsealed
cracks and openings. Kitchen or bath exhaust fans can
compete with the stove for available air and compound
the problem.
When poor draft is caused by a low inltration rate, open-
ing a ground oor window on the windward side of the
house and in the vicinity of the stove will usually alleviate
the problem.
Another solution is to install a permanent outside air supply
to the stove and/or room. In some areas, in fact, bringing
air for combustion from outside the home directly to the air
inlet of the stove is required for new construction.
An outside air supply is not affected by pressure variations
within the house, and improved stove performance often
results. An Outside Air Adaptor Kit for the Intrepid II is avail-
able from your local Vermont Castings dealer.
Your Intrepid II must be connected 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,
or the High Temperature (650°C) Standard ULC S-629 for
Canada. Whatever kind you use, the chimney and chimney
connector must be in good condition and kept clean. Figure
2 shows the two chimney types.
ST241
chimney types
12/13/99 djt
A prefabricated
double-wall insulated
chimney
A tile-lined ma-
sonry chimney
ST241
Standard chimney types.
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Intrepid®II Woodburning Stove
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If you use an existing masonry chimney, it must be inspect-
ed to ensure 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 a roof, and at least
2’ (610 mm) higher than any portion of a building within
10’ (3 m). (Fig. 3)
For proper draft and good performance, any chimney used
with an Intrepid II 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
AC617
The 2’-3’-10’ Chimney Rule.
Reference Point
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,
or blockage. Repair any defects before using the chimney
with your stove.
Seal any unused openings in an existing masonry chimney
with masonry to the thickness of the chimney wall, and re-
pair the chimney liner. Openings sealed with pie plates or
wallpaper are a hazard; seal them 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
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 ma-
sonry 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 prefabricated metal chimney must be one tested and
listed for use with solid-fuel burning appliances to the High
Temperature (650°C) Standard ULC S-629 for Canada.
An Intrepid II is approved for venting into a masonry chimney
with a maximum ue size of 8” x 8” (203 x 203 mm), and
into a round ue size of 6” (150 mm).
It may not be vented into larger chimneys without a liner
to reduce the effective ue size to 6”(150 mm) diameter.
Larger chimneys must have their ues relined for proper
stove performance.
Accessories to make the connection between stainless
steel chimney liners and your Intrepid II are available
through your local dealer.
Chimney connector is the double-wall or single-wall pipe
that connects the stove to the chimney. The chimney is a
masonry or prefabricated structure that encloses the ue.
Chimney connectors are used only to make the connection
from the stove to the chimney.
Double-wall chimney connectors must be tested and
listed for use with solid-fuel burning appliances. Single-
wall chimney connectors should be made of 24 gauge or
heavier steel, and should be 6” (150 mm) in diameter. Do
not use galvanized connector; it cannot withstand the high
temperatures that can be reached by smoke and gases,
and may release toxic fumes under high heat.
If possible, do not pass the chimney connector through a
combustible wall or ceiling. If passage through a combus-
tible wall is unavoidable, refer to the section following on
Wall Pass-Throughs. Do not pass the chimney connector
through an attic, a closet, or any similar concealed space.
The whole connector should be exposed and accessible
for inspection and cleaning.
In horizontal runs of single-wall chimney connector without
protective shields, maintain a clearance of at least 26” (660
mm) from the ceiling. For information on reduced clear-
ances using shields on single-wall chimney connector or
using double-wall connectors, see the clearance chart on
Page 14.
Keep the horizontal run of chimney connector as short
and direct as possible, with no more than two 90° turns.
Slope horizontal runs of connector upward 1/4” per foot
(20 mm per m) going from the stove toward the chimney.
The recommended maximum length of a horizontal run is
3’ (914 mm). The recommended total length of chimney
connector is 8’ (2.4 m).
In cathedral ceiling installations, extend the prefabricated
chimney down to within 8’ (2.4 m) of the stove.
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Intrepid®II Woodburning Stove
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The listing for the Intrepid II for the U.S. and Canada in-
cludes use of double-wall chimney connectors that have
been tested and listed for use with solid-fuel burning ap-
pliances by a recognized testing laboratory.
Information on assembling and installing double-wall con-
nector is provided by the manufacturer of the double-wall
pipe. Follow the manufacturer’s instructions exactly as
you assemble the connector and attach it to the stove
and chimney. Using connectors and chimneys from the
same manufacturer makes the assembly and installation
straightforward.
• Beginning at the ue collar of the stove, assemble the
chimney connector. Insert the rst crimped end into the
stove’s ue collar, and keep
each crimped end pointing
toward the stove. Using the
holes in the flue collar as
guides, drill 1/8” (3 mm) holes
in the bottom of the rst sec-
tion of chimney connector and
secure it to the ue collar with
three #10 x 1/2” sheet metal
screws.
• Secure each joint between
sections of chimney connec-
tor, including telescoping
joints, with at least three sheet
metal screws. The pre-drilled
holes in the top of each sec-
tion of chimney connector
serve as guides when you drill
1/8” (3 mm) holes in the bottom of the next section.
• Secure the chimney connector to the chimney. Instruc-
tions for various installations follow.
• Be sure the installed stove and chimney connector are
correct distances from nearby combustible material.
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.
For prefabricated chimneys, follow the installation instruc-
tions of the chimney maker exactly as you install the chim-
ney. The maker of the chimney will supply the accessories
ST242
Chimney connector
12/13/99 djt
The crimped end of
the connector points toward
stove.
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 adaptor 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. When as-
sembled in this way, any soot or creosote falling from the
inner walls of the chimney will stay inside the chimney
connector.
For masonry chimneys, both freestanding and replace
chimneys may be used for installation of your Intrepid II.
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.
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
“breach”) must be lined with either a ceramic or metal cylin-
der, called the “thimble”, which is cemented rmly in place.
The t must be snug and the joint between the thimble and
the chimney wall must be cemented. (Fig. 6)
A special piece called the “thimble sleeve,” slightly smaller
in diameter than standard connector and most thimbles,
will facilitate the removal of the chimney connector system
for inspection and cleaning. Thimble sleeves should be
available from your local dealer. (Fig. 5)
To install a thimble sleeve, slide it into the breach 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
8
Intrepid®II Woodburning Stove
2000966
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 breach 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 Intrepid II may be connected to a chimney above a
replace opening also. 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. (Fig. 7)
The chimney liner should extend to the point at which the
chimney connector enters the chimney.
If the chimney connector from 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 stove and the chimney
connector, and any combustible trim or the mantel. Use
the necessary combination of mantel, trim, and connec-
tor heat shields to achieve the required clearances.
• Check the clearance between the chimney connector
and the ceiling. If no heat shields are used, the clear-
ance should be at least 26” (660 mm). To nd out how
much this clearance may be reduced with heat shields,
refer to the clearance chart on Page 14.
• 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 height is at least 25” (635 mm), you may
install an Intrepid II with standard legs through the replace
opening using a “positive connection” kit available from
your local dealer. These 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 clearances for the Intrepid II replace
installations on Page 14.
Floor protection requirements also apply to replace instal-
lations. Floor protection 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.
ST492a
Intrepid II
freestanding
installation
11/00
I
N
T
R
E
P
I
D
I
I
Chimney
Elbow
Slip Pipe
Standard
Chimney
Connector
Flue Collar
Flue
Flue
Liner
Thimble
ST492a
Chimney connection in a freestanding installation.
ST244
Plymouth
fplc over mantel
12/99
Chimney Connector
Shields
* Check
These Clear-
ances
*
*
Mantel
Seal the
Damper
ST244
Chimney connector enters chimney above the replace.
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Intrepid®II Woodburning Stove
2000966
ST245
fireplace
flex connector
12/99
Flexible Connector
Mantel Shield
Fireplace Adaptor Kit
ST245
Chimney connector enters chimney through the re-
place opening.
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 ap-
proving 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.
T
ST493a
Brick pass thru
11/00
INT
I
P
D
RE
I
I
Wall Stud
Chimney
Connector
Floor
Protection
12” of
Noncombustible
Material
ST493a
An approved wall pass-through for the United States.
Three other methods are also recommended by NFPA:
• Using a section of double-wall chimney with a 9” (230
mm) clearance to combustibles.
• Placing a section of chimney connector inside a ventilated
thimble, which in turn is separated from combustibles
by 6” (150 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” (50 mm) of air space between the
chimney section and combustibles.
The Canadian Standards Association has es-
tablished installation guidelines. The following illustration
shows one method, in which all combustible material in the
wall is cut away to provide the required
18” (460 mm) clear-
ance 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.
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.
T
ST494
steel
wall pass thru
11/00
INT
I
P
D
RE
I
I
18” (460mm) clearance all
around the pipe
Flush Mounted
Sheet Metal Cover
ST494a
An approved wall pass-through for Canada.
Do not vent your Intrepid II 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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Intrepid®II Woodburning Stove
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A tremendous amount of heat radiates from the bottom
plate of an Intrepid II, and the oor beneath requires two
kinds of special protection.
Heat protection is provided by a Bottom Heat Shield, part
#0307.
Spark and ember protection is provided by a oor protector,
which may be any noncombustible material.
For a new hearth, we recommend a noncombustible oor
protector such as 1/4” non-asbestos mineral board or its
equivalent, or 24 gauge sheet metal. If carpeting is present,
it must be removed before installation of the oor protector.
The oor protector may be covered with a noncombustible
decorative material if desired. When using brick, tile, or
stone, individual pieces must be mortared so sparks can-
not fall through.
Even with the bottom heat shield installed, you must also
use a oor protector.
the oor protector required under the
stove must extend at least 16” from the front of the stove
- not from the ashlip - (Labeled ‘E’ in Fig. 11), and at least
6” from the sides and rear (‘D’, Fig. 11).
To meet the requirement in the United States, a oor pro-
tector must be at least 34” wide and 40” deep.
the oor protector required under the stove must
extend 18” (460 mm) to the front (labeled ‘E’, Fig. 11), and
8” (203 mm) from the sides and rear. (‘D’ ,Fig. 11)
To meet Canadian requirements, a oor protector must be
at least 38” (965 mm) wide and 44” (1118 mm) deep.
Floor protection also must extend under the chimney con-
nector and 2” (51 mm) to either side. (‘C’, Fig. 11) For 6”
(152 mm) connector used with the Intrepid II, the protector
must be a minimum of 10” (254 mm) wide, centered under
the connector.
Do not assume your replace hearth is completely non-
combustible.
Many replace hearths do not satisfy the “completely non-
combustible” requirement because the brick or concrete in
front of the replace opening is supported by heavy wood
framing as in Figure 12. Because heat passes through brick
or concrete readily, 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.
D
E
DD
A
B
D
D
A
E
D
C
ST500
intrepid
floor protection
11/10/00
A. 34” 38” (965 mm)
B. 40” 44” (1118 mm)
C. 10” 10” (254 mm)
D. 6” 8” (203 mm)
E. 16” 18” (457 mm)
ST500
Required oor protector dimensions.
ST247
Rear exit floor dgrm
12/14/99 djt
Wood framing requires
protection from radiant heat ST247a
Supporting timbers under replace hearth are consid-
ered to be combustible.
Keep in mind that many raised hearths will extend less than
the required clearance from the front of the heater when
it is installed. 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: 18” (460mm) from the front in Canada.
Fireplace hearths must also offer the required protection
of 8” (203 mm) on either side.
Optional 3” (76 mm) short legs may be used only on such
hearths that meet the width and depth requirements out-
lined previously under “oor protection.”
Hearth rugs do not satisfy the requirements for oor pro-
tection.
Fireplace installations also have special clearance require-
ments to the side walls, side decorative trim, and replace
mantle. Refer to the information on replace and mantel
trim shields in this section.
11
Intrepid®II Woodburning Stove
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Both a stove and its chimney connector radiate heat in all
directions when operating, and dangerous overheating
of nearby combustible materials can occur if they are too
close to the heat. 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
(measured from the back edge of the stove’s top plate) or
chimney connector, and nearby walls, oors, the ceiling,
and any other xed combustible surface. Your stove has
special clearance requirements that have been established
after careful research and testing to UL and ULC standards.
These clearance requirements must be strictly observed.
In addition, furnishings and other combustible materials
must be kept away from the stove as well. In general, a
distance of 48” (1220 mm) must be maintained between
the stove and moveable combustible items such as dry-
ing clothes, furniture, newspapers, rewood, etc. Keep-
ing those clearance areas empty assures that nearby
surfaces and objects will not overheat.
Stove clearances may be reduced by using heat shields
attached to the stove. Chimney connector clearances may
be reduced by using heat shields on single-wall connector,
or by using double-wall connector. Clearances may also be
reduced by using wall shields. All shielding used to reduce
clearances must be listed by a recognized testing laboratory
and approved by the local regulatory body.
Clearance requirements are established for many different
installations. In general, the greatest clearance is required
when you are placing a stove and its connector with no
heat shields near a wall with no heat shield.
For example, when the Intrepid II is installed parallel to
the rear wall and no shielding is used, it must be at least
30” (760 mm) from the wall behind it and at least 24” (610
mm) from walls on either side.
If the Intrepid II is installed in a corner and no shields are
used, the corners of the stove must be at least 20” (510
mm) from nearby walls.
The least clearance is required when both the stove and
its connector, as well as the wall, have heat shields.
When shields are attached to the stove or chimney con-
nector, they are mounted 1” - 2” (25-51 mm) away from the
stove or connector surface on non-combustible spacers.
Air owing between the stove (and/or chimney connec-
tor) and nearby shields carries away heat. Do not block
the air ow by lling this empty space with any insulating
material.
The shiny shield surface facing the heat source must be
left unpainted, enabling it to reect heat back towards the
stove or connector and away from the wall.
Shields are never used on double-wall connectors.
Clearances may be reduced only by means approved by
the regulatory authority, and in accordance with the clear-
ances listed in this manual.
The Intrepid II Rear Heat Shield is one way to reduce the
clearance to the rear wall. The rear heat shield may be
installed on either rear- or top-exiting stoves. However,
since the chimney connector also radiates heat toward the
wall in top-exiting installations, either single-wall connector
with connector heat shields, or listed and approved double-
wall chimney connector should be used whenever the rear
heat shield is used on top-exiting stoves.
Clearance reductions with the rear heat shield apply only
to the wall to the rear in parallel installations. Neither the
side clearance requirement nor the clearance requirement
in corner installations may be reduced.
Clearances may be reduced by using a wall shield con-
structed of 24 gauge or heavier sheet metal, or of another
non-combustible material such as 1/2” (13 mm) insulation
board or common brick “laid on at,” with the 3¹⁄₂" (90 mm)
side down. Figure 13 shows such a wall shield.
ST248
wall shield construction
12/14/99 djt
Air Flow
Stud Wall
Framing
Wall Shield
Noncombustible
spacers and
fasteners
Drywall
Air Flow
Shield
Metal Spacer
ST248
Approved wall shield construction.
12
Intrepid®II Woodburning Stove
2000966
Shields must be spaced out from the combustible surface 1"
(25 mm) on noncombustible spacers. 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 should
be open and the shield must be open at the top. (Fig. 13)
The wall shield for a stove must extend 10” (254 mm) above
the top of the stove, or a height of 35” (890 mm). The wall
shield for the chimney connector must be 36” (914 mm)
wide, centered behind the connector; for installations that
use an approved prefabricated chimney to pass through the
ceiling, the chimney connector shield used with single-wall
connector must stop 1” (25 mm) below the ceiling.
Chimney connector clearances may be reduced by using
heat shields on single-wall connector or by using double-wall
connector. One of these methods should be used whenever
the rear heat shield is used in top-exit installations, or in
any other situation when it is necessary to protect nearby
combustibles from the heat of the chimney connector. The
ceiling above horizontal runs of chimney connector must
be protected as well if the clearance is inadequate. Refer
to the Clearance Charts.
In top-exiting installations in which the single-wall connec-
tor extends to the ceiling and connects to a prefabricated
insulated metal chimney, the connector shield must extend
to within an inch of the ceiling. A ceiling heat shield must be
installed that is 22” (560 mm) in diameter and, as explained
above, that extends 1” (25 mm) below the ceiling. The ceil-
ing shield must be constructed of 24 gauge or heavier sheet
metal, must be centered on the chimney, and must meet
any wall protector that is also a part of the installation.
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.
Noncombustible shields installed 1” (25 mm) away from
the combustible surface on noncombustible spacers, called
ventilated shields, may be used to reduce clearances.
(Fig. 14)
To protect a mantel from the heat of an Intrepid II in a
replace installation, the ventilated mantel shield must be
at least 48” (1220 mm) long, and it must be centered over
the stove. Ventilated shields for side trim must extend the
full length of the trim.
An unprotected mantel (‘A’, Fig. 15) cannot be more than
9” (230 mm) deep and must have a minimum clearance of
30” (760 mm), measured from the stove’s top plate. With
a ventilated shield, this clearance may be reduced safely
to 14” (360 mm).
Unprotected top trim (B) protruding 2” (50 mm) or less
from the face of the replace must be a minimum of 24”
(610 mm) from the stove’s top surface. With a ventilated
trim shield, this clearance may be reduced safely to 14”
(360 mm).
Unprotected side trim (C) that protrudes 2” (50 mm) or less
from the face of a replace must have a minimum clear-
ance of 15” (380 mm), measured from the stove’s top side
edge. With a ventilated trim shield, the clearance may be
reduced safely to 10” (254 mm). If the trim extends more
than 2” (51 mm), wall clearance requirements apply.
1" (25mm)
1/4" (6mm)
ST501
mantel and
trim shield
11/10/00 djt
ST501
A custom-formed mantel shield.
ST253
trim clearances
12/15/99 djt
CC
AB
ST253
Measured from the top and sides of the stove
A. Mantel 30” (762 mm) 14” (356 mm)
B. Top Trim 24” (610 mm) 14” (356 mm)
C. Side Trim 15” (381 mm) 10” (254 mm)
Maintain clearances to combustible components of the
mantelpiece.
13
Intrepid®II Woodburning Stove
2000966
The charts and sample installations that follow list the clear-
ances required for the various installation congurations
of the Intrepid II.
Because of their restricted air ow and heat retention
characteristics, specic construction requirements and
special clearances apply to installations into alcoves. No
stove or chimney connector heat shields are used in alcove
installations.
The following illustrations show noncombustible ceiling
framing and maximum and minimum permitted dimensions
for alcove construction.
36"
Max.
48" Min.
ST502
Intrepid
Alcove floor plan
11/10/00 djt
Use recommended
oor protection
7/16” Durock®
(or equivalent)
spaced 1” off
wood studs on
noncombustible
spacers
ST502
Alcove oor plan. Sheetrock on front face butts to
Durock® (or equivalent) alcove lining.
ST503
Alcove side view
11/10/00 djt
Metal
Stud
Combustible
facing may
overlap metal
studs by only
1”
1” air gap
top and bot-
tom, on both
sides and
back wall
7/16” Durock® (or
equivalent)
Joist Shield
(Supplied
by Chimney
Manufac-
turer)
ST503
Alcove side section.
St504
Alcove cutaway
11/00
ST504
Cutaway perspective of alcove installation.
24"
14¹⁄₄"
48" Min.
11"
Min.
36"
Max.
ST505
Alcove Ceiling plan
11/00
Existing Combustible
Framing
Metal studs
support 7/16”
Durock® (or
equivalent)
ceiling
ST505
Reected ceiling plan.
65" 62" Min.
to Alcove
Ceiling
ST506
Alcove front view
11/00
Ceiling sup-
port package
extends 2”
below Durock®
(or equivalent)
ceiling
1” air gap,
top, bottom,
on both
sides and
back wall
ST506
Front view: 65” minimum clearance form hearth to com-
bustibles on front face. Combustible facing may overlap metal
studs by only 1”. It should not extend below the height of the
noncombustible ceiling.
From 62” to
65” must be
covered by
a noncom-
bustible
material.
14
Intrepid®II Woodburning Stove
2000966
* Clearances with double-wall connectors and protected surfaces have not been tested for the Intrepid II.
1. Shielding for a top exit stove must include the stove rear heat shield insert to protect the area behind the ue collar.
2. Chimney connector heat shields, in an installation that goes through a combustible ceiling, must extend to 1” (25 mm) below
the ceiling heat shield, which is 22” (559 mm) in diameter. The ceiling heat shield should be 24 gauge or heavier sheet metal,
centered on the chimney connector, and mounted on noncombustible spacers.
3. Rear exit—horizontal from ue collar directly back through wall.
4. The ceiling heat shield required when chimney connector shields are used should meet the wall protector. This will require trim-
ming the ceiling shield along the line of intersection with the wall protector.
5. In top exit installations, this clearance requires the use of the rear heat shield with the shield insert installed.
No stove heat shields (A) 24” (B) 30” (C) 20” (D) 12” (E) 16” (F) 10”
(610 mm) (762 mm) (508 mm) (305 mm) (406 mm) (254 mm)
Top exit, rear stove h.s.,
single-wall chimney (G) 24” (H) 16” (I) 12” (J) 12” (K) 9” (L) 10”
connector with connector (610 mm) (406 mm) (305 mm) (305 mm) (229 mm) (254 mm)
heat shields1,2
Rear exit, rear stove (M) 24” (N) 14” n/a (P) 12” (Q) 9” n/a
heat shield3 (610 mm) (356 mm) (305 mm) (229 mm)
Top exit, rear stove h.s., (G) 24” (H) 16” (I) 12” *
double-wall (610 mm) 406 mm) (305 mm)
chimney connector5
Single-wall chimney
connector, no 26” (660 mm) 12” (305 mm)
connector heat shields
Single-wall chimney
connector, with 10” (254 mm) 5” (127 mm)4
connector heat shields
Double-wall 12” (305 mm) *
connector5
All Installations 48” (1219 mm)
15
Intrepid®II Woodburning Stove
2000966
D
E
F
F
C
C
A
B
J
K
L
L
I
I
G
H
ST507
Intrepid Clearance
Diagrams
11/00
P
Q
M
N
Top Exit Installations, no heat shields
Top Exit Installations, rear heat shield, and chimney connector heat shields or double-wall connector
Rear Exit Installations, rear heat shields.
ST507
16
Intrepid®II Woodburning Stove
2000966
IN
TR
E
PID
II
C
C
C
C
D
F
AB
E
D
ST508
Intrepid II
wall shield
11/00
ST508
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.
A = 36” (914 mm)
B = 30” (762 mm)
C = 1” (25 mm)
D = 35” (889 mm)
E = 44” (1118 mm)
F = 40” (1016 mm)
IN
T
R
E
PID
II
B
F
G
C
D
CE
A
D
ST509
Wall shield
BB
11/00
A = 36” (914 mm)
B = 13” (330 mm)
C = 35” (889 mm)
D = 1” (25 mm)
E = 40” (1016 mm)
F = 30” (762 mm)
G = 44” (1118 mm)
ST509
Parallel installations with rear wall pass-through, 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. Wall pass-through must comply with
codes.
BB
A
D
A
CC
A
D
A
ST510
Wall shield
cc
11/00
A = 1” (25 mm)
B = 34” (864 mm)
C = 48” (1219 mm)
D = 35” (889 mm)
ST510
Corner installation, vertical chimney connector, with rear,
stove, connector and wall shields. Wall shields meet at
corner. Connector heat shield extends 28” (710mm) above ue
collar. A 24” (610mm) diameter ceiling heat shield must surround
the chimney and be suspended 1” (25mm) from ceiling.
IN
TR
E
PID
II
C
C
C
C
D
F
AB
E
D
ST508
Intrepid II
wall shield
11/00
A = 36” (914 mm)
B = 30” (762 mm)
C = 1” (25 mm)
D = 35” (889 mm)
E = 44” (1118 mm)
F = 40” (1016 mm)
ST508a
Parallel installation, vertical chimney connector, with
stove, connector and wall shields. Maximum reduction for rear
and side walls. Wall shields may meet at corner. A heat shield
24” (610mm) in diameter suspended 1” (25mm) below the ceiling
must surround the chimney.
B
F
G
C
D
CE
A
D
ST509a
Wall shield
BB
11/00
A = 36” (914 mm)
B = 13” (330 mm)
C = 35” (889 mm)
D = 1” (25 mm)
E = 40” (1016 mm)
F = 30” (762 mm)
G = 44” (1118 mm)
ST509a
Parallel installation with rear wall pass-through, with stove,
connector and wall shields. Wall shields may meet at corner.
Connector heat shield extends 28” (710mm) above ue collar, or
below elbow, whichever is less. Wall pass-through must comply
with codes.
BB
A
D
A
CC
A
D
A
ST510
Wall shield
cc
11/00
A = 1” (25 mm)
B = 34” (864 mm)
C = 48” (1219 mm)
D = 35” (889 mm)
ST510a
Corner installation, vertical chimney connector, two wall
shields. Reduced side clearances. Wall shields meet at
corner.
17
Intrepid®II Woodburning Stove
2000966
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 charts on Page 14.
** To locate center of ue collar for corner installation, add 7” (180mm) to the clearance distance form stove corner to wall. Mark off the resulting
distance from the corner along both walls. Next, measure the same distance form these two points out from the walls. These last two measure-
ments will meet at a point representing the center of the ue collar. Refer to the diagrams above.
Side (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)
34³⁄₄” 15” 18³⁄₄” 22³⁄₄” 8” 16³⁄₄”
(883 mm) (381 mm) (476 mm) (578 mm) (203 mm) (426 mm)
ST511a
Intrepid
flue centerline
Diagrams
11/16/00
ABCDEF
ST511a
Side (A) Rear (B) Corner (C) Side (D) Rear (E) Corner (F)
34³⁄₄” 29” 26³⁄₄” 22³⁄₄” 15” 16³⁄₄”
(883 mm) (737 mm) (680 mm) (578 mm) (381 mm) (426 mm)
ST51
Intrepid
flue centerline
Diagrams
11/16/00
*
ABC
*
DEF
ST511
* 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: 31” in the United
States and 33” (840mm) in Canada.
18
Intrepid®II Woodburning Stove
2000966
At the factory the griddle is coated with vegetable oil to
prevent rusting while the stove is in transit and storage.
Remove the oil with a dry rag or paper towel before you
use the stove.
Remove any loose parts from inside the stove. Place a
protective pad on the oor, arrange some sections of 4 x
4 lumber on the pad for support, and carefully tip the stove
onto them, on its back.
Remove and discard the four large slot-head screws from
the stove bottom (Fig. 27) and install the stove legs, using
the hex head bolts from the parts bag. Use 3/8” washers
with three of the legs; the door/damper handle holder
installs in place of a washer on the right front leg. Position
the holder so the hole to accept the handle nub faces out
from the right side of the stove. Tighten the bolts rmly.
ST513
Remove leg bolts
11/00
Slotted
Screws
ST513
Remove the slotted screws from the stove bottom.
A bottom heat shield must be used unless the stove is to
be situated on a completely noncombustible hearth, such
as unpainted concrete over earth. To install the bottom heat
shield, loosen the leg bolts, and slip the bottom heat shield
C-clips onto the bolts. Attach the bottom heat shield to the
C-clips with the wing nuts, and tighten the leg bolts. Align
the shield as shown in Figure 28.
Use the removable handle to open or close the front doors,
or to change the position of the damper. After using it, re-
move it so it won’t get hot, and store it in the handle holder
installed behind the right front leg. (Fig. 29)
10³⁄₄"
9³⁄₄"
ST512
Attach
bottom heat
shield
11/00
ST512
Attach bottom heat shield.
ST514
Bottom heat shield
& clips
11/00
Door Handle Holder
Bottom Heat Shield
Bracket
Wing Bolt ST514
Handle holder and heat shield positions.
You can reverse the ue collar by removing the two screws
that attach the collar to the back of the stove. (Fig. 30) Be
sure the gasket around the ue collar opening is in position
when you screw the collar back on to the stove.
ST515
reverse
flue collar
11/17/00 djt
Flue Collar Screws
ST515
Reversing the ue collar.
19
Intrepid®II Woodburning Stove
2000966
Install the handle on the griddle. Place the griddle upside
down at the edge of a at surface and assemble the handle
as shown. (Fig. 31)
With the handle pointing 45° from its nal position, tighten
the nut as far as possible with pliers. Move the handle to
its nal position while still holding the nut with the pliers.
Take care not to overtighten, as tab may snap.
ST516
Attach
griddle handle
11/17/00 djt
ST516
Attaching the griddle handle.
The , located at the right rear
corner 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 level.
For the greatest air supply and maximum heat output (but
the shortest burn time), move the lever to the left. For a
re that will last longer with less heat, move the lever to
the right. You can set the lever anywhere in between the
left and right extremes. (Fig. 33)
The Intrepid II features an automatic thermostat to ensure an
even heat output at any setting you select. The thermostat
senses the heating and cooling of the stove surface and
adjusts the air shutter accordingly.
ST518
Intrepid II
controls
11/20/00 djt
Air Control Lever
Griddle
Handle
Damper Handle
Door Handle
Door Handle
Holder
(Behind Leg)
Ash Pan
Andiron
ST518
The Intrepid II controls.
ST517
Intrepid II
Thermostat
positions
11/17/00 djt
ST517
The thermostat handle may be positioned anywhere
between the two extremes for different heat levels.
The stove has two controls to regulate performance: a
supplies oxygen for the re, and a
directs air ow within the stove to activate and
deactivate the catalytic combustor.
Additional air for catalytic combustion is regulated automati-
cally, and does not require operator control.
Symbols cast into the stove are reminders of the correct
directions for opening and closing the controls. In these
directions, ‘left’ and ‘right’ assume that you are facing the
front of the stove.
The opens and closes the damper to
direct air ow within the stove, and is next to, and to the
right of, the primary air control lever on the right side of
the stove. (Fig. 34)
When the handle points to the oor, the damper is open,
letting smoke pass directly into the chimney. The damper
be open when starting or reviving a re, and whenever
the griddle or doors are opened.
When the handle points to the front, the damper is closed.
Smoke from the re travels through the catalytic combus-
tion system where it can burn further for greater efciency,
before passing up the chimney.
The damper has no intermediate positions. Figure 28 shows
the handle’s open and closed positions.
20
Intrepid®II Woodburning Stove
2000966
The Intrepid II’s griddle lifts for convenient top-loading of
logs, and is the easiest way of regularly adding fuel. How-
ever, the front doors open as well for adding an occasional
log to a re. (Fig. 36)
ST519
Intrepid II
damper
11/20/00 djt
(Updraft Mode)
(Catalytic Mode) ST519
The damper is either open or closed. There are no
intermediate positions.
ST520
Intrepid
andirons
11/20/00 djt
ST520
Remove the andirons for front loading.
INTREPID II
ST521
Intrepid
loading
11/00
ST521
Top loading is the best way to add fuel during regular
use. Front loading is useful for kindling a re.
The glass panels in the doors have a heat-reective coating
on the outside surface. Heat reected back to the inside of the
glass helps keep the inner surface at a higher temperature
than the outside. In combination with pre-heated primary
combustion air ‘washing’ over the inside of the glass, this
helps provide clear re-viewing at most operating levels.
Your stove has andirons to keep logs away from the glass
panels. The andirons are important to maintain clear
reviewing and should be removed only while reloading
through the front doors.
Wear heavy stove gloves when removing the andirons,
and place them on a noncombustible surface until you
replace them in the stove. Most stove owners will prefer
the convenience of top loading through the griddle, and
will leave the andirons in place permanently.
You can open (or even remove) the front doors and place
the optional Intrepid II spark screen in the front opening
for open-re viewing.
To open the front doors, insert the handle into the door
latch stub and turn it to the left and up. To close them,
always close the left door rst. Turn the handle in the right
door to the left and up (to the open position) and close the
door. Push on the door as you turn the handle to the right
and down. The doors will draw in slightly, and the handle
should offer some resistance as you turn it to the closed
position. (Fig. 37)
Avoid striking the glass or slamming the doors to reduce
the risk of breaking the glass.
When you’re not using the door handle, store it in the holder
behind the right front leg of the stove.
The Intrepid II is designed to burn natural wood only; do not
burn fuels other than that for which it was designed.
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